Cat 621G 623G 627G Npi

Service Training November 2000
NEW PRODUCT INFORMATION
621G/623G/627G
WHEEL TRACTOR-SCRAPERS
PRELIMINARY INFORMATION
621G/623G/627G
WHEEL TRACTOR-SCRAPERS
AUDIENCE
Service personnel responsible for the introduction, delivery and preliminary support of the
621G/623G/627G Wheel Tractor-Scrapers.
CONTENT
This presentation describes the changes in machine features and systems. The presentation covers
component locations, and basic systems operation.
OBJECTIVES
After learning the information in this presentation, the serviceman will be able to:
1. identify the major changes in the machine features and systems;

2. explain the basic operation of each new system;
3. locate new components; and
4. explain the function of the new components.
Estimated Time: 1 Hour

Visuals: 43 (2 X 2) Slides
Date: 11/00
© 2000 Caterpillar Inc.
620G Series NPI -3-
11/00
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................5
Machine Arrangements.....................................................................................................6
Machine Features ..............................................................................................................7
OPERATOR’S STATION........................................................................................................8
ELECTRICAL SYSTEM .....................................................................................................18
ENGINE................................................................................................................................23
3406E Tractor Engine .....................................................................................................23
3306 Scraper Engine .......................................................................................................28
POWER TRAIN ...................................................................................................................30

Tractor Power Train ........................................................................................................31
Scraper Power Train........................................................................................................36
ELECTRO-HYDRAULIC IMPLEMENT SYSTEM...........................................................40
STEERING SYSTEM ..........................................................................................................47
CONCLUSION.....................................................................................................................49
SLIDE LIST..........................................................................................................................50
620G Series NPI -4-
11/00
INSTRUCTOR NOTES
620G Series NPI -5-
11/00
INTRODUCTION
• Introduce machines This presentation will introduce the new features of the 621G/623G/627G
Wheel Tractor-Scrapers. Also covered are component locations and basic
systems operation.
The 621G/623G/627G Series Wheel Tractor-Scrapers are a direct

replacement for the 621F/623F/627F Series Wheel Tractor-Scrapers.
620G Series NPI -6-
11/00
620G SERIES MACHINE CONFIGURATIONS
MODEL STANDARD CONFIGURATION OPTIONS
BOWL EJECTOR APRON

621G
BOWL EJECTOR APRON AUGER
623G BOWL EJECTOR ELEVATOR
BOWL EJECTOR APRON
627G BOWL EJECTOR APRON BAIL
BOWL EJECTOR APRON AUGER
Machine Arrangements
The 620G Series Wheel Tractor-Scrapers are available in several

configurations. The chart in this view lists the 620G Series standard
machine configurations and the options available.
• 621G Model The 621G Wheel Tractor-Scraper (top left) is shown in the standard
configuration with a bowl, ejector and apron. The 621G Wheel Tractor-
Scraper can also be equipped with an auger.
• 623G Model The 623G Wheel Tractor-Scraper (top right) is shown in the standard
configuration with a bowl, ejector and elevator. The elevator is standard
equipment on the 623G model.
• 627G Model The 627G Wheel Tractor-Scraper (bottom left) is shown with a bowl,
ejector, apron, and with the optional bail (push/pull arrangement). The
627G can also be equipped with an auger. The auger attachment on the
627G model includes a slip limiter. The auger slip limiter is not available
on the 621G wheel tractor-scraper.
620G Series NPI -7-
x/00
MACHINE FEATURES
• 3406E EUI Diesel Engine
• AMOCS Radiator
• Electro-Hydraulic Implement System
• Electronically Controlled Transmission
• Updated Operator's Station
• Caterpillar Monitoring System
Machine Features
• Machine features: 3406E EUI Engine: The 3406E Electronic Control Unit Injection (EUI)
engine in the tractor is dual horsepower and electronically controlled.
- 3406E engine
Advanced Modular Cooling System (AMOCS) Radiator: The
- AMOCS radiator modular design AMOCS radiator is less prone to plugging with a lower
fin density. Serviceability is improved by allowing one module to be
- Electro-hydraulic
replaced rather than the entire radiator.
implement system
Electro-Hydraulic Implement System: The implement system provides
- Electronically
single lever implement control from the cab. The implement pilot system
controlled
transmission is electronically controlled which provides precise control of the
implements.
- Updated operator’s
station Electronically Controlled Transmission: The electronically controlled
transmission reduces power train stress by selecting the proper gear for
- Caterpillar any given engine rpm and ground speed, and by synchronizing engine and
Monitoring System transmission speed while shifting.
Updated Operator’s Station: The operator’s station includes an

improved operator seat, new instrument panel and new switch console.
Caterpillar Monitoring System: The Caterpillar Monitoring System

