Genuine Cat® Parts SolutionS

from Barloworld Equipment

KEEP IT REAL. KEEP IT CAT®
2 contents

04
CONTENTS
Repair Indicators

08 Undercarriage

23 Ground Engaging Tools (Get)

49 Engines

67 Preventative Maintenance and Fluids

87 Filters

99 Braking Systems

103 Drive Train

122 Bearing Maintenance

129 Hydraulics
CONTENTS

145 General Usage

150 Cabs and Accessories

159 Contact Us
 3

CONTENTS
4 REPAIR INDICATORS

Quick Reference Guides

Engine, Drive Train, and Hydraulic Repair

Indicators
Machine life cycle management should combine preventative and predictive maintenance strate-
gies to achieve optimal results.

Planned Indicators
Planned Indicators Description
 •O•S Services provide the best insight into internal component wear and potential
S
S•O•SSM Services
failure.
 ach machine’s Operating and Maintenance Manual gives general guidelines for
E
Service Meter Hours
servicing based on service meter hours.
Experience
Talking with your machine’s operator can reveal many potential component problems.
• Observation and Discussion
Service History Service history indicates how frequently routine maintenance is performed.
Fuel Consumption Indicates when a piece of equipment is operating at less than optimum efficiency.
Site Operations Maintenance  OMA is a software that assesses customers operating and maintenance practices and
S
Advisor (SOMA) provides component life estimates.

The following quick reference guides provide a useful checklist for identifying potential problems
and their possible causes.

Cat Engine Repair Indicators

Problem Indicators Possible Causes Problem Indicators Possible Causes
Dirty primary/secondary air cleaner Malfunctioning fuel nozzles/injectors
Excess black smoke
Operating in too high a gear Malfunctioning turbocharger
at full load
Over fuelling Unusual Noises Worn piston pin bushings
(hot, unburned fuel)
Overloading Worn rod/main bearings
Malfunctioning fuel nozzles/injectors Too much valve lash
Malfunctioning turbocharger Incorrect adjustment of governor
Increased fuel
Dirty air cleaner linkage
consumption
Improper set point Malfunctioning fuel nozzles/injectors
Fuel leak Slipping torque converter
Lack of power
Worn turbocharger seals Improper set point
Blue smoke Worn rings/liners Dirty fuel filter
(oil consumption) Worn valve guides Dirty air cleaner
Hours on engine Low quality fuel

White smoke Malfunctioning temperature

(steam: water Cracked head and/or liners regulator
in combustion Leaking head gasket Incorrect adjustment or worn belts/
chamber) pulleys
Overheating Incorrect operator technique
White smoke Incorrect starting procedure Plugged radiator core (external and
(on start-up: Incorrect fuel injection timing internal)
unburned fuel) Faulty injector Low coolant level
Worn or broken rings/liners Dirty air cleaner
Increased oil
Worn turbocharger seals
consumption
Worn valve guides
(excess blow-by)
Hours on engine
 5

Quick Reference Guides

Cat Engine Repair Indicators

(continued)
Problem Indicators Possible Causes
Malfunctioning fuel nozzles/injectors
Improper starting technique
Worn fuel injector pump
Hard starting
Slipping torque converter
(engine missing)
Low cranking speed
Low quality fuel (low cetane rating or
water in fuel)

Coolant/fuel leak into crankcase

Oil level over full
Improper oil fill

Coolant/fuel leakage into crankcase

Extended oil change period
Debris in oil filter Damaged bearings
Incorrect oil use
Dirt in entryway

Cat Final Drive Repair Cat Transmission Repair

Indicators Indicators
Problem Indicators Possible Causes Problem Indicators Possible Causes
Worn plates and discs Worn plates and discs
Brake Slippage Wrong oil used Linkage out of adjustment
Linkage out of adjustment Low fluid level
Hesitation/Slippage
Worn plates and discs Linkage not free
Unusual Noises Dirt in entryway Incorrect pressure settings
Low fluid level Wrong oil used

Wrong oil used Worn gears/bearings

Overheating Low fluid level Dirt in entryway
Unusual Noises
Worn or damaged seals Aeration/cavitation
Low fluid levels
Dirt in entryway
Wrong oil used Bent drive shaft
Debris on Magnetic Vibration Gear failure
Extended oil change period
Plug Bearing failure
Disc disintegration
Worn gears or bearings Wrong oil used
Gear failure Plugged radiator
Vibration Sprocket failure Worn pump/pressure relief valve
Overheating
Bearing failure Worn or damaged seals
Low fluid level
Worn, hard, cracked seals Worn or dirty control valve
Leaks Sprocket failure
Bearing failure Dirt in entryway
Wrong oil used
Debris in Filter/ on
Extended oil change period
Magnetic Screen
Worn gears/bearings
Disc disintegration
Leaks Worn, hard, cracked seals
6 REPAIR INDICATORS

Quick Reference Guides

Engine, Drive Train, and Hydraulic Repair

Indicators (continued)
Cat Differential Repair Cat Hydraulic Repair
Indicators Indicators
Problem Indicators Possible Causes Problem Indicators Possible Causes
Bent or Damaged System pressure too high
External damage
Lines Scored or bent cylinder rod
Worn gears/bearings Failed or incorrect seals
Unusual Noises Leaks Improperly torqued hose connection
Ring and pinion need adjustment
(when travelling Worn or damaged hoses, tubes and
Dirt in entryway
straight) fittings
Low fluid level
Missing guards
Worn differential case assembly
Unusual Noises Valve adjustment needed
Worn spiders
(when turning) Scored cylinder
Worn spider gears Excessive cylinder
Failed seal or seals
Gear failure drift
Scored valve
Spider failure Contaminated oil
Vibration
Differential failure
Bearing failure Engine performance
Faulty Valve
Contamination entry (dirt/debris) Slow cycle times Low fluid level
Debris on Magnetic Extended oil change period Worn system components
Plug Wrong oil used Contaminated oil
Worn gears/bearings
Engine performance
Worn/damaged seals (pinion/ Low fluid level
Leaks differential) Restriction in system
Worn bearings Noisy operation
Aeration
Wrong oil used Worn system components
Overheating Low fluid level Faulty relief valve
Worn or damaged seals Faulty oil cooler
Low fluid level
Plugged filter
Worn system components
System overheating
Faulty relief valve
Wrong viscosity or contaminated oil
Restriction in system
Poor operator habits
Worn rod or cylinder eye/trunnion
Loose cylinder
Poor lubrication
joints
Improper PM schedule
Pinhole leaks in liner material
Blisters or Poor hose routing
abrasions in hose External damage
System overheating
Improper clamping or routing of
Excessive hose
hose
movement
Aeration/cavitation
 7

Parts,
service
backup,
far better
with one
solution
KEEP IT REAL, KEEP IT CAT®
You have to push every day. To meet tomorrow’s
dead-line. To secure the next contract. To stay ahead
of the competition. No matter what challenges lie
ahead, Caterpillar and Barloworld Equipment are
committed to bringing you machines, solutions and
support to help your business keep pushing forward.
SAFETY BUILT IN.

For more information contact our call centre on

0800 21 22 48 or visit www.barloworld-equipment.com

Follow us on Facebook
Barloworld Equipment
Southern Africa

Follow us on Twitter
@Barloworldequip
8 undercarriage

Contents
09 Positive Pin Retention Track

10 Heavy Duty Track

11
Undercarriage

System Management

Cat Undercarriage is designed to

12 Operating and Maintenance Tips

Custom Track Service
Factors Affecting Wear
12
12
work and wear as a system to
reduce your operating costs. You
make daily decisions that impact
undercarriage wear and costs.

15 Track Adjustment Procedures

Elevated Sprocket Tractors
(with and without Carrier Rollers)
15
This guide can help you and
your operators understand how
undercarriage works and how
Low Sprocket Tractors and Loaders 17 to reduce wear and save money.
Hydrostatic Loaders 18
Hydraulic Excavators 19
Although wear can’t be halted,
we are committed to helping you
make each undercarriage system

20 Hardware Requirements
last with correct operation and
maintenance.
 9

Positive Pin Retention Track

Resists link end play and increases sealability for maximum track life

Designed for high impact and high loading applications such as mining, heavy construction, dem-
olition, and waste disposal, Positive Pin Retention Track is an exclusive Caterpillar design that
mechanically locks the link to the pin. This system:

• R esists end-play generation and link movement on the pin;

and
• Increases joint sealability in applications where end-play
growth can exceed the capacity of the seal.

Standard on D9T, D10T, D11R* and optional on D8T elevated

sprocket tractors, Positive Pin Retention helps maximise
undercarriage wear life and minimise your owning and
operating costs.

(*Current D11R link assemblies also contain Sleeve Bearing Track.)

Exclusive design maximises track life

Positive Pin Retention Track features specially machined
links and pins that allow for the use of a metal retaining ring.
This ring is pressed into the groove between the pin and
link, locking the joint to a predetermined factory end-play
specification. This in turn:

• P revents end-play generation (the outward movement of

the links on the pin); and
• Ensures seal-to-bushing face contact and oil retention on
sealed and lubricated track.

This exclusive Caterpillar design is recommended for

mining, heavy construction, demolition, and waste disposal
applications – conditions that generate high loading and
impact, twist the track chain, and cause end-play.
Positive Pin Retention Track features specially machined links and pins
that allow for the use of a metal retaining ring.
Machines equipped with wider shoes, Extreme Service
shoes, or Super Extreme Service shoes should also consider
Positive Pin Retention Track.

Undercarriage management lowers costs

Track Link
Stepped Bushing
To help you get the most from your Cat undercarriage,
Barloworld Equipment offers the Cat Custom Track Service Oil Reservoir
(CTS), a comprehensive programme for managing your track
system. We analyse your application to determine if Positive
Pin Retention Track will improve undercarriage wear life and
lower your cost per hour.

By monitoring and inspecting your track regularly and

providing reports that list service options, we help you make
informed decisions – so you can plan maintenance and avoid
costly unscheduled downtime.
Pin
When your track does need repair, we have the trained
professionals, proper equipment, and excellent parts
availability to get your machine up and running quickly and Oil Passage
Rubber Stopper
reliably. and Plug Positive Pin Rigid Seal
Retention Ring Thrust Ring
10 undercarriage

Heavy Duty Track

A sealed and lubricated track for medium size T, R, N and H-Series track-type tractors

material has been added to Expect longer life

the links for increased wear
life. In most underfoot conditions,
you can expect Heavy Duty
Combined structural and Track to extend undercarriage
wear life enhancements system life an average 20%.
result in lower owning and
operating costs through: The greatest benefits are
• Enhanced track joint realised in aggressive, high
retention and sealability. impact applications such as:
• Stronger components • Logging/reforestation.
that resist cracking and • Side-sloping work.
breakage. • Rocky conditions.
• Extended system wear • Any uneven terrain
life. with wide track shoes
(specifically LGP
machines).

Increased durability Innovative design

and wear life
Heavy Duty Track is more 2
T, R, N and H-Series than an enhancement of 1
machines, because of conventional Sealed and
Lubricated Track. It is a 1 Wider pin boss
their versatility, are used 2 Wider bushing
in all types of underfoot completely new design,
engineered to match the strap
conditions. 3 Longer track
requirements of medium
size T, R, N and H-Series 4 pin and bushing
This tests the limits of 4 More rail wear
undercarriage structural machines. It features 3
redesigned links, pins, and material
reliability, wear life, and
sealability. Heavy Duty bushings that significantly
Track is designed to meet offset the effects of high
the needs of T, R, N and impact loads and stresses.
H-Series machines. It is Additionally, 20% more wear
strong enough for aggressive
impact applications, yet has HEAVY DUTY COMPONENT COMPARED TO SALT* BENEFIT
the necessary wear material Structural enhancements
for long life in abrasive Link bushing strap 65% wider • Greater bushing retention
conditions. • Increased strength
It features: Link pin boss 20% wider • Increased pin retention
• Redesigned links, Bushing 10% longer • More press fit area
pins, and bushings for • Increased retention
enhanced strength,
Pin 14% longer • More press fit area
durability, and retention.
• Increased retention
• 20% additional rail wear
material for extended Wear life enhancement
system life.* Link rail 20% more wear material • Extended link/roller system life
*Results may vary.
*SALT stands for Sealed and Lubricated Track. Comparison percentages based on D6H.
 11

System Management
Undercarriage Optimisation

The Importance of Track Adjustment

Incorrectly adjusted track can cost you money both in
accelerated undercarriage wear and downtime.

If the track is too tight, damaging non-productive

loads are placed on the undercarriage and its manual
components.

Tight track accelerates track wear and reduces tractor

drawbar horsepower. Adjustment procedures take
only a few minutes and require only one person. When
adjusting your track on any Cat machine:

1. A lways adjust the track in the working area.

2. Do not try to squeeze any packing material from in
between the track.
3. Never loosen the relief valve more than one turn.
Grease and oil are under extreme pressure and can
penetrate the body, causing serious injury.

Operating Checklist Maintenance Checklist

1. A
 lways use the narrowest shoe possible, which still 1. C
 all your Barloworld Equipment parts and service
allows adequate flotation. representative for expert advice and service.

2. M
 inimise high operating speeds in non-productive 2. A
 djust the track for correct tension. Always adjust track
situations, especially in reverse. in its working environment. Correct track adjustment is
critical.
3. A
 lternate turning direction since turning only in one
direction wears out one side of the machine faster than 3. T
 ighten the track hardware correctly, using Caterpillar’s
the other. torque-turn method.

4. R
 otate the track from side to side if you or your operators 4. M
 ake daily visual inspections of the equipment. Check
tend to work on one side of the machine more than the for loose bolts, leaking seals, and abnormal wear.
other.
5. K
 eep the undercarriage clean of mud and debris so
5. D
 o not spin the tracks since it reduces production while rollers can turn properly.
increasing wear on all undercarriage components,
especially on grouser bars.

Work it hard. Make it last. Fix it right.

12 undercarriage

Operating and Maintenance Tips

Cat Undercarriage is designed to work and wear as a system to reduce your operating costs. You
make daily decisions that impact undercarriage wear and costs. This guide can help you and your
operators understand how undercarriage works and how to reduce wear and save money. Al-
though wear can’t be halted, we are committed to helping you make each undercarriage system
last with correct operation and maintenance.

Custom Track
Service
Your undercarriage is an
expensive investment. It
accounts for as much as
20 percent of the price of
a new track-type machine.
Undercarriage can represent
as much as 50 percent of
machine maintenance costs.

Our goal is to help keep

your undercarriage operating
cost per hour or per km as
low as possible. That’s why
we developed Custom Track
Service (CTS).

Our parts and service

representatives: Dozing and push loading usually shift the machine weight
• Have the best training and tools to manage your toward the front, causing faster wear rates on the front rollers
undercarriage system. and idlers.
• Regularly inspect and measure wear on your
undercarriage. Ripping and drawbar shift the weight toward the back,
• Prepare reports with maintenance and repair alternatives increasing wear on the rear rollers, idlers, and sprockets.
so you can make informed decisions to reach the lowest
possible cost-per-hour or per km of operation. Loading, as with a carry dozer, shifts the weight from the
rear to the front of the machine as it changes from digging to
While there is no substitute for Custom Track Service, you carrying. Wear will occur more on the front and rear rollers
also play an important role in maintaining undercarriage life. than the centre ones.
The following pages describe conditions and situations that
affect undercarriage and highlight ways you can help slow or Excavating shifts the weight to the side where the digging is
reduce wear. being done. Spreading dumped material tends to create more
wear on the undercarriage side where the operator hits the
Factors Affecting Wear pile, due to the material entering the undercarriage from the
side.
Application
The type of job the machine is doing and the type of materials Packing
it is working in can affect the rate of wear on different During operation, materials can stick to and pack between
components. The following situations all assume level terrain: mating components such as rollers, links, sprocket teeth, and
bushings. Packing prevents parts from engaging correctly. This
can cause higher loads and increased wear rates. Packing is
inevitable in many applications. However, there are things you
can do to reduce the effects of packing.
 13

• U se centre punched shoes in certain situations to help on the components and parts on the sides that are on the
relieve extrudable materials such as wet sand, clay, or upper side of the hill.
snow.
• Clean out your undercarriage as often as possible. Working on a crown shifts the load to the inboard
Garbage, twigs, stones, and demolition debris cannot be components, increasing wear on inner links, inner roller, idler
extruded through the centre punched shoes. treads, and grouser ends.
• Use roller guards only when necessary because they
may trap debris and increase the effects of packing. They Working in a depression shifts the load to the outboard
are designed primarily for use in high impact underfoot components, increasing wear on outer links, outer roller, idler
conditions. treads, and grouser ends.

Terrain Factors Affecting Wear

Most of the time you can’t control the terrain you are working
in. However, it is important to understand how contours and Always use the narrowest shoe possible
slopes affect undercarriage wear. Use narrow shoes which still provide adequate flotation for
your application. Proper flotation helps to reduce wear by
Working uphill shifts the weight and load balance to the rear, keeping track from being submerged in material, but using
causing higher wear on rear rollers and increasing forward wider shoes than required by your application can lead to:
drive side sprocket and bushing wear.
• Increased bushing and sprocket wear
Working downhill shifts weight and load balance forward Turning resistance, loads, and weight increase with wider
causing a relatively higher wear rate on front track rollers and shoes, especially in rough underfoot conditions. This
idlers. added stress causes faster wear rates for bushings and
sprockets.
Working on a side hill shifts the weight and load balance to
the downhill side of the machine. This increases the wear rate • Increased link, track roller, idler tread, and flange wear
Using shoes that are too wide increases the interference
between these surfaces, causing them to wear faster.

• L
 oosening of pins, bushings, and shoe hardware
Leverage forces increase with wider shoes. In high impact
or especially rough terrain, greater leverage forces may
lead to premature loosening of bolted and pressed-fit
components.

• R
 eduction of track joint life
Bending forces are exaggerated when using wide shoes
in high impact applications, causing pressed track joints to
“open up.” This may lead to loss of lubricant, internal wear,
and replacement or reconditioning of track joints sooner
than expected.
14 undercarriage

• Shoe breakage Be sure your track is always properly adjusted

Severe turning resistance in extreme conditions and Every application affects undercarriage wear differently and
bending forces may cause wide shoes to break. requires proper track adjustment. Adjust your track in the
underfoot conditions in which your machine is working. For
Your parts and service representative can help determine the example, if track that is correctly adjusted for a non-packing
best shoe width for your underfoot conditions. application is put into a packing situation, packing materials
will increase track tension, making the track adjustment too
Control the operation of your machine tight. Added track tension increases both the load and the
One of the best ways to protect your machine against wear on all mating components of your undercarriage.
unnecessary wear is to make sure it is used properly. All of
the following can cause additional wear on the components of Improperly adjusted track can result in problems and wear on
your undercarriage: other components such as:

• S lipping the track reduces production and increases wear • B

 ushing and sprocket accelerated wear
on all undercarriage components, especially on grouser Tight track increases loads which advances wear. Wear
bars. occurs as the bushing rotates and/or slides in the sprocket.
• Avoid unnecessary reverse operations. Non-productive
reverse operation compounds bushing and sprocket • L
 ink, track roller, and idler accelerated wear
wear. If the machine must be taxied from one location to To a lesser extent, tight track increases loads between the
another, reverse operation will cause more bushing wear links, rollers, and idlers. This particularly accelerates wear
regardless of speed. on the idlers. For information on how to adjust your track,
• Operating the machine at a non-productive high speed see Track Adjustment Procedures.
may cause link, tractor roller, and idler tread wear. Wear
increases proportionally to speed. Undercarriage repair options
• Always turning the machine in one direction may cause Maximise the life of your undercarriage and reduce your cost
link side rail/track roller flange and idler flange wear. Wear per hour by taking advantage of these undercarriage repair
increases on one side of the machine because of the options:
greater horsepower and distance travelled.
• Wet bushing turn.
• Idler resurfacing.
• Track shoe regrousering.

Keep it Real.
Keep it Cat ®

You have to push every day. To meet tomorrow’s

deadline. To secure the next contract. To stay ahead
of the competition. No matter what challenges lie
ahead, Caterpillar and Barloworld Equipment are
committed to bringing you machines, solutions and
support to help your business keep pushing forward.
SAFETY BUILT IN.

For more information contact our call centre on

0800 21 22 48 or visit www.barloworld-equipment.com

Follow us on Facebook
Barloworld Equipment
Southern Africa

Follow us on Twitter
@Barloworldequip
 15

Track Adjustment 1

Procedures

Elevated Sprocket Tractors

1. M
 ove the tractor forward and let it coast to a stop without
applying the brakes. Make sure slack is between the
sprocket and front idler. Then park the machine and turn
off the engine. Place a tight line over the grouser tips from
the sprocket to the front idler.
B
2. F
 or machines without carrier rollers, measure the distance A
“A” from the line to the grouser tip at the lowest point of
sag. Refer to Chart 1 to determine the correct sag for each
model.
3
 or machines with carrier rollers, measure the distance
F
from the line to the grouser tips in two places at the
lowest point of sag between the front idler and carrier
roller “A” and between the carrier roller and sprocket “B.”
Then average the two measurements. Refer to Chart 2 to
determine the correct sag for your model.

 or SystemOne machines with or without carrier rollers,

F
refer to chart 3.

3. If your track requires adjustment, locate the hydraulic fill

and relief valve in the rear roller frame, and remove the 4
inspection cover. Using a manual grease gun, add grease
at the adjustment mechanism to tighten the track. To
loosen the track, open the relief valve and allow grease to
escape. Then close the relief valve.
B
4. O
 perate the machine in forward and reverse; then re-
measure track tension. To avoid damage to internal roller
frame components, do not allow the length of the exposed
tube “B” to exceed the dimensions listed in Chart 4.
16 undercarriage

Chart 1. Chart 4.
Proper Track Sag Track Roller Frame Extension Specifications
Machines without carrier rollers Machines with and without carrier rollers
Inches Millimetres Model (Serial Number Range) Inches Millimetres
Model Min Target Max Min Target Max
D11T, D11R (AAF) (7PZ) (9TR00202-UP (9XR00154-UP) 7.8 198
D11T, D11R, D11N, D10 6.1 6.5 6.9 155 165 175
D10T, D10R, D10N, D9L, 589 5.7 6.1 6.5 145 155 165 D11R, D11N 7.0 178
D9T, D9R, D9N 4.7 5.1 5.5 120 130 140 D10T (RJG), D10R (AKT) (3KR01331-UP), D10 7.3 186
D8T, D8R, D8N, 578, 583T/R 4.1 4.5 4.9 105 115 125 D10N (2YD1-515) 5.8 148
D8L 5.1 5.5 5.9 130 140 150 D10R (3KR1-1330), D10N (2YD516-UP) 6.8 173
D7R, D7H, 572R 4.1 4.5 4.9 105 115 125
D9T (RJS), D9R (ACL) (ABK) (8BL1422-UP)
D6T, D6R, D6H, 527 4.1 4.5 4.9 105 115 125 7.0 178
(7TL1212-UP)
D5H, D4H, 517, 561H, 561M 3.5 3.9 4.3 90 100 110
D9R (8BL1-1421) (7TL1-1211), D9N 5.9 150
D9L, D8L, 589 6.5 165
D8T, D8R, 583T/R (7XM5094-UP) (6YZ) (KPZ) 6.0 152
Chart 2. D8R (7XM1-5093), D8N (9TC) (5TJ) 5.6 142
Proper Track Sag
Machines with carrier rollers D8 T/R SystemOne 6.0 152
Inches Millimetres D8N, 578 (9TC) (5TC) 5.6 142
Model Min Target Max Min Target Max D7R – STD, XR 5.4 136
D11T, D11R, D11N, D10 2.6 3.0 3.4 65 75 85 D7R – LGP, 572R 5.4 136.5
D10T, D10R, D10N, D9L, 589 2.4 2.8 3.2 60 70 80
D7H – STD, XR 5.0 126
D9T, D9R, D9N 2.2 2.6 3.0 55 65 75
D8T, D8R, D8N, D8L, 578, 2.2 2.6 3.0 55 65 75 D7H – LGP 5.0 127
583T/R D6R – STD (2YN1-544) (3ZN1-763) 6.2 156.8
D7R, D7H, 572R 2.2 2.6 3.0 55 65 75 D6T, D6R – STD (2YN545 and UP) (3ZN764 and UP)
D6T, D6R, D6H, 527 1.8 2.2 2.6 45 55 65 5.8 147.5
(AFM) (AEM)
D6N, D6M, D5H, 517 1.8 2.2 2.6 45 55 65 D6R – XR (6JN1-415) (7KN1-450) 6.2 156.8
D5N, D5M, D4H, 561H, 561M 1.0 1.4 1.8 25 35 45
D6R – XR (6JN416 and UP) (7KN451 and UP) 5.8 147.5
D6R – LGP (8LN1-528) (9PN1-1578) 6.0 151.8
D6T, D6R – LGP (8LN529 and UP) (9PN1579 and UP)
5.6 142.5
(ACJ) (ADE)
D6R – XL (4MN1-503) (5LN1-2765) 6.0 153.5
Chart 3. D6T – XL, XW, LG, D6R – XL (4MN504 and UP)
Proper Track Sag SystemOneTM 5.7 144.2
(5LN2766 and UP)
Machines with carrier rollers*
D6R – XW 5.7 144.2
Inches Millimetres
D6H – STD, XR 6.4 161.8
Model Min Target Max Min Target Max
D6H – LGP, 527 6.2 156.8
D8T, D8R 2.2 2.6 3.4 45 65 75
D6H – XL 6.0 153.5
D6T/R/H, D6N/M, D5H 1.6 1.8 2.0 40 45 50
D6N/M – XL 4.0 102.4
D5N/M, D4H 1.0 1.4 1.8 25 35 45
D6N/M – LGP 4.3 108.2
Machines without carrier rollers*
D5N/M – XL 3.6 91.7
D8T/R 3.1 4.5 4.9 80 115 125
D5N/M – LGP 3.5 88.5
D6T/R/H 4.1 4.5 4.9 105 115 125
D5H, 517 4.4 112
* If excessive track jumping occurs, run the track adjustment to the
minimum side of the track sag range.
D4H, 561H/M 3.9 100
 17
1

2
Low Sprocket Tractors and Loaders
1. M
 ove the machine forward and let it coast to a stop A B
without applying the brakes. Then park the machine and
turn off the engine. Place a tight line over the grouser tips
from the sprocket to the front idler. Track sag should be
about 50 millimetres. If your track requires adjustment,
complete the following steps.

2. C
 onnect the grease gun to the fitting at the track 3
adjustment mechanism “A” located under the inspection
plate. “B” is the front idler bearing assembly.

3. A
 dd grease to extend the hydraulic track adjuster until
the idler is at maximum forward position. The relief valve
should remain closed. After adding grease, the track should
be almost straight between the front carrier roller and idler.

4. O
 n machines with one carrier roller per side, place a mark
on the track roller frame 10 mm behind the rear edge of the 4
front idler bearing assembly “B.” On machines with more
than one carrier roller per side, mark the track roller frame 13
mm behind the rear edge of the assembly.

5. Open the hydraulic relief valve.

6. P
 lace a track pin or drawbar pin between the sprocket
teeth near the link assembly.

7. T
 ravel in reverse until the idler backs up at least 13 mm. 5
Move the machine forward until the pin is free of the track,
then remove the pin.

8. C
 lose the hydraulic relief valve. Using the grease gun,
extend the hydraulic track adjuster until the rear edge
of the idler bearing assembly aligns with the mark on
the roller frame. The resulting sag should be about 50
mm. Operate the machine in forward and reverse, then
reinspect track adjustment.
6 and 7

8
18 undercarriage

A
Hydrostatic Loaders
1. M
 ove the machine forward and let it slowly come to a
stop. Then park the machine and turn off the engine.
Place a tight line over the grouser tips from the sprocket
to the front idler. Measure the distance from the line to
the grouser tips at the lowest point of sag. Proper track
tension is about 50 mm. 4

2. If the track requires adjustment, remove the cover for

the adjusting mechanism. Connect the grease gun to the
fitting. Add grease to move the idler forward until the track
is tight.

3. U
 sing a straight edge, make a mark on the rod even with
the recoil housing “A.”

4. P
 lace a second mark on the rod 10 mm from the first
mark, in the direction of the idler. On the Cat 973, place
the mark on the rod 13 mm in the direction of the idler. 5

5. O
 pen the relief valve and let the idler drift back until the
second mark is behind the recoil housing. Then close the
relief valve. Using a grease gun, move the idler forward
until the second mark is even with the recoil housing.
The resulting sag should be about 50 mm. Operate the
machine in forward and reverse, then reinspect the track.

6. A
 s wear increases on the track link and rolling
components, the distance between the piston “B” and
recoil housing “C” will increase. Consult a Caterpillar 6
Service Manual or contact us when the distance exceeds:
• 50 mm on 943 and 953 track loaders; and
• 60 mm on 963 and 973 track loaders.
C
B
 19

Hydraulic Excavators
1. Operate the machine in the direction of the idlers.

2. S
 top with one track pin directly over the front carrier roller.
Park the machine and turn off the engine.

3. P
 lace a tight line or straight edge on top of the grousers 3
between the front carrier roller and idler.

 easure the distance from the straight edge to the

M
grouser tip at the lowest point of sag, midway between
the front carrier roller and idler. Refer to the chart below to
determine the correct sag for each model.

4. If the track is too tight, loosen it by opening the relief valve
and allowing grease to escape.

5. T
 ighten track by adding grease at the hydraulic fill and
relief valve. Travel in forward and reverse to equalise 4
tension throughout the track. Then reinspect adjustment.

Proper Track Sag

Inches Millimetres
Model Min Target Max Min Target Max
All 200-Family
1.0 1.3 1.5 25.0 32.5 40.0
series excavators
All E-Family
1.6 1.85 2.1 40.0 47.5 55.0 5
series excavators
All 300-Family
1.6 1.85 2.1 40.0 47.5 55.0
series excavators
All 500 and TK-Family
1.6 1.85 2.1 40.0 47.5 55.0
series excavators
5080, 5090B, 5130,
1.6 1.85 2.1 40.0 47.5 55.0
5130B, 5110B
20 undercarriage

Hardware Requirements
Track Roller and Idler Caps
Inadequate clamping of the track roller and idler caps can
result in broken retaining bolts and damage to the frame or
bogie bore.

To install roller and idler hardware:

1. L ubricate the bolt threads with 5P3931 Anti-seize

Compound.
2. Align the shaft and cap dowel holes to ensure proper Sprocket Segment
bearing lubrication and shaft movement.
3. Completely tighten the bolt/bolts on the side having metal The principal cause of segment loosening and subsequent
contact. loss and/or damage to other parts is incorrect segment
4. Completely tighten the bolt on the side that has a gap. hardware installation.
5. Tighten the bolts to the specified torque shown in the
charts below. To install segment hardware:

Elevated Sprocket – Roller Hardware Torque Requirements 1. L ubricate the bolt threads and the washer face of the nut
Model Bolt Size Torque with 5P3931 Anti-seize Compound.
2. Tighten all nuts on any one segment to the specified initial
D4H, 943 with caps 5/8” 200 ± 20 lb ft (270 ± 25 N·m) torque shown in the chart. This draws the mating parts
D5H, D4H, 953 5/8” 200 ± 30 lb ft (270 ± 40 N·m) together tightly.
3. Tighten each nut an additional 1/3 turn. This stretches the
D5N, D5M, D6N,
bolt properly for good retention.
D6M, 953 M16 200 ± 30 lb ft (270 ± 40 N·m)
D6H, 963 3/4” 320 ± 45 lb ft (430 ± 60 N·m)
D6T, D6R, 963 M20 340 ± 50 lb ft (530 ± 70 N·m)
Elevated Sprocket – Sprocket Segment Hardware Initial Torque
D7R, D7H, D8T, D8R,
Model Bolt Size Initial Torque
D8N,D8L, D9T, D9R, D9N 7/8” 550 ± 50 lb ft (750 ± 70 N·m)
D6T, D6R, D6N, D6M, 5/8” 130 ± 30 lb ft (175 ± 40 N·m)
850 ± 75 lb ft (1125 ± 100 D5N, D5M D5H, D4H
D9L, D10T, D10R, D10N 1”
N·m)
D8T, D8R, D8N, D8L, D7R 3/4” 220 ± 40 lb ft (300 ± 50 N·m)
1015 ± 105 lb ft (1350 ± 135
D10 1-1/8” D9L 7/8” 650 ± 50 lb ft (870 ± 70 N·m)
N·m)
D9T, D9R, D9N 7/8” 480 ± 50 lb ft (650 ± 70 N·m)
1650 ± 150 lb ft (2200 ± 200
D11T, D11R, D11N 1-1/4” D10T, D10R, D10N, D10 1” 650 ± 50 lb ft (870 ± 70 N·m)
N·m)
D11T, D11R, D11N 1-1/8” 650 ± 50 lb ft (870 ± 70 N·m)
Elevated Sprocket – Idler Hardware Initial Torque Requirements
Model Bolt Size Torque
Low Sprocket – Sprocket Segment Hardware Initial Torque
D5H, D4H 5/8” 200 ± 30 lb ft (270 ± 40 N·m)
Model Bolt Size Initial Torque
D5N, D5M M16 200 ± 30 lb ft (270 ± 40 N·m)
D4K, D3K, D4G, D4C,
D6N, D6M M16 220 ± 30 lb ft (300 ± 40 N·m) 1/2” 50 ± 8 lb ft (70 ± 10 N·m)
D3G, D3C, 935
D6T, D6R M20 430 ± 60 lb ft (570 ± 80 N·m) 953C M16 75 ± 15 lb ft (100 ± 20 N·m)
D6H 3/4” 360 ± 45 lb ft (475 ± 60 N·m) D6K, D5K, D6, D5G, D5C,
D7R, D7H 7/8” 515 ± 65 lb ft (700 ± 90 N·m) D5, 973, 963, 955, 953B, 5/8” 130 ± 30 lb ft (175 ± 40 N·m)
943, 939
850 ± 75 lb ft (1125 ± 100
D8L 1” D7, 977, 973 3/4” 220 ± 40 lb ft (300 ± 50 N·m)
N·m)
1365 ± 105 lb ft (1850 ± 135 D9, D8, 983 7/8” \250 ± 50 lb ft (340 ± 70 N·m)
D9L 1-1/8”
N·m)
1650 ± 105 lb ft (2200 ± 200
D9L 1-1/4”
N·m)
D9T, D9R, D9N, D8T, D8R, 1185 ± 150 lb ft (1600 ± 200
1-1/8”
D8N N·m)
1700 ± 220 lb ft (2300 ± 300
D10T, D10R, D10N, D10 1-1/4”
N·m)
2220 ± 260 lb ft (3000 ± 350
D11T, D11R, D11N 1-3/8”
N·m)
 21

Conventional Shoe and Link Excavator/Front Shovel Track – Initial Torque for fastening shoes
Model Bolt Size Initial Torque
The number one cause of shoe loosening is improperly
225, 215, 213, 211, 205 5/8” 130 ± 30 lb ft (175 ± 40 N·m)
tightened shoe hardware. Use the following procedure to
tighten your track bolts. 235, 231, 229, 225, FB227 3/4” 220 ± 40 lb ft (300 ± 50 N·m)
521, 522, TK711, TK721,
1. L ubricate the bolt threads and bolt washer faces with 3/4” 300 ± 50 lb ft (400 ± 70 N·m)
TK722, TK741
5P3931 Anti-seize Compound.
2. Install Self-Locking Track Nuts with the rounded corners 235 7/8” 250 ± 50 lb ft (340 ± 70 N·m)
against the link. 245 1” 4\00 ± 50 lb ft (540 ± 70 N·m)
3. Tighten the bolts to the specified initial torque shown in 307 1/2” 165 ± 15 lb ft (220 ± 20 N·m)
the chart below.
4. Give each bolt an additional 1/3 turn. Initial torque draws 307, 308 14 mm 185 ± 18 lb ft (245 ± 25 N·m)
the parts together tightly. An additional 1/3 turn gives the 311, 312, 313, 314 16 mm 130 ± 30 lb ft (175 ± 40 N·m)
bolt correct stretch for good retention. This ensures that 315, 317, 318, 319, 320,
the bolt’s maximum clamping force is used. 320S, 321, 322, 323, 324, 20 mm 300 ± 50 lb ft (400 ± 70 N·m)
325, 511, TK711
350 1” 370 ± 50 lb ft (500 ± 70 N·m)
Elevated Sprocket Track – Initial Torque for fastening shoes and
split master links 330, 532, 541, TK732 22 mm 370 ± 50 lb ft (500 ± 70 N·m)
Track Size Bolt Size Initial Torque 345, 551, 552, TK751,
24 mm 370 ± 50 lb ft (500 ± 70 N·m)
TK752
D5N, D5M, D5H, D4H 5/8” 130 ± 30 lb ft (175 ± 40 N·m)
365 27 mm 400 ± 50 lb ft (540 ± 70 N·m)
D7H, D6T, D6R, D6N,
3/4” 300 ± 50 lb ft (400 ± 70 N·m) 385. 5090 30 mm 675 ± 70 lb ft (990 ± 100 N·m)
D6M, D6H, 527, 517
D7R,D7H 7/8” 250 ± 50 lb ft (340 ± 70 N·m) 5080, 375 27 mm 400 ± 50 lb ft (540 ± 70 N·m)
D8T, D8R, D8N, D8L, 1100 ± 110 lb ft (1500 ± 150
7/8” 480 ± 50 lb ft (650 ± 70 N·m) 5130 1-3/8”
D8T SystemOne N·m)
D9T, D9R. D9N, D9L 1” 650 ± 50 lb ft (870 ± 70 N·m) 5110 1-1/8” 650 ± 50 lb ft (870 ± 70 N·m)
D9H 1” 300 ± 50 lb ft (400 ± 70 N·m)
D10T, D10R, D10N, D10 1-1/8” 650 ± 50 lb ft (870 ± 70 N·m)
1100 ± 110 lb ft (1500 ± 150
D11T, D11R, D11N 1-3/8” Split Master Link
N·m)

The importance of correctly assembling and torquing cannot

Low Sprocket Track – Initial Torque for fastening shoes and split be overemphasised. Follow these steps for both new and
master links used split master links.
Model Bolt Size Initial Torque
D4K, D4G, D4C, D3K, 1. B efore installing the track, the point of connection for the
9/16” 65 ± 15 lb ft (90 ± 20 N·m) master link must be clean and undamaged. Remove all
D3G, D3C, D3, 931, 935
paint from points of connection.
D5K, D5G, D5C, D5, D4, 2. Use 4C5593 Lubricant or 5P3931 Antiseize Compound on
5/8” 130 ± 30 lb ft (175 ± 40 N·m)
953, 943, 941, 939 master bolt threads.
D6, D7, 977, 973, 963, 955 3/4” 220 ± 40 lb ft (300 ± 50 N·m) 3. Put master links together and check alignment of holes for
master bolts. Install one master bolt in each link. The bolts
D8, 983, 973 7/8” 250 ± 50 lb ft (340 ± 70 N·m)
must turn easily, by hand, in the threads.
D9 1” 400 ± 50 lb ft (540 ± 70 N·m) 4. Remove the bolts. Install the master track shoe and all four
master bolts. Turn the master bolts by hand.
5. Tighten the master bolts to the specified initial torque
shown in the chart.
6. Give each bolt an additional 1/2 turn. Give a 1/3 turn for
D6T, D6R, D6H, D7H (SandL), D8L, D8T, D8R, D8N, D9L,
D9T, D9R,D9N, D10T, D10R, D10N, 589, 578, 245, 235.
 22
GROUND ENGAGING TOOLS (GET)
Appreciating the Cat GET advantage
Ground Engaging Tools
 23

Contents
24 Understanding Bucket Wear

26 BLADES: Dozers
Carry Dozer Edge Systems
for the Cat D11
26

Extreme Extended Wear Cast End Bits 28

for Dozers

30 BUCKETS: Wheel loaders

Corner Protectors
Cutting Edges: Bolt-On for
30
31
Cat 966 to 972 CGS Buckets
Hammerless Tip Protection: 32
J800 Retrofit for Cat 994s
High Abrasion Buckets for the Cat 990: 33
Half Arrow Segments and Top Wear Plates
Side Cutters: K Series Buckets 34
Wear Plates for Wheel Loaders 35

36 Mechanically Attached Wear Plates

Wear Plates for Total Protection 36

41 Motor Graders

43 Cat Moldboard Components

48 Underground Loaders
24 GET

Understanding Bucket Wear

A worn bucket costs you money every day you run your machine. It means your loader or exca-
vator works harder to accomplish less. Your productivity is cut and in most cases downtime for
‘patch-up’ repairs is increased. That’s why regular bucket inspections are so important to ensure
that signs of worn parts and structural damage are identified early before they can rob equipment
owners of valuable production time.