monitors the machine status and provides warning indications to the
operator.
620G Series NPI -8-
11/00
OPERATOR’S STATION
• Styling, visibility and The 620G Series operator's station provides styling, visibility and
comfort
comfort. The revised steering column has increased the interior leg room
and less frequently used switches have been moved to the overhead
console to improve visibility.
• Instrument panel A redesigned instrument panel includes the Caterpillar Monitoring
System, indicator lights and a switch to start the rear engine from the cab.
• Operator’s seat The operator's seat is fully adjustable and includes non-cinching
retractable seat belts and armrests.
• Air conditioning Standard air conditioning increases operator comfort and ventilation
louvers have been relocated to improve airflow to the operator.
• Storage locations Convenient storage locations provide space for a lunch box, first aid kit
cupholder and ashtray.
620G Series NPI -9-
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8
8
1
6
2 3 5 7
• Instrument panel: The operator's station in the 620G Series wheel tractor-scrapers includes a
redesigned instrument panel and the Caterpillar Monitoring System.
1. Scraper engine start
switch The instrument panel components shown in this view are:
2. Heater/air
conditioner switch - Scraper engine start switch on the 627G (1)
3. Fan speed switch
4. Ether starting aid
- Heater/air conditioner switch (2)
switch - Fan speed switch (3)
5. Temperature
- Ether starting aid switch (4)
control knob
6. Key start switch - Temperature control knob (5)
7. Engine overspeed
- Key start switch (6)
switch
8. Caterpillar - Engine overspeed test switch (7)
Monitoring System
- Caterpillar Monitoring System panels (8)
panels
620 G Series NPI - 10 -
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CATERPILLAR MONITORING SYSTEM

SPEEDOMETER/ MAIN DISPLAY ACTION
GAUGE CLUSTER TACHOMETER MODULE LAMP
MODULE MODULE
C kPa Miles KM RPM Liter SERV

MPH
12 km/h 3F . ..
CODE
X10
ACTION
ALARM INPUT
CATERPILLAR
COMPONENTS
DISPLAY DATA LINK
CAT DATA LINK
MONITORING SYSTEM C kPa Miles KM RPM Liter SERV
SCRAPER DISPLAY
MODULE
. ..
CODE
X10
INPUT
COMPONENTS
TRACTOR SCRAPER ENGINE ECM IMPLEMENT ECM

TRANSMISSION ECM TRANSMISSION ECM
INPUT INPUT
COMPONENTS COMPONENTS
INPUT INPUT
COMPONENTS COMPONENTS
3
1
2 5 4
5 6
• Caterpillar monitoring The Caterpillar Monitoring System continuously monitors machine

system: systems. The "heart" of the system is the main display module where
information is received from switches, sensors and the machine ECMs
1. Main display
module over the CAT Data Link and processed. The main display module then
2. Speedometer/ activates various outputs.
tachometer module
3. Gauge cluster The monitoring system major components include a main display
module module (1), a speedometer/tachometer module (2) and a gauge cluster
4. Scraper display module (3) in the cab. The 627G Wheel Tractor-Scrapers are equipped
module with a scraper display module (4) on the scraper control panel.
5. Action lamp
6. Mode select switch The main display module contains the processing functions for the
7. Tractor-Scraper system, a section that displays ten alert indicators (top half of module) and
select switch
a bottom section that displays a digital readout.
The alert indicator section uses inputs from switches, sensors, senders,
and the CAT Data Link to alert the operator of machine conditions.
➥
620G Series NPI - 11 -
11/00
The digital display area provides a six digit readout that shows machine
operational hours, engine speed, distance and diagnostic information.
The speedometer/tachometer module displays the engine speed (gauge),