Bucket bottom and end plates The best way to reduce this kind of wear on general and multi-
purpose buckets is with the Cat Corner Guard System.
The bucket bottom is an area that receives much abuse. As
the bucket scrapes along the ground, the bottom wears thin For buckets with teeth, a bolt-on corner adapter and tip
resulting in cracked wear plates and weld areas. When wear protect the bucket from excessive corner wear and protect
patterns develop on bucket bottoms replace the wear plates the bucket bottom. For buckets with bolt-on edges, the Corner
before other bucket parts are affected. Guard System uses bolt-on end bits to protect the corners.
For rock buckets you can weld a tooth in the corner to reduce
Corner wear corner wear. A two strap adapter will protect the bucket
bottom.
The most critical wear point in your bucket is the corner. It
receives the most abuse. Severely worn or cracked corners
can cause other bucket components to wear faster.

The widest range

of mining machines
from one solution
You have to push every day. To meet tomorrow’s
deadline. To secure the next contract. To stay ahead
of the competition. No matter what challenges lie
ahead, Caterpillar and Barloworld Equipment are
committed to bringing you machines, solutions and
support to help your business keep pushing forward.
SAFETY BUILT IN.

For more information contact our call centre on

0800 21 22 48 or visit www.barloworld-equipment.com

Follow us on Facebook
Barloworld Equipment
Southern Africa

Follow us on Twitter
@Barloworldequip
 25

“Never run a bare bucket: always use

either bucket teeth or bolt-on edges.”

Worn and missing tips and adapters Conservation – your answer to lower costs
Much of your bucket’s penetration capability depends on Conservation is one of your best defences against rising
teeth. Even one or two missing teeth will reduce your maintenance costs. The following conservation practices have
bucket’s digging ability. A missing tooth also speeds up base been tested and proven:
edge wear. Tips also protect the more expensive adapters.
• Always replace worn edges with the latest Cat edges.
A worn tip is almost as bad as not having any tips at all. Blunt • Rotate bucket tips from the ends to the centre and from
or broken tips cut the bucket’s digging ability, making it work the centre to the ends.
harder to do the same amount of work. • Turn bucket tips over. The results are a re-sharpened tip
and extra wear life.
Base edge scalloping • Reuse rings and pins. Also inspect hardware for reuse and
discontinue the practice of automatically burning it off.
The base edge is the primary support for the entire bucket • Minimise ground contact with the bucket. Some operators
system. When it wears thin or cracks, it weakens the lower the bucket to the ground long before they are ready
whole bucket structure. The bottom and sides of the bucket to enter the stockpile. This extra scraping unnecessarily
can warp and bend. Also cracks may develop in the weld wears the bucket bottom.
areas of the bucket. All this means expensive repair and • Protect the bucket bottom with bolt-on or weld-on wear
downtime. Downtime that could have been reduced through a plates. They can prevent expensive structural damage to
programme of planned repair and maintenance. the bucket resulting in longer bucket life; and
• Lubricate the bucket linkage pins or install sealed linkage
You can reduce base edge scalloping by using either bolt- pins where possible.
on edge segments or weld-on half arrow edge segments
between the teeth. Edge segments protect the base edge
from scalloping and bolt-on edge segments have the added
benefits of being reversible and easily replaced.
26 GET

D11 Carrydozer
Edge Systems
Along with the new fully reversible line of
dozer cutting edges, Caterpillar supplies a
line of one-way dozer cutting edges for the
D11 carry dozer.

The Cat reversible cutting edge system is avail-

able in three styles for Cat D11 carry dozers
in either a 45mm thick, 60mm thick, or 60mm
thick with ARM (Abrasion Resistant Material)
configuration on a standard 19 inch wide plate.

Compared to an unsymmetrical edge of similar style,

equipment owners will experience around a 31% reduction
in GET cost per hour by using the reversible cutting edge
system.

When installing this system, always bolt the cutting edge to

the blade utilising the upper row of bolt holes.

One-way cutting edges

Along with the new fully reversible line of dozer cutting edges,
Caterpillar has introduced a new line of one-way dozer cutting
edges for the D11 carry dozer. These 406mm (16 inch) thick
edges offer less throw away than previous generation Cat
unsymmetrical edges translating into a 16% reduction in GET
cost per hour.
27
28 GET: BLADES

Cat Eewl (Extreme Extended

Wear Life) Cast End Bits
EEWL cast end bits are designed for Cat D11 and other selected track-type tractors that utilises a
Semi-U Blade or Universal Blade. This cast end bit offers more wear material, easier installation,
and decreased change-out times as it is shipped ‘ready to install’.

The new D11 cast end bit is recommended for low to Cutting Edge Supports: An Integral System
moderate impact and low to high abrasive applications. When
installing the new EEWL cast end bits, it is recommended
Component
that EWL or EEWL cutting edges be installed to ensure a
The cutting edge support is an integral part of the blade
balanced system life.
structure to which the cutting edges and end bits are bolted.
Together, they ensure guaranteed dimensional accuracy.
The EEWL end bit has 237.7 lbs. of available wear material
versus the EWL (Extended Wear Life) end bit with 147.9 lbs.
These cutting edge support plates are available for factory
bulldozer blades on D6R through D11R track-type tractors.
The mounting surface of
the end bit, which attaches
The cutting edge support consists of a one piece element
to the blade support, has
for Straight, Angle, and Carrydozer blades. The Universal and
been machined for optimum
Semi-U blades use a three piece cutting edge support system
flatness. The mounting
that consists of one support in the centre along with another
surface should be flat to
support for the right and left hand sides.
ensure that maximum
clamping force can be
(Note to readers: Prolonged operation with loose hardware can cause
obtained, which allows better the bolts to elongate the mounting holes in the support. This makes
bolt retention. Having good it increasingly difficult to keep hardware tight. Repeatedly burning off
bolt retention keeps the end hardware also weakens the support around the bolt holes. If cutting
bit tight against the blade edges and end bits are not replaced soon enough, severe wear and
support, greatly reducing the damage can occur to the cutting edge support. If a blade is suffering
chances of end bit cracking from any of these problems, a genuine Cat cutting edge support will
and/or breakage. ease the pain with its guaranteed dimensional accuracy.)

Lifting Eyes
Another advantage of the
Cat EEWL cast end bit is
that “lifting eyes” have been
designed near the top-face of
the end bit, and topside for
ease of handling and installer Lifting eyes enable safe
installation and removal. Front and rear perspectives: the mounting surface of the end bit,
safety. which attaches to the blade support, has been machined for optimum
flatness.
 29

Blade Maintenance and

Production Tips
• U
 se new bolts and nuts when installing new GET
components.

• W
 hen installing cutting edge bolts, start at the
centre and work out toward the ends, or begin at
one end and work to the other.

• W
 hen downtime and production schedules are
key factors, it is usually more economical to turn
or replace all edges and bits simultaneously, even
though all parts are not completely worn.

• T
 he torque values specified for GET plow bolts and
nuts are greater than the standard specifications.
However, after a short period of operation, the
mating surfaces will seat more uniformly and the
bolt torque will reduce to approximately standard
values.

• D
 uring dozing, avoid excessive speed. Slow, steady
prying force is more desirable than high-speed
impact when a boulder or other tough obstacle is
encountered. Speed also accelerates track wear
and imposes potentially damaging loads on dozer
frames, drive train, and hydraulics.

You have to push every day. To meet tomorrow’s

deadline. To secure the next contract. To stay
ahead of the competition. No matter what
challenges lie ahead, Caterpillar and Barloworld
Equipment are committed to bringing you
machines, solutions and support to help your
WHEREVER YOU
business keep pushing forward.
SAFETY BUILT IN.
ARE, WE ARE THERE.
For more information contact
KEEP IT REAL, KEEP IT
our call centre on 0800 21 22 48 or visit
www.barloworld-equipment.com
CAT®

Pg 29 (90x210).indd 1 2013/05/31 11:24 AM

30 GET: buckets

Bucket Corner Protectors

Even the toughest buckets undergo severe punishment in normal applications. That’s why
it is important to protect bucket corners from unnecessary wear.

Cat corner protectors are cast using DH-2 steel and are through hardened for longer wear life.
These corner protectors have two bolt holes so they can be placed in the same location as 2-bolt
corner adapters. They are compatible with all Cat bolt-on cutting edges.

The sharper profile increases penetration and production by

funnelling loose material into the centre of the bucket.

Bucket corner configurations

Former buckets with 1-bolt corners can be re-worked to
accept corner protectors by replacing the bucket corner
with a 2-bolt corner piece. (Be sure to follow appropriate
welding procedures with adequate pre-heat when working on
hardened base edges/sidebars.)

• Penetrates better.
• Funnels material flow into the bucket.
• Increases productivity.
• Increases wear protection.
• Eliminates gaps between sidebar protectors and
corner guards.

Cat corner protectors

NEW SHARPER CORNER PROTECTORS FOR 924 – 988 LOADERS are designed to
Model Corner Adapter Size Increased Wear Material protect bucket
924G, 928G, 930G, 938G J250 20% corners from wear
950G, 953C, 960F, 962G J300 19% when bolt-on cutting
962G, 963C, 966G, 972G, 973C J350 27% edges are used.
980F, 980G, 980H, 988G, 988H J400/J460 86%

Caterpillar’s new corner protectors feature extra wear material

to make them last even longer.

Increases in wear material range from 19% in the J300 size

to 86% in the J400/460 size. The new design for the J400/
J460 adapter size allows for greater sidebar protection by
eliminating the gap between the sidebar protector and corner
protector on the Caterpillar 980G/H HDGP bucket system.

Caterpillar’s new corner protectors

feature extra wear material to make
them last even longer.
 31

Bucket Protectors

Bolt-On Half Arrow Cutting Edges for

966-972 CGS Buckets
Cat bolt-on half arrow edge protection systems are ideal for abrasive and dense
material applications where severe bucket wear can occur.

The system fits all Cat base edges drilled to accept standard
and heavy-duty cutting edges and consists of three centre
edges and two end edges. These cutting edges protect the
full length of the bottom and leading edge of the base edge,
where wear can be severe.

The half arrow profile provides protection for the front and
top bevel area of the base edge. For still greater wear, centre
and end edges with ARM (Abrasion Resistant Material) are
available as an option.

Both the end and centre edges have lifting eyes that will aid
in handling and installation. This is especially useful when
changing edges in the field where fixtures and other mounting
tools, aside from a simple hoist, are unavailable.

The end edges, which typically wear faster than the centre
edges, are thicker to extend their wear life to more closely MACHINE MODELS
match that of the centre edges. Bucket Type: GCS Bucket Width(s)
Cat 966D, E, F, G 3 035mm
Cat 966G 3 200mm
3 035mm
970/970F
3 200mm

3 035mm
972G
3 200mm

980 Series Loaders

The bolt-on half-arrow cutting edge system is available for selected Cat 980 Series wheel loaders with CGS base edges.
Machine Model 980C 980F 980F 980G
Bucket Width 130.8” 130.8’’ 134.1” 134.1”
(3323 mm) (3323 mm) (3406 mm) (3406 mm)
Bucket Type CGS CGS CGS CGS
Base Edge 7V4188 9V6574 111-9770 111-9770
9V6574
7V0909
Center Edge 217-4725 217-4725 217-4727 217-4727
Hardware-Cntr Edge
Nut (4) 3K-9770 (4) 3K-9770 (4) 3K-9770 (4) 3K-9770
Bolt (4) 5P-8823 (4) 5P-8823 (4) 5P-8823 (4) 5P-8823
End Edge 217-4726 217-4726 217-4726 217-4726
End Edge (A.R.M) 229-6526 229-6526 229-6526 229-6526
Hardware-End Edge
Nut (3) 3K-9770 (3) 3K-9770 (3) 3K-9770 (3) 3K-9770
Bolt (3) 5P-8823 (3) 5P-8823 (3) 5P-8823 (3) 5P-8823
Overall Edge Thickness 3” (76 mm) 3” (76 mm) 3” (76 mm) 3” (76 mm)
Bolt-plate Thickness 1 7/8” (48 mm) 1 7/8” (48 mm) 1 7/8” (48 mm) 1 7/8” (48 mm)
32 GET: buckets

Cat J800 Retrofit

A hammerless tip option for Cat 994 wheel loaders and 385 hydraulic excavators

Incorporating Caterpillar’s groundbreaking Cap-

Sure™ retention design, the Cat J800 Retrofit What to consider when choosing tips
system greatly simplifies the replacement of Cat bucket tips come in diverse shapes and sizes:
bucket tips. your selection will be determined by three factors,
namely impact, penetration and wear.
As an alternative to conventional pin driven GET retention
Impact
options, Caterpillar’s Capsure innovation makes a major
Choose tips with the ability to withstand penetrating
difference when it comes to faster serviceability and safer tool
shocks, extensive digging and extreme breakout
changeover times on specified Cat models.
forces.
A retrofit pin and washer inserted in the J800 adapter mates
Penetration
with the hammerless tip design, without introducing the need
Make sure the tips will penetrate tough material
for special tools. The tip and retainer are one integral system.
whether it’s rocky, hard-packed or frozen. It’s important
to remember that sharp tips should only be used when
All maintenance crews need is a 180 degree anti- or clockwise
penetration is more important than wear life.
turn with a 19 mm (¾ inch) ratchet to either loosen or secure
the Capsure locking system when replacing GET tips. A
Wear
positive stop is cast into the tip and protector to prevent
Select the tip that will withstand wear, gouging and
over-rotation. The tip locks and unlocks using approximately
abrasive action associated with material handling.
136 Nm of torque.

The locking system placement is on the side of the tip,

reducing exposure to wear, which results in easier change
outs.

CapSure correct / incorrect locking sequence A retrofit pin and washer inserted in the J800 adapter mates with the
hammerless tip design, without introducing the need for special tools.

TIP STYLES
The J800 Retrofit option is available in the following tip styles:
Choosing the right
Style Application Benefit
tip for the job site
Heavy Duty Penetration Hard to penetrate,  ery good penetration:
V
will increase safety
highly abrasive long life ensured by and uptime.
materials. heavy wear pad.

Heavy Duty Abrasion Easy to penetrate, Long life ensured by

highly abrasive heavy wear pad.
materials.

Long General excavation Good combination of

and loading. penetration, strength
and wear material.

Penetration Hard-to-penetrate, Very good penetration. A heavy duty abrasion tip,

low-abrasion materials. Tips stay sharp with fitted with the CapSure locking
use. system.
 33

High Abrasion
Buckets: Cat 990
New wider half arrow segments and top
wear plates for Cat 990 high abrasion rock
buckets: field proven in abrasive, low-
to-high impact shot rock truck loading
applications in mines and quarries.

New, wider half arrow segments and top wear

plates provide enhanced value for Cat High
Abrasion Rock Buckets by reducing the gap be-
tween the segment/top wear plate and adapter
cover. This should eliminate wear in that area of
the base edge, which can occur in some mate-
rial conditions.
The segments match the adapter cover bottom thickness to
provide flat under-bucket surfaces, while the half arrow shape
protects base edge blunt height from wear. Top wear plates
reduce wear on the bevel and the top front surface of the
bucket base edge and are designed to match half arrow wear
life, reducing bucket downtime for parts replacement.

Half arrows are 60 mm thick to match the bottom thickness of

the adapter covers, providing a flat bottom surface. They have
been made 60 mm wider across the front to reduce clearance
between the segment and adapter cover. Top wear plates in
turn are 25 mm thick and bent to follow the 35º base edge
bevel.

You have to push every day. To meet

tomorrow’s deadline. To secure the
next contract. To stay ahead of the
competition. No matter what challenges
lie ahead, Caterpillar and Barloworld
Equipment are committed to bringing you
machines, solutions and support to help

Keep it Real, Keep it Cat

your business keep pushing forward. ®
SAFETY BUILT IN.

For more information contact

our call centre on 0800 21 22 48 orvisit
www.barloworld-equipment.com
34 GET: buckets

Side Cutters For K Series Buckets

For Cat 320 to Cat 390D L hydraulic excavators

Caterpillar’s new side cutters feature an innovative design that offers a sharper profile, helping
the bucket cut through tough material with less resistance, whilst staying sharper for longer.
Additionally, the new side cutter profile increases heaping, which can help the bucket load more
material.

These improvements in
penetration and heaping
promote a significant
increase in productivity in
nearly all digging and loading
applications. It is estimated
that bucket performance may
increase up to 4% with the
use of the new side cutters

As with all Cat GET, side

cutter components are
warranted against breakage
for the normal wear life
of the product. However,
Caterpillar will not provide
warranty coverage under
the breakage terms of the
warranty statement if the
wear plates are worn beyond
the wear indicators on the
wear plate.

KEEP IT REAL. KEEP IT CAT®

You have to push every day. To meet tomorrow’s deadline.

To secure the next contract. To stay ahead of the competition.
No matter what challenges lie ahead, Caterpillar and
Barloworld Equipment are committed to bringing you
machines, solutions and support to help your business
keep pushing forward. SAFETY BUILT IN.

For more information contact our call centre on 0800 21 22 48

or visit www.barloworld-equipment.com
Barloworld
Equipment was
here.

Pg 34 (120x210).indd 1 2013/05/31 11:40 AM

 35

Top Mounted Wear Plates for

Wheel Loaders
General purpose and multi-purpose buckets

These wear plates are specifically designed for use with bolt-on half arrow cutting edges and
will fit standard Cat base edges for selected wheel loader models with 119.5”, 126” and 134.5”
bucket widths.

These wear plates protect the bevel and top of the base edge
along its entire length where wear can be severe in highly
abrasive, dense material applications.

Description
Top mounted wear plates are made from through-hardened
DH-2™ steel section for optimum strength and wear life. The
wear plate system consists of two centre edges and a left and
right-hand end edge. Each edge is approximately 16mm thick
and is intended to match the wear life of the half arrow cutting
edges so that maintenance is minimised.

Features
The wear plates are angled downward at the forward edge
to tuck in behind the half arrow edge that sticks up above the
base edge to provide unobstructed material flow.

The rear edge of the wear plates is tapered to a very low

profile to reduce material “carry back” after a load has been
dumped. The half arrow edges and the top mounted wear
plates work together to protect the top and bottom surfaces
of the base edge along its entire length.

The top mounted wear plates bolt in place quickly and easily,
using longer cutting edge bolts and nuts. The Benefits
• L onger base edge life by eliminating wear on the
“Lower your bucket maintenance upper surface of the base edge and in the area of
and repair costs in abrasive loading the base edge bevel.
applications.” • Tight, bolt-on fit eliminates part-to-part wear from
excessive movement.
• No danger of base edge cracking from hard-facing
MACHINE MODELS application.
• More uptime due to quick and easy wear plate
962G11/963C removal and installation as compared to hardfacing
966G, GII 966D, E, F, G, GII application.
980F, G, H 970/970F 970/970F • Tapered rear edge prevents “carry back” of
972G/972GII 972G/972GII material.
973C
BUCKET WIDTH
134.1” 126” 119.5”
BUCKET TYPE
CGS, MP CGS, MP CGS, MP
36 GET: WeAr Plates

Total Wear Protection

The Total Wear Protection line from Caterpillar consists of the Mechanically Attached Wear
Plate System (MAWPS), heel shrouds, chocky bars, wear buttons, roll bars and wear
blocks.

This wide variety of product designs and sizes allows for maximum wear protection in virtually
any type of environment or application.

plates can be quickly replaced without hammering or welding,

making installation quick and easy.

Reduced Downtime and Maintenance

In two minutes or less, the wear plates can be changed,
reducing downtime and maintenance.

Extended Wear. The system’s patented compression

retainer is positioned low in the base plate, allowing for a
greater percentage of the wear plate to be worn away before
replacement.
Mawps Systems
Versatility. The weld-on base plate can be welded onto
The solid Mechanically virtually any flat or moderately curved surface that requires
Attached Wear Plate System wear protection.
provides a hammerless
method for installation and Wear Indicator. Inspections are quick and easy. When the
removal of wear plates. holes become exposed in one or more corners, it is time to
MAWPS are available in a change the wear plate.
variety of sizes. Each size is
also available in two different Each part features two layers, which are bonded together
thicknesses: standard and through a copper-brazing process.
heavy-duty.
Chrome White Iron (CWI). Heat-treated ASTM Class 2, Type
The solid MAWPS is designed B with a minimum hardness of Rockwell C 60 for high wear
for extended wear protection resistance.
in a variety of areas, such
as bucket bottoms and sides, dozer push arms, hydraulic Mild-Steel Backing Plate. Provides impact absorption for
excavator ski runners and sides, and crusher hoppers. It greater durability.
offers equivalent wear protection at less weight than weld-
on or bolt-on wear plates. The compression retainer provides
a hammerless method of installation and removal, reducing
downtime during replacement. It allows for quick replacement
and makes it easy to swap out wear plates. The retainer snaps
into place to firmly hold the wear plate to the base plate.

MAWPS allows you to achieve a greater payload over other

manufacturer’s wear protection systems without exceeding
gross vehicle weight limits. Exceeding those limits can result
in greater tyre wear, more fuel consumption, and a higher
possibility of structural, drive train, and engine damage which
can all greatly increase operating costs.

The skeletal Mechanically Attached Wear Plate System

provides the same hammerless means of installation and
removal as the solid MAWPS, but is for use in the rear portion
of truck bodies. The skeletal plates are designed to trap
material, allowing for material-on-material wear rather than
wear on the steel body liner.

Mechanical, “Hammerless” Installation

The Mechanically Attached Wear Plate System consists of a
wear plate, which slides onto a weld-on base plate and is held
in place with a patented compression retainer. Worn wear A range of Cat wear protection items, showing (top, clockwise) a
wear block, chocky bar, wear button, and roll bar (centre).
 37
All-Round Protection

Heel Shrouds
Heel shrouds are used to protect the lower outside
corner of all types of Cat buckets, as well as other
brand buckets. The heel shrouds wrap around
the bottom and side to give wear protection and structural Wear Blocks
support to the bucket. For moderate wear applications and
sites especially concerned about mechanically fastened parts, Cat wear blocks are used in
these weld-on heel shrouds are an excellent option. areas where a single piece
needs to cover a large or
• E xtra wear material is concentrated in the corner where it specific surface area.
is most needed.
• The inside corner is reinforced to prevent interference with • T he wear block has a
the bucket structure and weld joints. thicker profile, which
• Straight and curved heel shrouds are available in two provides extended
different sizes to best match bucket contour and size, as wear life in extreme
well as abrasiveness of the application. applications.
• The “zig zag” inset design
Chocky Bars allows for material-on-material wear and prevents the
detrimental channel wear common to wear plates that
Cat chocky bars, designed in four distinct shapes, conform to have grooves parallel to the direction of media flow.
virtually any surface or application.

• T he “V-groove” design allows these items to be bent Part Number Part Name Description Length Width Thickness
around a radius (i.e. side bucket profiles) or separated to (mm) (mm) (mm)
change the length requirement needed. 280-4099 Block As.– 6” x 8” Tile 203 152 38
• The inset of the Cat logo allows for the trapping of fine Wear
material in each section, extending the life of the wear
material itself.
Cat Wear Buttons
Cat wear buttons have been designed for use in applications
Part Number Part Name Description Length Width Thickness that lend themselves to optimising their round profile, or
(mm) (mm) (mm) where the round design is needed to cover a specific surface
area.
280-4088 Block As.– 1.5” Chocky 241 38 25
Wear • T he buttons utilise a “tri-bar” design, which traps fine
280-4089 Block As.– 2.0” Chocky 241 51 25 media between the three raised bars.
Wear • The trapped media will provide material-on-material wear,
280-4090 Block As.– 2.5” Chocky 241 64 25 prolonging the life of the product.
Wear
280-4091 Block As.– 4.0” Chocky 241 102 25
Wear Part Number Part Name Description Diameter Thickness
(mm) (mm)
280-4092 Block As. – Wear 2.5” Button 64 22
Roll Bars 280-4093 Block As. – Wear 3.5” Button 89 29
Cat roll bars are a unique product designed to protect the 280-4094 Block As. – Wear 4.5” Button 114 33
leading edge of earthmoving machinery such as dozers, 280-4095 Block As. – Wear 6.0” Button 152 35
loaders, and mining shovels.
Bolt Protectors
• T heir round profile is designed to provide maximum wear Designed to provide maximum protection to hardware and
protection while minimising drag as the edge proceeds retention components, Cat bolt protectors are welded around
through the media. the components to protect them from wear. Chrome white
• Roll bars offer impact deflection, improved media iron and a mild steel backing plate combine with a uniquely
penetration, and overall weight reduction. engineered design to provide an effective solution for a wide
range of environments.

Part Number Part Name Description Length Width Diameter

(mm) (mm) (mm)
280-4096 Block As.– 1.25” Roll 229 38 32
Wear Bar
280-4097 Block As.– 2.0” Roll 305 52 51
Wear Bar
280-4098 Block As.– 3.0” Roll 305 69 76
Wear Bar
38 GET: WeAr Plates

Wear Protection
Mechanically Attached Wear Plate System (MAWPS) (cont’d.)

Parts Consist
Mechanically Attached Wear Plate System
Series Suggested Models Base Plate (thk) Wear Plate (dimension) Compression Radius Capability (1) Retainer Plug
Retainer
20 Series 844, 966, 980, 988, 138-0020 138-0022 138-0006 7.87 in (200 mm) 275-5444
345B, other similar 0.70 in thick (18 mm) 8.85 in x 7.87 in x 1.38 in minimum
sizes 5.35 lb (2.43 kg) (225 mm x 200 mm x 35 mm)
14.151b (6.42 kg)
Heavy Duty same same 138-0023 138-0006 same 275-5444
8.85 in x 7.87 in x 1.97 in
(225 mm x 200 mm x 50 mm)
23.91b (10.85 kg)
Heavy Duty same same 264-2195 136-0006 same 275-5444
ARM
30 Series 854, 990, 992, 375, 138-0030 138-0032 138-0006 15.75 in (400 mm) 275-5444
5080, other similar 0.86 in thick (22 mm) 10.8 in x 7.87 in x 1.77 in minimum
sizes 8.21b (3.72 kg) (275 mm x 200 mm x 45 mm)
21 .3 lb (9.67 kg)
Standard ARM same same 229-7067 same same 275-5444
Heavy Duty same same 138-0033 138-0006 same 275-5444
(10.8 in x 7.87 in x 2.36 in)
275 mm x 200 mm x 60 mm
32.61b (14.8 kg)
Heavy Duty same same 317-3350 138-0006 same 275-5444
ARM
40 Series 5110, 5130, other 138-0040 138-0042 138-0007 31.50 in (800 mm) 275-5444
similar sizes 1.14 in thick (29 mm) 10.8 in x 7.87 in x 2.36 in minimum
10.151b (4.61 kg) (275 mm x 200 mm x 60 mm)
29.251b (13.28 kg)
Heavy Duty same same 138-0043 138-0007 same 275-5444
10.8 in x 7.87 in x 2.95 in
(275 mm x 200 mm x 75 mm)
41.21b (18.7 kg)
50 Series 994, 5230, other 138-0050 138-0052 138-0007 47.25 in (1200 mm) 275-5444
similar sizes 1.14 in thick (29 mm) 11 .81 in x 9.8 in x 2.95 in minimum
13.41b (6.08 kg) (300 mm x 250 mm x 75 mm)
55.25 lb (25.08 kg)
Heavy Duty same same 138-0053 138-0007 same 275-5444
11 .81 in x 9.8 in x 3.93 in
(300 mm x 250 mm x 100 mm)
83.151b (37.75 kg)
Skeletal Mechanically Attached Wear Plate System
Series Suggested Models Base Plate (thk) Wear Plate (dimension) Compression Radius Capability (1) Retainer Plug
Retainer
Standard Off Highway Trucks 138-0020 138-0024 138-0006 7.87 in (200 mm) 275-5444
0.70 in thick 8 in x 12.2 in x 1.38 in
(18mm) (202 mm x 310 mm x 35 mm)
5.35 lb (2.43 kg) 12.9 lb (5.9 kg)
Heavy Duty Off Highway Trucks 138-0020 138-0025 138-0006 7.87 in (200 mm) 275-5444
0.70 in thick 8.15 in x 12.2 in x 1.77 in
(18mm) (207 mm x 310 mm x 45 mm)
5.35 lb (2.43 kg) 18.3 lb (8.4 kg)
1
Not recommended for convex radii smaller than those specified in this chart.
 39

For more information

please contact 011 929 0067

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Barloworld Equipment
Southern Africa

Follow us on Twitter
@Barloworldequip
40 GET: WeAr Plates

Heavy-Duty Wear Plates: Quarrying and

Industrial Buckets
Abrasion Resistant Material Benefits
For tough applications, Caterpillar’s top mounted wear plates
with ARM (Abrasion Resistant Material) provide added
durability for straight, spade rock and HD (heavy-duty) quarry
buckets. These plates are used with bolt-on half arrow
segments.

Wheel Loader Models

• Cat 988 (HD Quarry Bucket).
• Cat 990, 992C, 992D and 992G ( HD Quarry, Straight, and
Spade Rock Buckets).

ARM plates protect the bevel and top part of the base edge
between the adapters where wear can be significant in
moderate to high abrasive, dense material applications. Top Plates are divided into three separate parts (Centre, Left Hand
plates are made from through hardened DH-2 steel section for and Right Hand) to match the shape of the spade bucket.
optimum strength and wear life. Straight base edges require only the centre top plate.

As an added benefit, the life of the top wear plate is intended

to match the wear life of the half arrow so that maintenance is
minimised.

Genuine Cat ®

parts - Find
them on line!
Keep it Real. Keep it Cat® For more information
contact our call centre on 0800 21 22 48 or visit
www.barloworld-equipment.com
 41

Motor Graders
Choosing the right Cat Ground Engaging Tools makes a difference in motor grader
performance and productivity.

From the Cat GraderBits™ System to a range of moldboard components and more than 200
available cutting edges, Cat Ground Engaging Tools for motor graders are built to deliver superior
performance and long wear life. Each provides certain benefits when used in the appropriate ap-
plication.

This guide will help you make

informed GET decisions
when choosing the right
cutting edge, which is critical
for enhancing production
and keeping total costs to a
minimum.

The three factors to consider

in choosing a cutting edge
are:

• Shape. • Width • Thickness

Edge Shape Correct moldboard position

There are two basic edge shapes – flat and curved – with Correct moldboard position reduces wear and
serrated edges available in both configurations. In addition, extends edge life. If the grading angle is too shallow,
the Cat GraderBits System dramatically expands the range of penetration will be poor and heat will build up on the
edge shape options. edge. This causes mushrooming or slivering, which
reduces edge life. (Slivering can also create a tyre
Edge width translates into wear material, so a wider edge hazard.)
usually delivers longer life. For example, a 203mm edge
provides twice as much available wear material as a 152mm
edge at only about 35% more cost. Plus hardware usage and
edge replacement downtime will be cut by 50%.

To extend cost savings even further, a 254mm cutting edge value may be a narrower and/or thinner cutting edge. This
will last three times longer than a 152mm edge when used reduces costs by minimising the amount of usable iron
under comparable conditions. thrown away.

The influence of Crowning Edge thickness

Crowning is a normal wear pattern in which the cutting edge Penetration requirements determine how thick your edge
eventually conforms to the profile of the material being should be. Harder-to-penetrate materials call for the use of a
graded. When extreme crowning occurs or when finishing thinner edge. In easier-to-penetrate materials, the edge can be
applications require tolerances of less than 6mm, the best thicker to extend wear life.
42 GET: motor graders

Serrated Edges are

designed to loosen hard-to-
Flat Edges are usually Curved Edges are usually penetrate materials such Cat GraderBits are part
wider and thicker than narrower and thinner than as packed gravel, frozen of the revolutionary Cat
curved edges because flat edges. They provide the earth and ice. Because of GraderBits System. These
they are designed for more superior penetration and their ability to penetrate replaceable, tungsten
demanding applications, rolling action necessary quickly, serrated edges carbide tipped bits extend
including road maintenance for fine grading and finish may last longer in some downward from the blade
and pioneering. In general, work. applications. For the most like a row of teeth to
flat edges provide better severe impact conditions, provide the best possible
abrasion and impact they can be installed over combination of penetration
resistance. a 6” (152 mm) edge for ability and long life.
improved resistance to
tooth breakage.

The quality of a moldboard cutting edge is usually judged on of bucket teeth, GraderBits are inserted into the adapter and
three factors: are individually replaceable.

• Hardness. Each bit is held in place with a snap ring. Different sizes
• Wear resistance. of GraderBits can be used in combination to create edge
• Breakage resistance. patterns that deliver optimum performance in a wide variety
of surfaces – from rough haul roads to paved roads with
Cat Tungsten Carbide Edges are available in all three basic compacted ice and snow.
shapes for use in areas of high abrasion and low–to–medium
impact. Advantages Over Conventional Edges
GraderBits penetrate to the desired depth immediately – even
Cat Tungsten Carbide Cutting Edges combine the toughness on highly compacted surfaces – so shaving and scuffing are
of Cat DH-2 steel with the wear resistance of tungsten eliminated.
carbide. They provide extended life in highly abrasive
conditions to lower operating costs. Tests show that tungsten Fines and gravel flow through the gaps between bits and don’t
carbide edges can provide up to 20 times the life of a standard end up wasted in windrows. At the same time, subsurface
DH-2 edge. gravel is brought back to the surface for reuse – greatly
reducing the expense of spreading new gravel. As a result,
Features: most road maintenance jobs can be accomplished in a single
• Curved edge improves penetration and rolling action. pass.
• Trapezoid-shaped tungsten carbide tile on leading edge
stays sharp as it wears for improved penetration and Other advantages include:
longer wear life. • 6-10 times longer life than standard flat (1” x 10”) through-
• Available in 609 mm and 914 mm sections for easy hardened edges.
handling. • Less time required on blade and edge maintenance.
• Smaller, easier-to-handle edges allow rotation – • More distance covered in less time means lower overall
substantially reducing downtime and crowning. cost per mile/kilometre.
• Reversible DH-2 overlay end bits are available to protect • Significantly less new road material required.
end sections from damage. • Better water retention helps control dust and erosion.

Developed for high-abrasion, low-to-medium impact ap- Caterpillar also offers high-carbon edges for those light-duty
plications, such as: applications where impact is extremely low. High carbon
• Unimproved earthen material roads. edges have a relatively high surface hardness and will provide
• Public sand and gravel roads. good life in high abrasion applications or in finish work. It is
• Mining or logging haul roads. important to realise that high-carbon edges will not withstand
the impact of a DH-2 edge and care should be taken to
Caterpillar GraderBits System choose an application with very low impact.
The Cat GraderBits System is a flexible, high production road
maintenance edge system that saves time and money. Caterpillar utility edges are heat-treated DH-2 edges that offer
an economical option for Cat 24H / 24m motor graders. These
How Cat GraderBits Work edges are intended for use in highly abrasive applications
The GraderBits System starts with adapters bolted onto the where high impact and breakage are not an issue.
moldboard in place of a conventional cutting edge. Like a row
 43

Cat Moldboard Components

Cat moldboard end bits, overlays, repair plates and hardware help you protect, maintain
and repair moldboards and working edges for longer life and lower total costs.

Overlay End Bits

Overlay end bits are recommended for applications such
as ditching that cause severe wear on the cutting edge
and moldboard corners. They add strength and limit corner
wear, which extends cutting edge life when an edge would
otherwise be thrown away due to excessive wear at the
corners.