the ground speed (left display) and the transmission actual gear and
direction (right display).
The monitoring system also includes an action lamp (5), which flashes
when a serious abnormal condition exists.
The mode select switch (6) is used to select the functions on the display
window. The tractor/scraper select switch (7) on the 627G machines,
allows the operator to display information for the tractor or the scraper.
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1
2 3 4 5 6 7 8
• Overhead panel: The overhead panel is located above the operator and includes the
following toggle switches:
1. Panel/tail/running
light switch - Panel light/tail light/running light switch (1)
2. Front floodlight
switch - Front floodlight switch (2)
3. Warning/Hazard - Warning/hazard light switch (3)
light switch
4. Rear floodlight - Rear floodlight switch (4)
switch - Scraper transmission neutral/run control switch (5) on 627G only
5. Scraper
transmission switch - Front windshield wiper switch (6)
6. Front windshield - Rear windshield wiper switch (7)
wiper switch
7. Rear windshield - Front/rear windshield washer switch (8)
wiper switch
8. Front/rear
windshield washer
switch
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1 2
• Right console: The implement control lever (1) is located on the right console next to the
transmission control lever (2). The implement control lever sends
1. Implement control electrical signals to the implement ECM, which controls the implement
lever
valve solenoids.
2. Transmission
control lever The transmission control lever is used to select the desired machine
3. Throttle lock control
direction and speed.
switch
4. Parking brake The throttle lock control switch (3) is located on the right console
control knob
between the joystick and the transmission control lever. Depressing the
top of the switch will engage the throttle lock and maintain the engine at
the current rpm. Depressing the bottom of the switch will disengage the
throttle lock.
The parking brake control knob (4) is also located on the right console.
11/00
2
1
• Floor of cab: The service brake pedal (1) and governor pedals (2) are located on the
floor of the operator’s station.
1. Service brake pedal
The differential lock switches (3) are also located on the floor of the
2. Governor pedals operator’s station. Both differential lock switches activate the electronic
differential lock. The left switch is used with the operator’s seat facing
3. Differential lock
forward and the right switch is used when the seat is turned to the right.
switches
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2 4
1
10
• Steering wheel and The steering wheel (1) provides machine directional control. The steering
column: column tilt and telescope control lever (2) and headlight dimmer
switch (3) are located on the left side of the steering column.
1. Steering wheel
2. Steering column The retarder control lever (4), located on the right side of the steering
tilt/telescope
column provides speed reduction during machine operation.
control lever
3. Headlight dimmer
switch
4. Retarder control
lever
11/00
2
5
4
3
11
• Operator’s seat: The air suspension seat in the operator’s station can be adjusted in five
different positions. This view from below the seat shows the following
1. Swivel release lever levers that control the seat positions:
2. Fore/aft lever
3. Up/down knob
- Swivel release lever (1)
4. Recline lever
5. Lumbar support - Fore/aft lever (2).
lever
- Up/down knob (3)
- Recline lever (4)
- Lumbar support lever (5)
11/00
12
• Left of operator’s The diagnostic connector (1) is located on the electrical center (2) to the
seat: left of the operator's seat. The diagnostic connector allows the
Communications Adapter II service tool (3) or the ET service tool (not
1. Diagnostic
connector shown) to be connected to the machine electrical system.
2. Electrical center
3. Communications
Adapter II service
tool
11/00
5 7
6
2
13
ELECTRICAL SYSTEM
• Left of operator's The electrical center (1) is located at the left side of the operator’s seat.
seat:
The machine fuses (2) are located inside the electrical center.
1. Electrical center
2. Fuses The following circuit breakers are located on the front of the electrical
3. Keyswitch circuit center:
breaker
4. Blower motor - Keyswitch circuit (3)
circuit breaker
5. Engine circuit
- Blower motor circuit (4)
breaker - Engine circuit (5)
6. Alternator circuit
breaker
- Alternator circuit (6)
7. Hourmeter
The hourmeter (7) is also located on the left side of the electrical center.
x11/00
620G SERIES WHEEL TRACTOR-SCRAPER

ELECTRONIC CONTROL SYSTEM
TRACTOR SCRAPER SCRAPER

ENGINE TRANSMISSION TRANSMISSION MAIN DISPLAY IMPLEMENT MONITOR
CONTROL ECM ECM MODULE ECM DISPLAY
1 2 3 4 5
1 2 3 4 5
6 7 8 9 10
6 7 8 9 10
C kPa MILES KM KPH LITER

C kPa MILES KM KPH LITER
SERV SERV
CODE CODE
X10
X10
CAT DATA LINK
TRACTOR SCRAPER
TRACTOR TRACTOR SCRAPER BOWL ENGINE ENGINE
ENGINE TRANS TRANS CONTROL STATUS/ STATUS/
FAULTS FAULTS
TRACTOR SCRAPER
EXHAUST BRAKING ENGINE EJECTOR
TRANS TRANS
BRAKE SYSTEM PRELUBE CONTROL
FAULTS FAULTS
TRACTOR APRON OR SCRAPER REPORTS

FUEL RAIL BRAKING
ENGINE ELEVATOR ENGINE TO TRACTOR
PRESSURE SYSTEM
OVERSPEED CONTROL FAULTS EMS II
TRACTOR SCRAPER SCRAPER

SUPPL
ENGINE ENGINE TRANS
STEERING
PRELUBE DERATE FAULTS
TRACTOR SERVICE PORT CONNECTOR SCRAPER

AUGER
ENGINE (OPERATOR STATION) CMS
CONTROL
DERATE FAULTS
SERVICE PORT CONNECTOR
(SCRAPER)
14
• Electronic Control The 620G Wheel Tractor-Scrapers Electronic Control System modules
System components: communicate across the CAT Data Link. The Electronic Control System
modules are:
- Engine ECM
- Tractor transmission Engine ECM

- Scraper
transmission ECM
Tractor transmission ECM
- Implement ECM
Scraper transmission ECM
- Tractor main display
module Implement ECM
- Scraper display
module (627G) Tractor main display module (part of Caterpillar Monitoring
System)
Scraper monitor display on 627G models (part of Caterpillar

Monitoring System)
11/00
15
• Tractor transmission The tractor transmission ECM (arrow) is located below the cab on the left
ECM (arrow) side of the machine.
11/00
16
• Scraper transmission The scraper transmission ECM (arrow) is located below the scraper on the
ECM (arrow) left side of the machine.
620 G Series NPI - 22 -
11/00
620G SERIES WHEEL TRACTOR-SCAPER

ELECTRICAL SYSTEM WIRING HARNESS DISCONNECT POINTS
OPERATOR
STATION
CHASSIS HARNESS
WIRING HARNESS STARTER ENGINE

IMPLEMENT
CONTROL VALVES
DISCONNECT POINTS RADIATOR

BAIL VALVE
SOLENOID
TRANSMISSION
ENGINE
HITCH SCRAPER
+ -
LIGHTS
BATTERY
CUSHION HITCH
VALVE SOLENOID
= HARNESS CONNECTOR
17
• Wiring harness The machine wiring harness contains several disconnect points at various
disconnect points: locations throughout the machine. The graphic in the top, right view
shows all the 620G Series machines electrical system wiring harness
1. Tractor engine
wiring disconnect disconnect points.
2. Scraper engine
The tractor engine wiring disconnect (1) is shown in the bottom left view
wiring disconnect
and the scraper engine (627G) wiring disconnect (2) is shown in the
bottom right view.
11/00
1
2
3 5
18
ENGINE
3406E Tractor Engine
• Right side of 3406E The following components are located on the right side of the 3406E
engine: tractor engine:
1. Air cleaner housing - Air cleaner housing (1)

2. Air conditioning
receiver-dryer
- Air conditioning receiver-dryer (2)
3. Alternator
4. Air filter element
indicator - Alternator (3)
5. Windshield washer
solvent reservoir - Air filter element indicator (4)
6. Engine disconnect
switch
- Windshield washer solvent reservoir (5)
- Engine disconnect switch (6)

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4 3
19
• Right side of 3406E The following components are also located on the right side of the 3406E
engine: tractor engine:
1. Engine oil filler cap - Engine oil filler cap (1)
2. Engine oil dipstick
3. Engine oil filter
- Engine oil dipstick (2)
4. Primary fuel/water
separator
5. Fuel shutoff valve - Engine oil filter (3)
- Primary fuel/water separator (4)
- Fuel shutoff valve (5)

11/00
20
• Left side of 3406E The following components are visible on the left side of the tractor
engine: engine:
1. Engine wiring - Engine wiring harness disconnect point (1)
harness disconnect
point
- Oil pressure sensor (2)
2. Oil pressure sensor
x11/00
620G WHEEL TRACTOR-SCRAPER

TRACTOR ENGINE CONTROL
FUEL INJECTORS (6) CAT DATA LINK
GROUND LEVEL SHUTDOWN SWITCH
THROTTLE LOCK/BACKUP SWITCH
COOLANT TEMP. SENSOR

START AID SWITCH
FUEL TEMP. SENSOR
1 2 3 4 5 15
20
10
CATERPILLAR MONITORING SYSTEM

5 25
6 7 8 9 0
INTAKE AIR TEMP. SENSOR C kPaMILESKM KPHLITER
SERV
CODE
X10
0
MPH
km/ h3F
X100
30
ATMOSPHERIC PRESS. SENSOR

KEY SWITCH
TURBO INLET PRESSURE SENSOR

THROTTLE SENSOR
TURBO OUTLET PRESS. SENSOR
ENGINE OIL PRESS. SENSOR THROTTLE LOCK LAMP
COOLANT FLOW SWITCH
PRELUBE RELAY
TIMING CALIBRATION PROBE
TOP SPEED/TIMING
PRELUBE SECONDARY RELAY
BOTTOM SPEED/TIMING
PRELUBE STARTER (ATTACHMENT)
21
• 620G Engine Control The 3406E engine ECM communicates with the 620G machine modules
System over the CAT Data Link. The engine ECM receives inputs from various
sensors and switches. The ECM process the signals and sends
corresponding output signals to the fuel injectors, Caterpillar Monitoring
System and other output components over the Cat Data Link.
11/00
22
• Engine ECM (arrow) The engine ECM (arrow) is located on the left side of the engine.
11/00
6
5 4
23
3306 Scraper Engine
• Left side of 3306 The following components are located on the left side of the 3306 scraper
engine: engine (machine right side):
1. Air cleaner housing Air cleaner housing (1)
2. Air filter element
indicator
Air filter element indicator (2)
3. Circuit breakers
4. Scraper
transmission oil Circuit breakers (3)
filter housing
5. Scraper engine oil Scraper transmission oil filter housing (4)
cooler
6. Engine oil change
quick coupler
Scraper engine oil cooler (5)
7. Differential oil fill
tube Engine oil change quick coupler (6)
Differential oil fill tube (7)

11/00
3
4
1
24
• Right side of 3306 The following components are located on the right side of the 3306
engine: scraper engine (machine left side):
1. Primary fuel filter Primary fuel filter (1)
2. Fuel priming pump
3. Secondary fuel filter
Fuel priming pump (2)
4. Fuel shutoff valve
5. Governor linkage
Secondary fuel filter (3)
Fuel shutoff valve (4)
Governor linkage (5)

x11/00
WHEEL TRACTOR-SCRAPER
POWER TRAIN COMPONENTS
25
POWER TRAIN
• Major power train This view shows the major power train component locations on the 620G
components: Series machines. The colors used to identify the various components are:
- Engine Yellow - Engine
- Transmission
Red - Transmission
- Driveshaft
- Final drive Blue - Driveshaft
Brown - Final drive
The 620G Series wheel tractor-scrapers use an electronically controlled

power shift transmission in the tractor and scraper. The tractor
transmission provides one reverse and eight forward gears. The scraper
transmission provides one reverse and four forward gears.
x11/00
TRACTOR POWER TRAIN COMPONENTS
RETARDER
DIESEL
ENGINE
DRIVE
TRANSFER SHAFT
GEARS
FINAL
DRIVE
DIFFERENTIAL
TORQUE PINON
CONVERTER TRANSMISSION GEAR
26
Tractor Power Train

• Tractor power train This view shows the main tractor power train components and power
components and flow.
power flow
Power flows from the 3406E engine to the optional retarder (if equipped)
though the transmission drive shaft to the transfer gears.
The transfer gears send power to the torque converter. The torque
converter transfers power to the Individual Clutch Modulated (ICM)
power shift transmission.
Power from the transmission flows through the pinon gear to the
differential, axles and final drives at each wheel.
The final drives transfer power to the wheels.