When worn on one side, overlay end bits can be rotated for a
second wear life.

Moldboard End Bits

Cat moldboard end bits are recommended for all applications.
Made of through-hardened DH-2 steel for added strength and
service life, they protect moldboard edges from wear.

Moldboard Repair Plates

Most moldboard damage can be avoided through routine monitoring of cutting edge wear and
timely edge replacement. But when unexpected damage occurs, repair plates provide a cost-
Excessive down
effective way to extend moldboard life. pressure can
dramatically shorten
Hardware
Caterpillar Grade 8 hardware is performance-matched to Cat GET in both strength and
edge life.
durability. Grade 8 nuts and forged dome head bolts have a minimum proof load of 120,000 psi
(830 MPa) and a tensile strength of 150,000 psi (1035 MPa). If penetration is a
When replacing ground engaging tools, always use Caterpillar standard hardware regardless of
problem, choose
the application. a thinner edge, a
serrated edge or
Motor Grader Edge Inspection and Installation
Before installing new edges be sure to carefully inspect the face and underside of the
the Cat GraderBits
moldboard: check for bent or cracked areas as well as severe wear. If necessary, weld System for the
moldboard repair plates in place. most compacted
materials.
44 GET: motor graders

Scarifiers and Components

While the main focus of motor grader operations is the
moldboard, there are also important choices to make when
selecting scarifier components and ripper-scarifier tools.

Caterpillar offers a range of built-tough ripper and scarifier

tools and components that make a difference by enhancing
production and extending motor grader versatility.
Scarifier Tips
Scarifiers are available in two configurations, V-Block and Caterpillar offers three types of scarifier tips for use on
Straight Block. Both have tapered locking grooves to hold tips washboarded and potholed road areas or where surface
securely in place. reconditioning is needed. They feature a range of materials
to suit various ground conditions, with material combinations
V-Block scarifiers are the best choice for breaking up blacktop optimised for wear, strength and low operating costs. In
and loosening compacted surfaces, rocky subgrades and normal to light-duty applications, the General Purpose Scarifier
frozen ground. Cat V-Block Scarifiers, also known as mid Tip will provide excellent reconditioning capabilities. The
mounts, fit ahead of the blade, hold up to 11 shanks and General Purpose Tip is made from through-hardened DH-2
loosen a path 46” (1168 mm) wide. They are available to fit Cat steel and provides the lowest operating costs of the three
12, 120, 140 and 112 motor graders. options.

Straight Block scarifiers are mounted on the rear of the

machine and are best used for higher-speed applications (up
to 3rd gear) in shallow, low-impact applications.

Available to fit Cat 12 and 14 motor graders, Cat Straight Block

Scarifiers accept up to 17 shanks and loosen a path 72” (1828
mm) wide. In some light-duty applications, straight block
scarifier arrangements may be used as a mid-mount scarifier.

The Heat Resistant Scarifier Tip is made from DH-3

material and is intended for use in applications where
surface temperature is in excess of 400O F. This material is
specially formulated to resist the damaging effects of high
temperatures and deliver longer wear life in applications
where heat build up is a problem. One such application
would include relatively deep penetration of more than 2”
and contact with the road bed for extended distances of a
kilometre or more.

Ripper-Scarifiers
Scarifier Shanks are through-hardened and tempered to Rear-mounted ripper-scarifiers enhance versatility over
resist wear, bending and breakage. conventional forward-mounted scarifier configurations.
Shanks are available in two lengths:
• Short for most applications. Simply by changing shank position, it’s possible to either rip or
• Long for applications requiring extra penetration ability. scarify as work conditions require. Curved ripper shanks are
recommended for continuous ripping in tougher materials.

Ripper tips for motor graders are available in two designs –

centreline and penetration. Centreline tips are appropriate for
most applications; whilst penetration tips are best for high-
impact or hard-to-penetrate materials.
 45

8” (203 mm) FLAT CUTTING EDGES

Edge Length
Edge 3’ 4’ 5’ 6’ 7’ 8’ Bolt
Thickness 912 mm 1217 mm 1522 mm 1826 mm 2131 mm 2436 mm Size*
0.75” 4Z8129** 4Z8119** a 4T3034 4T3007 4T3036 4T3035 0.63” (16 mm)
19 mm 4T3033 4T3032 4T3037 0.75” (19 mm)
1” 135-9692 7T3497 7T3499 7T3498 7T3496 0.63” (16 mm)
25 mm 4Z8926 7T3493 7T3494 7T3495 0.75” (19 mm)
Bolt Quantity 5 9 11 13 15 17
** 12” (304.8 mm) centres on bolt holes. a 4Z8119 uses bolt quantity of 6.

10” (254 mm) FLAT CUTTING EDGES

Edge Length
Edge 6’ 7’ 8’ Bolt
Thickness 1826 mm 2131 mm 2436 mm Size*
1”
4T6502 4T6508 4T6511 0.75” (19 mm)
25 mm

6” (152 mm) CURVED CUTTING EDGES

Edge Length
Edge 2’ 4’ 5’ 6’ 7’ 8’ Bolt
Thickness 607 mm 1217 mm 1522 mm 1826 mm 2131 mm 2436 mm Size*
0.63” 9W1835 7D4508 5D9553 5D9554 8J4043 0.63” (16 mm)
16 mm 9J3657 9J3658 9J3655 0.75” (19 mm)
0.75” 3G7966 5D9556 5D9557 0.63” (16 mm)
19 mm 4Z8785 0.75” (19 mm)
Bolt Quantity 4 9 11 13 15 17

8” (203 mm) CURVED CUTTING EDGES

Edge Length
Edge 2’ 4’ 5’ 6’ 7’ 8’ 9’ Bolt
Thickness 607 mm 1217 mm 1522 mm 1826 mm 2131 mm 2436 mm 2743 mm Size*
0.63” 109-3137 a 132-1088 7D4509 5D9562 5D9561 5D9731 0.63” (16 mm)
16 mm 3G2166 134-1773 9J7701 7D1158 8J9821 0.75” (19 mm)
0.75” 6G8623** 132-1087 9W6252 5D9558 5D9559 5D9732 195-7269 0.63”(16 mm)
19 mm 3G2165 109-3124 4Z8131** b 7D1576 7D1577 7D1949 0.75” (19 mm)
1” 253-0214 4T2240 4T2244 4T2242 4T2237 0.63” (16 mm)
25 mm 109-3150 4T2231 4T2233 4T2236 0.75” (19 mm)
Bolt Quantity 4 9 11 13 15 17
** 12” (304.8 mm) centres on bolt holes. a 109-3137 uses bolt quantity of 5. b 4Z8131 uses bolt quantity of 7.
46 GET: motor graders

CATERPILLAR CURVED HIGH-CARBON STEEL CUTTING EDGE SIZES

Length
4’ 5’ 6’ 7’ 8’ 9’ 10’ 11’ 12’ 14’
Thickness Width Bolt Hole (1219 mm) (1524 mm) (1828 mm) (2133 mm) (2438 mm) (2743 mm) (3048 mm) (3201 mm) (3353 mm) (4267 mm)
1/2” 6” 5/8”(16 mm) 9W2293 9W2295 9W2297 9W2299 9W2301 4Z8968 9W2303 9W2305 9W2307
(13 mm) (152 mm) 3/4”(19 mm) 9W2294 9W2296 9W2298 9W2300 9W2302 9W2304 9W2306 9W2308
5/8” 6” 5/8”(16 mm) 9W2325 7T1640 7T1633 7T1645 7T1632 4Z8652 4Z8653
(16 mm) (152 mm) 3/4”(19 mm) 9W2326 9W2327 7T1637 7T1626 7T1629
1/2” 8” 5/8”(16 mm) 9W2309 9W2311 9W2313 9W2315 9W2317 9W2319 9W2321 9W2323
(13 mm) (203 mm) 3/4”(19 mm) 9W2310 9W2312 9W2314 9W2316 9W2318 9W2320 9W2322 9W2324
5/8” 8” 5/8”(16 mm) 9W2328 7T1641 7T1636 7T1643 7T1631
(16 mm) (203 mm) 3/4”(19 mm) 9W2329 9W2330 7T1639 7T1624 7T1628
3/4” 8” 5/8”(16 mm) 9W2338 9W2340 7T1634 7T1623 7T1630
(19 mm) (203 mm) 3/4”(19 mm) 9W2339 9W2341 7T1638 7T1625 7T1627

REPLACEMENT PARTS FOR SCARIFIERS

V-Block V-Block Straight Block No.6
Components (Rear Notched) (Front Notched) (Rear Notched) (Non-Current)
Shank
Standard 5B-0947 195-7218 195-7219 6K-5704*
Long 7D-4501
Tips
General Purpose(DH-2) 195-7234* 195-7234* 195-7234*
High Temperature 6Y-5230** 6Y-5230** 6Y-5230** 5K-0450*
(DH-3)
High Abrasion (A.R.M.) 143-3074** 143-3074** 143-3074** 143-3074**
* Uses DH-2 steel.
** Uses 6B-3260 tool for driving scarifier tips off shanks.

HARDWARE
Size Application Bolt Nut Washer
0.63” (16 mm) All 3F5108 4K0367 5P8247
0.75” (19 mm) Except 14G, 16G, and H 4F7827 2J3506 5P8248
Series
0.75” (19 mm) 140H, 143H, 160H, 163H, 5J4773 2J3506 5P8248
14G, 14H
0.75” (19 mm) 16G except 16’ blade 5J4771 2J3506 5P8248
0.75” (19 mm) 16H, 16G with 16’ blade (20) 5F8933 2J3506 5P8248

0.75” (19 mm) (2 bolt part numbers for 16H (22) 5J4771 2J3506 5P8248
and 16G with 16’ blade)
1” (25 mm) 24H (16) 1J3527 2J3507 5P8250
1” (25 mm) (2 bolt part numbers for 24H) (54) 4J9058 2J3507 5P8250

Note: The 140H and 143H Motor Graders use both 0.63” (16 mm) and 0.75” (19 mm) bolts depending on the blade group number. See table below for application.
Blade Group No. Bolt Size
8X8011 0.63” (16 mm)
8X8016 0.63” (16 mm)
112-4520 0.75” (19 mm)
112-4521 0.75” (19 mm)
 47

MOLDBOARD END BITS

Grader End Bit Moldboard Hardware
Model S/N Qty. End Bit Qty. Bolt Nut
16G 93U1-93U2777 9D4880/1 4 4F7827 2J3506
16G, 16H 93U2778-Up 2 8E5530 5 1J6762 a 2J3506
16 All others 9J4407/8 4 3F5108 4K0367
14G 96U1-7324 9J4405/6 4 4F7827 2J3506
14G 96U7325-Up 2 8E5529 5 5J4773 2J3506
14 All others 7D2083/4 5 3F5108 4K0367
112, 12, All 2 7D2052* 5 3F5108 4K0367
120, 130, 9W2945**
140
120H, 135H, 12G, 2 8E5531 5 3F5108 4K0367
12H, 140H, 143H
with 5/8” holes
160H 2 8E5529 5 5J4773 2J3506
212 All 2 9J4411 4 3F5108 4K0367
24H All 2 109-3118 6 1J3527 2J3507
NOTE: For machines equipped with power blade arrangement, refer to the appropriate parts book for the correct moldboard end bit.
* Use 8E5531 End Bits on the following machines:
12G (61M11716-UP)
120G (87V08135-UP)
130G (74V02293-UP)
140G (72V09829-UP)
** 9W2945 is 1/8” (3 mm) thicker than 7D2052 and is recommended for use when installing overlay end bits.
a Use larger 5F8933 bolt where rear moldboard reinforcing plates are used.

MOLDBOARD REPAIR PLATES***

Moldboard Length Dimensions
feet/mm W-H-T (inch) W-H-T (mm) Part
13-14 3962-4267 75 x 15.25 x 0.38 1905 x 387 x 10 4D5821*
12-13 3658-3962 63 x 15.25 x 0.38 1600 x 387 x 10 4D5820**
* Use 8W5266 for larger radius moldboards. Radius is 16.25” (413 mm). ** Use 8W5265 for larger radius moldboards. Radius is 16.25” (413 mm).
*** Blank Plate without Bolt Holes .

You have to push every day. To meet

tomorrow’s deadline. To secure the
next contract. To stay ahead of the
competition. No matter what challenges
lie ahead, Caterpillar and Barloworld
Equipment are committed to bringing you
machines, solutions and support to help

Keep it Real, Keep it Cat

your business keep pushing forward. ®
SAFETY BUILT IN.

For more information contact

our call centre on 0800 21 22 48 orvisit
www.barloworld-equipment.com
48 GET: underground loaders

Underground Loaders
More life from new weld on bucket protection system

Caterpillar’s new weld on GET for underground mining loaders is designed to be more productive
than the previous half-arrow system and offers more wear material to maximise wear life and
bucket protection.

This new weld-on system also reduces downtime. Cat model match
Traditionally, corners wear faster than edge segments causing
the machine to be idled twice for maintenance. The new Please note that only centre-edge segments should be used
design was developed for an even wear rate between corners on Cat R1300 machines due to the narrower width of their
and edge segments, allowing both to be replaced at the same buckets: using the corner segments reduces the spade
time. profile. Machines larger than R1300s should use the corners
with centre-edge segments.
The new system consists of four new parts: a right and left
corner; along with two lengths of centre-edge segments (850 For complete installation instructions, contact your Barloworld
and 1150 mm long.) Centre-edge segments are offered in two Equipment customer service representative.
lengths to minimise waste when cutting and fitting the parts.

Improved wear material for corner components ranges from

73 to 95%, and centres between 14 and 28%, depending on
the GET model match.
 49

Contents
50 Cat 3516B Engine Upgrade:
Cat 793 Off-Highway Trucks

51 Electric Power and Marine:

Cat Certified Engine Rebuilds

53 Engine Bearings

54 Piston Rings, Liners and Rods

57
ENGINES

Precious Metal Engine Rebuild Kits

61 Reman Products for Engines

63 Starters and Alternators

50 ENGINES

Cat 3516B High Displacement

Engine Upgrade
For Cat 793B and 793C mining trucks

The Cat 3516B High Displacement (HD) engine upgrade delivers substantial savings by using less
fuel, extending time between repairs, and lowering the overall cost per tonne. The Cat 3516B
HD gets its improved performance from a 13% increase in displacement, compared to previous
standard-stroke (SS) engines.

Owners of Cat 793B and 793C mining trucks can upgrade their equipment by purchasing an HD Reman engine and conversion
parts package, and returning their old 3516 short-stroke cores.

Fuel Consumption Improvement* Hours-to-overhaul improvement*

7-8% Less Fuel 793C 793B

Used compared 16% 25%
to the SS engine Longer Longer
versus the HD Time to Time to
Overhaul Overhaul

SS HD
SS HD SS HD

*Performance may vary, depending on application, load

factors and other variables.

HD Advantage
Features
• 13% more displacement.
• New turbos.
• Extended repair and maintenance
intervals.

Benefits
• Significantly less fuel
consumption.
• Better response.
• Lower repair and maintenance
costs, and lower cost per tonne.
 51

Electric Power and Marine:

Cat Certified Engine Rebuilds
3300/3400/3500/3600 Engine Family Series

An investment in productivity Inspection/Evaluation

This vital first step is a thorough process during which we
A Cat engine is the best investment in productivity you can develop a customised rebuild plan and cost estimate for you.
make. But eventually, every piece of equipment reaches the
end of its useful life. Through the Cat Certified Engine Rebuild Disassembly
programme, a member of the Cat 3300, 3400, 3500 or 3600 Once the rebuild plan is established, your engine will be
engine family can be rebuilt for a second life, at a fraction of completely disassembled. The parts will be inspected and
the cost of an engine replacement. measured against our strict reusability guidelines. Those parts
that do not meet our high standards will be replaced with new
Rebuild specifications meet all Caterpillar standards, providing Cat parts.
the kind of quality you have grown to expect. Parts are built
to exact tolerances and undergo rigorous testing to ensure Reconditioning
reliable performance. This phase of the process addresses equipment needs not
typically included in an engine overhaul.
These Cat Certified Engine Rebuilds also come with extended
service coverage options, the latest required updates and Engineering updates
optional performance enhancement upgrades, which could During reassembly, your engine will receive any required
result in: updates and your choice of optional performance
enhancement upgrades that have occurred since your engine
• Improved fuel consumption. was originally manufactured.
• Reduced emissions.
• Solutions for governmental or international regulations: Reassembly
 SOLAS Reg. number 15.2.9 Our professional technicians will carefully and completely
 SOLAS Reg. number 15.2.10 reassemble your engine.
 SOLAS Reg. number 15.2.11
• Reduced owning and operating costs.
• Technology upgrades like:
 EIS Technology
 G3600 ESS to ADEM III
 G3500A Gas Compression EIS to ADEM III
52 ENGINES

Testing and validation Available coverage

Following the original commissioning procedures of
the rebuild process, the engine will be retested and re-
commissioned. 3300 and 3400 Series
3304 G3304
Repainting
Your engine will perform like new and look like new, after a 3306 G3306
paint job. A Cat Certified Engine Rebuild decal will also be 3406 G3406
issued. 3408 G3408

New Cat Certified Engine Rebuild identification numbers 3412 G3412

A new Cat Certified Engine Rebuild number identifies your
engine and entitles you to Caterpillar extended service 3500 Series
coverage options. 3508 3508 – G3508 G3508B –
3512 3512B 3512B HD G3512 G3512B –
Customer evaluation 3516 3516B 3516B HD G3516 G3516B G3516C
The rebuild process is not considered complete until your
– – – G3520 G3520B G3520C
operators are satisfied with the performance of your engine in
3524 3524B – – – –
its working environment.
3532 3532B – – – –
Model coverage
Contact our Cat Certified Engine Rebuild team for 3600 Series
3300/3400/3500/3600 Engine family serial number specific 3606 G3606
data.
3608 G3608
3612 G3612
Cat Certified Engine Rebuild Extended 3616 G3616
Service Coverage 3618 –
Inspection/Evaluation
The Cat Certified Engine Rebuild programme doesn’t
end with the rebuild process. The value of your engine
is further increased with new-engine extended service
coverage options.

Ask your Barloworld Equipment Customer Service

representative for details on additional extended
service coverage options available through the Cat
Certified Engine Rebuild programme.

Available coverage:
• 2-year or 12,000 service hours
• 2-year or 16,000 service hours
• 3-year or 18,000 service hours
• 3-year or 24,000 service hours

You have to push every day. To meet tomorrow’s

deadline. To secure the next contract. To stay ahead of
the competition. No matter what challenges lie ahead,
Barloworld Equipment
Caterpillar and Barloworld Equipment are committed
to bringing you machines, solutions and support to
help your business keep pushing forward. SAFETY
was here. Keep it Real,
BUILT IN.
Keep it Cat®
For more information contact our call centre on
0800 21 22 48 or visit www.barloworld-equipment.com

Pg 52 (75x210).indd 1 2013/05/31 12:01 PM

 53

Engine Bearings
• Aluminium Alloy Bearings (Bi-metal)
• Aluminium Alloy Bearings (with overlay)
• Copper/Lead Bearings

Built to protect your engine investment

Bearings play vital roles inside your engine – preventing
damage to crankshaft journal surfaces and maintaining correct
oil flow and pressure between parts – so installing the correct
bearing is critical.

By installing Cat engine bearings, you can prevent damage

to expensive engine components, minimise repairs, and
maximise uptime. of oil is the proper thickness, helping prevent the friction and
metal-to-metal contact that can cause excessive wear and
premature failure.
Three bearing choices optimise system
performance Precise crush height: Cat bearings feature precise crush
height, which helps ensure proper clearance and contact
Caterpillar is constantly looking for new and improved engine pressure between the bearing and bore.
bearing material and designs to match engine performance
demands. The three bearing designs described below offer Our comprehensive support helps you
optimised performance based on variables unique to each
engine system. lower costs

• B i-metal bearings feature an advanced aluminium alloy and Contact your Barloworld Equipment customer service
no overlay, providing more consistent bearing clearance representative for more information on Cat engine bearings.
and little wear. With Cat parts, you receive the correct bearings to match
• Aluminium alloy bearings feature aluminium bearing your system, together with the right technical support for
and copper bonding materials to prevent scuffing and dependable engine system operation.
corrosion, reducing the chance of failure.
• Copper/lead bearings feature greater fatigue strength,
increasing durability and reliability.

Quality construction, extended life, greater Engine Bearings

protection Aluminium alloy bearing Aluminium alloy bearing
(bi-metal) (with overlay)
Consistent construction means Cat engine bearings deliver
maximum performance and life, and provide greater
protection for other, more expensive engine components.
• •
Consistent wall thickness: When the main or rod cap is • •
bolted in place, the bearing and crankshaft journal are in close
• •
Aluminium Copper
proximity. A film of oil exists between the two components Steel back
alloy bonding
during engine operation to protect them from damage. The material Aluminum
consistent wall thickness of Cat bearings ensures that the film Steel back alloy
Lead/tin/copper
overlay

Cat engine
Copper/lead bearing
bearings:
• F eature consistent
wall thickness to •
•
distribute oil properly. • •
• Have precise crush Nickel
height to ensure proper clearance and oil flow. Steel back
dam
• Are made of the correct material to optimise Copper/lead
performance under varying cylinder pressures. alloy
Lead/tin/copper
overlay
54 ENGINES

Cat Pistons, Rings,

Liners and Rods
Built to meet your engine’s demands

Pistons, rings, liners and rods form the heart

of your engine, controlling the combustion pro-
cess and transferring mechanical energy to the
crankshaft.

To protect your engine from harsh conditions, Cat pistons, genuine CAT PARTS
rings, liners and rods are:
• Designed to work and wear as a system in your Cat Comprehensive service and support
engine for smooth, efficient operation and long life.
• Manufactured and tested to close tolerances to ensure top When your engine needs service, our professional
engine performance. technicians have the training and tools to get you back
• Heat treated to deliver strength and durability during to work quickly. We provide off-the-shelf component
engine operation. availability backed by Caterpillar’s worldwide parts
network.
Quality materials and controlled manufacturing processes
also mean Cat piston crowns and connecting rods can
be remanufactured for a second life. Cat Reman Cylinder
Packs offer same-as-new performance, long life, and quick
turnaround, all at a fraction of new prices.

New Cat pistons, rings, liners, and rods are designed and
manufactured using quality materials and controlled processes
for maximum performance and durability.

One Piece Pistons

• Improved structural
capability of the single
piece forged steel piston
simplifies assembly and
eliminates the number of
parts.
• New oil jet with higher oil
velocity provides more
concentrated cooling.
• Reduces thermal
expansion and allows piston fit to be tighter for a reduction
in cavitation.
• Reduction in surface area provides less friction and helps
improve fuel consumption.

Two Piece Pistons

• T wo piece ‘articulated’ design for reduced piston slap,
better combustion and reduced emissions due to rings
located closer to the top of the piston.
• Steel crown for heat resistance, and higher cylinder
pressure.
• Aluminium skirt for weight reduction.

Cat Liners
• Inside surfaces feature a uniform cross hatch pattern
for faster ring seating, proper ring seal, uniform oil
distribution, and long life.
 55

• F langes are roll burnished in the radius for increased • N

 ormal chromium wear exposes new ceramic particles
strength and resistance to cracking. resulting in less surface cracking/ring flaking, reduced wear
• Heat-treated high-grade gray iron construction provides of both ring and cylinder bore, significant life improvement,
exceptional strength and long life. and better spalling resistance.
• Controlled flange head thickness guarantees a precise
match with the block and head. Fractured Rod
• Precise manufacturing tolerances ensure perfectly round
bores for efficient oil control and proper fit in Cat engine • P erfectly matched joint surfaces allow rods to accept
blocks. higher loads.
• Fractured uneven surface helps locate the rod end and
Cat Rings cap, eliminating the need for a locating dowel.
• Automatic bolt insertion and fastening equipment ensures
• P recise plasma or chrome plating guarantees exceptionally the cap and rod stay together, eliminating the possibility of
long wear life. a mismatched cap and rod during material handling.
• Proper surface finish provides smooth operation and long
wear life. REMAN CYLINDER PACKS
• Barrel-faced top ring maintains the proper oil film thickness
on the cylinder liner for reduced liner damage and oil Remanufacturing transforms used Cat components to new
consumption. parts standards. When you need repairs, Cat Reman Cylinder
• Durable heat-treated ductile iron construction resists Packs will get you back to work quickly, reliably, and affordably.
breaking and impact loading. Completely remanufactured to include all critical engineering
• Precise fit with grooves ensures proper oil control and updates and design improvements, Cat Reman Cylinder Packs
sealing between the crankcase and combustion chamber provide same-as-new performance and long life.
for efficient operation, long wear life and reduced blow-by.

Strict remanufacturing processes

Chrome Ceramic Ring
• N ew articulated piston bushings are installed using correct
• C oating of several layers of hard chromium for higher installation methods to ensure retention of bushing in
scuffing resistance. bore.
• A network of tiny micro-cracks on each layer for better • New liners and rings are installed for exact fit and smooth
thermal fatigue properties. operation.
• Ceramic particles embedded into each layer of chrome • All components are extensively tested and inspected for
improve consistency properties over the entire coating conformance to factory specifications.
depth.
56 ENGINES

Cat Pistons, Rings, Liners and Rods

Continued

Fast, easy installation

Cat pistons, rings and liners versus
Cat Reman Cylinder Packs contain the cylinder liner, piston,
rings, pin, retainers, connecting rod, and all necessary seals. competitor parts
They come preassembled and ready for installation as a unit,
reducing your turnaround time. Caterpillar randomly tests competitive parts to
determine quality differences. These comparisons
Plus, our special tooling and repair technique can save up consistently reveal the following shortcomings about
to an hour per cylinder during installation, so it’s possible to competitive pistons, rings and liners.
complete an entire in-frame overhaul in one day. No other
engine manufacturer offers this kind of service. Competitive pistons

Fully warranted, low-cost repair options • Imprecise fit can cause liner scuffing and piston
seizure.
Cat Reman Cylinder Packs are priced at 45-50% of the cost of • Partially disbonded ring bands and out-of-spec ring
new parts and offer the same factory-fresh performance. To grooves can cause blowby and cylinder damage.
prove it, Caterpillar backs Reman Cylinder Packs with a same-
as-new parts warranty. Competitive rings
• T hin chrome plating can reduce wear life.
• Soft, gray iron construction can reduce durability
Cat engine bearings resist scuffing and lead to failure.
and friction, prevent corrosion, and
ensure proper clearance and oil flow for Competitive liners
maximum performance and protection of • L ack of heat treating and roll burnishing can lead to
engine parts. flange cracks and breaks.
• Random cross hatch pattern can result in poor oil
control and increased oil consumption.

Cat liners are plateau bored for proper mating of piston

rings and liner, better oil control and long life.

Pistons, Rings and Liners

Competitive liners are non-plateau bored and require
breaking in, producing wear and delays proper oil
control.

Quality materials and controlled

manufacturing processes ensure Cat
pistons, rings, liners, rods and Reman
Cylinder Packs deliver top performance
and long life.
 57

Firing on all Cylinders

Precious Metals Engine Rebuild Kits
Introducing the Precious Metals Engine Rebuild Kit series for 3176, 3306, 3406, 3406C and
3406E engines

Caterpillar’s recently launched Precious Metals Engine Rebuild series comes in pre-packaged kits
that contain all the necessary components to effect maintenance interventions at set stages in
an engine’s working life.
To get machines back to work fast, there are four kit options: in turn includes the Bronze kit, plus six Cat Reman cylinder
Bronze, Silver, Gold and Platinum with all parts enclosed pack assemblies; whilst Platinum incorporates all Gold kit
meeting Caterpillar’s exacting quality standards. components plus a Cat Reman cylinder head, Reman fuel
injectors, and Reman water and oil pumps.
Bronze covers basic repairs typically caused by factors such
as dust ingress, whilst Silver and Gold kits are designed for At this stage Precious Metals Engine Rebuild Kits are being
mid-life top and bottom rebuilds. Platinum kits meet complete introduced locally for 3176, 3306, and 3406, 3406C or 3406E
rebuild requirements, optimising the second and third life engines. The 3406 series caters for the following machine
capabilities of Cat engines. models:
• Cat 980G and 980F wheel loaders.
As the basic building block for all higher levels, Bronze • Cat D8N and D8R track-type tractors.
includes components that one might not think of replacing, • Cat 735 and Cat 740 articulated trucks.
but which could lead to unplanned downtime and costly • Cat 824G wheel dozers.
failures, a prime example being exhaust manifold sleeves. • Cat 826G compactors; and
• Cat 621G, 623G, 627F and 627G scrapers.
Bronze components include gaskets and seals; oil and fuel
filters; camshaft bearings; turbo nuts and bolts; and a coolant The 3306 rebuild kit caters for models that include:
temperature regulator. • Cat 140H and 160H motor graders.
• Cat 966G wheel loaders.
Silver builds on Bronze with the addition of pistons, • Cat D7 dozer.
cylinder liners, wrist pins, piston rings and retainers. Gold

Rebuild It Right. The Right Parts, Right Now.

• G et more for your money. Pre-packaged kit options feature improved pricing and contain everything you need for a cost-effective
repair solution.
• Count on quality. Genuine Cat engine components are manufactured to precise specifications and engineered for a reliable
rebuild, boosting productivity and minimising downtime. They work together as a system to give your machine new life.
• Save time and effort. Because there’s no need to select individual parts for the repair, you always get exactly what you need – no
more, no less. That simplifies ordering and handling, shortens turnaround time and reduces the chance for errors.
58 ENGINES

Firing on all Cylinders

Continued
FIND THE LEVEL THAT’S RIGHT FOR YOU.

BRONZE LEVEL
Features
• Basic building block for all higher levels.
• Includes additional value-add components, such as rod
bearings.
• Includes components you might not think of replacing, but
that could lead to unplanned downtime and costly failures,
such as exhaust manifold sleeves.
• Includes required gaskets and seals to reassemble the
engine (out of frame rebuild kit).

Benefits
• Includes all parts necessary for low-cost repair option.
• Ideal for repair before failure.

SILVER LEVEL
Building from the Bronze Level, a cost-effective option for a
basic rebuild, the Silver Level includes: new pistons, liners,
wrist pins, rings, retainers and a rodless, unassembled
cylinder pack.

Features
• Includes Bronze Kit.
• 6 pistons, liners, wrist pins, rings and retainers.
• Rodless, unassembled cylinder pack.

Benefits
• Basic rebuild.
• Where Reman is not a preference.
• Similar consist to aftermarket kits.
• Additional engine components can be ordered as needed.

GOLD LEVEL
Features
• Includes Bronze Kit.
• Includes 6 Cat Reman cylinder pack assemblies.

Benefits
• Basic rebuild.
• Cat Reman cylinder packs are preassembled with
connecting rods, pistons, rings, wrist pins and liners,
saving four to six hours of labour during engine rebuild.
• Ideal for repair before failure.
• Additional engine components can be ordered as needed.

“Choosing the best engine kit option for

each stage in the life of your machines
will significantly extend their overall
utilisation.”
 59
PLATINUM LEVEL
The Platinum Level is the most complete rebuild option;
designed to maximise the built-in second and third life of your
engine.

Features
• Bronze Kit.
• 6 Cat Reman cylinder packs.
• 6 Cat Reman injectors or fuel nozzles.
• Cat Reman complete cylinder head, water pump and oil
pump.

Benefits
• More complete engine rebuild option.
• Preassembled Reman cylinder packs and cylinder head will
save additional labour hours during engine rebuild.
• Maximises the built-in second or third life of your engine.
• Additional engine components can be ordered as needed.
60 ENGINES

Firing on all Cylinders

Continued
ALL YOU NEED TO DO IT RIGHT
Precious Metals Engine Kits come in four levels: Bronze, Silver, Gold and Platinum.
Whatever level you choose, you’ll find unmatched value as compared with competitive kits.

Typical Engine Rebuild Kit Non-Genuine

Genuine Cat Why is this part included in the Cat Engine
Consist Introduced at Each Aftermarket
Rebuild Kits Rebuild Kit and not by competitors?
Level* Kits*
Camshaft Bearings ✔ ✔
Drive Gear Bushings ✔ ✔
Rear Structure Gasket Set ✔ ✔
Front Structure Gasket Set ✔ ✔
Head Gasket Set ✔ ✔
Oil Pan Gasket ✔ ✔
Fuel Injector Gasket Set ✔ Re-use of injector seals may cause fuel dilution
and additional damage to the engine
Bronze Level

Exhaust Manifold Sleeves ✔ Debris from unexpected failure may damage

turbo and internal cylinder components
Oil Pan Isolator Assemblies ✔ Replacement ensures compliance
with Emissions and Noise Regulations
Exhaust Manifold High ✔ Maximises reliability
Temperature Studs
Thermostat ✔ To ensure proper cooling and to prevent
engine overheating
Valve Cover Gear Seal ✔ Replaced to prevent any leaks from
when seal was removed
Advanced Efficiency Oil Filter ✔ Ensures your significant investment is protected
Advanced Efficiency Fuel Filter ✔ Ensures your significant investment is protected
Manifold and Turbo Lockouts ✔ Locknuts are not reusable
Liners ✔ ✔
Piston Crowns ✔ ✔** Recommended by Caterpillar’s engineers
Silver Level

to maximise performance and reliability

Piston Body Skirts ✔ ✔
Rings ✔ ✔
Wrist Pins ✔ ✔
Liner Seals ✔ ✔
Liners ✔** ✔
Piston Crowns ✔** ✔*** Recommended by Caterpillar’s engineers
to maximise performance and reliability
Gold Level

Piston Body Skirts ✔** ✔

Rings ✔** ✔
Wrist Pins ✔** ✔
Liner Seals ✔** ✔
Connecting Rods ✔** Recommended by Caterpillar’s engineers
to maximise performance and reliability
Complete Reman Cylinder Head ✔
Platinum

Complete Set of Reman Fuel ✔ Cat Reman parts provide same-as-new

Level

Injectors performance, improved turnaround time

and reliability at a fraction of the cost
Reman Water Pump ✔ of buying new parts
Reman Oil Pump ✔

Actual consists may vary according to Engine Model and product options and attachments associated with your engine arrangement
** As compared with the Silver Level, the Gold Level not only includes Reman Connecting Rods, the cylinder packs are pre-assembled, saving additional
labour hours
*** Aftermarket kits typically require piston crowns to be ordered separately from the kit, depending on engine sales model and kit manufacturer
 61

Remanufactured Engines and Engine

Components
As good as new, as strong as ever

At Barloworld Equipment we stock Cat Reman engines, engine overhaul kits and engine compo-
nents so we can get you back in operation quickly, affordably, and reliably.

Factory Remanufacturing Short and Long Blocks

Cat Reman long and short
Remanufacturing is more than rebuilding. It is a process blocks are disassembled,
of returning engines and components to their original thoroughly flushed to meet
performance specifications through the use of state-of-the- rigid cleanliness standards,
art salvage techniques, strict reuse guidelines, advanced and 100% inspected for
manufacturing systems, and unequalled quality control. cracks, erosion, or other
damage. Block and cylinder
Restoring original performance is possible since new head faces are resurfaced
Cat engines and engine components are built to be to factory specifications.
remanufactured for a second life. This attention to detail Crankshafts are reground,
ensures that Cat Remanufactured engines and engine polished, and checked for
components provide like-new quality and reliability. lift and endplay. All bearings,
seals, gaskets, and piston
rings are replaced with new
Cat parts. Blocks are tested
electronically to ensure
consistent quality and long life.

Cylinder Heads
Reman cylinder heads are 100%
magnafluxed to detect cracks,
erosion or other damage, and are
updated to include engineering
changes. The bottom deck is
resurfaced to ensure a tight seal
and to help prevent combustion gas and coolant leaks. All
critical wear and sealing components are replaced with new
Cat parts. Cat Reman cylinder heads are pressure tested for
Engines leaks before they leave the factory.
Cat Reman engines are remanufactured using only Cat parts,
many of them new. Engines are upgraded to include critical
design improvements. Plus, each engine is dynamometer Air Compressors
tested for operational and performance indicators. This Crankshaft and journal surfaces are reground and polished and
ensures that Cat Reman engines meet the same performance cylinder bores re-honed to exact dimensions. Each unit has
specifications as new Cat engines. All blocks are tested new piston rings, rubber parts, springs, seals, gaskets, and
electronically to ensure consistent quality and long life. washers to help deliver like-new performance.

Generators Alternators/Starters
Reman generators provide To ensure same-as-new performance, all alternator gaskets
an off-the-shelf solution and seals, and starter O-rings, seals, and boots are replaced.
which helps customers
avoid the lengthy processing
time required by a Crankshafts
generator rewind shop. Crankshafts are 100% magnafluxed to detect cracks.
Reman generators are Crankshaft journals are machined to the same surface finish,
remanufactured in a factory roundness, and location tolerance of new crankshafts to
environment with Cat extend service life.
controlled processes and are
tested with the same rigor as a new Cat generator. Reman
generators are shipped without a “doghouse” providing more
flexibility for your application
62 ENGINES

Remanufactured Engines and

Engine Components
Continued

Cylinder Packs Water Pumps and Oil Pumps

Cat Reman cylinder packs ensure Cat Reman water and oil pumps are
your engine is overhauled using updated to meet the latest design
performance-matched Cat parts. standards and feature 100% replacement
Only Caterpillar preassembles the of bearings and seals.
connecting rod, liner, and piston as a
unit, cutting overhaul time by as much Simple core acceptance reduces costs
as 25%.
Cat Reman engine components are typically priced at 40-70%
of new with the return of your used core through our easy
ECUs core acceptance programme.
Cat Reman has developed its own line
of remanufactured ECUs. This ensures Our simple core acceptance criteria allow a quick
electronic control units are thoroughly determination of core credit. We visually inspect the core on
diagnosed and remanufactured, and the spot, providing an immediate decision on core condition
critical engineering updates are completed. When the and credit, so you don’t have to wait for or guess about repair
remanufacturing process is complete, the units pass through costs. Our two-level pricing system ensures that engines with
rigorous durability test requirements. broken, cracked, or welded blocks can earn a partial refund.
Plus, knowing the exchange price in advance means you’ll
avoid mid-job surprises.
Flywheels
Cat Reman flywheels are balanced to factory specifications Basic Core Criteria
with factory surface finish, which means a smoother engine • Component not visibly cracked, broken or welded.
operation and better clutch break-in. Cat Reman also inspects • Fully assembled and complete.
all ring gears and replaces when necessary. • No non-operational damage (mishandling, excessive rust,
corrosion, or pitting).
• Acceptable part number – Cat part.
Fuel Injection Pumps and Governor Groups
All gasket seals and worn parts are replaced with new. Each Core refund criteria vary by component and are subject to
unit is computer-tested for 20 critical quality points to ensure change. Partial core refunds are available for some Cat Reman
maximum performance and fuel economy. components. Contact you Barloworld Equipment customer
service representative for more information.