11/00
27
• Tractor Transmission This view shows the transmission located at the rear of the 620G Series
tractor.
1. Transmission
2. Transfer gear case The transmission (1), transfer gear case (2) and torque converter housing
3. Torque converter (3) are visible in this view.
housing
The transmission operates in converter drive during REVERSE, FIRST
and SECOND gear. The transmission operates in direct drive from
THIRD gear though EIGHTH gear.
x11/00
620G TRACTOR
TRANSMISSION HYDRAULIC SYSTEM
DOWNSHIFT PRIORITY SELECTOR T/C PRESSURE SCAVENGE

AND UPSHIFT VALVE GROUP INLET CONTROL PUMP
SOLENOIDS VALVE GROUP
DRIVE
SHAFT FLYWHEEL
OIL BEARING CASE RETARDER
FILTER CONTROL
TRANSMISSION VALVE
DRIVE SHAFT
CASE
CHARGE
AND
SCAVENGE DIFF LUBE
PUMPS CASE LINE
OIL
COOLER
MAGNETIC
SCREEN
RETARDER
AIR VALVE
SCAVENGE TRANSFER T/C RETARDER SCAVENGE COOLER
SCREEN GEAR CASE SCREEN RETURN LINE
28
• Tractor power train oil This view illustrates the oil flow through the tractor power train hydraulic
flow system components.
Oil is drawn from the bevel gear case through the magnetic screen to the
transmission charge pump. Oil flows from the charge pump through a
filter to the upshift and downshift solenoids, the priority valve and the
selector valve group.
Oil flow to the selector valve group flows to the pressure control group for
transmission clutch engagement and to the torque converter.
Oil from the torque converter flows to the retarder control valve (if
equipped), the flywheel, and to the transmission case.
The flywheel scavenge pump pumps oil to lubricate the drive shaft
bearing.
The transmission scavenge pump draws oil from the transfer gear case and
sends the oil to the differential and bevel gear case.
11/00
1
2
29
• Right console in cab: The transmission control lever (1) is located on the right console in the
cab. The transmission control lever is used to select the desired machine
1. Transmission
direction and speed. The transmission control lever has five positions:
control lever
2. Transmission REVERSE, NEUTRAL, FIRST, SECOND and DRIVE. The
control lever lock transmission control lever lock button (2) must be pressed to
button mechanically unlock the lever before it can be moved.
3. Gear select button
When the transmission control lever is in the DRIVE position the
transmission will automatically shift between SECOND and any higher
speed that is selected. The top gear select button (3) is used to select the
desired top speed. With the engine running and the transmission control
lever in the DRIVE position, pressing and holding the top gear select
button will cycle the gear indicator through the available gears. When the
top gear select button is released, the top drive gear is set. The
monitoring system will show the gear position on the display panel.
NOTE: The machine is equipped with an engine neutral start system.

The transmission control lever must be in the NEUTRAL position to
allow the engine to start.
x11/00
620G TRACTOR ELECTRONIC

TRANSMISSION CONTROL SYSTEM
INPUT COMPONENTS OUTPUT COMPONENTS
ECM LOCATION CODE CAT DATA LINK

ELECTRONIC SERVICE TOOL
SHIFT LEVER
POSITION SWITCH ENGINE ECM
TRANSMISSION
GEAR SWITCH IMPLEMENT ECM
ENGINE OUTPUT SCRAPER TRANSMISSION ECM

SPEED SENSOR
TRANSMISSION OUTPUT CATERPILLAR MONITORING
SPEED SENSOR C kPaMilesKM RPM Liter SERV SYSTEM
CODE
... X10
KEY START SWITCH
TRACTOR TRANSMISSION UPSHIFT SOLENOID

NEUTRAL/RUN SWITCH
PILOT SUPPLY DOWNSHIFT SOLENOID
PRESSURE SENSOR
RETARDER
STARTER RELAY
PRESSURE SWITCH
TRACTOR AIR
PRESSURE SENSOR SECONDARY STEERING RELAY
TRACTOR SERVICE BRAKE TRACTOR PARK
PRESSURE SWITCH BRAKE SOLENOID
TRACTOR PARKING BRAKE SCRAPER PARK
PRESSURE SWITCH BRAKE SOLENOID
SCRAPER AIR
PRESSURE SENSOR ENGINE OVERSPEED LAMP
SCRAPER SERVICE BRAKE
PRESSURE SWITCH RETARDER LAMP
SCRAPER PARKING BRAKE BACK-UP ALARM