Oil Coolers
Unlike other rebuilders who clean and Warranties protect your investment
reuse bundles, Cat Reman oil coolers use
only new tube bundles and end sheets, Cat Reman Engines
which increases reliability and performance We have various warranties depending on the sales model
levels. and application.

Cat Reman engine components

Turbochargers Cat backs Reman engine components with a same-as-new
Centre housings are tested for seal warranty, honoured worldwide.
integrity. All thrust and antifriction
bearings are replaced to ensure long life
and performance.

Good for the

Unit Injectors and Fuel Nozzles environment
Every component is completely
disassembled, cleaned, and extensively Generous core
inspected to ensure same-as-new acceptance reduces
quality and reliability. Advanced salvage cost, reduces waste,
techniques are applied to ensure keeping non-renewable
components meet specifications. All seals resources in circulation
and O-rings are replaced. Fully assembled for multiple lifetimes.
remanufactured injectors are tested and calibrated to new
product specifications.
 63

Cat Starters and Alternators

Built to meet your engine’s demands

New and remanufactured Cat starters and alternators are built to work together, meeting the
demands of your engine and operating environment.

A large amp alternator for a Cat 140K motor grader. A starter motor for a Cat D10T dozer.

Starters Cat Reman starters and alternators reduce

downtime and costs
Cat starters are designed specifically to handle the high
current experienced during the cranking of Cat engines. They When you need repairs, Cat Reman starters and alternators
are built to work hard and deliver reliable performance even in get you back to work quickly, reliably, and affordably.
tough, dirty environments. Completely remanufactured to include the latest engineering
updates, Cat Reman starters and alternators provide same-as-
Caterpillar starters with the PRELUB® system new performance and long life.
Cat starters with the PRELUB® system help to prevent the
wear caused by dry starts. This innovative starter combines
an oil pump with the body of a conventional starter. The pump
automatically draws engine oil from the sump and pressurises
the engine before allowing the starter to crank the engine. Cat
starters with the PRELUB® system can be easily retrofitted to
your machine. Caterpillar Starters: Power and
Reliability
(PRELUB® is a registered trademark of RPM Industries.)
• P ositive-engagement shift mechanism ensures
Alternators precise pinion-to-ring gear engagement.
• Seamless one-piece solenoid case protects against
Cat alternators are divided into two categories: brush type corrosion.
and brushless. Brush type alternators use one-piece brushes • Rotatable
and constant pressure springs for even brush wear. Brushless drive housing
alternators feature tighter air gap tolerances and superior allows flexible
sealing for longer life in dusty, dirty environments. Both mounting.
alternator types are superior high-output charging systems • Brush holder
that are quiet, compact, and lightweight. provides
constant spring
pressure for
even wear.

Starters crank your engine to starting

RPM while alternators supply electrical
power to operate electrical attachments
and/or accessories.
64 ENGINES

Cat Starters and Alternators

Continued

Strict remanufacturing processes

•  omponents are stripped down to the piece parts.
C
• New O-rings, seals, bushings, and bearings are installed.
• Rewound coils are sealed with new insulation.
• Heat sink compounds are replaced.
• All components that cannot be remanufactured to
Caterpillar specifications are replaced with new parts.
• Each part is checked individually, and the finished product
is performance tested to ensure it meets like-new
specifications.

Coverage and availability

Cat Reman starters and alternators are available off-the-shelf
for nearly all Cat engine applications. Coverage includes Cat
Reman starters with the PRELUB® system, as well as a wide
amperage range of alternators (up to 145 amps).

Fully warranted, low-cost repair options

Cat Reman starters and alternators are priced at 40-50% of
the cost of new parts and provide same-as-new performance
and long life. To prove it, Caterpillar backs Reman starters and
alternators with a same-as-new parts warranty.
AN EASY WAY TO
Caterpillar INCREASE EFFICIENCY.
Alternators
CAT ® CERTIFIED USED.
• B uilt-in electronic
voltage For more information contact our call centre on
regulators. 0800 21 22 48 or visit www.barloworld-equipment.com
• High-efficiency
cooling system.
• Brushless
design for harsh
environments.

KEEP IT REAL, KEEP IT CAT ®

For more information contact our call centre on 0800 21 22 48 or visit

www.barloworld-equipment.com

Pg 64 (65x210).indd 1 2013/05/31 3:15 PM

 65

LONGER LIFE.
LOWER COSTS.
KEEP IT REAL. KEEP IT CAT ®

CAT® PRECIOUS METALS ENGINE REBUILD KITS

Rebuild your engines to run not just longer, but longer at peak performance.
With four levels of Precious Metals Rebuild Kits, you can choose one that
meets your rebuild needs and your budget.

For more information contact our call centre on 0800 21 22 48 or visit

www.barloworld-equipment.com

Follow us on Facebook
Barloworld Equipment
Southern Africa

Follow us on Twitter
@Barloworldequip
66 Preventative Maintenance and Fluids

Preventative Maintenance and Fluids

 67

Contents
68 Fuel Contamination Control
An introduction

69 Bulk Fuel Filtration

71 Cat Fuel Water Separators and Primetime™

Priming Pumps

72 Cat Non-Pressurised Fast Fill Fuel Kits

73 Fast Fuel Conversion Kits

74 Oil Safe Containers

75 Cat GO

76 Cat DEOTM

78 Cat DEOTM Monograde

79 Cat MTO

80 NGEO™ Advanced 40

81 Cat FDAOTM

82 Cat TDTO™

84 Cat NGECTM

85 Cat ELC
68 Preventative Maintenance and Fluids

Fuel Management
Fuel Contamination Control
An Introduction

Contamination control is increasingly important for maximising performance and service life in
fuel systems. Some Cat fuel systems exceed pressures of 30 000 psi in order to deliver more
horsepower, better fuel economy and fewer emissions. This necessitates tolerances smaller than
five microns between parts. These tolerances and injection pressures make fuel systems more
vulnerable to wear and abrasion.

• Injector nozzles: Contaminants move quickly in high- Filtering Contamination

pressure systems, causing damage, eroding orifices
and resulting in incomplete atomisation of fuel and The precision components in today’s fuel systems require
over-fuelling. This harms performance and fuel economy. specially designed fuel filters.
Contaminants also result in hard starts and increased
emissions. Larger contaminants can actually clog orifices. Cat advanced high efficiency fuel filters use exclusively
• Injector plungers and barrels: Abrasive particles designed filtration media to remove more than 98% of
cause wear between an injector’s plunger and barrel. particles, four microns in size and larger. These Cat fuel filters
Contaminants scuff metal surfaces, causing metal-to- feature:
metal contact and eventual injector seizure.
• Control valves: contaminants damage valves that control • S piral roving and acrylic beads to maintain pleat stability
fuel pressures, eroding mating parts of the valves. This and spacing to better trap and hold contaminants.
excessive wear causes leaks and eventual loss of engine • A non-metallic centre tube for strength and to prevent
power. metal contamination.

Size of Contamination Measuring Contamination

A particle five microns across can damage fuel systems. A Contamination is measured by counting particles and
micron is one millionth of a metre. To give you an idea of how reported by comparing those results to an International
small that is, an average human hair is 80 microns in diameter. Standards Organisation (ISO) code. This ISO standard refers
Tolerances in Cat fuel injectors are 1/20th the diameter to the number of particles in three different size categories
of a human hair. It’s easy to understand how even small contained in a one-millilitre sample. The first number refers
contaminants can damage today’s fuel systems. to the number of particles that are greater than 4 microns,
the second number refers to particles that are greater than
Sources of Contamination 6 microns, and the third number refers to particles that are
greater than 14 microns.
• In the fuel: Contaminants can enter during storage
or transportation of fuel. A reliable supplier; filtered An ISO level of 18/15/13 would mean that a one-millilitre
dispensing; and periodic sampling and testing ensure sample of fuel contains ISO Code 18 or between 1300-2500
consistent quality. particles greater than 4 microns, ISO Code 15 or between
• During operation: Airborne particles can be drawn into 160-320 particles greater than 6 microns, and ISO Code 13
your fuel tank through the vent tube. A fuel tank vent can or between 40-80 particles greater than 14 microns. If the
ingest dust when it is not properly sealed. contamination level is allowed to rise one ISO Code, the
• External: Contamination can enter during maintenance amount of particles for that size will double.
and service, even when changing filters.
Cat filters Other brands of
filters

98% efficiency 50% efficiency

= 4 micron particle

Abrasive particles cause wear between

an injector’s plunger and barrel.
 69
Fuel Management
Bulk Fuel Filtration Strategies
Understanding the importance of coalescence

During laboratory analysis of a diesel engine injector valve seat, the results of poor fuel manage-
ment practices are clearly discernable under microscopic conditions. Here the evidence of inad-
equate contamination control procedures is exposed in the form of moderate to severe scouring
damage caused by water and debris ingress.
Left unchecked, this invisible threat will steadily erode
individual machine and overall fleet performance, increasing
downtime and pushing up owning and operating costs.

Some Cat fuel systems, for example, exceed pressures

of 30 000 psi in order to deliver more horsepower, better
fuel economy and fewer emissions, which necessitates
tolerances smaller than five microns between parts. Where
contamination is present, these tolerances and injection
pressures make fuel systems more vulnerable to wear and
abrasion.

However, this potentially underlying problem can be

countered efficiently by installing a bulk filtration system that
forms part of a strict contamination control programme, since
clean dry fuel is essential in order to achieve long injector life.

As part of its solutions offering, Caterpillar supplies bulk fuel

filtration plants in various litre flow rate configurations that
are designed to help maintain fuel to 18/16/13 per ISO 4406
(or below 4 micron). These bulk filtration units are positioned
along the supply pipeline between the fuel storage tank The Cat bulk fuel filtration system is intended for use in any
and fuelling station. They have the capacity to remove 3% application where users store fuel for machines or engines. Smaller
continuous free water-in-fuel by volume to less than .01% at Cat filtration units are intended for remote day tank or fuel truck
the rated flow of the unit. applications.

At the heart of the Cat bulk filtration process is the coalescer How is fuel cleanliness measured?
vessel, which contains multiple elements. Pre-filter elements (18/16/13 per ISO 4406)
remove dirt and particulate debris; the coalescer elements
then strip water from the fuel. ISO Code 18 16 13
Particles > 4 microns
Due to the high flow rate of fuel through the coalescer Particles > 6 microns
elements, flow forces will cause some small water droplets
to be washed off the coalescer’s hydrophilic filter fibres. Particles > 14 microns
The separator canisters fit over the coalescer elements Range Numb Micron Actual Particle Count
and prevent these droplets from escaping to the outlet Range (per ml)
of the coalescer vessel, so there is no chance of water 18 4+ 1,300 – 2,500
contamination.
16 6+ 320 – 640
Naturally, these filtration systems are not designed to clean 13 14+ 40 – 80
heavily contaminated fuel: a good portion of water and dirt
can routinely be removed from supply fuel by using proper
storage tank settling and draining practices. Bulk fuel filtration units
Flow rate capacities
Most of the remaining water and dirt can then be removed
by using Cat bulk filtration or adding filtration and water 50 GPM
separation capacity to each machine in the fleet. 100 GPM
200 GPM
Failure to maintain clean fuels that meet 300 GPM
or exceed 18/16/13 (per ISO 4406) will
lower fuel system reliability and engine
performance.
70 Preventative Maintenance and Fluids

Fuel Management
IS0 4406 Chart
Number of particles per ml Critical points when it comes to fuel
Range Number
More Than Up to and including
• U se fuels that satisfy all the performance
24 80,000 160,000 requirements of Cat Fuel Specification, ASTM
23 40,000 80,000 D975 or equivalent.
• Fill machine or engine fuel tanks with fuel that
22 20,000 40,000
meets or exceeds 18/16/13 cleanliness level per
21 10,000 20,000 ISO 4406.
20 5,000 10,000 • Change fuel filters per service requirements
(typically every 500 hours).
19 2,500 5,000
• Drain water separators daily in accordance with the
18 1,300 2,500 operating and maintenance manual (O & MM); and
17 640 1,300 • Drain fuel tanks of sediment every 500 hours or
three months per the O & MM.
16 320 640
15 160 320
14 80 160
13 40 80
12 20 40
11 10 20
10 5 10
9 2.5 5
8 1.3 2.5
7 .64 1.3
6 .32 .64

Genuine Cat ®

parts - Find
them on line!
Keep it Real. Keep it Cat® For more information
contact our call centre on 0800 21 22 48 or visit
www.barloworld-equipment.com
 71
Fuel Management
Cat Fuel Water Separators and
Primetime™ Priming Pumps
Advanced High Efficiency Fuel Water Separators

Diesel fuel acts as a lubricant in unit injectors. The film strength of diesel fuel prevents metal to
metal contact between the plunger and barrel. Water can compromise film strength, resulting in
scuffing and eventual seizure.

Cat fuel water separators have best in class water removal

capabilities essential for better protection of unit injectors. Cat
fuel water separators also deliver longer secondary fuel filter
life.

These Cat fuel water separators:

• Remove more than 98% of debris 10 microns and larger.
• Virtually eliminate free water in fuel.
• Remove 87% of dissolved water.

PrimeTime Priming Pump

Cat PrimeTime priming pumps are easily installed on the
frame or engine as retrofits. They prime the filter and fuel
system with a flip of the switch.

The benefits:
• No need to pre-fill the filter and risk debris reaching
injectors.
• Primes the fuel filter in two to six minutes.
• No time-consuming, difficult manual pumping.

While these two products are available separately, you will

get the best results when they are used together.

Retrofit Information
Axial seal filters are designed to retrofit engines in the field
while radial seal filters have an exclusive Cat design for
improved sealing performance on new engines. Both will
upgrade the durability and water removal performance over
previous Caterpillar offerings and other brands.
Check the collection bowl daily and drain as needed.

Easy to install pump

“Protect your
fuel system and
Electric priming pump works with the flip of a switch, extend the life of
priming in two to six minutes. unit fuel injectors:
Resilient mounting extends pump life and absorbs
un-dissolved water
some of the shock load. quantities greater
Primary fuel filter removes more than 98% of debris 10 than .1% can cause
microns and larger. major damage.”
Water separator removes virtually all free water and
87% of dissolved water from diesel fuel.

Reusable water collection bowl has capacity of 90ml, is

transparent for easy monitoring and drains in less than
one minute.
72 Preventative Maintenance and Fluids

Fuel Management
Cat Non-Pressurised Fast Fill Fuel Kits
Faster, safer, more accurate filling

Now there are non-pressurised fast fill fuel kits available for Cat and non Cat equipment. These
easy-to-install kits do not depend on a traditional pressure sensing nozzle to shut off fuel flow, but
instead rely on a valve to control fuel shut-off.

Cat Non-Pressurised Fast Fill Fuel Kits can be used to retrofit

existing pressurised fast fill systems or added to machines
without fast fill provisions.

Better technology for better results

Environmentally Friendly
• Prevents over/under-filling of tank (does not rely on the
automatic nozzle for shut-off).
• Provides tank fill with greater accuracy.
• Improves contamination control through a closed loop
system.
• Incoming air is now filtered through a separate breather,
allowing for cleaner fuel.
• Closed vent lowers the risk of fuel spilling during severe
operations, side slope and rollover conditions.

Reduced Costs and Maintenance Time

• E liminates pressure in the fuel tank.
• Fast refuelling rates up to 150 GPM. Fills in 1/10th of the
time over standard gravity fill rates.
• Minimises fuelling downtime.
• Eliminates need to drain fuel tank for receiver servicing.
• Improved vent performance, resulting in less risk of fuel
leaks.

Safer Work Environment

Models
• G round-level fuelling eliminates dangerous climbs to reach
the fuel cap on the top of the tank. • O ff-Highway Truck/Tractor 769D; 773E; 776D; 777D.
• Fuel tank is not pressurised during nozzle shut-off. • Articulated Truck 725; 730; 730 Ejector; 735; 740;
• Shut-off levels are consistent. 740 Ejector.
• Excavator 385B; 385C; 5090B; 5110B; 5130B.
Durable Components • Quarry Truck 771D; 775E.
• Wheel Dozer 844; 844H; 854G; 814F.
• V ent and inlet valve have a long life. • Wheel Loader 980H; 988G; 988H; 990 Series II;
• Receiver connects to industry-standard fuel nozzles. 990H; 992G; 994F; 994D.

KEEP IT REAL, KEEP IT CAT ®

For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

Pg 72 (50x210).indd 1 2013/05/31 3:31 PM

 73
Fuel Management
Fast Fuel Conversion Kits
Flange-mounted receivers reduce fuel leaks and contamination

It’s now faster and easier to change fast fuel receivers. That’s because Caterpillar offers kits to
convert Cat or Wiggins fast fuel threaded receivers to flange-mounted units. So now many old
or new Cat machines equipped with fast fuel systems can benefit from greatly simplified field
changes and a reduced risk of fuel leaks.

• L ess thread damage: because threaded receivers can be

installed and removed several times a year, the tank port
threads can become worn or damaged. This results in both
fuel leaks and fuel contamination. With flange-mounted
fast fuel receivers, worn receivers can be changed
without replacing the reusable steel adapter…and without
damaging the tank port threads.
• No special tools: a common Allen wrench easily removes
and installs four bolts to change flange-mounted fast fuel
receivers.
• Two conversion kits: one conversion kit is available for
threaded receivers on Cat fast fuel systems and another
kit is designed for threaded receivers on Wiggins fast fuel
systems.

Installation just got easier

 asy access. A 10 mm Allen wrench removes the four
• E
bolts holding the two split flanges, so removal and
installation can be performed with less clearance. There’s
no more need for large, cumbersome wrenches in tight
conditions, as is the case when changing threaded
receivers.

 ompatibility. Cat flange-mounted fast fuel receivers are

• C
compatible with existing Wiggins and other brands of fuel
system nozzles without degradation of fuel flow or fuel
nozzle shut-off valve performance. The fuel tank adapter
accepts Cat flange-mounted fast fuel receivers and
mounting flanges where space permits.

Convert Cat or Wiggins fast fuel

threaded receivers to flange-mounted
receivers.

KEEP IT REAL, KEEP IT CAT ®

For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

Pg 73 (50x210).indd 1 2013/06/04 7:48 PM

74 Preventative Maintenance and Fluids

Oils

Oil Safe Containers

Protect fluid quality, reduce contamination

Recognise this? Features and Benefits

Poorly stored fluids can become contaminated and will lead to •  vailable in 5 sizes: 1.5L, 2L, 3L, 5L, and 10L.
A
accelerated component wear, robbing equipment of efficiency. • Interchangeable lids and drums.
• Sold separately or in a kit.
Oil Safe Way • Vent control with button in handle.
• Quick twist spout is easy to open and close; it controls
•  rotects fluids from contamination.
P flow rate and keeps dirt out.
• Prevents spills from open containers. • Semi-transparent cylinder with graduated markings makes
• Reduces accidents. liquid levels easy to see.
• Allows easy access to hard to reach locations. • Durability tested:
• Durable.  Withstands extreme temperatures ranging from -40°(F)
• Manual flow rate control. to 176°(F).
 Flash Point at 340°C.
 Manufactured from High Density Polyethylene (HDPE)
Fluid Contamination incorporating anti-static agents and ultraviolet (UV)
stabilisers.
Oil exposed to air immediately becomes contaminated.

Poorly stored fluids will become contaminated and will lead to

accelerated component wear, like:
• Shortened component and fluid life.
• Catastrophic failures and costly downtimes and repairs;
and
• Reduced productivity.
It only takes a half teaspoon of dirt to
contaminate a 55 gallon drum of fluid.
System efficiency can drop 20% before the operator detects a
problem. That’s a loss of one day per week.
 75
Oils
Cat GO
Gear oil for Cat manual transmissions, differentials and final drives
(SAE 80W-90, SAE 85W-140)

Cat GO is a multi-grade API GL-5 classification gear oil intended for extreme-pressure applica-
tions, such as the following:

Differentials and final drives on Cat wheel tractor-scrapers,

specific articulated trucks, wheel excavators, and backhoe
loaders.

Cold Planer direct drive transmissions, differentials, and final

drives.

Drum bearings on vibratory soil compactors.

Discover the Difference

Cat GO is tested and approved by Caterpillar to meet the
same high standards as Genuine Cat Parts.

• L onger gear and bearing life: superior thermal stability

and oxidation resistance reduce deposits and wear.
• Extreme pressure performance: provides extra
protection for improved performance and life in extreme-
load conditions.
• Simplified maintenance: multi-purpose capability reduces
number of gear lubricants needed for maintenance.
• Wide temperature range: provides excellent stability
at high temperatures and superior performance at low
temperatures for easier start-ups.

TYPICAL CHARACTERISTICS*
SAE Viscosity Grade 80W-90 85W-140
Gravity, API (ASTM D287) 26.6 25.1
Flash Point, °C (°F) (ASTM D92) 210 (410) 230 (446)
Pour Point, °C (°F) (ASTM D97) -27 (-17) -18 (0)
Viscosity
  cP @ -26° C (ASTM D2983) 110,000 N/A
  cSt @ 40° C (ASTM D445) 139 333
  cSt @ 100° C (ASTM D445) 14.5 25.4
Viscosity Index (ASTM D2270) 104 99
Phosphorus, % wt. (ASTM D1091) 0.087 0.087
* The values shown are typical values and should not be used as quality control parameters to either accept or reject product. Specifications
are subject to change without notice.

KEEP IT REAL, KEEP IT CAT ®

For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

Pg 75 (50x210).indd 1 2013/05/31 3:33 PM

76 Preventative Maintenance and Fluids

Oils
Cat DEOTM
Diesel engine oil for world wide application (except North America)

SAE 15W-40, SAE 10W-30 performance when used in conjunction with the S•O•S
Services oil analysis programme.
• Proven Performance: Tested thoroughly in Cat diesel
Recommended Use engines including Cat engines with ACERT Technology to
ensure excellent engine life and performance.
• C at earthmoving, commercial, marine* and on-highway
• Long-Lasting Protection: Improved soot control and
truck diesel engines.
enhanced shear stability enable oil to maintain proper
• Low-emission diesel engines including Cat engines with
viscosity for longer operating periods in Cat engines with
ACERT® technology.
ACERT technology, especially those equipped with HEUI
• Heavy-duty diesel engines made by other manufacturers
systems.
that recommend API CI-4, CH-4 or CG-4 classification
oil. (Please refer to the “Typical Characteristics” table for
more information.)
• Automotive gasoline engines that require API SL
classification oils.

* Excluding 3126 and 3116 MUI Marine and MaK diesel

engines. The 3116 and 3126 MUI Marine diesel engines with
closed crankcase ventilation systems should use Cat SAEO™.

Discover the Difference

Cat DEO is developed, tested and approved by Caterpillar to
meet the same high standards as all Genuine Cat Parts.

• U sed as standard factory-fill for Cat machines.

• Increased Engine Life: Resists oxidation and prevents
build-up of deposits on pistons and rings.
• Extended Drain Intervals: Extends oil drain intervals
while providing excellent engine protection and

Cat DEO Performance

This table indicates the differences between ECF-2 standards and the proprietary standards
of Caterpillar.
Tested
Performance Requirements Test Commercial
ECF-2
Cat DEO
Beyond
Cat 3406E Endurance Test
Cat C13 ACERT Endurance Test
Cat Proprietary
Cat Proprietary
Industry
Cat 3500 Series Test
Cat C13 ACERT Series Wheel Loader Test
Cat Proprietary
Cat Proprietary
Standards
C13 500 Hour Engine Test
In addition to the
Improved Soot-Viscosity and Shear Control tests required for the
ECF-2 classification,
High Temperature Shear
Cat DEO undergoes
Elastomer Compatibility
four proprietary multi-
Piston ring and Cylinder liner wear
cylinder endurance
Valve train wear, sludge, oil filter plugging
tests, a variety of
Aeration Control quality assurance
Bearing Corrosion tests and thousands of
Cam roller follower pin wear hours of field service.
Copper, lead and tin erosion Only when it has
Foaming Control passed all these tests
Viscosity Shear loss can it be approved by
Viscosity Increase from soot Caterpillar.
Oxidation
Piston deposits and oil control
 77
Oils
Cat DEOTM
Continued
Typical Characteristics*
SAE Viscosity Grade 15W-40 10W-30**
API Service Classification: Diesel CI-4, CH-4 CI-4, CH-4
Gasoline SL SL
ACEA Classifications E5/B3/A2
OEM Performance Level: Caterpillar ECF-2 ECF-2
MB 228.3
MAN 3275
Volvo VDS-3 VDS-3
RVI RLD
Cummins CES 20071/72/76/77 CES 20071/76/78
Mack EO-M PLUS EO-M PLUS
Flash Point, °C (ASTM D92) 230 222
Pour Point, °C (ASTM D97) - 30 - 36
Viscosity: cSt @ 40° C (ASTM D445) 103 76
cSt @ 100° C (ASTM D445) 14.2 11.5
Viscosity Index (ASTM D2270) 135 144
Sulfated Ash, % wt. (ASTM D874) 1.3 1.3
TBN (ASTM D2896) 11.3 11.3
Zinc, % wt. (ASTM D4951) 0.146 0.146
Gravity @ 16° C: API (ASTM D287) 29.3 31.3
Specific 0.880 0.869
* The values shown are typical values and should not be used as quality control parameters to either accept or reject product.
Specifications are subject to change without notice.
**Not available in all regions.

PRODUCTIVITY THAT GIVES

YOU THE CUTTING EDGE ®

Caterpillar has a seamless range of continuous miners covering both soft-

and hard-cutting applications in any seam thickness. The range includes
machines capable of operating in seams from 0.76 m to 4.70m
• Less downtime through Longer Overhaul Intervals
• Superior performance via higher output engine
• High maneuverability allows faster positioning and optimum cutting

For more information contact our call centre on 0800 21 22 48 or visit

www.barloworld-equipment.com

Pg 77 (100x210).indd 1 2013/05/31 4:33 PM

78 Preventative Maintenance and Fluids

Oils
Cat DEOTM Monograde
Monograde Diesel Engine Oil for Cat 3600 Series
Diesel Engines
SAE 30, SAE 40
Recommended Use when used in conjunction with the S•O•S Services oil
analysis programme.
• C at DEO Monograde is the only oil approved by Caterpillar • Proven performance: Tested in Cat 3600 series diesel
for use in 3600 series diesel engines operating on distillate engines worldwide.
diesel fuels.
• Cat DEO Monograde is recommended for older Cat Sulphur-level compatibility
engines equipped with pre-combustion fuel injection
systems that permit the use of American Petroleum Cat DEO Monograde provides excellent performance and
Institute CD or CF oil. protection for the following Cat engines operating at or below
• Cat DEO Monograde can be used with low-sulphur these fuel sulphur levels:
diesel fuel and protects Cat engines operating on higher • 3600 Series Direct Injection 1.30%.
sulphur diesel fuels (3600 series engines operating on • Pre-combustion 0.65%.
fuel containing up to 1.30% sulphur, and pre-combustion
engines operating on fuel containing up to 0.065% sulphur For higher fuel sulphur content, an S•O•S Services oil analysis
fuel). programme is recommended to optimise oil drain intervals.

Discover the Difference

Cat DEO Monograde is developed, tested and approved by Tested Beyond Industry Standards
Caterpillar to meet the same high standards as Genuine Cat
Parts. The large-bore, medium-speed Cat 3600 engines
• Used as standard factory-fill for Cat 3600 series diesel require oils that meet a unique standard not defined
engines. by any industry classification. Cat DEO Monograde
• Increased engine life: Resists oxidation and prevents meets that proprietary Caterpillar standard. If other
build-up of deposits on pistons and rings. brands of lubricant are used instead of Cat DEO, the
• Longer intervals: Extends oil drain intervals while manufacturer must demonstrate that the oil meets the
providing excellent engine protection and performance same standard.

S•O•S Services for early problem detection

Typical Characteristics* Protect your investment with Cat S•O•S Service,
SAE Viscosity Grade 30 40** the ultimate detection and diagnostic tool for your
API Classification CF*** CF*** equipment. S•O•S helps you detect potential
problems before they can lead to major failures and
CCMC D3 D3 costly, unscheduled downtime.
Manufacturer Tests
  Caterpillar (engine) 1M-PC 1M-PC Cat Filters: Complete protection for your
equipment
  Allison (transmission) C-3 C-3 Combine Cat Fluids with Cat Filters for the highest
Gravity, API (ASTM D287) 26.8 26.2 level of contamination control and protection for your
Flash Point, °C (ASTM D92) 234 234 equipment. We recommend Cat Filters for all Cat
equipment applications.
Pour Point, °C (ASTM D97) -33 -33
Viscosity:
  cSt @ 40°C (ASTM D445) 103 133
  cSt @ 100°C (ASTM D445) 11.6 13.8
Viscosity Index (ASTM D2270) 100 100
Sulfated Ash, % wt. (ASTM D874) 1.9 1.9
TBN (ASTM D2896) 13.0 13.0
Zinc, % wt. (ASTM D4951) 0.119 0.119
Phosphorus, % wt. (ASTM D1091) 0.106 0.106
* The values shown are typical values and should not be used
as quality control parameters to either accept or reject product.
Specifications are subject to change without notice.
** Passes FZG DIN 51354-2 A/8, 3/90 FLS 12
*** Can be used in applications where the obsolete API CD
classification oil is recommended
 79
Oils
Cat MTO
Tractor oil for multi-application use in older Cat backhoe loader rear axles and Cat
Challenger™ tractors

Recommended Use
Recommended for older Cat backhoe loader rear axles and
Typical Characteristics*
Cat Challenger tractors, Cat MTO can also be used in the
following applications: Gravity, API 28.6
Flash Point, °C (°F) (ASTM D92) 214 (417)
• C at components and systems recommending
multipurpose tractor fluid that meet Ford/New Holland Pour Point, °C (°F) (ASTM D97) -42 (-44)
M2C134D specification. Viscosity
• Most Cat hydraulic systems.   Brookfield, cP at –20°C 4300
• Other manufacturers’ machines and components. (Please
refer to the “OEM Compatibility” table.)   cSt @ 40°C (ASTM D445) 58
  cSt @ 100°C (ASTM D445) 9.3
Discover the Difference Viscosity Index (ASTM D2270) 140
Zinc, % wt. 0.15 min.
Cat MTO is developed, tested and approved by Caterpillar to
* The values shown are typical values and should not be used
meet the same high standards as Genuine Cat Parts.
as quality control parameters to either accept or reject product.
Specifications are subject to change without notice
• Improved braking and clutching: Where approved for
use, MTO enhances control and extends life in clutches
and wet brakes.
• Lower maintenance costs: Exceptional anti-wear
properties extend equipment and component lives.
• Cold-weather operation: Can be used in temperatures as
low as -25°C.
• Simplified maintenance: Can be used in multiple
compartments, reducing inventory and the chance of using
the wrong oil.
• Long-lasting performance: Offers high thermal stability
and oxidation resistance for long service life in severe
applications.

OEM Compatibility

Cat MTO meets the following OEM specifications:

API GL-4
CNH MAT3525
Ford New Holland FNHA-2-C-201.00
Kubota UDT
Volvo WB 101/BM

Cat MTO can be substituted in applications that require

the following:
Agco Powerfluid 821 XL
Allison C4 (Agriculture Applications Only)
Denison HF-0/HF-1/HF-2 (T5D and P46) “Combine Cat fluids and
Ford ESN-M2C 134 D Cat filters for the highest
JI Case MS 1204-07/09 level of contamination
John Deere JMD J20C control and protection for
Massey Ferguson MF 1135/1141 your machine.”
Vickers 35VQ25
80 Preventative Maintenance and Fluids

Oils
NGEO™ Advanced 40
For natural gas engines requiring low-ash oil (SAE 40)

Cat NGEO Advanced 40 oil is designed for specifications that provide superior lubrication per-
formance in low-emission, high-output, four-cycle engines using natural gas fuel. Cat NGEO Ad-
vanced 40 has been tested and approved by Caterpillar to meet the same high standards as
Genuine Cat Parts.

Customer Benefits Typical Characteristics*

SAE Viscosity Grade 40
• R educed Piston and Cylinder Wear: Anti-oxidant and anti-
nitration properties prevent deposit buildup to minimise Gravity @ 16°C
scuffing, scoring, and wear.   API (ASTM D287) 28.4
• Increased Spark Plug and Valve Life: Excellent detergent
  Specific 0.885
and dispersant additives protect against deposits and
damage. Flash Point, ºC (ASTM D92) 252
• Corrosion Protection: Acid neutralisers protect parts from Pour Point, ºC (ASTM D97) -12
rust and copper corrosion.
• Extended Drain Intervals: Provides extended oil drain Viscosity
capabilities when using the Cat S·O·S Services oil analysis   cST @ 40ºC (ASTM D445) 115
programme.   cST @ 100ºC (ASTM D445) 13
• Comparable viscometric properties as Cat NGEO EL 250
and EL 350. All are SAE 40 grade oils. Viscosity Index (ASTM D2270) 95
TBN, mg KOH/g (ASTM D2896) 6
Recommended Uses Sulfated Ash, % wt (ASTM D874) 0.50
Phosphorous, % wt (Spectro or AA) 0.030
The oil may be used in engines that use high-sulphur gas,
provided that shorter drain intervals are employed. NGEO Calcium, %wt (Spectro or AA) 0.130
Advanced 40 is formulated from select base stocks blended * Values shown are typical values and should not be used as quality
with special additives to provide: control parameters to either accept or reject product. Specifications
• Excellent anti-oxidation/nitration properties. are subject to change without notice.
• Thermal stability.
• Reduced carbon and sludge formation.
 81
Oils
Cat FDAOTM
Final drive axle oil for off-highway trucks, large track-type tractors, pipe layers and track
skidders (SAE 60)

TYPICAL CHARACTERISTICS
Viscosity Grade
  SAE 60
  ISO 320
Caterpillar Test FD-1
Gravity, 16° C Recommended Use
  API (ASTM D287) 25.9
• T he preferred lubricant for Cat off-highway truck front
  Specific 0.899 wheels, differentials and final drives. Recommended drain
Flash Point, °C (°F) (ASTM D92) 255 (491) intervals are at around 4 000 hours for off-highway trucks
as determined by S•O•S Services.
Pour Point, °C (°F) (ASTM D97) -15 (5) • Preferred lubricant for Cat large track-type tractor, pipe
Viscosity layer, and track skidder final drives (steel-tracked machines
  cSt @ 40° C (ASTM D445) 334 with elevated final drives except the D5M, D6M and
561M).
  cSt @ 100° C (ASTM D445) 25.2
Viscosity Index (ASTM D2270) 97 Compatible with Cat final drives and axles that previously
Brookfield Viscosity specified TO-4 lubricants and do not contain friction material.

  cP @ -10° C (ASTM D2983) 75 000

Discover the Difference
Copper Strip (ASTM D130, 2 hrs @ 100° C) 1A
* The values shown are typical values and should not be used Cat FDAO is developed, tested and approved by Caterpillar to
as quality control parameters to either accept or reject product. meet the same high standards as Genuine Cat Parts.
Specifications are subject to change without notice.
• U sed as standard factory-fill for Cat off-
Recommended Drain 6000 highway trucks and large track-type
Intervals* tractors.
(Cat Final Drives for Off- 5000 • Extended drain intervals: Allows
Highway Trucks) for double-length drain intervals
4000 in off-highway truck final drives, as
4000 compared to TO-4 commercial oils.
Hours

3000 • Minimal foaming: formulated to protect

against the damaging effects of air.
2000
2000
1000
* Possible with
S•O•S Services 0
TDTO FDAO
82 Preventative Maintenance and Fluids

Oils
Cat TDTO™
Transmission and drive train oil for Cat transmissions, final drives and wet brake
compartments (SAE 10W, SAE 30, SAE 50)

Recommended Use
Tested Beyond Industry Standards
• T he preferred lubricant for Cat power shift transmissions,
and most final drives and wet brake compartments. The TO-4 specification defines a minimum standard of
• Cat machine compartments where TO-4 and TO-4M performance for transmissions and drive train oils, but Cat
specification oils are recommended. TDTO is required to pass five additional Caterpillar tests.
• Other manufacturers’ machines that recommend TO-4 or
TO-4M or specification oils for their transmissions, final It is only through these tests and thousands of hours of field
drives and wet brake compartments. (Please refer to the experience that Caterpillar is confident in saying Cat TDTO will
“Typical Characteristics” table.) deliver long life and excellent performance when used in Cat
transmissions and final drives.
Discover the Difference
Cat TDTO is developed, tested and approved by Caterpillar
to meet the same high standards as Genuine Cat Parts.

• U sed as standard factory-fill for Cat machine

compartments where TO-4 oils are
specified.
• Longer Clutch Life: Prolongs clutch
disc life up to 45%.
• Optimum Wear Life: Ensures long life
and excellent performance for gears,
bearings and friction disc material.
• System-Matched Formula:
Engineered as an integral
part of Cat power shift
transmissions, most wet
brake compartments, and
hydrostatic systems.

TYPICAL CHARACTERISTICS
SAE Viscosity Grade 10W 30 50
Caterpillar Test TO-4 TO-4 TO-4
Allison Test C-4 C-4 C-4
ISO Viscosity Grade 46 100 –
Gravity, API (ASTM D287) 29.7 27.0 24.7
Flash Point, °C (°F) (ASTM D92) 202 (395) 224 (435) 240 (464)
Pour Point, °C (°F) (ASTM D97) -33 (-27) min -18 (0) min -15 (5) min.
Viscosity
  cP @ –25° C (ASTM D5293) 6840 – –
  cSt @ 40° C (ASTM D445) 42.0 100 195
  cSt @ 100° C (ASTM D445) 6.3 11.2 18.0
Viscosity Index (ASTM D2270) 97 97 96
Calcium, % wt. .298 .298 .298
Zinc, % wt. (ASTM D4951) .127 .127 .127
Phosphorus, % wt. (ASTM D4951) .110 .110 .110
Sulfated Ash, % wt. (ASTM D4951) 1.2 1.2 1.2
TBN (ASTM D2896) 7.9 7.9 7.9
* The values shown are typical values and should not be used as quality control parameters to either accept or reject product. Specifications
are subject to change without notice.
 83

I keep
my fleet
real. I keep
it Cat
®

You have to push every day. To meet tomorrow’s

deadline. To secure the next contract. To stay ahead of
the competition. No matter what challenges lie ahead,
Caterpillar and Barloworld Equipment are committed to
bringing you machines, solutions and support to help your
business keep pushing forward. SAFETY BUILT IN.

For more information contact our call centre on

0800 21 22 48 or visit www.barloworld-equipment.com

Follow us on Facebook
Barloworld Equipment
Southern Africa

Follow us on Twitter
@Barloworldequip
84 Preventative Maintenance and Fluids

Coolants and Antifreeze

Cat NGECTM
Natural Gas Engine Coolant
(Premix 50/50)

Prevents Freezing While Providing Superior S•O•S Fluid Analysis Services for Early
Component Protection Problem Detection
Cat NGEC (Natural Gas Engine Coolant) is a heavy-duty Protect your investment with Cat S•O•S Coolant Analysis,
cooling system fluid designed to prevent freezing and boiling the ultimate detection and diagnostic tool for your engines.
while providing superior component protection. Refer to the Caterpillar Operation and Maintenance Manual
for the recommended intervals of S•O•S Level 1 Coolant
NGEC is approved for use in all Cat natural gas and diesel Analysis (e.g. every 250 hours). Level 2 Coolant Analysis
engines, as well as in most diesel, gas or natural gas is recommended at least annually for all Cat engines and
engines made by other manufacturers (when following OEM machines.
recommendations).
Testing Nitrite Levels
Benefits
Field testing of coolant nitrite levels can be performed using
Performance the 4C-9301 test kit. Results are immediate and SCA additions
Cat NGEC protects the cooling system of your natural can be made as needed.
gas engine over a temperature range of -37°C to 129°C.
Additional freeze protection can be gained when the coolant Coolant Maintenance Resources
concentration is raised to 60%.
For in-depth information on coolant maintenance, refer to your
Cat NGEC contains inhibitors that provide superior protection Barloworld Equipment customer service representative.
for metal components, especially aluminium, against pitting
and corrosion. The formulation of Cat NGEC minimises the
formation of foam.
Typical Characteristics1
Ready-To-Use ASTM Specification ASTM D6210
Cat NGEC is premixed with de-ionised water and
embitterment. No supplemental coolant additive is needed. Colour Magenta

Cat NGEC Provides Top Component Boiling Protection – 15 psi (1 bar) radiator cap
Protection 50% Cat NGEC/50% water 129°C
60% Cat NGEC/40% water 2
132°C
Aluminium can be a very difficult metal to protect from
corrosion and cavitation (boiling) damage. Cat NGEC is
formulated to provide excellent protection for all metals used Freeze Protection
in cooling systems. In testing (ASTM D2809) with aluminium
50% Cat NGEC/50% water -37°C
water pumps, Cat NGEC demonstrated
its superior ability to protect 60% Cat NGEC/40% water 2
-52°C
compared to competitive
heavy duty coolants.
pH (50% solution) 10.5
Nitrite (50% solution) 1,200 ppm
Drain Interval
Molybdate (50% solution) 310 ppm
When used in Cat Silicon (in the form of silicates) (50%
natural gas engines 120 ppm
solution)
and properly
Phosphate 0 ppm
maintained with Cat
SCA, Cat NGEC has
1
The values shown are typical values and should not be used
a drain interval of as quality control parameters to either accept or reject product.
Specifications are subject to change without notice.
three years. Refer
to the Operation and
2
Higher levels of glycol reduce the heat transfer performance of
Maintenance Manual the coolant. For optimum performance, Caterpillar recommends a
50/50 percent mix of Cat NGEC and water, unless additional freeze
of your specific
protection is required.
machine/engine for
drain intervals based Formulated to meet or exceed the following ASTM standards:
on service hours. D3306, D4985, D6210, TMC RP302, and TMC RP329.
 85
Coolants and Antifreeze
Cat ELC
Extended Life Coolant for Cat and original equipment manufacturer (OEM) diesel and
gasoline engines (50/50 Premix)

Recommended Use
Cat DEACTM
Cat ELC meets or exceeds the requirements of the following 3 000 Hour Life or
specifications and guidelines: 333 000 km
• Cat EC-1 • TMC RP-329 • TMC RP-338.
• ASTM D-3306 • ASTM D-6210 • SAE J1034. Cat Supplemental Coolant Additives Every 250 Hours or 25 000 km

Cat ELC (Machines and Commercial Engines)

Cat ELC also meets the performance requirements of
Cummins, Detroit Diesel, International, Mack and Volvo.

Discover the Difference Cat Extender Every 6000 Hours* 12,000 Hour Life or 6 Years**
(whichever comes first)
Cat ELC is developed, tested and approved by Caterpillar to
Cat ELC (Truck Engines)
meet the same high standards as all Genuine Cat Parts.
• Used as standard factory-fill for all Cat machine cooling
systems.
• Lower Maintenance Costs: Reduces engine coolant
Cat Extender Every 500 000 km* 1 000 000 km or 6 Years**
and additive costs by as much as 500% compared
(whichever comes first)
to conventional coolants. It eliminates the need for
supplemental coolant additives, extends coolant change- * Or one-half of the coolant service life.
out intervals and reduces disposal requirements. ** These coolant change intervals are only possible with annual
S•O•S Level 2 coolant sampling and analysis.
• Advanced Metal Protection: Incorporates an advanced
formula technology with organic acid additive corrosion
inhibitors, such as a combination of mono and
dicarboxylates for maximum protection of copper, solder,
brass, steel, cast iron and aluminium. S•O•S Services for early problem
detection
Typical Characteristics* Protect your investment with Cat S•O•S Coolant
Analysis, the ultimate detection and diagnostic tool
Colour Strawberry Red
for your equipment. We recommend S•O•S Level 1
Boiling protection with 15 psi (1 bar) Coolant Analysis according to the engine’s Operation
radiator cap and Maintenance Manual, and Level 2 Coolant
  50% Cat ELC/50% water 129°C Analysis annually for all your Cat equipment.
  60% Cat ELC/40% water (ELC
concentrate added)
132°C Cat ELC Extender for Longer Life
Freezing protection • E xceeds Cat EC-1 performance requirements.
  50% Cat ELC/50% water -37°C • Protects against cylinder liner/block pitting and
  60% Cat ELC/40% water (ELC cavitation erosion.
-52°C • Should be added at 500 000 km for Cat powered
concentrate added)
on-highway trucks and 6 000 hours for commercial
Nitrite (50% solution) 500 ppm engines.
Molybdate (50% solution) 530 ppm • Extender is only necessary once during the life of
*The values shown are typical values and should not be used the coolant.
as quality control parameters to either accept or reject product. • Ensures Cat ELC performance to 1 000 000 km or
Specifications are subject to change without notice. 12 000 hours.

Cat ELC Extender and Flush Intervals

Cat ELC Extender should be added after 6 000 hours
or 500 000 km of operation, and the system should
be drained and flushed with clean
water after 12 000 hours or
1 000 000 km. No cleaning
agents are needed. If
S•O•S Services are
used regularly, safe
operation with Cat ELC
may extend beyond 12 000
hours.
86 FILTERS

FILTERS
 87

Contents
88 Air Filters
Cat UHE Air Filters
Cat Air Filter Service Indicator
88
89

90 Engine Oil Filters

92 Fuel Filters

95 Radial Seal Air Filters

96 Transmission Filters

97 Turbine Precleaners
88 FILTERS

Cat UHE Air Filters

Early filtration efficiency provides longer engine life

Cat UHE (Ultra High Efficiency) air filters feature a unique surface that extends filter life up to six
times that of standard filters and benefits engine life. Caterpillar engineers its UHE air filters to
provide best protection for your engine components.

So-called “dirty” filters can be more efficient than new ones

because dust cake build-up on the surface actually increases
filtration. Designed with this concept in mind, UHE air filters
feature a unique media. This media has a very fine synthetic
surface layer that covers the entire outside diameter of the
filter. Here’s how it works:

• F ine particles (dust, heavy carbon/coal dust, soot, talc,

etc.) immediately cake on the surface, quickly making
the filter very efficient. Less dust gets to the engine,
improving fuel economy while reducing wear and
maintenance costs.
• Surface particle cake is more porous than dust-coated
media, causing less restriction during filter life to improve
capacity, engine performance, and fuel economy. In tests,
air flow restriction through UHE air filter media increased
at a lower rate than five other major brands.
• Because particles get trapped in the build-up on the
surface of UHE air filters, the media stays permeable
longer– unlike filters with standard media, which become
dust-filled deep inside. This extends filter life and filtration
efficiency up to six
times that of
standard media.
Extending filter
change intervals
also means the
engine will be Avoiding excessive dust on the job site
exposed to less
may not be possible. Avoiding damage
dust over its life.
the dust can cause is possible with Cat
UHE air filters.

If only I had used Genuine Cat parts!

®

KEEP IT REAL. KEEP IT CAT®

You have to push every day. To meet tomorrow’s deadline. To secure the next contract. To stay ahead
of the competition. No matter what challenges lie ahead, Caterpillar and Barloworld Equipment are
committed to bringing you machines, solutions and support to help your business keep pushing forward.
SAFETY BUILT IN. For more information contact our call centre on 0800 21 22 48 or visit
www.barloworld-equipment.com

Pg 88 (80x210).indd 1 2013/05/31 3:53 PM

 89

Cat Air Filter Service Indicator

Getting the longest life from your air filters

Equipment filters working in low dust conditions last longer. Since it is not possible to visually
determine when a filter reaches capacity, changing air filters too soon can result in unnecessary
labour and filter costs. Conversely, in highly contaminated air, you may need to change filters ear-
lier than scheduled to ensure full airflow and engine power. You’ll know exactly when to change
your air filters when you use the Cat Air Filter Service Indicator.

In applications where there is a high percentage of fine dust

particles or high amounts of exhaust soot, Cat UHE Air Filters
will improve early filtration and provide longer engine life. Accurate and easy
to read
• R educed engine wear: Particles collect on the filter’s
surface layer of very fine fibres, quickly building a cake that It is impossible to visually
allows less dust to reach the engine. determine when a filter has
• Higher efficiency: UHE filters are at peak efficiency when reached capacity. Instead,
brand new. This surface particle cake is more porous the Cat Air Filter Service
than dust-coated media fibres, causing less restriction Indicator accurately reads a
throughout the filter life. filter’s condition.
• Better engine performance and fuel economy: The
lower restriction allows the engine to “breathe” more
easily, and fuel economy improves because it takes less Checking for This reading indicates a clean
filter element. Readings may
power to pull in air. Accuracy vary with system design.
• Longer filter life: The unique surface helps extend air filter
life up to six times as long as standard filters, limiting filter The air filter service
changes and the chance of contamination during service. indicator will help you
avoid changing filters too
frequently which wastes
filter life, costs money and
Limits Filter Changes and Saves Money unnecessarily introduces
contaminants. To make
sure the service indicator
A Cat Air Filter Service Indicator can often save eight filter
is operating properly,
changes when in a cleaner environment for 6 000 operating
Caterpillar recommends
hours.
changing it once a year.
It should be checked
Number of Changes every 250 hours in normal As the filter element fills
Without With conditions or daily if dust is with dust and soot, the
indicator* indicator severe. indicator moves up the
calibrated gauge to show
Primary Filter 24 18 the exact percentage of
There are two steps to
Secondary Filter 8 6 check the operation: filter life remaining.

Total 32 24 • Reset: The indicator

should reset within
* When changing the primary element at 250 operating hours and
the secondary element at 750 operating hours. three pushes.
• Yellow Core
Movement: After the
engine accelerates to
high idle, the yellow
core should latch at
The Benefits or near the highest
vacuum attained during
• S hows you how much filter life remains and
the acceleration test.
ensures optimum engine performance.
• Minimises filter changes and reduces filter costs.
If the indicator will not
• Indicates airflow resistance even when the
easily reset or not latch at
machine is not running. This reading shows the
the highest vacuum level
• Can be reset with the spring-release button. filter is no longer allowing
attained, the indicator sufficient air into the
should be replaced. engine and must be
changed.
90 FILTERS

Cat Advanced High Efficiency Engine

Oil Filters
Improved filtration for a cleaner engine

Cat Advanced High Efficiency engine oil filters increase contamination control performance pro-
viding for a much cleaner running engine lubrication system. Cat Advanced oil filters provide
enhanced filtration without the shorter change intervals often required by other brands’ higher
efficiency filters.

The Cat 1R-1807 and 1R-1808 filters contain an improved, 1R-1807 Efficiency Performance
higher efficiency filter media. This media is designed to 120
increase contaminant capturing efficiency while maintaining
100
excellent dirt holding capacity characteristics.
80
The Cat 1R-1807 and 1R-1808 filters offer better filtration
efficiency than standard oil filters, improved engine 60 1R-1807
cleanliness and a longer component life. 1R-0739
40
An option for improved engine oil filtration
20
Cat Advanced oil filters are now installed on new engines in
0
production. They are also the approved upgrade option for Cat 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
engine models that use the 1R-0739 and 1R-0716 Standard Particle Size (Microns)
Efficiency Engine Oil Filters.
1R-1808 Efficiency Performance
120
Improved filtration for less wear
100
To increase contamination control capability, the Cat
Advanced Oil Filter combines improved filtration efficiency, 80
excellent contaminant holding capacity and low pressure drop
characteristics. 60 1R-1808
1R-0716
The graphs to the right demonstrate in blue the improved 40
filtration efficiency the 1R-1807 and 1R-1808 filters offer over
20
the corresponding standard efficiency filters. The result is less
wear on oil lubricated engine parts. 0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Particle Size (Microns)
 91

Negligible impact on contaminant holding

capacity
The Cat Advanced Oil Filter provides improved filtration
efficiency with little effect on dirt holding capacity. Therefore,
the condition of the oil as determined by S•O•S
Services analysis, and not filter capacity, is the major factor in
determining the recommended oil change interval.

The bar graph below illustrates the relative dirt holding

capacity of the Advanced Filters and corresponding Standard
Efficiency Filters.

Caterpillar advanced high efficiency oil filter

dirt holding capacity performance

200
180
160
Retained Capacity (grams)

140
120
100
80
60
40
20
0
Consistent quality from filter to filter: Caterpillar engineers its 1R-1807 1R-0739 1R-1808 1R-0716
liquid filters to avoid metal contaminants, leaks, pleat bunching and Improved efficiency with minimal loss in reserve capacity and
movement.
no impact on recommended change interval.
92 FILTERS

Cat Ultra High Efficiency Fuel Filters

Maximum engine performance, maximum engine life

Cat Ultra High Efficiency (UHE) fuel filters provide unsurpassed contamination control to ensure
that only clean fuel reaches your engine. Clean fuel is important because diesel engines now
have advanced designs and emissions reduction technologies that use fine tolerances between
parts, and pressures up to 30 000 psi. Under these conditions, even smaller, micron-sized con-
taminates can cause premature component wear, reduced performance, and/or emissions com-
pliance issues.

Unsurpassed component protection: With the ability Reliable emissions reduction performance
to capture particles four microns in size and smaller, Cat
UHE fuel filters trap and hold contaminates to provide Cat engines are equipped with after-treatment devices that
the protection necessary to achieve the designed life of lower emissions levels. Filters are an important part of this
components. emissions treatment process. The primary and secondary fuel
filters work together to remove nearly all contaminates and
Maximise engine performance: High filtration efficiency is water before combustion.
important because contaminated fuel can rob your engine of
its rated power and cause hard starts. It is important to use the correct filter for each and every
change because using the wrong filter can jeopardise the
Easier serviceability: Cat UHE fuel filters have a positive performance of the emissions reduction system, taking your
stop, so they can’t be over-tightened, and, in most cases, can engine out of emissions compliance as a result.
be changed without the need for tools. Less maintenance
time means more uptime. Fuel systems are sensitive to damage by contaminates carried
in diesel fuel. To minimise this type of damage, Cat UHE fuel
Lower cost: The filter housing is reusable so only the filters are designed to maintain a tight separation between
cartridge needs to be changed. Less waste is created which the “dirty” and “clean” sides of the filter. All the fuel is forced
reduces disposal costs. through the media, where more than 98% of the particulates
four microns in size and larger are captured, before entering
the clean side.

Cat Fuel Water Separator Cat Secondary Fuel Filter

The Cat Fuel Water Separator removes more than 98% of the
particles 10 microns in size and larger, while removing virtually
all the free water and 87% of the dispersed water. This is
important because with the fine tolerances between parts in
today’s engines, diesel fuel acts as a lubricant. Removing the
water also eliminates the biggest source of pitting damage to
fuel injectors.

• Sub-ten micron efficiency Next, the Secondary Fuel Filter removes more than 98% of
• Reusable housing the remaining particles down to four microns in size. Testing
• Integrated seals has shown that the filter remains highly efficient with particles
• Easy-disposal element below four microns in size as well.

Reusable Housing: A reusable housing reduces waste and • Sub-ten micron efficiency
disposal costs. • Reusable housing
• Integrated seals
Clean Drain Valve: The patented Clean Drain Valve lets you • Easy-disposal element
drain the fuel before removing the filter. The valve also locks
the filter in place and makes it possible to change the filter
without using tools.
 93

Supporting Sustainable Progress

Cat Filters help support your sustainability efforts. The
filter housing was designed for the life of the machine,
reducing waste. The element can be incinerated after
use. And because the correct filter is used change
after change, your machine continues to operate at its
designed levels of performance.

Filter structure: the essential ingredients

Prefill deterrent: The top end cap prevents dirty

fuel from entering the clean side of the fuel
system, even during prefill.

Integrated seals: A number of

integrated filter seals maintain a tight
separation between the “clean” and
“dirty” sides of the fuel system.

Non-metallic centre tube:

Centre tubes are made out of
fibreglass-reinforced nylon that is
30% stronger than typical metal
tubes to help prevent collapse
during pressure spikes and cold
starts. Non-metallic centre tubes
also eliminate a common source
of metal contamination.

Advanced filter media: A layer of

cellulose/synthetic media is combined
with a second layer of melt-blown
polypropylene media to increase
dirt-holding capacity and take filtration
efficiency of the secondary filter to the
sub-four micron level.

Spiral roving: A fibreglass spiral roving is used

to prevent the pleats from flexing. This keeps
contaminants locked in the filter.

Acrylic beads: Pleat spacing

is rigidly maintained by
acrylic beads that prevent
bunching and provide
maximum filtration surface
area throughout the life of
the filter.
94 FILTERS
 95

Cat Radial Seal Air Filters

Larger capacity, longer service life and lower costs.

This rugged filter has all of the outstanding fea-

tures of other Cat air filters and more.
Get 100% of filter life

It provides up to 50% more capacity for longer service life, Use the Cat Air Filter Service Indicator to get an
and one-piece urethane end caps for a more consistent bond accurate, continuous reading of how much life remains
to the filter media. A more reliable seal permits quick servicing in your filter. The easy-to-understand graduated
with no tools required. readings let you change the filter only when needed.
Over-servicing and under-servicing are eliminated, so
Radial seal filters feature a special adapter ring that can be you get the lowest possible cost per hour. Contact
easily retrofitted to most existing equipment. Once the ring is your Barloworld Equipment customer service
in place, installation is fast and easy so you spend less time representative about retrofit options on most Cat
on routine maintenance. machines.

Cat radial seal filters are the best value on the market,
with standard filter elements for normal duty and ultra
high efficiency elements for extremely dusty and high soot
conditions.

Air filter structure and benefits

• R adial seal design: No tools are required
so service times and maintenance costs are
minimised.
• All steel adapter ring: Most new Cat machines
leave the factory with Radial Seal Air Filters
installed. Most older machines can be easily
converted with a retrofit adapter ring. It quickly
bolts into position to accept the new filter design.
• One-piece moulded urethane end caps: Forms
a tough, reliable, corrosion proof bond to paper
media. Up to 30% more seal contact area for a seal
that is more reliable than conventional elements.
• Densely pleated filter paper: Large media area
provides superior capacity without impeding Change filters without tools and take advantage of up to 50%
more capacity with Cat radial seal air filters.
airflow.
• Built-in pleat support and positive pleat
spacing: Prevents pleat bunching and ensures
optimum filter media surface area.
Radial seal filters feature a special
• Heavy-duty metal inner and outer wrap: adapter ring that can be easily
Increases structural strength and durability. retrofitted to most existing equipment.
• Baked-on enamel outer filter wrap: Creates a
corrosion resistant filter wrap.

KEEP IT REAL, KEEP IT CAT®

For more information contact our call centre on 0800 21 22 48 or visit
www.barloworld-equipment.com

Follow us on Facebook
Barloworld Equipment
Southern Africa

Follow us on Twitter
@Barloworldequip

Strip ADs (58x200).indd 5 2013/04/08 11:12 AM

96 FILTERS

Cat Transmission Filters

Filters designed specifically for transmission and powertrain oil applications.

A line of Cat filters has been introduced to better meet the specific needs of transmission ap-
plications. These new Cat transmission filters feature a synthetic media designed to deliver a
high level of filtration performance and to reduce pressure drop across the media. The end result:
significantly higher dirt holding capacity and better cold weather performance.

Caterpillar recommends Cat Advanced High Efficiency Improved Transmission Performance

Transmission Filters for transmission applications because
they are designed to meet the specific needs of the The test results below demonstrate that Cat Advanced High
powertrain. Efficiency Transmission Filters with synthetic media reduce
pressure drop issues in comparison to hydraulic filters with
Switching to these new filters greatly increases filter life synthetic media. This means reduced bypass and less wear of
and provides better transmission component protection. transmission components.
Cat Transmission Filters perform better in cold weather,
and during cold starts instances of filter bypass are greatly
reduced, especially when using higher viscosity oils.
Pressure Drop
(30W Oil at 62˚F)
100
Pressure Drop (PSID)

System and Performance Benefits 80

Hydraulic Filter
60
• G reater dirt holding capacity for longer life. Transmission Filter
• A filtration efficiency matched to the needs of 40
transmission applications.
• Reduced pressure drop across the media. 20
 Better cold weather performance.
0
 Fewer instances of filter bypass.
5 10 15 20 25 30 35 40
• Improved protection for sensitive electronic
Flow (GPM)
control valves.

Did you know...

That Cat oils have specially formulated additives that play multiple
roles in protecting diesel engine systems? These additives act as…
A detergent: keeping all hot parts of the engine clean.
A dispersant: keeping undesired particle elements in
suspension until the next scheduled oil drain interval.
An anti-wear system: protecting main components
against wear caused by friction.
A rust inhibitor: to protect against corrosion caused
by sulphur elements.
An anti-corrosion barrier: to avoid corrosion of
metallic parts.
An anti-oxidant: to counter potential oxidation of the
oil.
A VI improver: to keep viscosity stable when
temperatures change.
An anti-foaming agent: to avoid foam in the oil.
All oils are not equal and don’t perform in the
same manner.
It’s important to make sure the right fluid is in the
engine…both type and brand.
 97

Cat Turbine Precleaner

Three times the filter life means less maintenance downtime

Air filter life is directly related to the amount of debris ingested through the engine air intake.
Installing a Cat Turbine PreCleaner as the first stage of an air intake system prevents nearly all of
the heavier-than-air particles from entering the system, which results in longer air filter life, more
efficient engine performance, and decreased maintenance expenses.

Benefits
Significantly lower owning and operating costs.

• L owers cost per operating hour because cleaner air means

longer filter life.
• Lowers air restriction, which increases useable
horsepower and improves fuel economy.
• Three times filter life with a reduction in labour, parts, and
downtime.

No routine maintenance requirements

• D
 ebris is immediately ejected from the unit, so no
cleaning is required.

Built to last
• R ugged polymer construction gives the strength of steel
with the light weight of plastic.
• Sealed bearing cavity eliminates wear due to moisture or
corrosion. Debris-laden applications may require an optional heavy debris basket
screen as shown on this Cat 953D unit.
• No spot welds that will break over time.

Breakaway technology: The dome is designed to break

Features away from the base if heavily impacted by an obstacle on the
jobsite. This feature prevents costly damage to the engine air
Pre-screen eliminates clogs: The inlet pre-screen on the
intake system.
underside eliminates clogs and jams by preventing any debris
larger than the ejection slot from entering the precleaner.
Heavy debris screen kits: Kits are available for debris-laden
applications, such as landfill, forestry, etc.
Internal strakes (angled fins on sidewall) catch debris in outer
orbits and channel the debris horizontally to the ejection slot.
Recommended Uses
Toroidal dome: The shape enhances the separation process
by preventing debris from being sucked in through the Air flow range: Eight models in sizes that range from 3” to
ejection port. Debris is ejected and clean air continues to rise, 8“ to handle 50 – 1 400 cubic feet per minute (CFM), and
until the dome shape folds it and sends it into the engine air much higher CFMs with multiple-unit installations. (Please
intake. contact your Barloworld Equipment customer service
representative for more information.)
Rotor technology: Large rotor arm cross-sectional area
ensures that the rotor will not snap under load when impacted Mounting and equipment types: Mounts on all vertical and
with mixed debris fields like wood chips, chaff, or small rocks. horizontal air cleaner housings, on all machines.
The rotor accelerates the airflow to improve the separation
process and curved swept arms sling debris to the outer Recommended uses: Construction, mining, forestry, landfills,
orbits of the toroidal dome. farming, military and more.

Exclusive sealed bearing cavity: Bearings are packed in a Debris types: Expels all types of mixed debris, including mud,
20% grease concentration – instead of the typical 10-15% snow, rain, leaves, sawdust, chaff, dust, etc. Debris-laden
used by competitors – to allow operation in extreme cold. The applications may require an optional Heavy Debris Basket
bearings are protected with a labyrinth seal, an o-ring seal, Screen.
and a top cap to keep debris and moisture out.
98 FILTERS

Cat Turbine Precleaner

Continued
Online savings calculator
Field installation kits make it easy: The
Make your own cost-saving case study with the Cat Turbine precleaner fits directly onto the engine
PreCleaner online Savings Calculator.
air inlet pipe. Adapter kits are available
www.cat.com/parts/precleaner if reduction, expansion, or extension is
needed.
Enter your own data and costs to see how much time and
money the Cat Turbine PreCleaner can save you each year.

Case Studies
Five times filter life with concrete dust

Location: Ready-mix plant, FL, USA

Machine: Medium wheel loader
Test period: 5 000 hours
Front End
End Loade
Loaderr
Before precleaner Filter
Filter Change
ChangeInterva
Intervall
3000
installation, filters were
2500
blown-out every 250
H
hours (not recommended) o
2000

and changed every 500 u 1500

r
hours in accordance with s 1000

the planned maintenance 500

schedule. 0
Before After

After precleaner installation, only two filters were used

during 5 000 hours of operation. The filters were never
blown out and were only changed when the restriction
gauge indicated a change was necessary.

Four times filter life improvement with quarry dust

and debris

Location: Rock quarry in England

Machine: 777D large mining truck with dual air
How it works: filters
Test Period: 2 000 operating hours
Step 1: Air and debris pass through a pre-screen on the
Before precleaner Mining
Mining Truck
Truck
underside, entering the unit through recessed vanes Filter
installation, both filters Filter Change
ChangeInterval
Interval
underneath the particle accelerator blades. 800
were changed every 150
hours and blown out 600

Step 2: The curved particle accelerator blades force air and every 60 hours. Filters H
o
debris into the sidewall. were changed when the u
400

restriction light came on. r

s
200

Step 3: Strakes (angled fins) along the interior surface After precleaner
0
move heavier-than-air debris towards the ejection slot, installation, both filters Before After
where it is expelled back into the atmosphere. were changed at 610
hours, even though there was no restriction indicated
by the signal light.
Step 4: Clean air continues to spin upward, until it is
compressed and folded. The clean air is then forced down
into the engine air inlet pipe.
 99

BRAKING SYSTEMS

Contents
100 Cat Friction Material

102 Cat Extended Life Friction Material

100 BRAKING SYSTEMS

Cat Friction Material

The type of friction material your equipment requires is based on machine size and application.
Heavy-load applications like mining, for example, require friction material with different functional
properties than cycling applications like construction.

Caterpillar engineers match the characteristics of friction Built to perform in Cat machines
material to the function it performs, the equipment in which
it operates, and the fluids and other components used in that Components made with Cat friction material allow proper fluid
system. flow and heat dissipation, resulting in longer life and lower
maintenance costs than other brands. That’s why it’s critical to
Total system design helps ensure safe performance, balanced select Cat components when it’s time to choose replacement
component life, and maximum parts reusability. brake, transmission, and steering parts.

Only Cat friction material is proven to deliver long, reliable

performance in Cat machines. Caterpillar provides reusability
guidelines so you know what is required for servicing, another
way we help you manage your owning and operating costs.

Separator Plate Extended Life Elastomeric Paper Bronze

FRICTION MATERIAL USES

Machines Applications
Paper Off-highway trucks Brakes
Wheel loaders Transmission clutches
Track-type tractors Steering clutches
Bronze Track-type tractors Brakes
Elastomeric Off-highway trucks Transmission clutches
Wheel loaders
Extended Life Off-highway trucks Brakes
Wheel loaders
Separator Plate All machines All applications
Using genuine Cat friction material ensures your parts are designed for the best performance, safety, and reliability.
 101

Built to last, even under incredible stress

Drive train components operate under incredible stress
and their ability to stand up to tough conditions can mean
significant cost savings. The friction material used in Cat
components is designed to last until regularly scheduled
assembly overhauls. Its life is better matched to that of other
drive train components, so you can make all repairs and
replacements at once, minimising repair costs and downtime.

Genuinely Better
Cat friction material is designed just for Cat drive train
components working in Cat machines.

Here are a few examples of problems that can be avoided

by using Cat friction material:

Material selection
• U napproved adhesives can result in poor bond strength or
premature bond failure.
• Improper density, weight, hardness, thickness or
composition can affect braking and shifting and cause
premature wear, noise, drag, creep, and damage to the
mating part in the system.

Heat treatment
Improper heat treat can cause premature spline wear and
damage to the mating part. Real-world validation delivers better
performance
Manufacturing processes
• C aterpillar invests millions of dollars to design,
• Improper forming of materials can cause misalignment, test, and develop friction material for each
premature wear, and power overloading. machine application, a process that can take years.
• Improper groove type, width, and depth can affect oil flow All friction material must undergo a stringent
and cooling, resulting in higher running temperatures, loss certification process to ensure it performs to
of coefficient of friction, wear, glazing, and discolouration. Caterpillar specs.
• Improper positioning of the friction material on the core • Cat elastomeric friction materials, for example,
can interfere with the mating part. feature an exclusive material designed by
• Failure to conform to Caterpillar specs for blanking, tooth Caterpillar that is moulded and bonded to a core
shaping, and broaching can create improper fit, resulting in for use in transmissions and load clutches in off-
premature failure and damage to the mating part. highway trucks and wheel loaders.
• Choosing Cat friction material is your assurance
Stress relieving of safety and reliability – the result of real-world
validation, quality assurance, and experience
Lack of or improper stress relieving can cause premature gained by millions of hours of operation. Other
wear, warping of the separator plate, and damage to the brands may not be subjected to such extensive
mating part. validation.

Surface finish and cleaning

• Improper surface preparation can result in poor bond
strength with the core, resulting in partial or complete
separation from the core plate. Optimum drive train performance
• Poor surface finish can result in accelerated wear on the depends on the right friction material.
friction disk, as well as noise, creep, drag, and reduced
coefficient of friction.
• Failure to remove loose material can clog fluid filters and
affect fluid flow, resulting in poor lubrication and higher
running temperatures.
102 BRAKING SYSTEMS

Cat Extended Life Friction Material

Purpose-designed for off-highway trucks and large wheel loaders

Caterpillar offers a friction material that provides extended

life and increased heat resistance in wet brake systems.
In certain applications, friction material may no longer be
the limiting factor in the life of a final drive. This follows the
development of Cat Extended Life Friction Material, which
uses an innovative carbon paper for braking. A unique bonding
process adds strength and helps prevent premature failures.

A significant step forward in braking technology, the relative

wear life of Cat Extended Life Friction Material is up to four
times greater than the Cat standard paper friction material
and is twice as resistant to glazing. This resistance to glazing,
which occurs during periods of high-temperature braking, is
especially well-suited to heavy load applications like mining.

• Improved material life • Better heat Brake Kits

resistance • Better wear rate • Consistent
braking power • Less glazing Cat Extended Life Friction Material is available in brake kits for
selected models. Give us a call for details on availability.

Relative life of brake friction materials

Results May Vary Depending on Application & Severity
5
Cat Extended
Cat Extended Life
Life Standard
Standard Cat
CatDisc
D isc

{
4
This graph demonstrates that the relative wear life of Cat
2x - 4x Extended Life Friction Material is up to four times greater
3
Relative Life

Longer Life
than the Cat standard paper material and is twice as resistant
to glazing. This resistance to glazing, which occurs during
2
periods of high-temperature braking, provides consistent
braking power. It may also lessen audible brake noise.
1

0
Glazing Resistance Wear Resistance
Failure M ode

Friction material cost comparison

TIME

Final Drive Final Drive Final Drive Fewer

Friction Disc Friction Disc Labour Hours
Application Friction Discs
Overhaul Replacement Only Overhaul Replacement Only Overhaul Savings*
Consumed*

Light 33% None

Normal 40% 64-102

Severe 57% 128-204

Cat Extended Life Standard Cat Disc * Percentages reflect fewer friction discs consumed final drive overhaul cycles using the Cat Extended Life
Discs over Standard Discs. Labour hour savings based on brake replacements performed outside of normal
overhaul cycle and may vary based on machine type (Models 777-789).

Brake life better matched to final drive life cycle: The chart above illustrates the potential reduction in the number of
friction discs required and labour hours saving over the life of final drive overhaul cycles for off-highway trucks using
Cat Extended Life Friction vs. Cat standard friction discs.
 103

Contents
104 Differential Maintenance
An Introduction
Preventative Maintenance
104
105
Contamination Control 105
Differential Steering 106
Bearings / Gears 107
Key Components / Component Durability 107
Repair Options / Scheduling and Record Keeping 108

109 Final Drive Maintenance

Preventive Maintenance 109
DRIVE TRAIN

S•O•SSM Services 110

Contamination Control 111
Repair Management / Repair Indicators 112
Repair Options / A Look at the Key Components 112
Bearings / Gears 113
Duo-Cone™ Seals 114
Key Steps to Improve Component Durability 114
Scheduling and Record keeping 115

116 Transmission Maintenance

Importance of S•O•S Fluid Analysis
Preventative Maintenance
117
118
Thorough Inspections 119
Transmission DOs and DON’Ts 120
Training, scheduling and record keeping 120
104 Drive train

Differential Maintenance
An Introduction

This guide discusses preventative maintenance, repair management options and highlights the
components that wear and fail in the differential. By understanding these topics, machine owners
can minimise owning and operating costs while maximising on-site productivity.

Understanding how differentials work

The differential plays a critical role within a machine’s drive
train by changing the direction of the power coming from the
transmission 90 degrees to allow the axles to be driven. They
also allow speed and torque differences between the left and
right axles.

When a machine is turning, the differential lets the outside

wheel move at a faster speed than the inside wheel, allowing
for easier turning and less wear on tyres or tracks. The gears
in the differential also provide speed reduction and torque
increases.

In order to get the productivity and life you demand, it is

important to maximise the life of these components by
properly managing and maintaining them.

The key components of the differential are:

• The differential assembly, which turns the spider and
pinion gears that mesh with the side gears, turning the
axle shafts.
• Pinion gears, which transmit power from the spider to the
side gears that are attached to the axle shafts.
• Side gears, which are splined to the axles and driven by
the pinion gears.
• The spider, which serves as the mounting for the pinion
gears, and rotates with the differential assembly.
The key functions of a differential are:
• The bevel pinion gear, driven by the drive shaft.
• T ransferring power coming from the transmission
• The bevel ring gear, which meshes with the bevel pinion
to the left and right axle shafts.
gear, and is mounted to the differential assembly.
• Balancing the power according to the demand of
each wheel.
• To transmit the power to the wheels while allowing
Differential Cross Section them to rotate at different speeds.
• Gears in the differential further reduce speed and
Side Gear Spider increase torque to drive the rear wheels.

Bevel Ring Gear

There are four types of
Pinion Gears differentials:

• Standard (as shown).

• Limited Slip.
• No Spin.
Differential Assembly
• Locking.

Bevel Pinion Gear

 105

Preventative maintenance: Cat Gear Oil provides:

• Excellent stability under high temperature conditions.
Optimise equipment life • Superior low temperature performance.
• Protection against rust and corrosion.