PRESSURE SWITCH RELAY
30
• Tractor Electronic The Transmission ECM receives inputs from various sensors and
Transmission Control switches. The ECM process the signals and sends corresponding output
System
signals to the other machine ECMs, the Caterpillar Monitoring System,
the tractor transmission solenoids and various other output components
over the Cat Data Link.
x11/00
SCRAPER POWER TRAIN COMPONENTS
TORQUE
CONVERTER
DIESEL RETARDER
ENGINE (OPTIONAL)
TRANSMISSION
FINAL PINON
DRIVE DIFFERENTIAL GEAR DRIVE SHAFT
31
Scraper Power Train

• Scraper power train This view shows the main scraper power train components and power
components and flow.
power flow
Power flows from the 3306 diesel engine to the torque converter and
though the optional retarder (if equipped) to the transmission.
In the transmission, power is sent to the transfer gears. The transfer gears
send power through the drive shaft and pinon gear to the differential. The
differential transfers power to the axles and final drives at each wheel.
The final drives transfer power to the wheels.

11/00
32
• Rear of scraper: In this view at the rear of the scraper, the transmission (1), the transfer
gear case (2) and the drive shaft yoke (3), are visible.
1. Transmission
2. Transfer gear case The ejector cylinder rod (4) is also visible in this view.
3. Drive shaft yoke
4. Ejector cylinder rod
x11/00
627G SCRAPER
TRANSMISSION HYDRAULIC SYSTEM
TRANSMISSION
OIL HYDRAULIC
FILTER CONTROLS
TORQUE
CONVERTER
TRANSMISSION
CHARGE
PUMP UPSHIFT SYNC
SOLENOID SOLENOID OIL
DOWNSHIFT COOLER
TO
MAGNETIC SOLENOID
TRANSMISSION
SCREEN
CLUTCHES
TRANSMISSION LUBRICATION
HYDRAULIC LUBRICATION RELIEF VALVE
OIL TANK
SCAVENGE
SCREEN
TRANSMISSION
CASE RESERVOIR
SCAVENGE
PUMP
33
• Scraper power train This view illustrates the oil flow through the 627G scraper transmission
oil flow hydraulic system components.
The transmission charge pump draws oil from the hydraulic oil tank
through a magnetic screen. The charge pump sends the oil through the
transmission oil filter to the priority valve in the transmission hydraulic
controls.
Oil in the transmission flows to the selector valve. The transmission

selector valve directs oil to the transmission clutches for gear engagement.
Oil also flows to the torque converter, through the oil cooler and to the
transmission lubrication relief valve. Some of this oil is used for
planetary gear lubrication, and the remaining oil flows to the transmission
case reservoir. The scavenge pump pulls the oil from the transmission
case reservoir through a magnetic screen and sends the oil back to the
tank.
x11/00
627G SCRAPER ELECTRONIC

TRANSMISSION CONTROL SYSTEM
INPUT COMPONENTS OUTPUT COMPONENTS
CAT DATA LINK

ECM LOCATION CODE ELECTRONIC SERVICE TOOL
TRANSMISSION CATERPILLAR MONITORING

GEAR SWITCH SYSTEM (TRACTOR)
C kPaMilesKM RPM Liter SERV
... CODE
X10
TRANSMISSION OUTPUT
SPEED SENSOR CATERPILLAR MONITORING
C kPaMiles KMRPM LiterSERV
SYSTEM (SCARPER)
CODE
.. . X10
KEY START SWITCH

UPSHIFT SOLENOID
TRACTOR TRANSMISSION
NEUTRAL/RUN SWITCH DOWNSHIFT SOLENOID
SYNC SOLENOID
LOCATION CODE PLUG
SCRAPER THROTTLE
LOCK SOLENOID
ACTUAL GEAR SWITCH SCRAPER SLIP
LIMITER SOLENOID
TRANSMISSION SYNC LAMP
STARTER RELAY
SCRAPER PRELUBE TIMER RELAY
34
• Scraper Electronic The Scraper Transmission ECM receives inputs from various sensors and
Transmission Control switches. The ECM process the signals and sends corresponding output
System
signals to the Caterpillar Monitoring System, the scraper transmission
solenoids and other output components over the Cat Data Link.
x11/00
LEFT BOWL RIGHT BOWL

CYLINDER CYLINDER
SHUTTLE
VALVE
SHUTTLE
VALVE EJECTOR
QUICK QUICK CYLINDER
620G ELECTRO-HYDRAULIC DROP
VALVE
DROP
VALVE
PRESSURE
SWITCH
IMPLEMENT SYSTEM
APRON EJECTOR
CYLINDER CYLINDER
PRESSURE
REDUCING SEQUENCE
IMPLEMENT
IMPLEMENT VALVE VALVE
CONTROL
CONTROL VALVE
LEVER
FILTER
CAT
DATA SHUTTLE
IMPLEMENT
LINK VALVE
ELECTRONIC
CONTROL TO CUSHION
MODULE HITCH VALVE
TO STEERING
SYSTEM
CUSHION IMPLEMENT
HITCH/PILOT & STEERING
PUMP PUMP
ELECTRONIC SYSTEM PILOT HYDRAULIC SYSTEM MAIN HYDRAULIC SYSTEM
35
ELECTRO-HYDRAULIC IMPLEMENT SYSTEM
• Electro-hydraulic The electro-hydraulic implement system includes a pilot hydraulic system

implement system and a main hydraulic system. The pilot system controls the functions of
the main control valve. The pilot system consists of the electronic system
and the pilot hydraulic system.
• Electronic system The main electronic system components (brown) are the implement
electronic control module (ECM), the pilot control actuator solenoids and
the implement control lever. The implement control lever contains lever
position sensors which send input signals to the implement ECM.
• Pilot hydraulic system The pilot hydraulic system (orange) consists of the cushion hitch pump
which provides the pilot oil supply, the pressure reducing valve and the
pilot actuator valves.
• Main hydraulic system The main hydraulic system (red) consists of the implement and steering
pump, the implement control valve and the implement cylinders.
➥
x/00
• Additional The implement electronic control system also controls the following
components components (not shown) depending on the machine configuration: auger,
elevator and bail.
x11/00
620G SERIES WHEEL TRACTOR-SCRAPER

IMPLEMENT CONTROL SYSTEM
IMPLEMENT ECM
IMPLEMENT CONTROL LEVER CONVERTER OIL TEMP SENSOR
PILOT SUPPLY SOLENOID

AUGER SLIP LIMITER SWITCH
BAIL SOLENOID
AUGER REVERSE SWITCH CUSHION HITCH SOLENOID
EJECTOR CYLINDER EJECTOR FORWARD SOLENOID

PRESSURE SENSOR EJECTOR REVERSE SOLENOID
PUMP CASE DRAIN
FILTER SWITCH BOWL UP SOLENOID
CHARGE PUMP FILTER BOWL DOWN SOLENOID

PRESSURE SWITCH
ELEVATOR ENABLE SOLENOID
MOTOR CASE FILTER
PRESSURE SWITCH APRON RAISE SOLENOID
APRON LOWER SOLENOID
ELEVATOR DIRECTION SOLENOID
AUGER FORWARD SOLENOID
ELEVATOR SPEED SOLENOID
AUGER REVERSE SOLENOID
GEAR HOLD LIGHT
EJECTOR RETURN LIGHT TRACTOR MODE SELECT LIGHT
APRON FLOAT LIGHT SCRAPER MODE SELECT LIGHT
36
• Implement control The Implement ECM receives inputs from various sensors and switches.
system The ECM process the signals and sends corresponding output signals to
the implement control solenoids over the Cat Data Link.
11/00
3
2 4
37
• Right console in cab: The implement control lever (1) is located on the right console in the cab.
The implement control lever contains position sensors, which send input
1. Implement control
signals to the implement ECM. The ECM processes the signals and sends
lever
2. Left button corresponding output signals to energize or de-energize the pilot actuator
3. Right button solenoids.
4. Thumb wheel
Forward and backward implement lever movement controls bowl RAISE
and LOWER. Left and right implement lever movement controls ejector
FORWARD and RETURN. The left button (2) activates or deactivates
transmission hold. The right button (3) controls the cushion hitch.
The thumb wheel (4) controls the apron on the 621G and 627G models, or
the elevator on the 623G model.
The trigger switch (not visible) controls the auger on the 621G model and
the auger or the bail on the 627G model. On the 623G model, the trigger
switch controls elevator speed.
11/00
38
• Left side of machine: The implement control valve (1) is located on the left side of the tractor,
between the cushion hitch and the left wheel fender.
1. Implement control
valve When the implement control lever at the operator station is moved from
2. Actuator solenoids the HOLD position, an electrical signal is sent to the actuator solenoids
3. Pilot control
(2). The solenoids activate the pilot control actuators (3) which direct
actuators
pilot oil to the implement control valve spools.
11/00
39
• Right side of machine: Two bowl cylinders (1) are located at the front of the bowl (2). The bowl
cylinders raise and lower the bowl.
1. Bowl cylinders
2. Bowl The apron cylinder (not visible) controls movement of the apron (3) on
3. Apron 621G and 627G models. The apron cylinder is located near the top of the
4. Ejector
scraper gooseneck.
The ejector cylinder (not visible) controls ejector (4) movement and is
located below the scraper transmission.
11/00
1
2
40
• Elevator on 623G: The chain driven elevator (1) on the 623G models is powered by a
variable speed, reversible motor (2). The motor is mounted on the left
1. Elevator
side of the machine.
2. Motor
The elevator motor is driven by the elevator pump (not visible), which is
mounted on the rear of the tractor transmission.
x11/00
STEERING SYSTEM COMPONENTS
STEERING CONTROL SUPPLEMENTARY STEERING