The key components in differential preventive maintenance Some applications require additives for the extreme pressures
include quality oils and filters, regular S•O•S Oil Analysis and that can occur at the edges of the components. For these
contamination control. applications, Cat Gear Oil provides the extra protection. Cat
Gear Oil should not be used in compartments that specify
TO-4 or TO-4M oil.
Proper oil use
S•O•S Services
The three main functions of oil are to provide cleaning, cooling
and lubrication. Modern Cat drive train systems feature new
metals, elastomers and paper disc materials which may Importance of S•O•S Oil Analysis
have advanced lubrication needs, requiring you to change oil
regularly, properly, and use the right drive train oil to achieve Scheduled Oil Sampling is a crucial part of machine
top performance. management. Oil sampling at scheduled intervals validates
your maintenance procedures, tracks what is going on inside
of the equipment and forecasts wear-related problems.
Use the right drive train oil
Our S•O•S Oil Analysis programme is well recognised for
Cat differentials experience high gear and bearing loads and
its ability to detect potential failures before they occur. Each
temperatures. In these conditions, it is important gears and
S•O•S Services test is designed to reveal specific information
bearings are protected.
about the condition of Cat products.
It is essential that components be run in the correct oil.
The four types of analysis are below:
Always consult your Operations and Maintenance Manual for
• Wear Metal monitors and tracks metal wear particles,
the specific oil needed.
contaminants and oil additive package elements.
• Oil condition compares used oil to new oil to see if it is
Cat TDTO (Transmission Drive Train Oil) is specially formulated
providing adequate lubrication and protection.
to increase the life and performance of your Cat drive train
• Oil Cleanliness determines if abrasive contaminants are
components.
causing accelerated wear.
• Oil Contamination detects water, glycol, or fuel in oil.
This oil:
• Reduces transmission slippage.
• Controls brake chatter. Control Contamination: reduce overall
• Provides greater machine rimpull. operating costs
• Increases friction material life up to 45 percent.
Dirt, sand, grit and even the finest dust can cause problems
Cat TDTO surpasses the TO-4 specification requirement when they find their way into the differential. They cause parts
and is specified as factory fill for all Caterpillar machine to wear faster, making them more prone to premature failure.
compartments where TO-4 is the primary recommendation.
There are four ways contamination can get into machine
Cat FDAO (Final Drive Axle Oil) was developed specifically to systems:
protect gears and bearings in bevel gears, differentials, final 1. Contaminants can be built in during manufacturing and
drives and axles that do not contain friction materials. assembly operations.
2. Contaminants can enter during servicing and maintenance
Cat FDAO is the preferred lubricant for Cat off-highway truck procedures.
front wheels, differentials and final drives. It is compatible 3. Contaminants can enter with new fluid.
with Cat final drives and axles that previously specified TO-4 4. Contaminants can enter during operation through pitted
lubricants and do not contain friction material. shafts, broken breathers, worn seals and other trouble
spots.
Cat FDAO has the following qualities:
• Compatible with Cat Transmission Drive Train Oil (TDTO). Fortunately there are steps you can take to prevent fluid
• Excellent protection against rust and copper corrosion. contamination. An effective contamination control programme
• Minimises foaming for increased lubrication. is made up of many small steps that help maintain fluid
• Low oxidation rate for improved oil life. cleanliness and reduce opportunities for contaminants to
• Maintains desired viscosity and film strength. get in machine systems. Caterpillar recommends a four-part
• Provides reduced wear from debris particles suspended in contamination control programme consisting of:
the oil. 1. Clean fluids.
2. Clean components.
Cat Gear Oil offers maximum protection against the following 3. Clean facilities.
damage: scoring of the gear teeth, pitting of the gear teeth, 4. Clean shop-repair processes.
and pitting of the parts in roller bearings.
By following these steps, you will be better prepared to
control contamination, reduce overall operating costs and
keep your Cat equipment performing at its best.
106 Drive train

Filters
Control contamination inside your differential through the
use of Cat fluid filters. By changing filters regularly and
properly, and by selecting the right filters you maintain system
cleanliness, reduce component wear and lower costs.

For further information on selecting the correct fluid filters,

consult your machine’s Operation and Maintenance Manual
or contact your Barloworld Equipment customer service
representative.

Repair management/
Repair indicators

Repair management is only one factor that influences

your owning and operating costs. You should also address
Understanding differential
operating technique and application as well as preventative steering
maintenance.

In the area of operating technique: Differential steering uses three planetary gear sets and a
• Avoid high-speed direction changes. hydraulic motor to change the speed of each track.
• Avoid backing over obstructions.
• Avoid extreme braking. This system delivers uninterrupted power to both tracks
• Operators should adequately warm-up the machine. during turns. Power from the transmission is delivered
• Pay attention to warning lights. through the bevel gears to three planetary gear sets, then
• Do daily walk around inspections. to the final drives and tracks. By adding power to one of the
planetary gear sets, the motor adds (or redistributes) power
Application concerns might involve: to the steering differential, and by its direction of rotation,
• Ambient temperature. speeds up one track and slows down the other to make turns.
• Design of haul roads and repetitiveness of the work.
By rotating one direction, it makes a right turn, and by rotating
Repair Indicators the other direction, it makes a left turn. Thus the hydraulic
motor determines the direction and degree of the turn.
There are two types of indicators: planned and problem.
Planned indicators are part of a good differential maintenance The results are turns of any degree, from slight to sharp,
management programme that will give you before-failure without interruption in power. The operator turns, reverses
repair options to lower your operating costs. Planned direction and changes speed ranges using one hand on
indicators are those that are performed or checked routinely a single tiller. This Caterpillar patented steering system is
such as S•O•S oil analysis, technical analysis, service meter available in the Cat D6R through D9R, and Challenger tractors.
hours, service history and Site Operations Maintenance
Advisor (SOMA) software. (SOMA assesses customers’
operating and maintenance practices and provides component
life estimates.)

Problem indicators are usually found during inspection and

include noises, leaks, overheating, and poor performance.
Even with excellent maintenance, eventually repairs will
be needed. However, problems can be caught early by
performing daily inspections and responding quickly to repair
indicators.

Keep in mind determining the cause is usually easier said

than done. A visual exam may identify the type of damage,
but it may not aid in recognising what is causing the problem.
Remember, if you merely replace the failed component
without finding and fixing the root cause, the replacement
component will most likely endure the same wear and
damage as the original.
The basic function of gears in the
For a list of planned and problem indicators for Cat differential is to transfer power from the
differentials see the “Repair Indicators’ section in this
handbook. drive shaft to the axle shafts.
 107

Bearings and gears:

How they work

Bearings are used in the differentials to maintain position

and alignment of gears and shafts, and to minimise friction,
heat and wear. They also carry the weight of the vehicle and
payload, subjecting them to very high loads and temperatures.
Cat bearings have precision surfaces that are separated by a
film of lube oil.

It is critical that the surface of the contact areas retains an

adequate oil film thickness to prevent metal-to-metal contact
with the mating part.

Loads are transferred through gears by gear teeth pushing

against each other. Gears used in the differentials are put
Causes of premature bearing failure through a carburising and hardening process. This creates a
durable outside surface enabling them to carry very high loads
In order to maximise bearing life, it is important to for thousands of hours. The gears are machined and precision
eliminate the four primary causes of premature failure: ground to exact tolerances, making it crucial for the lubricating
oil to be at its proper level to avoid metal-to-metal contact. The
• Improper installation: bearings are not properly heat treatment, material and machining processes used on
installed with the correct pre-load. gears are based upon the specific application.
• Improper tolerances: width tolerances are incorrect
for the application. Caterpillar bearing design is application driven, which means
• Overload (fatigue), resulting from machine Caterpillar offers the correct bearing for the application.
overloading or long hours of use.
• Contaminated lube oil, which causes accelerated
surface pitting and premature failure.

Causes of premature gear failure

Key components/
There are five primary causes of premature gear
failure:
Component durability
• P itting from surface: normal end-of-life failure
mode; however, consistent overloading accelerates
this scenario.
A look at the key components
• Contaminated lube oil: causes accelerated
Understanding how differentials work and wear is the key to
surface pitting and cracking.
maximising component life. Differential repair parts can be
• Gear tooth bending fatigue: the result of severe
broken up into three groupings. They are:
gear overloading.
• Improper alignment: creates unbalanced loading
Level I: Fastest wearing parts; not reusable.
and contact on gears.
• Anti-friction bearings.
• Improper lube oil, which increases surface wear.
• Seals and gaskets.
• Duo-cone seals.

Level II: Slower wearing parts; possibly reusable.

• Plates.
• Discs.
• Gears.

Level III: Longest life; designed not to be replaced.

• Housings and axles.

In order to correctly identify failure modes for differentials, it

is necessary to understand how the component works, the
causes of its premature wear or failure, and the maintenance
steps that can be taken to minimise the causes of wear and
failure.
108 Drive train

Key steps to improving component After-failure repairs

Repairing before failure is the best way to reduce your
durability downtime and costs. However, if your differential system
does fail, we are in the best position to help you control costs
Clean lube oil
and save time. Part replacement costs are kept to a minimum,
By far, the most common and preventable cause of
using Cat Parts Reusability Guidelines and replacing only
component failure is due to contaminated lube oil. To ensure
damaged components.
components run in clean lube oil, it should be built clean,
installed clean and operated clean.
Possible options include using Exchange or Cat Reman
components. Cat Reman components are available from
Correct lube oil
inventory, offer same-as-new performance, and carry the
It is essential to the component’s life to be run in high-quality
same warranty as new components at a lower cost.
lube oil. Using the correct lube oil will improve component
wear life up to 40% in some applications.
After-failure overhaul is recommended when large pieces
of metal are discovered during magnetic plug inspections,
Proper installation and assembly
when failure occurs or when broken parts are discovered
Components are built with specific tolerances and preloads.
during before-failure procedures. It includes removal and
Proper installation and assembly practices are absolutely
replacement of the entire differential and axle group.
essential to component life.

Avoid overload and fatigue Scheduling and record keeping

Two factors that dramatically accelerate subsurface fatigue
and component life are excessive loads and rolling resistance. Good scheduling means maintenance, inspections and
planned repairs are done on time to prevent differential
Replace parts before failure failures caused by overlooked maintenance. You can also view
Differential piece parts do not have an infinite life. After being S•O•S Oil Analysis results on-line.
run for thousands of hours at high loads and temperatures,
the material will eventually fatigue. Thorough inspection of Record keeping
the components results in early detection of defect and
deterioration before parts fail completely and damage other By developing an accurate machine record-keeping system,
vital components. you can identify high-cost or problem areas, track work flow,
control costs, and increase machine resale value. An accurate
record keeping system documents drive train history by
Repair options/Scheduling and detailing component life and cost information. We can help
record-keeping you set up manual record keeping and work order systems,
or we can help you install computer software programs to
perform scheduling, checklists and other record keeping
functions.
Selecting the right repair option
Selecting the right repair option is a way to lower owning and
operating costs.

Before-failure repairs
Repairing before failure gets your machine back to work
sooner and costs two to three times less than after-failure
repairs.

Our before failure repair options:

• Help prevent major failures and failure of related parts.
• Maximise parts reusability designed into many differential
parts.
• Allow you to schedule downtime and plan costs.
• Maximise equipment life and productivity.

Differential repair options:

• Reseal: required when oil leaks are discovered during
inspections.
• Re-bearing and reseal: signalled by excessive leaks,
elevated S.O.S results or target hours.
• Before-failure overhaul: involves rebuilding the entire
differential.
 109

Final Drive Maintenance

A Management Guide

Final drives play a crucial role within a machine’s drive train by transferring power to the tyres or
tracks while providing speed reduction and torque increase.

Final drives are closed components and thus hidden from

view and for this reason it is easy to overlook routine
maintenance requirements. In response, effective system
management will lead to fewer failures, less downtime and
better machine resale value.

This guide discusses preventive maintenance, repair

management options, and highlights the main components
that wear and fail in final drive systems.

By understanding these topics, you could minimise

your owning and operating costs while maximising your
productivity.

Overview
Cat final drive components must endure incredible torque,
high-impact loads, and frequent direction and gear changes.
In fact, the final drive is where the highest torque increase
occurs.

Caterpillar designs and manufactures its final drive

components with these demands in mind, using testing
processes that simulate real-world applications. In order to get
Preventative maintenance
the productivity and efficiency you demand, it is important to
maximise the life of these components by properly managing
The key components in final drive preventive maintenance
and maintaining them.
include quality oils and filters, regular S.O.S Oil Analysis and
contamination control.
To withstand the forces of high torque and impact loads, Cat
final drive components are:
Preventive maintenance:
• Allows you to schedule downtime and plan for
• D esigned to work and wear as a system for smooth,
maintenance and repair costs.
reliable operation.
• Helps prevent major failures, including failure of related
• Manufactured and tested for precise fit and consistent
parts.
quality.
• Saves you money because you can often repair before
• Heat-treated for durability and long life in their specific
failure.
application.
• Reduces total downtime.
• Maximises parts reusability.
Controlled manufacturing processes, and use of high-quality
• Optimises equipment life to keep your machine productive
materials, enable Cat final drives to be remanufactured for
and on the job.
a second life. Cat Reman final drives offer same-as-new
• Increases machine resale value.
performance, long life and quick turnaround, all at a fraction-
of-new prices. Currently, Reman final drives are available for
off-highway trucks, large wheel loaders, large wheel dozers, Proper oil use
large compactors and specific track-type tractors.
The three main functions of oil are to provide cleaning, cooling
A good drive train management programme is a team effort and lubrication. Modern Cat drive train systems feature new
– your regular maintenance programme supplemented by metals, elastomers and paper disc materials which may
Barloworld Equipment’s maintenance support, products have advanced lubrication needs, requiring you to change oil
and services. Together, we can maximise drive train and regularly, properly, and use the right drive train oil to achieve
component performance, identify and react to any potential top performance.
problems before they become failures, and lower your owning
and operating costs.
110 Drive train

• D
 6R-D11 dozers, pipelayers (572, 583, 589) and track
skidder final drives (steel-tracked machines with elevated
final drives, except the D5M and 561M).

Change oil properly

It is critical to change oil properly and at the correct intervals.
Actual oil life is determined by many factors such as operating
conditions, applications and contamination control. To reduce
contamination, it is important to:

• D rain oil as quickly as possible, and when it is agitated and

warm.
• Use a filtered transfer cart when filling with or adding new
oil.
• Remove and install filters carefully.
• Keep filters in their package until ready for use.
• Cut open and inspect used filters before installing new
ones.

It is essential that components be run in the correct oil.

Always consult your Operations and Maintenance Manual for
the specific oil needed.

The Importance of S·o·s

Oil Analysis

S·O·S oil analysis is a crucial part of machine management. Oil

sampling at scheduled intervals validates your maintenance
procedures, tracks what is going on inside of the equipment
Use the right drive train oil and forecasts wear-related problems.
Cat final drives, axles and differentials experience high gear Our S·O·S oil analysis programme is well recognised for its
and bearing loads and temperatures. In these conditions, it is ability to detect potential failures before they occur. Each
important that gears and bearings are protected. Final Drive S·O·S Services test is designed to reveal specific information
and Axle Oil (FDAO) is the preferred lubricant for Cat final about the condition of every Cat product.
drives and axles not containing friction materials. FDAO is
used where T0-4 was previously specified, but should not be The four type of analysis are listed below:
used in compartments that contain friction material because
this oil does not generate a sufficient friction coefficient to • W ear Metal: monitors and tracks metal wear particles,
satisfy the requirements of most brakes and clutches. contaminants and oil additive package elements.
• Oil Condition: compares used oil to new oil to see if it is
Help your final drives reach a new level of performance providing adequate lubrication and protection.
with Cat FDAO: • Oil Cleanliness: determines if abrasive contaminants are
• Compatible with Cat Transmission Drive Train Oil (TDTO). causing accelerated wear.
• Excellent protection against rust and copper corrosion. • Oil Contamination: detects water, glycol or fuel in oil.
• Controls foaming for increased lubrication.
• Low oxidation rate for improved oil life. Advantages of using S·O·S Services:
• Maintains desired viscosity and film strength. Surveys have shown that there are many benefits to using our
• Provides reduced wear from debris particles suspended in S·O·S oil analysis programme:
the oil.
• E xperts can provide analysis and interpretation of trends
Cat FDAO is a factory fill for: and can forecast any excessive wear concerns.
• Off-highway truck front wheels, differentials and final • Test results are available within 24 hours after receipt of
drives. the sample.
• Easy-to-understand test reports call for specific action and/
or makes carefully outlined recommendations.
• Saves time and money by identifying trouble spots before
Repairing before failure gets your they become major failures.
machine back to work sooner and costs
S·O·S Services help you avoid complete failures. Often an
two to three times less than after-failure adjustment or replacement of a single part, based on S·O·S
repairs. Services findings, can prevent a small problem from growing
into a major repair. S·O·S Oil Analysis is different from other
 111
The final drive is where the highest
oil analysis programmes because it focuses on component torque increase occurs.
condition, not just oil condition.

Since only Caterpillar knows the exact design of your Cat

drive train system, we can help you analyse S·O·S reports,
determine what additional tests need to be performed, and
recommend the proper corrective action.

Particle count
Particle count is another way of assuring oil cleanliness. When
used in conjunction with fluid analysis, particle counting can
be a valuable tool in reducing failures in final drive systems.
The particle count instrument counts the number of particles
in several different size ranges, from as small as two microns
to over 100 microns.

It measures both metallic and non-metallic particles and

provides an early warning of abnormal component wear and
contaminant ingestion.

Contamination Control

Dirt, sand, grit and even the finest dust can cause problems
when they find their way into the final drive system. They
cause parts to wear faster, making them more prone to
premature failure.

There are four ways contamination can get into machine

systems:
1. Contaminants can be built in during manufacturing and
assembly operations.
2 Contaminants can enter during servicing and maintenance
procedures.
3 Contaminants can enter with new fluid. Change filters regularly
4 Contaminants can enter during operation through pitted In order to keep your drive train system running clean and
shafts, broken breathers, worn seals and other trouble at peak performance, it is important to change the filters
spots. regularly.

Fortunately there are steps you can take to prevent This reduces the chance of contamination, which causes
fluid contamination. An effective contamination control component wear and system failure. We recommend
programme is made up of many small steps that help changing fluid filters at least every 500 hours. This change
maintain fluid cleanliness and reduce opportunities for interval will vary with application, environment and type of
contaminants to get in machine systems. Caterpillar filter being used.
recommends a four-part contamination control
programme consisting of: Change filters properly
1 Clean fluids. It is important to remove old filters carefully to ensure the
2 Clean components. contaminants they hold do not re-enter the drive train system.
3 Clean facilities. It is also critical to keep new filters in their packaging until you
4 Clean shop-repair processes. are ready to install them. This protects the filter and reduces
the chances of contaminants entering the system, especially
By following these steps, you will be better prepared to on the clean side of the filter media.
control contamination, reduce overall operating costs and
keep your Cat equipment performing at its best. Select the right fluid filters
The use of fluid filters in final drive systems varies by machine
Filters type. Filters can be found on the 797 and 793 off-highway
trucks and machines using a common reservoir system such
Control contamination inside your final drive system through as backhoe loaders. For further information on selecting the
the use of Cat fluid filters. By changing filters regularly and correct fluid filters, consult your machine’s Operation and
properly, and by selecting the right filters, you maintain Maintenance Manual or contact your Barloworld Equipment
system cleanliness, reduce component wear and lower costs. customer service representative.
112 Drive train

Repair management / Problem indicators Possible Causes

Brake Slippage Worn plates and discs
Repair indicators Wrong oil used
Linkage out of adjustment
Repair management helps you select before-failure and after Incorrect pressure settings
failure repair options that allow you to control repair costs
Low fluid level
and minimise downtime. Performing daily inspections is an
important way to identify small problems before they become Unusual Noises Worn gears/bearings
major failures. Dirt entry
Low fluid level
Inspection
Daily walk-around inspections should include a complete Overheating Wrong oil used
visual and operational check of your machine. You should be Low fluid level
aware of any strange noises, leaks, slippage, overheating or
Worn or damaged seals
brake chatter. When used alongside Preventive Maintenance
and S·O·S Services, a good inspection programme maximises Debris on Magnetic Plug Dirt entry
equipment value by minimising repair costs and unscheduled Wrong oil used
downtime.
Extended oil change period
A preventive inspection plan can: Disc disintegration
• Detect potential problems and impending failures before Worn gears or bearings
any additional damage occurs.
• Help schedule maintenance and any needed repairs to Vibration Gear failure
plan for downtime and control costs. Sprocket failure
Bearing failure
Site Operations and Maintenance Advisor (SOMA)
Site Operations and Maintenance Advisor (SOMA) can Leaks Worn, hard or cracked
significantly reduce your owning and operating costs. SOMA seals
is a software tool that can help you identify repair before
failure opportunity windows. It is able to provide component
life estimates by assessing the machine’s operating and Repair Options
maintenance practices. Contact your Barloworld Equipment
customer service representative to arrange a comprehensive
SOMA study. Selecting the right repair option is a way to lower owning and
operating costs.
Repair indicators
Before-Failure Repairs
There are two types of indicators: planned and problem.
Planned indicators are those that are performed or checked Repairing before failure gets your machine back to work
routinely, such as S·O·S Oil Analysis, Technical Analysis, sooner and costs two to three times less than after-failure
service meter hours, service history and SOMA software. repairs. Our before failure repair options:
Problem indicators are usually found during inspections and
include noises, leaks, overheating and poor performance. • Help prevent major failures and failure of related parts.
• Maximise parts reusability designed into many final drive
Even with excellent maintenance, eventually final drive repairs parts.
will be needed. However, problems can be caught early by • Allow you to schedule downtime and plan costs.
performing daily inspections and responding quickly to repair • Maximise equipment life and productivity.
indicators.
Final drive repair options:
• Reseal: required when oil leaks are discovered during
inspections.
• Re-bearing and reseal: signalled by excessive leaks,
elevated S·O·S results or target hours.
• Upper pinion re-bearing and reseal (low-sprocket TTT):
recommended when an S·O·S report shows elevated
results of iron and lead.
• Steering clutch and brake reconditioning: addresses
worn friction materials to ensure proper steering and brake
performance.
• Before-failure overhaul: involves rebuilding the entire final
drive.
 113

After-failure repairs
Repairing before failure is the best way to reduce your
downtime and costs. However, if your final drive system
does fail, we are in the best position to help you control
costs and save time. Part replacement costs are kept to
a minimum, using Cat Parts Reusability Guidelines and
replacing only damaged components. Possible options include
using Exchange or Cat Reman components. Cat Reman
components are available from inventory, offer same-as-
new performance, and carry the same warranty as new
components at a lower cost.

After-failure overhaul is recommended when large pieces

of metal are discovered during magnetic plug inspections,
when failure occurs or when broken parts are discovered
during before-failure procedures. It includes removal and
replacement of the entire axle group and a complete rebuild
of final drives, the differential and brakes.

A look at the key components

Understanding how final drives work and wear is the key to

maximising component life. Final drive repair parts can be
broken up into three groupings. They are:
Bearings
Level I: fastest wearing parts, not reusable.
• Anti-friction bearings.
• Seals and gaskets. How they work
• Duo-cone seals.
Bearings are used in the drive train system to maintain
Level II: slower wearing parts, possibly reusable. position and alignment of gears and shafts, and to minimise
• Plates. friction, heat and wear. They also carry the weight of the
• Discs. vehicle and payload, subjecting them to very high loads and
• Gears. temperatures. Cat bearings have precision surfaces that are
• Shafts. separated by a film of lube oil. It is critical that the surface
of the contact areas retains an adequate oil film thickness to
Level III: longest life, designed not to be replaced. prevent metal-to-metal contact with the mating part.
• Housings, hubs and carriers.
Caterpillar bearing design is application driven, which means
In order to correctly identify failure modes for final drives, it we offer the correct bearing for the application.
is necessary to understand how the component works, the
causes of its premature wear or failure, and the maintenance Below are two examples of application-specific bearings:
steps that can be taken to minimise the causes of wear and • Textured anti-friction bearings for use in slow-speed, high-
failure. load applications.
• Debris-resistant anti-friction bearings in high-load, tight
tolerance applications provide twice the life of standard
bearings.

Causes of premature failure

In order to maximise bearing life, it is important to eliminate
the four primary causes of premature failure:

• Improper installation: bearings are not properly installed

with the correct pre-load.
• Improper tolerances: width tolerances are incorrect for
the application.
• Overload (fatigue): resulting from machine overloading or
long hours of use.
•  Contaminated lube oil: causes accelerated surface
pitting and premature failure.
114 Drive train

Duo-cone™ seals

Duo-Cone seals are metal-faced seals used to provide oil

sealing in extreme or abrasive rotating applications involving
high speed and load. They use two large flexible toric rings to
Gears apply force to the opposing metal sealing rings to hold them
together.

These seals carry the important function of keeping

How they work contaminants, dirt and debris out of the drive train, and oil in.
The basic function of gears in the final drive system is to
provide speed reduction and increase torque. Loads are Causes of premature Duo-Cone seal wear
transferred through gears by gear teeth pushing against
each other. Gears used in the final drives are put through a There are four primary causes of premature seal wear:
carburising and hardening process. This creates a durable • Improper installation: caused by uneven or excess seal
outside surface enabling them to carry very high loads for face load or handling damage.
thousands of hours. The gears are machined and precision • Polishing housing surfaces: allows toric rings to slide
ground to exact tolerances, making it crucial for the lubricating rather than roll, resulting in inadequate loading of the
oil to be at its proper level to avoid metal-to-metal contact. The metal sealing faces.
heat treatment, material and machining processes used on • Contaminated lube oil: abrasive particles accelerate wear
gears are based upon the specific application. of metal seal rings.
• Toric ring compression set from overheating:
overheating lube oil causes the toric ring to lose its ability
Causes of premature gear failure to apply the correct load to the seal faces.
There are five primary causes of premature gear failure:
• Pitting from surface fatigue: normal end-of-life failure Clean lube oil
mode; however, consistent overloading accelerates this
factor. By far, the most common and preventable cause of
• Contaminated lube oil: causes accelerated surface component failure is due to contaminated lube oil. To ensure
pitting and cracking. components run in clean lube oil, it should be built clean,
• Gear tooth bending fatigue: the result of severe gear installed clean and operated clean.
overloading.
• Improper alignment: creates unbalanced loading and Correct lube oil
contact on gears.
• Improper lube oil: increases surface wear. It is essential to the component’s life to be run in high-quality
lube oil, such as Cat FDAO. Using the correct lube oil will
improve component wear life up to 40% in some applications.

Proper installation and assembly

Components are built with specific tolerances and preloads.
Proper installation and assembly practices are absolutely
essential to component life.
 115

Avoid overload and fatigue Record keeping

Two factors that dramatically accelerate subsurface fatigue By developing an accurate machine record keeping system,
and component life are excessive loads and rolling resistance. you can identify high-cost or problem areas, track work flow,
control costs and increase machine resale value. An accurate
Replace parts before failure record keeping system documents drive train history by
detailing component life and cost information. We can help
Final drive piece parts do not have an infinite life. After being you set up manual record keeping and work order systems,
run for thousands of hours at high loads and temperatures, or we can help you install computer software programs to
the material will eventually fatigue. Thoroughly inspecting the perform scheduling, checklists and other record keeping
components results in detecting defects and deterioration functions.
before they fail completely and damage other vital
components. Maximise the life of your final drives
For any machine to be safe, reliable and productive, regular
preventive maintenance is vital. It is the most cost-effective
Scheduling and record keeping way to keep your final drives operating at peak performance.
If you take care of your final drives, then gears and shafts can
last through multiple rebuilds and the overall final drive life
Scheduling increases. Take a proactive approach by planning for scheduled
downtime, maintenance and repair costs. When you plan, you
Good scheduling means maintenance, inspections and save money and time – and who couldn’t use more of each?
planned repairs are done on time to prevent drive train failures
caused by overlooked maintenance. You can also view S·O·S
Oil Analysis results online.

A HIGHER YIELD
Medium Size Excavators. Our current range offers excellent
controllability and reliability, impressive lift capacity, better
fuel efficiency, simplified service and a more comfortable
operator station to increase your productivity and lower your
operating costs.

For more information contact our call centre on 0800 21 22 48

or visit www.barloworld-equipment.com

320D 323D 329D

Pg 115 (125x210).indd 1 2013/05/31 4:03 PM

116 Drive train

Transmission Maintenance
A Management Guide

The transmission is a critical part of a machine’s power train. Its function is to take the output
from the engine and manipulate it to control speed, direction and torque. Following a planned
maintenance programme and Caterpillar’s recommended maintenance guidelines can help en-
sure longer life for your transmission and reduce machine downtime.

Because of the wide variety of work they do, Caterpillar

products use several transmission types, including planetary
powershift, countershaft powershift, direct drive and
hydrostatic. Each is designed to convert engine power into the
exact combination of speed, direction and torque required for
the particular application.

Transmissions do this by various means such as hydraulic

clutches or a hydrostatic/hydraulic drive. Transmissions rely
on the engagement of gear groups to provide the transfer of
power to your machine components. Caterpillar designs all
parts, including these gear groups, to fall under three levels of
wear.

By understanding that different components are intended to

wear faster than others, you can inspect for signs of wear
and keep your transmission running smoother for longer.
For example, gears and shafts, if properly maintained, are
designed to last through multiple transmission rebuilds. But
components such as friction material, seals, gaskets and
bearings are faster wearing.

To increase productivity and prevent downtime, it’s vital to

make sure that all drive train components are constantly
monitored. Look at their condition to ensure contamination
isn’t entering their systems and to check that correct
operating techniques are being used.

This section focuses on how to identify problem indicators

and how to maximise the performance and life of your
transmission.
 117

Importance of s·o·s What do these S·O·S indicators mean?

Scheduled Oil Sampling is a crucial part of machine If excessive amounts of silicate (Si) and aluminium (Al)
management. Oil sampling at scheduled intervals validates are found in the transmission fluid, it means the oil is
your maintenance procedures, tracks what is going on inside contaminated with dirt. The S·O·S experts might recommend
the equipment and forecasts wear-related problems. you change your oil right away and to change it more
frequently in the future. High levels of copper (Cu), iron (Fe)
The Caterpillar S·O·S Oil Analysis programme is well and lead (Pb) would indicate abnormal wear of the bronze
recognised for its ability to detect potential failures before friction discs and steel separator plates. Recommendations
they occur. Each S·O·S Services test is designed to reveal would include stopping the machine and inspecting the
specific information about the condition of Cat products. transmission. Also, you would be advised to cut open and
inspect the oil filter for large particles.
The following wear table outlines transmission failures
and their common indicators, identified by using the S·O·S What tests are done by S·O·S Services?
Service.
The S·O·S Oil Analysis consists of four standard analysis
S·O·S Transmission Fluid Analysis Indicators tests:
• Component Wear Rate: determination of which
Friction Material Bearing or Bushing Failure
components are wearing and at what rate.
 Si, Cu, Pb (friction  Cu, Pb and/or Sn (bronze • Oil Contamination: What contaminates are showing up in
materials) bushing or thrust washer) the oil?
 Fe (separator plates)  Cr (rolling element • Oil Condition: Is the correct transmission oil being used?
bearing) Has the oil been exposed to excessive heat?
• Oil Identification: Is there coolant or water leaking into
 ISO Code (larger particles)  Fe (rolling element the oil? Is the right oil being used?
bearing, shaft, iron
housing) Consult your Barloworld Equipment customer service
 Oxidations (caused by  ISO Code (larger particles) representative for further information about the Barloworld
overheating the oil) Equipment Condition Monitoring Centre in Boksburg, which
 Incorrect fluid (difficult to incorporates the S·O·S laboratory.
identify)
Sticking Control Valves Dirt Entry
 ISO Code (larger particles)  Si and Al (dirt) 10:1 is a common payback ratio when
 Fe (debris)  Fe (separator plates, comparing the amount saved on repair
gears)
costs to the amount invested in S·O·S
 Oxidation (caused by  Cu, Pb, Sn (bronze
overheating the oil) bushings or thrust
Services.
washers)
118 Drive train

Preventative maintenance Efficiency Filters should be used for 250 service hours,
after any maintenance, rebuild or debris invasion, or when
suggested by particle count data from S·O·S Services. It’s
then recommended to switch back to standard filters.
Regular preventive maintenance is the most cost-effective
way to keep your transmission operating at peak performance.
When replacing an old transmission filter it’s extremely
Preventive maintenance focuses on transmission and drive
important to cut open the filter and inspect for signs of
train oils, filters, S·O·S and contamination control.
component wear or clogging. Pieces of metal may be found
in or around the magnetic screen and can indicate a certain
Preventive maintenance:
component is failing.
• Allows you to schedule downtime and plan for
maintenance and repair costs.
Possible sources of metal pieces:
• Helps prevent major failures, including failures of related
• Aluminium: torque converter.
parts.
• Bronze coloured: transmission clutches.
• Saves you money because you can often repair before
• Gray iron: transmission housing or pistons.
failure.
• Brass: rings in rotating clutches.
• Maximises parts reusability.
• Shiny metals: gear teeth.
• Optimises equipment life to keep your machine on the job.
• Shiny flaky material: bearings.
• Increases machine resale value.

Proper oil use Breathers

Breathers are extremely important in transmission preventive
Oil helps to perform three main functions: cleaning, cooling
maintenance. If breathers become plugged and temperatures
and lubricating the transmission. Today’s transmissions feature
dip down during the evening, the cab becomes a vacuum
new metals, elastomers and paper disc materials that require
because the cool air inside the cab shrinks.
advanced lubrication. You must use the right oil and change it
regularly and properly to achieve top performance.
As the air inside the cab shrinks it draws in air, dirt and other
contaminants through the gaskets and seals. If this occurs
Use the right drive train oil regularly, the gaskets and seals may sustain enough damage
to allow water and other contaminants into the cab. Dirt and
Caterpillar Transmission/Drive Train Oil (TDTO) is specially water are especially harmful to the electronics.
formulated to increase the life and performance of your Cat
drive train components. This oil reduces transmission slippage, Solenoids in your electronics control when and how
controls brake chatter, provides greater machine rimpull and quickly your clutches engage. When the solenoids become
increases friction material life up to 45 percent. Cat TDTO contaminated they become sluggish and your clutches
surpasses the TO-4 specification requirements and is specified may engage too quickly or they may slide. To get the most
as factory fill for all Caterpillar machine compartments where use out of this filter, cover the breather before washing
TO-4 oils are the primary recommendation. your equipment and check your breather for clogging when
inspecting other machine components.
Change oil properly
Contamination Control
Changing oil properly and at correct intervals is critical
to realising maximum component life. Actual oil life is Customers demand more power, faster cycle times and easier
determined by many factors such as operating conditions operation. To meet these needs, Caterpillar is responding with
and applications or contamination control. You can reduce higher system pressure and more sophisticated, productive
contamination by: machines.
• Washing the transmission tank and drain before removing
the cap. Controlling contamination is more critical than ever because
• Draining oil as quickly as possible and doing so when it is these high-tech machines require tighter clearances and
agitated and warm. fluid systems that are more sensitive to contamination.
• Using a filtered transfer cart to add new oil. Contamination leads to reduced efficiency, increased cycle
• Installing and removing filters carefully. times, shortened component and fluid life, and catastrophic
• Keeping filters in their packaging until ready for use. failure causing costly downtime and repairs.
• Cutting open and inspecting used filters before installing
new ones.
Causes of Contamination
Filters Contamination can be introduced at the refinery, during
machine operation or during maintenance.
Caterpillar filters are specifically designed around key factors
such as sediment capacity, collapsibility, burst strength and Contaminants include:
pressure fatigue. By properly and regularly changing filters and • Dirt.
by selecting the right filters, you maintain drive train system • Sealing material.
cleanliness, reduce component wear and lower costs. • Metals.
• Grease.
In addition to the standard Cat filters, Caterpillar also provides • Products from oil oxidation.
High Efficiency Filters. They use a synthetic media to remove • Weld spatter.
a higher proportion of both large and small particles. High • Heat.
 119

• Air. • Store oil drums on their sides.

• Paint flakes. • Use drum covers.
• Water. • Use the “kidney loop” system.
• Rag fibres. • Use high efficiency filters for extra filtration.

Effects of contamination in transmissions Repair and assembly:

• Place covers over open compartments.
Contaminants in transmissions cause: • Ensure that the root cause of failure has been identified
• Shifting problems from plugged control valves. and repaired.
• Premature clutch wear from spinning. • Use standard parts kits for all component installations.
• Leaks or premature wear.
• Premature bearing wear or bearing failure. Particle count monitoring:
• Premature gear wear. • Strive for oil cleanliness.
• Test oil in new machines after field assembly or after
adding new attachments.
Preventing contamination • Test oil before and after service repairs.

Prevent contamination by practicing good housekeeping in

the shop, using proper oil storage and transfer methods, Thorough inspection
keeping parts packaged during handling and storage, cleaning
components thoroughly during repair and assembly and A good inspection programme combines your daily
performing particle count monitoring. inspections with our periodic in-depth analysis. By
combining both, you can:
Good housekeeping practices: • Locate potential problems before they become major
• Sweep floors daily. repairs.
• Clean up spills immediately. • Schedule transmission maintenance and service.
• Keep workbenches uncluttered and free of debris. • Plan and control your operating costs and downtime.
• Limit use of floor storage.
Your daily visual inspection routine should include a complete
Proper oil storage and transfer methods: visual and operational check of your transmission. The
• Filter new oil. following chart summarises planned and problem indicators
that are associated with the transmission.

Cat Transmission Repair Indicators

Planned Description Problem Possible Causes Options
Indicators Indicators
S.O.S S.O.S Services Hesitation/ Worn plates and disks Technical Analysis Inspection
Services provide the best Slippage Linkage out of adjustment Repair Determination Inspection
insight into internal Low fluid level S.O.S Services
transmission wear Linkage not free Customer/Dealer Discussion
and potential failure. Incorrect pressure settings
Service Our dealers use Wrong oil used
Meter Hours service meter hours Unusual Worn gears/bearings Technical Analysis Inspection
as a repair indicator. Noises Dirt entry Repair Determination Inspection
Operator Talking with Aeration/cavitation S.O.S Services
Discussion your machine Low fluid levels Customer/Dealer Discussion
operator can reveal Vibration Bent shaft drive Technical Analysis Inspection
many potential Gear failure Repair Determination Inspection
transmission Bearing failure S.O.S Services
problems. Customer/Dealer Discussion
Overheating Wrong oil used Technical Analysis Inspection
Plugged radiator Repair Determination Inspection
Worn pump/pressure relief valve S.O.S Services
Worn or damaged seals Customer/Dealer Discussion
Low fluid level
Worn or dirty control valve
Debris in Dirt entry S.O.S Services
Filter/ on Wrong oil used Customer/Dealer Discussion
Magnetic Extended oil change period
Screen Worn gears/bearings
Disc disintegration
Leaks Worn, hard or cracked seals Repair Determination Inspection
Customer/Dealer Discussion
Bent or External damage Technical Analysis Inspection
Damaged Repair Determination Inspection
Lines Customer/Dealer Discussion
120 Drive train

Transmission maintenance DO’s and Scheduling

DON’Ts
We can help you develop an effective scheduling system by
Do’s providing you with time and cost record booklets or software
1. Make sure the fluid meets ISO standards before pouring it programs.
in your machine.
2 Use the correct transmission oil: Caterpillar recommended Use Maintenance Control System (MCS) software to
fluids found in the Operation and Maintenance Manual. schedule your maintenance and record machine operating
3. Use Cat filters. costs and time usage. This software allows you to download
4. Cut open old filters to inspect for indications of a problem. S·O·S reports from Trend Analysis Module (TAM) software.
5. Keep accurate records. You can also bring customised checklists from the Planned
6. Follow the proper machine service hour guidelines. Maintenance Planner (PMP) software into MCS. Print them
when each level of maintenance is due.
DON’Ts
1. Do not open your transmission system in a dirty Good scheduling means maintenance, inspections and
environment. planned repairs are done on time so you can prevent any
2. Always keep in mind proper Contamination Control transmission failures caused by overlooked maintenance.
guidelines.
3. Do not abuse your machine (application, operation, etc.). Record keeping
4. Do not pre-fill filters (fuel or oil).
An accurate record keeping system documents drive train
history by detailing component life and cost information.
Training, scheduling and We can help you set up manual record keeping and work
order systems, or we can help you install computer software
record keeping programs such as the Preventive Maintenance Planner (PMP)
or the Maintenance Control System (MCS). These programs
perform scheduling, checklists and other record-keeping
functions.
Training
By developing an accurate machine record keeping system,
Operating technique has a direct impact on drive train wear
you can identify high-cost or problem areas, track work flow,
and maximising machine life. Proper training is important to
control costs and increase machine resale value.
identify good and bad operator techniques.

Avoid:
• High-speed direction changes. Gears and shafts, if
• Backing over stumps or off a lowboy.
• Operating with a frozen undercarriage. properly maintained,
• Extreme braking. are designed to
last through
Implement:
• Adequate warm-up. multiple
• Periodic and proper shifting. transmission
• Attention to warning signs. rebuilds.
• Daily walk-around inspections.

Drive train life is also impacted by the applications

in which a machine operates throughout the year.
Key factors include the operating environment and
the layout of the jobsite.

Operating environment: Maximise the life of your

• Seasonal temperatures often affect fluid choices, transmission
change intervals, inspection and operating
practices. For any machine to be safe, reliable and
• Operating in water increases the chance of water productive, regular preventive maintenance
entering and contaminating the transmission fluid is vital. It is the most cost-effective way
system and may cause a loss of braking ability. to keep your transmission operating at
peak performance. If you take care of
Job site layout: your transmission, then gears and shafts
• Well-paved and maintained haul roads reduce the jarring can last through multiple rebuilds and the
impact on the drive train and other machine systems. overall transmission life increases. Take a proactive
• Repetitive and high-speed load and carry applications can approach by planning for scheduled downtime,
cause brake overheating. maintenance and repair costs. When you plan, you
save money and time, and who couldn’t use more of
each?
 121

Frequently asked questions

What are some of the subtle signs that you may have transmission problems?

Overheating, slippage or jerky shifting can signify a problem with a transmission component. If this occurs, carry out a thorough
machine inspection and take an S·O·S sample.

What are some of the primary causes of transmission failure and/or reduced power output or performance?

Low oil pressure can cause clutch slippage. Check your transmission filter and oil levels in the transmission. They may need
replacing. Incorrect pressure may cause transmission failure or reduced power output or performance. Transmissions are
designed to run at around 200 lbs of pressure. Check all pressures to ensure correct levels. Contamination from other failing
parts can cause plugged filters. Check all parts for contamination.

Are oil additives usually recommended?

Cat doesn’t recommend any additives; they are already in the lubricant.

What have been the major technological changes to transmission design in recent years and how have these affected
the maintenance and upkeep of transmissions?

As the expectations of life and durability of machines increase, Caterpillar engineers have responded by making many
mechanical and electrical changes that allow increased productivity and longer life of your product. However, these changes
require smaller tolerances and increases in pressure in your machine that make maintenance and the upkeep of your
transmission essential. Because these mechanical and electrical changes are advanced, they often require unique testing and
repair that only Barloworld Equipment can provide accurately.

When a company with a diverse fleet uses just one or two lubricating oils, what is the effect?

Using the incorrect lubricating oil can cause incorrect pressure, faster wear or slippage.

Are shared oil reserves with implement cylinders (vane or gear pumps) a problem?

Shared oil reserves can cause cross contamination. Newer machines are being designed without them.

Do different types of equipment wear out transmissions at different times? For example, how does a transmission
wear in load-and-carry operations vs. stay-at-home operations?

Transmissions do wear out at different intervals due to the applications they are in. If you are constantly shifting from gear to
gear or from forward to reverse, your clutches and gears may wear out faster.

Can cutting open a filter help you diagnose a problem?

Yes. Cutting open a filter is very important to determine the root cause of a problem. By finding pieces of metal in the filter, you
can determine what is failing. (Refer to the filter discussion under the Planned Maintenance section.)

What happens to the transmission when fluid becomes too hot?

The transmission oil additives deteriorate and lose their ability to control wear. Oil samples results will show high oxidation and
an increase in viscosity.

KEEP IT REAL, KEEP IT CAT ®

For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

Pg 73 (50x210).indd 1 2013/06/04 7:48 PM

122 Bearing Maintenance

BEARING MAINTENANCE

Contents
123 Bearing Maintenance
An Introduction

126 Trouble Shooting Charts

127 10 Factors Causing Premature Failure

 123

Bearing Maintenance
An Introduction

Caterpillar is known for having products that provide exceptional performance, extraordinary du-
rability and long life. Caterpillar bearings offer just that and more. Bearings are used in every drive
train component and virtually every mechanical component of Caterpillar machines. But because
of the varying speed, power, and torque and thrust force going through the drive train, one type
of bearing does not meet all the rigorous demands. Several types of bearings are needed, with
each bearing being highly crafted and precisely matched to the kind of load it carries.

Bearings serve to allow parts to move together smoothly with

minimum friction, heat and wear, often under extreme loads.

Caterpillar offers two fundamental types of bearings:

plain (bushing) and anti-friction. This section will focus on
antifriction bearings, which use balls and rollers as the primary
elements between contacting surfaces.

Anti-friction bearings consist of spherical or cylindrical

elements held in races that rotate with the adjoining surfaces,
preventing metal-to-metal contact and ultimately reducing
friction, heat and wear. Caterpillar offers a variety of different
antifriction bearings: ball bearings, roller bearings and needle
bearings. All three types of bearings have similar components:
hardened steel rings called races, and optional separators
or cages, which provide spacing for the rolling elements
between the races. In some applications, the rolling elements
are in direct contact with the shaft or other mounting.

It is evident that bearings play a critical role in safe and reliable Regardless of the type of lubrication system you are using,
equipment operation. A bearing failure can cause metal be sure to understand and follow the manufacturer’s
particles to enter the machine’s lubrication system, wearing recommendations to establish the right type and frequency
gear teeth and ultimately damaging the components. Thus, of lubrication that is needed for your specific bearing design
maintaining high quality operating conditions for the bearings and application. Additionally, set up an S·O·S oil analysis
will minimise repair costs and downtime. programme for your machines if one has not already been put
in place. This programme can easily help identify abnormal
The importance of lubrication wear prior to it becoming a major problem.

Lubrication is an important factor in bearing maintenance. Thorough inspection

Lubrication supplies an oil film for balls and rollers, reducing
friction between bearing components while providing a Detecting defects and deterioration before failure involves
protective coating to prevent rust, and transports heat away. periodically removing, cleaning and inspecting the bearings.
Using the appropriate quality, type and viscosity of lubricant is Remove bearings carefully as they can easily be damaged
vital to good bearing performance and life. during this removal procedure. (See ‘Frequently Asked
Questions’.) It is important to note that you should always use
Over-lubricating can lead to churning, causing friction and recommended tools and adhere to the outlined procedures
heat, which eventually initiates premature failure. Lack of in the machine’s service manual. Avoid harmful removal
lubricant can be harmful, given that not enough oil will procedures, such as flame cutting inner races or shrinking
be available to do the job. To ensure optimum bearing outer races with weld bead if possible. Using these practices
performance, Caterpillar offers a full line of Cat lubricants to can result in uncontrolled heat that can damage housings or
meet your everyday needs. shafts.

In splash lubrication systems, such as in final drives, it is When the removal process is complete, bearings should
imperative to retain the right type and quantity of lubricant always be cleaned before inspection. Follow Cat’s
in the housing, and to change the lubricant and filters at recommended guidelines to ensure the bearings are not
recommended intervals. Using lubricant rated for the proper damaged. Only use petroleum solvents that are suggested for
temperature must also be noted. When operating at extreme washing. It is important to remember that most solvents are
temperatures, it can lead to oxidising the oil and breaking flammable and toxic when inhaled or absorbed into the skin.
down of additives. Handle with caution.
124 Bearing Maintenance

When choosing
whether to replace
or reuse a bearing,
consider the load,
application, and the
number of service
hours.

To prevent contamination, clean bearings in a container that is If no signs of wear or damage are indicated and the bearing
large enough for the bearings to be splashed around without has low service hours, it can be reused after cleaning.
contacting the bottom where the dirt settles. However, if the bearing has high service hours, it is suggested
to go with a replacement. This is a precaution due to the fact
Allow the bearings to soak for an extended period of time to that the bearing might possibly fail and destroy other critical
loosen grease and dirt: possibly several hours or overnight. systems.
Use a short bristled brush that will not lose or break off its
bristles. After visually inspecting the bearing to see that all dirt Remember that many times it is challenging to determine
has been removed, rinse the bearing in a container of clean if a bearing is reusable just by visually inspecting it. Rolling
solvent; next dip the bearing in oil. contact stress fatigue originates beneath the surface and
cannot be seen. When choosing whether to replace or reuse
When drying the bearing, notice you should not use a bearing, consider the load, application, and the number of
compressed air to spin it dry. This can cause a non-lubricated service hours. In most situations, it is more economical to
bearing surface to be damaged. To dry the bearing, hold both replace a bearing that is in severe applications, under heavy
inner and outer races together to avoid spinning and blow air load, or has high service hours.
through the bearing.
Note that if you are not planning on reinstalling the inspected
After the bearing has gone through the cleaning process, bearing immediately, perform the following steps: oil the
examine it thoroughly for cracks in the race, dented seals, and bearing, wrap it in clean, oil proof paper, place it in a box and
damaged or broken separators, balls, or rollers. If a brownish- store it in a dry, dust-free place. These precautions will help
blue or bluish-black colour appears, it means the bearing has avoid corroding and shortening of the bearing life.
been overheated. At this point, replace the bearing. If the
bearing has a seal or shield, inspect it for damage or wear. Hints on replacement
If the seals are damaged or worn, you must replace the
complete bearing. A worn or damaged seal will permit dirt and Any time during inspection you decide to replace a bearing, be
moisture to enter the bearing, minimising its wear life. sure you replace it with a genuine Cat bearing. Only then are
you assured of the proper performance and long life of your
Check separable bearings for pitted, scratched or flaked balls, machine.
rollers or races. If any of these signs are visible, replace the
bearing. Inspect the inner surfaces and rolling components in Bearings must be compatible with the machine in the areas of
a non-separable bearing by shining a flashlight between the lubrication, fit, surface and load carrying ability. Many times a
balls and rollers. If you notice any pits, scratches or surface bearing will look like an original, yet it might not be a correct
damage replace the bearings. replacement. Bearings that are not compatible in all areas can
fail prematurely.
Further, scan the outer race for proper wear patterns such as
wear tracks that are centred without pits or scratches. If you Cat equipment requires the use of many specialised bearings.
do not visually notice any signs of wear or damage, lightly Some bearings are imprinted with the manufacturer’s code
lubricate the bearing and slowly turn the outer race. Never that supplies information on the bearing’s general dimensions.
spin it. If a clicking or sticking is observed, clean the bearing Cat bearings are made specifically for Cat products. Therefore,
again. If the condition still exists after cleaning, you will need they have no stamped dimensions. In some cases, even
to replace the entire bearing. A thrust bearing or tapered roller though a bearing might portray the same identification code
bearing can be tested the same way, but place the bearing as a standard bearing, it might be unique and have the ability
on a clean surface, lightly apply hand pressure and turn the to provide longer life in certain applications.
bearing.
 125
For example, a bearing could have a particular surface finish or Yet, the cause could be linked to various factors, such as
heat treat, or possibly include a different roller crown or cage insufficient or improper lubrication, improper adjustment
design. It is vital that you avoid using a standard bearing when or any combination of these factors. For this instance, you
a special bearing is specified. Selecting the incorrect bearing should carefully investigate the mounting, installation and
will shorten the life and can create further damage parts affecting the bearing operation to decipher the cause of
the damage.
Detect, then correct
Remember, if you merely replace the failed bearing without
If you correctly maintain your bearings, they will not incur finding and fixing the root cause, the replacement bearing will
premature failure. However, they will eventually fail due to most likely endure the same wear and damage as the original.
rolling contact stress fatigue. A premature failure happens
when bearings fail at low hours for causes beyond normal
material fatigue. If you identify any signs of possible bearing
failure, such as excessive noise and vibration, excessive Maximise the life of your bearings
heat, lubricant loss or shaft resistance to turning, refer to the
troubleshooting chart on the following page. For any machine to be safe, reliable and productive,
proper bearing maintenance is an absolute must.
This chart may help you determine the indicators, causes That’s because bearings are used in – and affect the
and proper repair options. If the recommended maintenance performance of – virtually all mechanical components.
options do not correct the problem, disassemble the bearing You could cross your fingers and hope nothing ever
and try to recognise the cause again. goes wrong. Or you could take a proactive approach by
eliminating bearing problems before they begin, with
Keep in mind, determining the cause is usually easier said prevention and scheduled maintenance programmes
than done. A visual examination may identify the type of that will ultimately minimise repair costs and
damage, but it may not aid it recognising what is causing downtime. And that’s what you really want from any
the problem. Take this situation for example, if a bearing has machine.
scored and heat-discoloration on the roller ends, you know it
is burned up and needs to be replaced.
126 Bearing Maintenance

Troubleshooting Chart
Problem indicators Causes Options
Excessive Noise and Vibration Insufficient lubrication Fill with correct amount of proper lubricant.
Incorrect lubricant Use recommended lubricant.
Defective bearing Replace bearing.
Dirt Replace bearing.
Corrosion Replace bearing. Use lubricant that resists corrosion.
Improper Load Adjust to specification.
Misalignment Determine what is misaligned: housing, shaft, or bores.
Shaft may be bent or housing bores not aligned.
Replace shaft or housing.
Bearings fit too loose  hrome plate or metalise shaft or bore and regrind to
C
specification, replace bearing if seating surfaces are worn.
Improper mounting Replace bearing. Correct installation/mounting problem.
Excessive Heat Insufficient lubrication Fill with correct amount of proper lubricant.
Incorrect lubricant Use recommended lubricant.
Improper setting Adjust to specification.
Misalignment Determine what is misaligned: housing, shaft, or bores.
Shaft may be bent or housing bores not aligned.
Replace shaft or housing.
Lubricant churning Use less lubricant or use a lower viscosity lubricant.
Be sure to use recommended lubricant.
Spinning race Either inner or outer race is sliding around its seated
surface.
Use proper sized components.
Lubricant Loss Too much grease Grease to proper level.
Improper lubricant Use high-temperature grease.
Leakage through seal Replace seal.
Check shaft for scratches or burrs that may have damaged
seal.
Shaft Resistant to Turning Incorrect lubricant Use recommended lubricant.
Dirt Clean bearing. Replace seals and bearing if damaged.
Corrosion Replace bearing. Use lubricant that resists corrosion.
Improper setting Adjust to specification.
Lack of lubrication Add proper lubricant. Check for damage.
Seal tight Use proper size and type of seal.
Bearing cocked If new installation, remove bearing and clean all mating
surfaces.
Reinstall bearing if not damaged.
Leakage between bearings Replace gasket.
caps and housing
 127
Frequently asked questions
Ten factors causing
What tools do I need to perform proper maintenance of
bearings? premature failure
You should always work with clean, recommended or Overloading is an especially common factor in
approved tools. Do not use a wooden mallet. Also work in premature bearing failure. Overloading causes the oil
clean surroundings, such as on a metal or a metal-covered to generate heat, which affects the oil viscosity.
bench. Heat will cause the oil viscosity to decrease and make
the lube film thin, allowing contact between the rolling
How should I properly handle a bearing? components and raceway.

Always handle the bearings with clean, dry hands or even The contact can cause damage similar to the damage
clean canvas gloves. Never hold a bearing with dirty or moist caused by insufficient lubrication.
hands, as contamination can easily be transmitted to the
bearing. When you are finished handling the bearing, lay the Caterpillar’s Solution: Caterpillar bearings are
bearing out on a clean surface. designed as an integral part of the total machine
system. By always using genuine Cat parts, you will
What should I use to clean a bearing? ensure the integrity of those systems and provide high
performance and long life, especially under high load
To clean a bearing you should use uncontaminated solvents applications.
and flushing oils. If it is necessary to wipe the bearing,
only use clean lint-free rags. It is important to note that 2. Improper Lubrication
you should never use cotton waste or dirty rags to wipe
a bearing. Further, never use the same container for both As mentioned before, proper lubrication is vital to
cleaning and final rinse of used bearings. high-quality bearing performance and service life.
Insufficient lubrication allows for metal-to-metal
What is the technique I should use to dry a bearing? contact of the major elements and especially of the
roller end against the rib, producing scoring in these
To dry a bearing, hold both the inner and outer races areas.
together and blow air through the bearing. You should never
spin any bearing with compressed air. Heat has the ability to turn various elements and roller
ends dark blue, or perhaps in extreme cases, black.
How should I store a bearing?
Caterpillar’s Solution: In applications where
When storing a bearing, remember the most important inadequate lubrication is a concern, Caterpillar uses
factor is protecting the bearing from dirt and moisture. You a proprietary bearing technology called “textured”
should be sure to keep the bearing wrapped in oil proof bearings. Texturing allows for better oil retention on
paper. Be sure that you do not scratch or nick bearing the contact surfaces which leads to longer bearing life
surfaces while handling and storing the bearing. especially in high load, slow speed applications.

What should I know about installing bearings? 3. Contamination

When installing a new bearing, install the bearing as it Contamination is any foreign substance that has the
comes from the package, without washing if it was received ability to damage a bearing. Moisture, dirt, sand or any
in a clean container. When installing used bearings you type of abrasive material will cause premature bearing
should thoroughly clean the inside of the housing prior to the breakdown. It is important to be able to recognise
installation process. symptoms of contamination, such as scratching,
scoring, brushing, pitting, grooving, bruising, matte or
What should I know about lubricants? satin finish or rust. Several causes of contamination
involve debris manufactured into the system, cracked
Lubricants are a critical aspect of bearing maintenance. It housings or hoses, dirt access through failed seals,
is vital that you always keep lubricants clean when applying minute metal particles and contaminated lubricant.
them, and cover the containers when not in use. Further,
always use the correct type and amount of lubrication, as Caterpillar’s Solution: When contamination is an
this will play a key role in bearing wear life. issue, Caterpillar offers “debris resistant” bearings.
These bearings utilise a combination of specialised
material and heat treat to produce bearings that are
extremely resilient to debris and contaminants in the
oil.
A worn or damaged seal will permit
dirt and moisture to enter the bearing,
minimising its wear life.
128 Bearing Maintenance

4. Distortion

When the housing or shaft is out of round, the bearing roller components are forced together where there is a
minimum amount of clearance. The heightened pressure can result in the race and other rolling elements to incur
surface flaking, something that typically happens with normal fatigue.

Caterpillar’s Solution: see “Improper Fit”

5. Misalignment

To maximise bearing life, the supporting seats and shoulders must meet manufacturer’s specific limits. If the
misalignment is beyond those particular limits, the load on the bearing will be intense on only a segment of the roller
and races, causing excessive stress and premature failure at that single point.

Caterpillar’s Solution: Caterpillar’s specialised roller profile provides optimum load distribution across the bearing,
even when misalignment is present. This serves to minimise stress in the bearing and maximise bearing life.

6. Improper Fit

Having proper bearing fit is essential to capitalising on bearing performance and life. A variety of improper fits can
cause significant damage, including forcing a bearing onto a shaft that is too large for the inside diameter of the bearing
race, fitting an outer race insecurely (too loose) in its housing and having a loose fit between the shaft and the inside
bore of the bearing. These inadequate fits can cause split races, fretting corrosion and creep wear.

Caterpillar’s Solution: Caterpillar bearings are made with specialised tolerances for precise fit of the bearing to the
shaft or housing and ensures exact positioning of related parts.

7. Vibration Damage

Anti-friction bearings must roll while under a load. Subsequently, subjecting a bearing to vibration while it remains
immobile can cause depressions on the race from fretting.

Caterpillar’s Solution: In Caterpillar bearings, eliminating vibration is a prime factor in determining the type of bearing
cage required. Brass cages and non-metallic bearing cages are two types which minimise vibration and provide
maximum life in harsh applications.

8. Defects in Material

Defects in antifriction bearings are particularly rare, especially when it comes to the material, forming, machining, heat
treat, grinding and assembly difficulties. The minimisation of defects is a result of the extreme cleanliness of bearing
steels and stringent quality control measures used in manufacturing facilities that supply Caterpillar bearings. Note that
usually only a metallurgist can characterise these types of defects from other causes of premature failures.

Caterpillar’s Solution: Caterpillar bearings are manufactured to the highest material quality standards in the industry
and will always provide for the optimum performance and component life of Cat machines.

9. Improper Servicing Techniques

It is critical to always follow the manufacturer’s recommendations summarised in your service manual. Further, this
means using the proper tools. Using inappropriate tools and procedures when removing, installing and handling
bearings can cause damage and possibly failure.

Caterpillar’s Solution: Always refer to your Cat equipment’s

Operation and Maintenance Manual and other service literature
for proper procedures and servicing techniques.

10. Electrical Current

Bearings pass electrical currents that initiate an arcing

and burning at the points of contact between the
races and rollers. This may produce a single burn or
multiple grooves called “fluting.” A burned bearing
allows for excessive noise and will need to be
replaced.

Caterpillar’s Solution: Be sure to find and repair the root cause of the
electrical ground to avoid damage to the new bearing.
 129

Contents
130 Cylinders and Rods
Advanced Surface Technology
Cylinder Rod Seals
130
131
Hydraulic Cylinder Reseal Service 132
Hydraulic Cylinder Seal Kits 133

134 Hoses and Couplings

Hose Service
Couplings: No-Skive and XT
134
135
Onsite Hose and Coupling Container Service 136
HYDRAULICS

ToughguardTM 137

139 Hydraulic Systems

Custom Hydraulic Service 139

140 O-Rings and Seals

Cat optional high-temperature fkm seals 142

143 Pumps and Motors

Pump and Motor Service
Reman
143
144
130 hydraulics

Cat Advanced Surface Technology

For off-highway truck suspension and hoist cylinders

Reman rods with Cat AST available to Superior wear characteristics

support Cat F-Series off-highway trucks
Because the metal alloy coating created by Cat AST is
harder than chrome plating, it provides greater resistance to
Introduced on the Cat F-Series off-highway trucks, Cat scratching and therefore helps prevent contaminants from
Advanced Surface Technology (AST) coated rods offer several entering the system. The Cat AST surface is also denser,
advantages over traditional chrome-plated rods. allowing it to extend component life. The process is good for
the environment, as Cat AST byproducts can be recycled or
Benefits: reused.
• They can last up to three times as long in the same
application.
• Offer better wear resistance.
• Are more environmentally friendly.

Superior wear characteristics and improved component

durability mean longer seal life, reduced downtime, and
improved machine availability and productivity.

Because many of these rods are compatible to earlier models,

Caterpillar is offering an “upgrade-to-AST” option. Owners of
older Cat trucks interested in upgrading to Cat AST Reman
Rods will receive core credit for their existing rods.

How Cat AST works

Here’s how the Cat Advanced Surface Technology process
works:

• S alvaged components undergo straightening.

• New and salvaged components undergo grit-blasting to
prepare and clean the surface for the thermal spray.
• Hot combustion gases near 2 760°C are channelled and
combined with a fine metal powder, and accelerated
through a nozzle at more than three times the speed • Suspension Cylinder Rods • Hoist Cylinder Rods •
of sound. This forms a stronger mechanical bond than • Hoist Cylinder Groups •
chrome plating.
• The surface is ground to like-new specifications. Models
• A final grinding operation gives the surface a super-fine • 769/771D • 770/772 • 773/775F • 777F •
polish. • LOHT: 785 – 797 •
 131

Hydraulic Cylinder Rod Seals

When it is time for repairs, you should not overlook any part, regardless of size. Even parts as
small as seals have a big impact on machine performance, contamination control and operating
costs. That’s why selecting the right seals is so important and why Caterpillar is dedicated to de-
signing the best-performing seals in the industry.

Cat rod seals are designed to work together to deliver

optimum sealing performance and lower operating costs in
Cat hydraulic systems, something you risk when purchasing Better Material
other brands of seals. All Cat rod seals – wiper, U-cup and
buffer – feature a proprietary urethane material and patented Cat hydraulic cylinder rod seals feature a proprietary
designs. urethane material that delivers improved performance
over the material used in previous seals. This
When you need new hydraulic cylinder rod seals, don’t proprietary material provides:
install doubt. Turn to us for genuine Cat seals. Discover the
difference better designs and better material make. • Better compression set
Compression set measures a material’s ability to
Wiper Seal rebound to its original shape after compression.
Cat urethane material offers up to a 25%
Cat wiper seals feature a patented double-lip design improvement in compression set capabilities over
that provides optimum contact with the rod to keep out previous materials, without sacrificing tensile
contaminants. Also, vents moulded into the radius of strength or seal hardness levels.
the internal lip help prevent these seals from unseating
themselves during operation. • Wider temperature application
Cat hydraulic cylinder rod seals can work in a wider
range of operating temperatures than previous
U-cup Seal designs, without seal degradation.
Cat U-cup seals also feature a double lip. This design ensures
uniform contact of the oil-sealing lip, helping deliver top Better Value
performance and wear life. Cat U-cup seals work together
with the buffer seals to optimise sealing performance while At Barloworld Equipment’s service centres, resealing
minimising pressure build-up. hydraulic cylinders involves more than installing
new seals. To help you get the full life of the new
seals, we light hone cylinder tubes. We also practice
Buffer Seal contamination control, have tooling for proper
disassembly and assembly, reassemble to Cat specs,
Cat buffer seals last longer because they are designed to be
and have pressure test capability
pressure-activated. Unlike compression buffer seals, these
Cat seals exert pressure on the rod only when necessary.
And because vents provide a passage for high pressure to
be relieved back into the cylinder, Cat buffer seals minimise
pressure build-up, reducing U-cup failure.

Better Design
Cat wiper, U-cup and buffer seals feature design
improvements that enhance performance, reduce leakage and
increase seal life.

Cat wiper, U-Cup and buffer seals are designed to work together to
provide optimum sealing performance in Cat hydraulic systems.
132 hydraulics

Hydraulic Cylinder Reseal Service

Count on our expertise to stop leaks and maximise system performance

Our Barloworld Equipment service team is committed to resealing hydraulic cylinders quickly and
correctly the first time. That means using proper disassembly and assembly procedures, honing
cylinder tubes, practicing contamination control, and installing the industry’s best hydraulic seals.
We even check for other problems – such as dented or scored rods – and we pressure test each
resealed cylinder.

There’s a lot more to resealing hydraulic cylinders than just

installing new seals. Find out how we can help you keep your
costs low and your cylinders performing at peak efficiency.

Five reasons we’re your best choice for hydraulic cylinder

reseal service:

Proper disassembly and assembly

Without the proper tooling, completing the repair can take
much longer. You also risk damaging reusable parts or ruining
the cylinder group. We use tooling designed to disassemble
and assemble cylinders quickly, without damaging
components.

Light honing
We light hone cylinder tubes to remove minor scratches and
other hard-to-see imperfections that quickly damage newly
installed piston seals and piston wear bands. This procedure,
in conjunction with proper contamination control practices,
substantially increases the life of new hydraulic cylinder seals.

Contamination control
Worn seals allow contamination to enter the hydraulic
cylinder. These contaminants can damage newly installed
seals – or worse, damage other system components such as
pumps or valves. We clean cylinder components and wash out
any contaminants before re-assembling the group.

Cat seals and seal kits

Caterpillar is dedicated to designing the best-performing seals
in the industry. That’s why we reseal hydraulic cylinders with
genuine Cat seals and money-saving seal kits. Cat seals are
specifically designed to handle the increasing pressures and
temperatures of today’s hydraulic cylinders. Don’t risk poor
performance or leaks, use seals that carry the Caterpillar Other ways our hydraulic service can
name. save you time and money
Quality assurance Resealing hydraulic cylinders quickly and effectively is
just one of the many ways we can help you lower your
We pressure test each hydraulic cylinder before returning it to operating costs and improve your hydraulic system’s
you, helping ensure reliable on-the-job performance. performance.

We’ll show you our wide range of repair options –

including Cat Reman components – and explain how
we can help you get maximum machine productivity at
the lowest possible cost.
 133

Hydraulic Cylinder Seals Kits

It’s frustrating to open a seal kit and find it contains too many, too few, or the wrong seals. Cat
hydraulic cylinder seal kits are designed to provide the exact seals you need. The key is ordering
the right seal kit.

Occasionally, Caterpillar changes the design of a cylinder

group in production. Sometimes these changes result in a
new cylinder group part number. Other times the part number
stays the same and a new “engineering change level” is
assigned. This makes it possible for multiple seal kits to
service the same cylinder group. Therefore, when ordering a
seal kit you need to know both the cylinder group part number
and its engineering change level. Speak to your Barloworld
Equipment customer service representative for expert advice.

Contents and packaging help ensure

quality and ease of use
Cat hydraulic cylinder seal kits contain genuine Cat seals,
many of which feature proprietary urethane material and
patented designs for superior compression set and broader
temperature applications. All are matched to your application,
helping ensure top performance and long wear life. Kits
themselves are carefully packaged to keep contamination out,
and they include a list of the contents, installation instructions,
and the engineering change level. For more information,
contact us today or visit the Cat website (www.cat.com).

With Cat hydraulic cylinder seal kits, you receive all the seals you
need – and only the right ones for your application. There’s no waste
or confusion, saving you time and money.

Easy-to-use kits simplify Cat cylinder

repairs
• C onvenience: One part number gets you all the
right seals for your application, no more, no less.
• Quality: Cat seal kits contain genuine Cat hydraulic
cylinder seals, matched to specific applications for
durability and long wear life.
• Protection: Careful packaging helps ensure seals
are protected from contaminants that can reduce
hydraulic system performance.
• Value: Available off-the-shelf for most cylinder
applications, Cat seal kits cost less than ordering
Light honing optimises seal the seals individually.
performance and life
Restoring the proper geometry and surface to the
cylinder bore can keep you from replacing seals earlier To ensure correct seal kit selection,
than necessary. That’s why before we install new locate the cylinder group part number
cylinder seals in our workshop we perform a simple
procedure called light honing. Light honing detects
and engineering change level on the
and corrects minor damage to the cylinder bore that outside of the cylinder.
left unchecked wears out internal seals and eventually
causes leaks inside the system.
134 hydraulics

Cat Hose Service

Fast, Dependable, Certified Clean

Superior Cat hose products: Barloworld Equipment hydraulics centres build hoses from their large inventory of Cat high,
medium and low-pressure hoses and couplings. These products are designed, built and tested as a system by Caterpillar to
exceed industry requirements.

Certified Crimp: Our hydraulics technicians visually and dimensionally check crimps to make sure they meet specifications.
Over and under crimped hoses can be detrimental to both hose performance and safety.

Certified Clean: We use a state-of-the-art process to remove contaminants created during the cutting and crimping of hoses. If
left inside hoses, these contaminants can damage cylinders, pumps and other hydraulic system components. We also cap the
ends of hoses to help prevent contaminant ingress prior to installation.

The benefits:
• One part number makes ordering hoses for Cat • C ertified Clean.
equipment quick and easy. • Certified Crimp.
• Hoses are assembled to original specifications by • While you wait service for Cat and other equipment
trained Barloworld Equipment technicians. brands.
• Use of superior Cat hose products. • On-site support for remote sites.

Barloworld Equipment technicians pneumatically clean hoses with foam projectiles to remove contaminants that can damage hydraulic system
components.

Work hard, Play hard.

Visit our Cat® clothing store for a wide range of quality Cat clothing,
shoes and merchandise. For more information call 011 929 0067 or
email pselebi@barloworld-equipment.com
 135

No-Skive Couplings: Added Flexibility

When Caterpillar first announced its decision to
move away from the Cat reusable coupling sys-
tem and introduce the No-Skive coupling se-
ries many people were apprehensive about the
change. After all, Cat reusable couplings have
been around since the late 60’s; they have also
been the only high pressure reusable coupling
system on the market for many years.

Once seen in operation, though, customers soon appreciate

that this latest Caterpillar R & D innovation is designed with
the express purpose of improving efficiencies still further.

No-Skive: Designed to lower inventory

No-Skive couplings satisfy the requirements for Cat XT-3, XT-5 and
holdings XT-6ES and ToughGuard ™ hoses.

Cat XT No-Skive couplings provide several benefits, a key

one being lower inventory requirements. That’s because each
No-Skive coupling satisfies the requirements for Cat XT-3, XT-5 coupling results in more consistent torque readings and easier
and XT-6ES and ToughGuard ™ hoses. hose assembly installation.

Additionally, as the name implies, No-Skive couplings Previously you could only use an XT-3ES coupling on an XT-
eliminate the need for the hose to be skived prior to 3ES hose and the same applied with Caterpillar XT-5ES and
assembly. In addition to reducing labour and assembly time, XT-6ES hoses. This meant having to carry one coupling for
it also reduces the chance for installation error and system each pressure hose. Now, however, with the new No-Skive
contamination from rubber particles. innovation one coupling will fit on all three hose pressure
ratings.
XT No-Skive couplings can be pushed on by hand in the Dash
6 and Dash 8 sizes while maintaining enough grip to ensure In addition to the No-Skive series, Barloworld Equipment’s
orientation placement, all while eliminating the need for a hose service centres across southern Africa provide
pusher. The swaged nut and improved plating process on each full support for all machines fitted with Cat reusable
couplings.

Reusable Couplings For Cat XT Hose

Cat reusable couplings for XT™ hose feature a unique two-
piece design that allows you to reuse the couplings. When
you need to replace worn hose, we just take off the coupling,
install the new hose, and reattach the coupling. We’ll have
your repaired hose assembly ready fast, so you can get back
to work quickly.

On new Cat machine models, Caterpillar has discontinued the

Reuseable Coupling series and replaced it with the No-Skive
Coupling Series. (See above)
136 hydraulics

On-Site Hose Support:

A Novel Container Service
When and where you need it.

For mines and contractors operating on remote sites, the introduction of Barloworld Equipment’s
hydraulic hose assembly container service cuts out part delivery lead times and ensures fast and
efficient maintenance. On the spot hose changes mean there’s minimal machine downtime and
all tooling meets the requirements for Cat no-skive and reusable couplings.

Catering for low, medium or high pressure applications, hose Hose tooling comprises a Cat S6.2 radial press with the
and coupling inventories are customized to match the client’s Series (III) Crimputer permanent coupling software set-up
machine population for both Cat and other OEM products. for no-skive products; an XT press for all reusable coupling
changes; a fully ventilated hose cutter; a workbench with vice;
The purpose-built 40 foot high-rise container comes equipped a contamination control cupboard; storage shelving; and hose
with the latest Caterpillar technologies and is manned and reel racking.
managed on-site by Barloworld Equipment Parts Department
personnel that include trained hose assemblers. Ongoing The container’s easy portability also means that the unit can
inventory management ensures that replacement parts are be loaded onto a truck and moved from site to site, when
always available. required.

Standard for each container configuration are features that

include an air conditioning system; an office area; and ISO
electrical points with lock-out.

The container’s easy portability also

means that the unit can be loaded onto a
truck and moved from site to site, when
required.

Each purpose-built 40 foot high-rise container comes equipped with

the latest Caterpillar technologies.
 137

Cat XT™ ES (Enhanced Spiral) hose has

an exclusive cover which is formulated
and manufactured by Caterpillar to
provide up to 20 times more abrasion
resistance than industry-standard hose.

Cat Toughguard™ Hose

The standard in hose performance

Cover abrasion is the leading cause of hydraulic hose failure, which in turn has downstream
impacts on machine availability and productivity.