VALVE STEERING CYLINDERS
PUMP
IMPLEMENT/
STEERING
PUMP
TRACTOR
TRANSMISSION
ECM
41
STEERING SYSTEM
• Steering system The steering system is a variable flow modulated system. The system
components provides the operator with an automotive type feel when steering.
This diagram shows the location of the major components of the steering
system. Hydraulic system operation is the same as the 620F Series Wheel
Tractor-Scrapers.
The tractor transmission electronic control module monitors the optional

secondary steering system.
x11/00
STEERING
CYLINDERS
STEERING SYSTEM
NO TURN
STEERING
CONTROL
VALVE
FROM
IMPLEMENT TO IMPLEMENT
SUPPLEMENTAL CONTROL VALVE CONTROL VALVE
STEERING
PUMP
FROM
SUSPENSION
VALVE
STEERING IMPLEMENT
PUMP PUMP
42
• Steering hydraulic In the steering system, oil flows from the steering side of the implement
system oil flow and steering pump to the steering control valve. The steering control
valve directs oil to the steering cylinders.
The supplemental steering pump provides the oil flow for the steering
system if the engine stops or the main steering pump fails.
11/00
43
CONCLUSION
This presentation has provided an overview of the 621G/623G/627G

Wheel Tractor-Scrapers.
11/00
SLIDE LIST
1. Machine view (front) 25. Machine power train components
2. Machine arrangements 26. Tractor power train components
3. Machine features 27. Tractor transmission
4. Operator s station 28. Tractor transmission hydraulic system block
5. Instrument panel diagram
6. Caterpillar Monitoring System 29. Transmission control lever
7. Overhead panel 30. Tractor electronic transmission control
8. Right console system
9. Cab floor 31. Scraper power train components
10. Steering wheel and steering column 32. Scraper transmission
11. Operator s seat 33. Scraper transmission hydraulic system block
12. Diagnostic connector diagram
13. Electrical center 34. Tractor electronic transmission control
14. Electronic control system system
15. Tractor transmission ECM 35. Electro-Hydraulic implement system block
16. Scraper transmission ECM diagram
17. Wiring harness disconnect points 36. Implement electronic control system
18. Tractor engine (3406E) right side 37. Implement control lever
19. Tractor engine (3604E) right side 38. Implement control valve
20. Tractor engine (3406E) left side 39. Ejector, bowl and apron (621G/627G)
21. Tractor engine control system 40. Elevator (623G)
22. Engine ECM 41. Steering system components
23. Scraper engine (3306) left side 42. Steering system block diagram
24. Scraper engine (3306) right side 43. Machine view (rear)
620 G Series NPI Printed in U.S.A.
11/00

Cat 621G 623G 627G Npi

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Service Training November 2000

NEW PRODUCT INFORMATION

1. identify the major changes in the machine features and systems;

Estimated Time: 1 Hour

ELECTRICAL SYSTEM .....................................................................................................18

POWER TRAIN ...................................................................................................................30

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM...........................................................40

STEERING SYSTEM ..........................................................................................................47

The 621G/623G/627G Series Wheel Tractor-Scrapers are a direct

620G SERIES MACHINE CONFIGURATIONS

MODEL STANDARD CONFIGURATION OPTIONS

BOWL EJECTOR APRON

623G BOWL EJECTOR ELEVATOR

BOWL EJECTOR APRON

627G BOWL EJECTOR APRON BAIL

BOWL EJECTOR APRON AUGER

The 620G Series Wheel Tractor-Scrapers are available in several

Updated Operator’s Station: The operator’s station includes an

Caterpillar Monitoring System: The Caterpillar Monitoring System

CATERPILLAR MONITORING SYSTEM

C kPa Miles KM RPM Liter SERV

CAT DATA LINK

MONITORING SYSTEM C kPa Miles KM RPM Liter SERV

TRACTOR SCRAPER ENGINE ECM IMPLEMENT ECM

• Caterpillar monitoring The Caterpillar Monitoring System continuously monitors machine

The speedometer/tachometer module displays the engine speed (gauge),

620G SERIES WHEEL TRACTOR-SCRAPER

TRACTOR SCRAPER SCRAPER

C kPa MILES KM KPH LITER

CAT DATA LINK

TRACTOR APRON OR SCRAPER REPORTS

TRACTOR SCRAPER SCRAPER

TRACTOR SERVICE PORT CONNECTOR SCRAPER

- Tractor transmission Engine ECM

Scraper monitor display on 627G models (part of Caterpillar

620G SERIES WHEEL TRACTOR-SCAPER

WIRING HARNESS STARTER ENGINE

DISCONNECT POINTS RADIATOR

3406E Tractor Engine

1. Air cleaner housing - Air cleaner housing (1)

- Engine disconnect switch (6)

- Primary fuel/water separator (4)

- Fuel shutoff valve (5)

620G WHEEL TRACTOR-SCRAPER

FUEL INJECTORS (6) CAT DATA LINK

GROUND LEVEL SHUTDOWN SWITCH

THROTTLE LOCK/BACKUP SWITCH

COOLANT TEMP. SENSOR

CATERPILLAR MONITORING SYSTEM

ATMOSPHERIC PRESS. SENSOR

TURBO INLET PRESSURE SENSOR

ENGINE OIL PRESS. SENSOR THROTTLE LOCK LAMP

COOLANT FLOW SWITCH

3306 Scraper Engine

Differential oil fill tube (7)

Fuel shutoff valve (4)

Governor linkage (5)

- Final drive Blue - Driveshaft

Brown - Final drive

The 620G Series wheel tractor-scrapers use an electronically controlled

Tractor Power Train

The final drives transfer power to the wheels.

DOWNSHIFT PRIORITY SELECTOR T/C PRESSURE SCAVENGE