Caterpillar’s research and development team has responded Besides helping to increase machine uptime, Cat ToughGuard
with the ToughGuard series, designed for XTTM ES (Enhanced hose significantly reduces material and labour costs
Spiral) hose. Engineered to meet the toughest working associated with other hose-protection options.
applications, ToughGuard covers provide up to 20 times more
abrasion resistance than industry-standard hose, as confirmed More flexibility
by ISO abrasion-resistance testing. (This ISO test requires a
50N steel tool to be cycled back and forth along the length Cat XT ES hose works at half of the SAE’s bend radius,
of the hose until the cover wears away to the point of wire allowing tighter routing, without sacrificing cold flex capability.
exposure.) These attributes, plus superior reliability, make Cat XT ES hose
the preferred choice in a variety of machines and applications.
ToughGuard: built to last
Each ToughGuard hose features a polyethylene exterior
that provides increased resistance to abrasion caused by
hoses rubbing together or against other abrasive materials.
Additionally, this cover:

• E liminates the need for nylon or plastic add-on protection

in most applications.
• Does not sacrifice minimum bend performance.
• Offers protection against chemicals and weathering.
• Is compatible with both Cat XT No-Skive and Cat XT ES
Reusable Couplings.
• Uses existing clips and grommets.
• Has been tested to two million abrasion cycles without
failure.
138 hydraulics

Cat Toughguard™ Hose

Continued

XT-3 ES Hose
Exceeds SAE 100R12 Standards
Part No. Hose I.D. in (mm) Hose Dash Size Max. Work Pressure Min. Bend Radius*
psi (kPa) in (mm)
238-8337 0.375 (9.5) -6 4,000 (28,000) 2.50 (64)
238-8339 0.500 (12.7) -8 4,000 (28,000) 3.50 (89)
238-8340 0.625 (15.9) -10 4,000 (28,000) 4.00 (102)
238-8341 0.750 (19.1) -12 4,000 (28,000) 4.75 (121)
238-8342 1.000 (25.4) -16 4,000 (28,000) 6.00 (153)
245-1420 1.250 (31.8) -20 3,000 (21,000) 8.25 (210)
245-1421 1.500 (38.1) -24 2,500 (17,500) 10.00 (254)
256-1390 2.000 (50.8) -32 2,500 (17,500) 12.50 (318)

XT-5 ES
Exceeds SAE 100R13 Standards
Part No. Hose I.D. in (mm) Hose Dash Size Max. Work Pressure Min. Bend Radius*
psi (kPa) in (mm)
293-4616 0.750 (19.1) -12 5,000 (34,474) 4.76 (141)
293-4617 1.000 (25.4) -16 5,000 (34,474) 6.02 (153)
293-4618 1.250 (31.8) -20 5,000 (34,474) 8.27 (210)
293-4619 1.500 (38.1) -24 5,000 (34,474) 9.99 (254)
5P-8358 2.000 (50.8) -32 5,000 (34,474) 12.52 (318)

XT-6 ES Hose
Exceeds SAE 100R15 Standards
Part No. Hose I.D. in (mm) Hose Dash Size Max. Work Pressure Min. Bend Radius*
psi (kPa) in (mm)
238-8343 0.375 (9.5) -6 6,000 (41,370) 3.00 (76)
238-8344 0.500 (12.7) -8 6,000 (41,370) 4.00 (101)
238-8346 0.750 (19.1) -12 6,000 (41,370) 5.25 (133)
238-8347 1.000 (25.4) -16 6,000 (41,370) 6.50 (165)
245-1412 1.250 (31.8) -20 6,000 (41,370) 8.75 (222)
245-1413 1.500 (38.1) -24 6,000 (41,370) 10.50 (267)
222-4844 2.000 (50.8) -32 6,000 (41,370) 25.98 (660)
 139

Custom Hydraulic Service

For peak performance and profitability

Custom Hydraulic Service (CHS) is a detailed inspection programme available through Barloworld
Equipment that is designed to keep today’s hydraulics-intensive machines operating at peak per-
formance.

Studies show that hydraulic

system efficiency can fall off by
as much as 20% before being
detected by operators.

Today’s hydraulic systems operate with higher pressures and SOS Fluids Analysis:
tighter tolerances that demand attention to contamination • Extraction of oil sample from the hydraulic compartment.
control. Dirt and other contaminants allowed to enter the • Analysis of oil sample to determine contamination level,
system accelerate parts wear. Along with higher service physical properties and wear material count.
costs, premature wear can also cause a loss of performance
that may go undetected for a long time. Corrective action recommendations:
• Analyse results of performance test, oil analysis and visual
CHS Inspections inspection.
• Provide a detailed report.
Recommended annually or every 2 000 hours, CHS • Recommend repairs if needed, as well as changes to the
inspections performed by Barloworld Equipment maintenance schedule.
technicians include:

Performance tests:
• Engine performance.
• Hydraulic cylinder drift.
• Hydraulic system cycle times and pressure.
Custom Hydraulic Service inspections
Visual inspection checks: identify when a machine’s hydraulics
• Hydraulic system.
• Engine and cooling system. are not performing up to par and enable
• Cab. corrective action to be taken.
• Electrical system.
• Undercarriage.
• Ground Engaging Tools.
140 hydraulics

Cat O-Rings
Matched to your Cat system and designed for maximum seal life in demanding
applications

Cat O-ring materials are specifically selected based on the different fluids, and fluid temperatures,
in Cat engines and machines. Seal material hardness is matched to the different fluid system
pressures to maintain proper sealing force, as well as minimise seal extrusion and seal abrasion.
In addition, some Cat O-rings have special coatings, like PTFE, to minimise friction and ensure
proper seal installation in tight seal grooves.

Precise seal dimensions help ensure Cat O-ring seals fit Cat Resealable O-Ring Packaging
properly into Cat seal grooves without damage to the seal,
and there are unique Cat O-ring sizes designed for use in Available alongside the
special applications where SAE standard sizes won’t perform Cat refillable kit option is
well. Caterpillar’s comprehensive
range of resealable O-ring
Packaged to save you time and money packets.

Caterpillar offers several O-ring seal kits, saving you time and Caterpillar now offers 67
up to 15 percent off the cost of ordering O-rings individually. different O-Ring packages
Seven different kits are available for hydraulic fittings and air- to match the most common
conditioning systems. types of hydraulic adapters
and hose fittings, each
Contact your Barloworld Equipment customer service available in a convenient,
representative for more information on the range of contamination-free poly-bag.
Cat O-rings available for your Cat equipment and other
applications. For order enquiries, please
contact your Barloworld
Equipment customer service
Cat Refillable O-Ring Seal Kits representative or any one of
our Parts Counters nationwide.
When you replace Cat hoses and tubes, it’s important to
have the right O-rings at your fingertips, which is where Cat
refillable O-ring seal kits prove invaluable.
Cat O-ring Materials
Stored in durable carry cases, Cat seal kits have individual Material Hardness
compartments to store a variety of seal sizes. Nitrile Buna Rubber (NBR) 55, 60, 70, 75, 80, 90

Caterpillar offers two types of application-specific seals: Highly Saturated Nitrile 60, 78
Standard Nitrile (NBR) and Fluorocarbon (FKM) rubber, made Buna Rubber (HNBR)
specifically for high-performance Cat hydraulic systems. Fluorocarbon Rubber (FKM) 60, 75, 80, 90, 95
Every O-ring Caterpillar makes Silicone (VMQ) 60, 70
meets specific material
and dimensional Ethylene Propylene Diene 50, 70
requirements. Modified Rubber (EPDM)
These are the primary materials used in Cat O-rings.
Seal kits for speciality Other materials, in a variety of hardness types, are used in
applications cater specialty applications.
for air conditioning
fittings, plus low-
pressure, high
temperature
environments.

Maintain your cooling system. High fluid

temperatures are the number one cause of
shortened seal life.
 141

10 O-Ring Tips
1. Keep O-rings packaged until installation.

2. Don’t store O-rings near heat.

3. Protect O-rings from UV rays.

4. R
 emove old O-rings with brass or plastic picks to
prevent groove damage.

5. Don’t reuse O-rings.

FKM Advantage
6. Clean the seal groove before installation.
FKM rubber seals are available for O-Ring face seals
(ORFS), straight thread O-rings (STORS) and D-rings.
7. Don’t soak O-rings.
ORFS FKM seals are designed for brake control lines,
8. Don’t twist or cut O-rings during installation.
fuel lines and hydraulic control systems.
9. D
 on’t select O-rings based on material colour. There is
STORS FKM seals are designed for fluid fittings and
no universal colour standard.
plugs in engines.
10. Maintain your cooling system. High fluid temperatures
D-Ring FKM seals are designed for high-pressure
are the number-one cause of shortened seal life.
hydraulic systems.

Don’t risk expensive components with

in-expensive after-market O-rings.
142 hydraulics

Cat Optional High-Temperature Fkm Seals

Longer lasting, more heat resistant

Cat FKM rubber seals offer you an upgrade on standard nitrile seals for exceptional high tem-
perature applications. This specially formulated material is available for O-Ring face seals (ORFS),
straight thread O-rings (STORS) and D-rings.

Key features: Longer seal life, less maintenance

• Superior heat resistance prevents hardening and ensures
sealing quality at extreme temperatures. In lab tests conducted at 135°C, FKM seals lasted 10 times
• Seal life can be as much as 10 times longer in longer than NBR seals. Longer-lasting seals mean less
exceptionally high-temperature working conditions, downtime to replace them, reducing costs.
resulting in less maintenance and fewer replacement
seals.
• Resistance to high pressures improves sealing
Improved resistance to high pressure
performance and prevents fluid contamination and leaks.
FKM seals can also be used in Caterpillar high-pressure
• Seals with PTFE (polytetrafluoroethylene) coating ease
applications that require improved performance. Increased
installation and prevent tears and damage.
material strength allows the O-ring to withstand higher
pressures without extrusion or “nibbling” on the outside
Superior performance in high temperatures diameter. The FKM seal material has better resistance to
“compression set,” or loss of sealing force.
Cat FKM seals are designed to perform optimally in
temperatures from -40°C to 175°C. They are an upgrade to
nitrile butadine rubber (NBR) seals, which can fail due to high
Easy installation
temperatures.
FKM ORFS and STORS seals are coated with a light blue
coloured polytetrafluoroethylene (PTFE) dry lubricant, which
NBR seals can experience hardening and a subsequent loss
makes seal installation easier. It reduces seal twisting and
of sealing capability with prolonged exposure to excessive
helps prevent cutting during installation.
operating temperatures (above 100° C) near mufflers,
aftercoolers and turbochargers.
 143

Cat Hydraulic Pump and Motor Service

Here are just a few reasons why you can trust us to
provide the best value in pump and motor service:
• Trained technicians. More options save you time and
• Caterpillar Parts Reuse Guidelines.
• Comprehensive repair options.
money
• Commitment to contamination control.
Gear-type Pumps and Motors
• Performance testing.
• Reseal.
• Rebuild.
• Section kit.
• Cat Reman pump.
• New pump/motor.
• Cat ClassicTM pump.

Vane-type Pumps and Motors

• Reseal.
• Cat Reman cartridge.
• Cat Reman pump/motor.
• New cartridge.
• New pump/motor.

Piston-type Pumps and Motors

• Reseal.
• Rebuild.
• Precision lapping.
• Cat Reman barrels, port plates and piston
assemblies.
• Cat Reman pump/motor.
• New pump/motor.

Control costs and maximise uptime

• N obody knows Cat hydraulics like our trained technicians.
They have the parts, tooling and expertise to diagnose and
resolve problems quickly and accurately.
• Caterpillar provides us with comprehensive Parts Reuse
Guidelines developed from decades of Cat dealer repair
data. Because we don’t replace parts unnecessarily, you
contain repair costs and realise the full value from your Cat
equipment investment.
• We offer the industry’s most comprehensive repair
options. More choices means you won’t pay for or wait
for repairs you don’t really need. Off-the-shelf Cat Reman
products, section kits and precision lapping are just a
few of the options we offer to help you keep your costs
and machine downtime to a minimum. We even offer Cat
ClassicTM pumps, an economical new-part alternative for
older Cat equipment.
• Disciplined contamination control procedures help to
keep your hydraulic systems clean and operating at peak
efficiency.
• Pumps and motors we service are performance-tested
before they leave our workshop to make sure they meet
factory specifications.
144 hydraulics

Cat Remanufactured Hydraulic

Components
• D eliver the same performance and life as new Cat
components.
• Are backed with a same-as-new parts warranty. Caterpillar incorporates the latest
• Offer the broadest line of remanufactured hydraulic engineering updates into all Cat
components in the industry.
• Are a fraction of the price of new.
remanufactured hydraulic components.

The difference is in the details

Reman hydraulic cylinders and rods

• P iston slippers and pistons are reconditioned or replaced.
• A ll tubes, rods, and other components are fully • Barrel assembly faces are re-machined, and bushings are
remanufactured to Cat specifications or replaced with new replaced and machined to new specifications.
Cat parts. • Vane pump rotors and cams are remanufactured to Cat
• All rods are induction-hardened, improving resistance to specifications or replaced with new components.
nicks and dents and extending seal life. • Vanes are all replaced with new components.
• Most rods feature inertia-welded eyes for superior • All cartridges, pumps, and motors are adjusted and tested
strength. to ensure like-new performance.
• All required new bearings are installed.
Core exchanges help reduce your costs
Reman hydraulic pumps, motors, and
The price of your Cat Reman hydraulic component is based
components on the condition of your used component, so the better the
condition of your core, the more you save. Because Cat
• A ll returned units are disassembled and thoroughly hydraulic components are designed to be remanufactured,
cleaned and inspected. we can often award credit even when you think a component
• Port plates are reconditioned and updated to the latest has no value left. That means the price you pay for Cat Reman
designs, or replaced with new parts. cylinders, rods, pumps, and motors is always less than that of
new parts.

Equipment coverage
Contact your Barloworld Equipment customer service
representative for the latest information, as we are
continually expanding our Cat equipment model
coverage.

Because Cat hydraulic components are designed to be remanufactured, we can often

award credit even when you think a component has no value left.
 145

Contents
GENERAL USAGE

146 Cat FlexportTM Tyres

148 Cat LED Work Lights

149 Cat Machine Security System

146 general usage

Cat FlexportTM Tyres

Designed specifically for skid steer loaders and compact, small and medium wheel
loaders

Created with operator comfort in mind, Flexport™ tyres use a series of elliptical-shaped ports
moulded through the outer ring of the sidewalls. The ports increase tyre flexibility to produce a
smoother, more cushioned ride on any surface, from waste and scrap to quarry and glass. The
ports won’t crush under the weight of a full bucket, and the innovative design also improves ma-
chine stability when lifting and carrying.

To meet demanding and diverse operating environments, Cat

Flexport tyres are available in three different tread patterns:
• Construction.
• Smooth-Tread; and
• OTR (Off the Road).

Construction Tread
The Flexport construction
tread design is the right
choice for maximum
performance in your
toughest environments. It is
designed for smaller machine
applications where better
traction is required.
FLEXPORT: Features and Benefits
• P atented sidewall ports make the ride more comfortable
for operators.
• Elliptical ports won’t collapse under heavy loads, reducing
stress points for longer wear life.
• Greater machine stability when carrying maximum loads. Smooth-Tread
• Deep tread delivers long wear life and excellent traction
on any surface. The Flexport smooth-tread
• Tread pattern handles tough terrain, and allows easy, design is ideal for special
smooth transitions from unimproved to improved applications where debris
surfaces. is an issue like scrap yards,
• Highest quality rubber compound manufactured to recycling centres and some
Caterpillar specifications means durability for longer wear waste transfer stations.
life and a consistent product.
• Puncture-proof design puts an end to fixing flats.
• One piece tyre-and-rim design reduces tyre servicing
costs.

Off the Road (OTR)

The OTR design has a
block pattern that provides
a degree of traction in
applications where debris is
not an issue.
 147

Flexport tyres for small and medium wheel

loaders

Cat Flexport tyres are available on new machines Cat Flexport tyres for small and medium wheel loaders are a
and from Barloworld Equipment as service parts. 2-piece tyre / rim design and are available in smooth and OTR
Contact your Barloworld Equipment customer service tread patterns.
representative for advice on Flexport tyre sizes to suit
your machine and working application. Installation of a Cat Flexport tyre on either a small or medium
wheel loader requires the use of an adapter plate and
hardware.

Please note: In certain small and medium wheel loader

configurations, Cat Flexport tyres may cause the machine to
exceed the Roll Over Protection Structure (ROPS) capacity.
To be certain that the machine does not exceed ROPS, the
machine should be weighed to verify that the ROPS limits
would not be exceeded with Flexport tyres. The ROPS
capacity can be found on the cab of the machine.

HEAD-TO-HEAD COMPARISON RESULTS

Caterpillar’s Flexport elliptical design far superior to round

design

Other tyre companies manufacture tyres with round

holes.
• The round design easily collapses into a flat shape under
a load, which creates corners that cause “pinch” or
“stress” points.
Flexport tyres for skid steers and compact • Stress point damage will typically result in cracking and
wheel loaders chunking of a tyre.

Cat Flexport tyres for skid steer loaders are a 1-piece tyre / rim Caterpillar designed Flexport Tyres with elliptical-
design and are available in directional construction, smooth shaped ports.
and OTR tread patterns. For most applications, the machine • Flexport’s elliptical ports are designed not to crush when
width can be customised by altering the placement of the rim compressed by heavy weight.
on the machine. • Because the ports don’t crush, this reduces stress points
– and increases wear life.

Flexport Warranty
Building & Framing

Pavement Profiling
Industrial Waste

Cat tyres have a separate warranty

Transfer Station
Quarry Cleanup

Applications statement covering defects in material

Landscaping
Hammering

Scrap Yard
Demolition

Recycling

and workmanship. For more information

Loading

on Flexport tyres, contact your

Barloworld Equipment customer service
representative.
Flexport™ Construction

Flexport™ Smooth-Tread
Comfortable, stable, and
Flexport™ OTR
durable.
148 General usage

Cat LED Work Lights

Light Emitting Diode (LED) technology eliminates lights maintenance

When you’re working against the clock or at night, it can be costly to shut down a machine to
change a light bulb. That’s why more and more machine owners are upgrading their equipment
to Cat LED Work Lights.

Unlike halogen lights, Cat LED Work Lights do not have a

filament that will burn out, so there are no bulbs to replace
or unexpected downtime. These lights also have a greatly
extended life – more than 50 000 hours – and deliver bright
illumination that improves operator safety and performance.

Suitable for a wide range of light and heavy-duty equipment

applications, Cat LED Work Lights feature a common two-pin
connector that permits easy change-outs of most same-sized
halogen lights on Cat and other brands of equipment.

Consider the advantages

LED Halogen
Average Life Expectancy 50 000+ hours 1 000 hours
Power Consumption @ 0,6 amps 2,5 amps
28 Volts

LED lights have an extremely long life. These lights may dim following
LED benefits explained extensive use, but they will never turn off.

• N o bulb replacement or
unexpected downtime.
• Extremely long life: LED
Bright illumination
lights may dim following improves operator safety
extensive use, but will never and performance.
turn off.
• Can be used in a wide range
of Cat and other equipment
applications.
• Bright illumination is closer
to daylight, lessening eye
strain and operator fatigue.
• Easy connection: use two-
pin Deutsche DT series
connector.
• One-fourth the current draw
of halogen lights minimises
the need for a larger
alternator.
• Environmentally safe: free
of mercury, lead and heavy
metals.
• Extremely efficient: with no
filaments, LED lights do not
cause heat buildup which
can damage other parts.
• Reliable: no moving parts
eliminate wear and limit
friction.
• Durable: LED lights are
completely waterproof and
vibration resistant.
• 3-inch x 3-inch spotlight and
floodlight options available.
 149

Cat Machine Security System

The key to theft deterrence

Theft and unauthorised use of equipment are big concerns. The Cat Machine
Security System keeps your equipment safe by giving you control over both
who can operate your machines and when.

Integrated into the electronics of Cat equipment, the Cat The Cat Machine Security System is superior
Machine Security System guards the starting system, engine, to more basic add-on theft deterrent devices
and transmission. Only a yellow or gray security key can start because it is integrated into the electronics of
the machine when the system is armed. the machine. This makes it virtually impossible to
defeat.
The Cat Machine Security System gives you many options to
help you manage your equipment. Each security key is unique Key Management
so operators can be restricted to certain machines or hours of
operation. The system can also be programmed to allow use Programming the Cat Machine Security System
of the standard black key during active periods, and then, for is simple. An authorised Barloworld Equipment
after hours, automatically rearm. technician can quickly program your machine to start with a
new key, or make changes for existing keys.
Benefits
A machine can be programmed to accept many unique
• Theft protection. security keys.
• Restrict machine access to only known operators.
• Easily installs on all Cat equipment. Availability
• Caterpillar designed and machine integrated.
• Potential insurance savings. • Factory available for many models.
• Can also be used on competitive equipment. • Can be field installed on your entire fleet, both Cat and
competitive machines.
How the Cat Machine Security System • Works on both 12-and 24-volt systems.
works
To find the field installation kit part number for your model,
Each yellow or gray security key has a unique identification please contact your Barloworld Equipment customer service
number. When a key is inserted into the ignition switch, the representative.
Cat Machine Security System electronic control module
checks that key against the preapproved list. If the key is
an unauthorised security key, or a standard black key, the
machine will not start.

Controlling Machine Access

The Cat Machine Security System is programmable to
give you the protection that best fits your needs:
• By limiting operators to specific machines,
which prevents access by untrained operators or
unauthorised personnel, thereby reducing damage
and injury risks.
• Controlling the days and hours equipment may
be started, which guards against unauthorised
‘weekend use’ of equipment.
• Programmable for active and inactive periods,
such as disarming the system during regular work
hours so that a standard key can be used and then
reverting to security keys after hours. The Cat Machine Security System is superior to more basic add-on
• Program security keys to expire at a specific period theft deterrent devices because it is integrated into the electronics of
of time. the machine.
• One security key can be programmed to operate
any machine in your fleet.
One security key can be programmed to
operate any machine in your fleet.
150 cabs and accessories

Contents
151 Cat Operator Environment

152 Access System Upgrade for Cat 777Ds

153 Cabin Air Filters

154 Cat Air Conditioning Kits

155 Retrofit Cabs for Cat 988G wheel loaders

156 Cat Comfort Seat

158 Retrofit Cabs for Large off-highway trucks

cabs and accessories
 151
The Cat Operator Environment
Employing the best operators starts with keeping them happy.

You can have the most productive machines on earth, but it doesn’t count for much unless you
have people who know how to get the most out of them.

That is why Caterpillar makes operator satisfaction a top Lights

priority, designing cabs with improved visibility and heating/ • High Intensity Discharge lights provide
cooling, as well as decreasing noise, vibration and fatigue twice the light and last ten times longer
with state-of-the-art ergonomic designs. It all adds up to an than halogen lights.
operator environment that’s safer and more comfortable, • Halogen lights are shock resistant to
helping make your operators’ workday easier and more provide longer life.
productive. • Light Emitting Diode (LED) lights
are designed for long life and lower
Choose from a wide range of options maintenance.

Air Conditioning Radios

• Retrofit kits are easy to • Heavy-duty radios have
install. been tested and exceed
• These systems are shock and vibration
designed to provide standard SAE J1455.
maximum cooling • They withstand both hot
efficiency in the most and cold temperature
rugged operating extremes.
conditions. • Both XM and SIRIUS
• And they are engineered satellite models are
to fit like a factory-installed system. available.

Cabs Seats
• Two types of replacement • Cat Comfort Seats have an
cabs are available: original ergonomic high-back design.
equipment and retrofit • Extra-thick, contoured cushions.
upgrades. • And adjustable lumbar support.
• Original equipment cabs
look and perform like Contact your Barloworld Equipment
new. customer service representative
• Upgraded retrofit cabs for advice on ways to help enhance
are designed to include both your operators’ environment
the latest engineering, and your bottom line.
productivity and comfort
updates.
152 cabs and accessories

Access System Upgrade:

Cat 777D Series Trucks
Improved bumper walkway and cab access

Caterpillar is pleased to announce the introduction of a field installed, diagonal stairway retrofit
kit for Cat 777D Series large off-highway trucks. The stairway improves access to and from the
bumper walkway and cab, thereby reducing risks of slips, trips and falls.

The 777D Series retrofit stairway is 600 mm (24”) wide and is Product Support
integrated diagonally across the front of the machine. This kit
Product Specifics:
includes a stairway, bumper extension, handrails and walkway. • D etailed step-by-step
Special Instructions
Cat 777D
Ordering Information (SI) with graphics are
• R etrofit stairway is
available electronically
600mm (24”) wide.
New 777D Series machines are equipped with the standard via SIS Web to reduce
• Field installed
ladders. The diagonal stairway kits must be ordered as an installation down time
attachment.
optional retrofit kit. Retrofit stairway kits and associated (Cat 777D – REHS5075
• Cat integrated and
serviceable components are available through the Barloworld “Installation of the Ladder
validated design.
Equipment parts system. Please contact your customer Gp and Catwalk As”).
service representative for further information. • Components individually
serviced and backed by
Model Upgrade Kit standard Caterpillar parts
Part Number service and warranty.
777D (3PR) 356-8750
777D (AGC) 356-8750
777D (FKR) 356-8750
777D (6XZ) 356-8750
777D (2YW) 356-8750

Ease of access is an important

factor in ensuring overall
operator safety.

Safety Tip:
It should be noted that
with the newly installed,
diagonal stairway
upgrade kit, Caterpillar
instructs that individuals
face the direction of travel
when using the stairs,
maintain a minimum of
two points of contact at
all times, and always have
one hand in contact with
the handrail.

New Cat 777D Series machines are equipped with ladders as standard.
 153

Cat Cabin Air Filters

A cleaner, more comfortable cab environment

Two high efficiency filters, the Cat Dust Reduction and the Cat Dust and Odour Reduction Cabin
Air Filter, improve ventilation and/or odour reduction in enclosed operator cabs. Advanced filtra-
tion technology reduces airborne irritants, creating a cleaner and more comfortable working en-
vironment for the operator.

An optional replacement for the standard filter, no equipment

modification is needed for installation.

Dust Reduction Filter Benefits:

• Higher efficiency for better dust reduction.
• Direct replacement for standard filter.
• Fits current filter housing.
• Easier to clean.

Dust and Odour Reduction Filter Benefits (in addition to

the above):
• High performance-activated charcoal ensures a fast rate of
absorption.
• Higher capacity extends life and reduces maintenance
costs. Standard
• Superior particle removal efficiency reduces eye, nose and
throat irritants.
• There is no adverse effect on air flow, heat or air Reduced odour, high dust capacity,
conditioning performance. longer life
Please note that dust reduction and odour reduction cabin Cat Dust and Odour Reduction Cabin Air Filters are
filters are not intended for filtering hazardous materials. designed for use in landfill applications or anywhere
superior odour reduction is necessary. They offer
Both Cat Dust Reduction and Odour Reduction Air Filters can extended service life without compromising heating
be cleaned with compressed air to extend life. They should or cooling capabilities. The activated carbon in the
not be cleaned if the dust / odour reduction capability is filter (see magnification below) provides a fast rate
diminished, if the filter is damaged or has been used for 12 of absorption. There is no operator exposure to loose
months of longer. carbon particles, even in rough applications.

Machine coverage An Ultra High Efficient air filter

• Integrated tool carriers.

• Track loaders.
• Track-type tractors.
• Off-highway trucks.
• Pipelayers.
• Soil compactors.
• Wheel loaders.
• Wheel tractors.

The Cat Dust Reduction Cabin Air Filter can be

used anywhere excessive cab dust exists.

KEEP IT REAL, KEEP IT CAT ®

For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com
154 cabs and accessories

Cat Air Conditioning Kits

Improve operator comfort and boost productivity

Cat air conditioning kits provide an effective retrofit solution to combat

the heat. All kits, except combined AC/Heater Kits, are designed for use
with machines that have an AC-ready heater group installed.

The benefits
• R ight fit: each kit is made for your Cat machine and
contains parts to install a highly efficient R134A system in
the cab.
• Durable: all parts are heavy-duty and made to withstand
harsh operating environments and severe vibration. Cat Air Conditioning Kits Cat Air Conditioning Kits
• Easy Installation: quickly install components with easy-
to-follow installation instructions.
• Good value: each part is covered under the Caterpillar
New Parts Warranty.

These kits provide a field-installed, 12-volt or 24-volt R134A

in-cab air conditioning system for the machines listed in the
table (right).
All kits, e
AC/Heater K
use with ma
AC-ready he

Kits are c
Caterpillar N
and inclu
instructio
component
except a
A roof mounted air conditioning system.

These kits pro

12-volt or 24-v
conditioning s
machines liste

For more inform

visit our Web

Table Notes:
* Incomplete kit. Additional parts required.
+ Combined AC/Heater Kit

PEHJ0148-01 www.cat.com/operatorenvironment © 2006 Caterpillar All Rights Reserved Printed in USA

CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow" and the POWER EDGE trade dress, as well as corporate and product identity used herein, are t
may not be used without permission.
 155

Retrofit Cabs For Cat 988G

Wheel Loaders
More Cab. Less Time.
Caterpillar is pleased to announce the availability of cost effective alternative solutions for cab
rebuilds and replacement cabs for certain Cat 988G large wheel loaders.

These new retrofit cabs are designed as “plug and play”

kits and they can be installed in a matter of hours. Further
modifications might be needed if any additional attachments
need to be transferred from the current machine cab. Large wheel loader customers around the world are
targeting longer service life from their Cat machines.
Cat Retrofit Cabs offer value by upgrading to newer A complete upgrade cab satisfies the customer
technologies and assuring ROPS integrity. On board is the Cat demand for improved machine availability and reduces
Comfort Seat with patented three point harness for improved concerns by providing newer technology and assuring
operator ergonomics, helping to reduce fatigue, and improve ROPS integrity, operator satisfaction, comfort and
alertness and general productivity. safety.

The upgraded cab has all necessary certification labelling,

including ROPS certification.

Features include:
• A/C.
• LED indicators in dash.
• EMS III.
• CB ready.
• HID lighting.
• Extended roof.
• Deluxe MP3 radio with USB port.
• Two 10 Amp Converters.
• Blade Fuses in E-bay.

Additional features include exterior paint schemes similar to

current production cabs, folding mirrors and rear laminated
glass.

For further information please contact your Barloworld

Equipment customer service representative.

Sales Model Serial Numbers Original Cab Upgrade Cab Installation Kit
988G 2TW 114-5145 346-3845 346-3844
988G BNH 202-9738 346-3845 346-3844

• 346-3844 – mounting hardware and films to support the cab installation

• 346-3845 – upgrade cab
156 cabs and accessories

Cat Comfort Seat

With three-point operator restraint: made for comfort, made for mining.

The Cat Comfort Seat is available as a retrofit option on a wide range of Cat off-highway mining
trucks and has proven advantages in terms of ergonomics and safety on the toughest sites.

Cat® Comfort Seat with three-point operator restraint

High-back design provides additional head and

neck support for maximum operator comfort. Dual Retractor Belt System with highly
visible two-inch orange shoulder belt
which is easily seen when properly worn
Infinitely
and latched.
adjustable
lumbar
support.

Extra-thick, contoured cushions with special

side bolsters keep the operator positioned in the
centre of the seat.

Fully adjustable arm rests can

be “flipped up” and out of the
way when not in use (dual arm
rests are available only on certain
applications).

Lower cushion tilt adjustment helps reduce

operator fatigue and fits a wider range of
operator sizes.

Cast gears for long

Dampener adjustment allows the operator to
life and durability.
tune the suspension to five “firmness” settings.
Proven Toggle Link Air Suspension
System compensates for the operator’s
weight and provides maximum
suspension travel.
Adjustment levers are at
the front of the seat for
easy operator reach.

The Benefits
As durable as it is
comfortable The Dual Retractor Belt System keeps the operator in the
seat for a secure ride
• R ip-resistant, tight- • Meets SAE J386 and SAE J2292 specifications.
weave fabric. • Bright orange shoulder belt is easily visible when properly
• Asphalt black. worn and latched.
• Slip-resistant material. • Six vertical adjustment positions provide optimum fit for a
• Special backing is wide range of operator heights.
fused, not sewn, to • Emergency Locking Restraint (ELR): the shoulder belt
the underside of the functions “sense and lock” when conditions demand.
material, allowing the • Lap belt comfort with Automatic Locking Restraint (ALR):
material to stretch the lap belt automatically locks into position, but still
without sagging. allows operator movement without cinching.
 157

Proven Toggle Link Air Suspension system ensures a

smooth ride
• Optimal “Ride Zone” positioning is accomplished by
adding (or removing) air to the proven Toggle Link Air
Suspension.
• An indicator gauge makes it easy for the operator to see
that the correct amount of air has been added to the
system.
• Once adjusted, the seat will maintain the correct setting
with no further adjustment until a shift change.
• The Toggle Link Air Suspension system has proven
extremely durable in the most rugged applications, with
over 10 000 hour life expectancy. COMMITMENT TO BRING
Cushions add to the comfort
• A negative rake feature enables cushion tilt adjustment,
YOU THE BEST.
ALL DAY. EVERY DAY.
even while the operator is in the seat.
• Side bolsters on the upper cushion help keep the operator First class equipment. First class solutions. First class support. An easy choice for a hard place. The
new E-Series hammers feature a symmetrical housing that can be rotated 180 degrees to compensate for
in the seat in rough applications. wear, extending the life of the housing, giving you greater uptime. Sound suppression for greater operator
• Cushion density designed for shift-long comfort. comfort. On the ground service backup. Our work tools generally have a high resale value giving you
a better return on your investment. What’s more, using them in combination with Cat® machines gives
• Cushions use a waterproof foam-in-place technology that you the perfect performance match. Uninterrupted productivity. And a single point of contact.
is easily cleaned. Work with confidence; use hydraulic hammers from Barloworld Equipment. For more information
• Upper and lower cushions are individually replaceable. contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

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E Series Hammer GAF (A5).indd 1 2012/10/29 11:08 AM

Model Serial Number Prefix Seat Part Number Special Notes
769D 5SS, BBB, 5TR
771D BCA, 6R, 6YS
773E BDA If the original machine seat
775E BEC had a two-point restraint, a
776D 5ER, AFS new riser must be installed
with the new Cat Comfort
777D 6XZ, AGY, AGC, DCB, 2YW, 228-3351
Seat with three-point
3PR, FKR restraint. Order 153-4001
785C 1HW, APX, 5AZ in addition to the specified
789C 2BW seat.

793C CBR, 4AR, TY, 4GZ

770 BZZ
772 RLB, 59X, 10S, 11S, 80S
773F EED
240-8716
775F DLS
777F RP
784B 5RK If the original machine seat
785B 6HK had a two-point restraint, a
new riser must be installed
789B 7EK with the new Cat Comfort
252-9713
793B 1HL Seat with three-point
restraint. Order 144-4184
in addition to the specified
seat.
797 5YW If the original machine seat
had a two-point restraint, a
new riser must be installed
with the new Cat Comfort
244-2803
Seat with three-point
restraint. Order 144-4184
in addition to the specified
seat.
797B SM 244-2803
158 cabs and accessories

Retrofit Cabs for Large Off-Highway Trucks

A lot more cab in a lot less time

How do you keep large off-highway trucks in operation while, at the same time, upgrading their
capabilities? The Cat Retrofit Cab is a rebuild or replacement option that can help do both by pro-
viding upgrades and cutting installation time. Rebuild time for an outdated cab is normally meas-
ured in weeks, but Cat Retrofit Cabs can be installed in less than a day.

The fully assembled cabs are available for Cat 785, 789 and
793 B and C Series off-highway trucks, with an exterior paint
scheme and markings similar to current production cabs.

Each Cat Retrofit Cab includes:

• All new components (including Electronic Control
Modules), ROPS and cab mounting hardware.
• New, updated wiring harnesses.
• New Vital Information Management System 4.0 (VIMS).
The cabs are equipped with VIMS 4.0 for better monitoring
of truck operations and payloads.
• The Cat Comfort Seat with patented three-point harness.
• A full-size buddy seat.

Cat Retrofit Cabs offer value by upgrading to newer

technologies and assuring ROPS integrity.

Retrofit cross-reference chart

The information in this chart will help match the Retrofit Cab
Upgrade Part Number to the truck application by machine
sales model and serial number prefix.

These Upgrade Retrofit cabs replace same series machine

cabs. These cabs are not intended to upgrade from a lower
series model. The “plug and play” design requires less
than a day for installation, minimising
The Retrofit Cabs that are compatible with Hydraulic
Automatic Retarder Control (ARC) are 785C and 789C series. downtime.
The Retrofit Cabs that are compatible with the Air ARC are
785B, 789B, 793B, and 793C.

Large OHT Serial Number New Retrofit Cab Part No. Original Cab Part No.
785B 6HK00433 and up 260-1831 114-9461
785C APX00451 and up 250-6900 174-0515
789B 7EK00277 and up 260-1830 114-9460
789C 2BW00659 and up 250-6899 174-0519
793B 1HL00195 and up 257-2728 135-9986
793B 1HL00195 and up 257-2728 114-9460
793C 4AR 259-6879 124-7684
793C 4GZ 250-6898 137-0793
793C ATY 250-6898 174-0523
 159

South Africa
Alexandra Bay 027 831 2880
Bellville 021 959 8200
Bloemfontein 051 409 1200
Boksburg 011 898 0000
Durban 031 569 8500
East London 043 736 1003
George 044 874 2227
Isando 011 929 0000
Khatu 053 723 9900
Kimberley 053 832 9300
Mthatha 047 531 4710
Middelburg 013 283 5500
Nelspruit 013 752 3264
Newcastle 034 315 2847
Phalaborwa 015 780 2405
Polokwane 015 297 5670
Port Elizabeth 041 402 4700
Pretoria 012 804 5538
Richards Bay 035 797 6300
Rustenburg 014 596 7727
Sandton 011 301 4000
Trichardt 017 638 1941
Welkom 057 352 4407
Wolmaranstad 018 596 3063
Mozambique
Beira 002 582 332 2540
Maputo 002 582 130 0331
Botswana
Francistown 00267 241 3547
Gaberone 00267 395 1781
Jwaneng 00267 588 4359
Orapa 00267 297 0027
Zimbabwe
Harare 00263 448 6609
Zambia
Kitwe 00260 212 211 191
Lusaka 00260 977 771 191
Swaziland
Manzini 00268 518 7048
Malawi
Blantyre 00265 187 0666
Lilongwe 00265 171 0344
Angola
contact us

Lobito 00244 272 224 927

Luanda 00244 222 460 220
Sao Tomé & Principé 00244 222 460 220
Lesotho
Maseru 00266 223 12995
Namibia
Walvis Bay 00264 6420 3454
Windhoek 00264 6128 04600
Democratic Republic of Congo
Lubumbashi 00243 992 901 300
160

Our Southern African Footprint