Operations and Maintenance Manual 2

SEBU7892-07
March 2011
Operation and
Maintenance
Manual
525C, 535C and 545C Wheel Skidders
5251-Up (Machine)
5351-Up (Machine)
5451-Up (Machine)
SAFETY.CAT.COM
i03991620
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identied by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identied by NOTICE labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without rst
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specic rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Cat dealers have the most current information available.
When replacement parts are required for this product Caterpillar recom-
mends using Cat replacement parts or parts with equivalent specica-
tions including, but not limited to, physical dimensions, type, strength
and material.
Failure to heed this warning can lead to premature failures, product
damage, personal injury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7892-07 3
Table of Contents
Table of Contents
Foreword .................................................................................................. 5
Safety Section
Safety Messages ..................................................................................... 9
Additional Messages .............................................................................. 23
General Hazard Information .................................................................. 28
Crushing Prevention and Cutting Prevention ......................................... 34
Burn Prevention ..................................................................................... 35
Fire Prevention and Explosion Prevention ............................................. 36
Fire Extinguisher Location ..................................................................... 44
Tire Information ...................................................................................... 45
Electrical Storm Injury Prevention .......................................................... 46
Before Starting Engine ........................................................................... 47
Visibility Information ............................................................................... 47
Engine Starting ...................................................................................... 48
Before Operation ................................................................................... 49
Operation ............................................................................................... 50
Engine Stopping .................................................................................... 51
Parking ................................................................................................... 51
Slope Operation ..................................................................................... 52
Work Tools ............................................................................................. 54
Equipment Lowering with Engine Stopped ............................................ 55
4 SEBU7892-07
Table of Contents
Sound Information and Vibration Information ........................................ 55
Operator Station .................................................................................... 57
Product Information Section
General Information ............................................................................... 58
Identication Information ........................................................................ 75
Operation Section
Before Operation ................................................................................... 83
Machine Operation ................................................................................ 88
Engine Starting .................................................................................... 143
Adjustments ......................................................................................... 146
Parking ................................................................................................. 150
Transportation Information ................................................................... 157
Towing Information ............................................................................... 163
Engine Starting (Alternate Methods) .................................................... 168
Maintenance Section
Tire Ination Information ...................................................................... 174
Lubricant Viscosities and Rell Capacities .......................................... 177
Maintenance Support ........................................................................... 184
Maintenance Interval Schedule ........................................................... 186
Reference Information Section
Reference Materials ............................................................................. 338
Index Section
Index .................................................................................................... 344
SEBU7892-07 5
Foreword
Foreword
Literature Information
This manual should be stored in the operator's compartment in the
literature holder or seat back literature storage area.
This manual contains safety information, operation instructions,
transportation information, lubrication information and maintenance
information.
Some photographs or illustrations in this publication show details or
attachments that can be different from your machine. Guards and covers
might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might
have caused changes to your machine which are not included in this
publication. Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine, or this publication,
please consult your Caterpillar dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In addition, this section
identies the text and locations of warning signs and labels used on the
machine.
Read and understand the basic precautions listed in the safety section
before operating or performing lubrication, maintenance and repair on
this machine.
Operation
The operation section is a reference for the new operator and a refresher
for the experienced operator. This section includes a discussion of
gauges, switches, machine controls, attachment controls, transportation
and towing information.
Photographs and illustrations guide the operator through correct
procedures of checking, starting, operating and stopping the machine.
6 SEBU7892-07
Foreword
Operating techniques outlined in this publication are basic. Skill and
techniques develop as the operator gains knowledge of the machine and
its capabilities.
Maintenance
The maintenance section is a guide to equipment care. The Maintenance
Interval Schedule (MIS) lists the items to be maintained at a specic
service interval. Items without specic intervals are listed under the "When
Required" service interval. The Maintenance Interval Schedule lists the
page number for the step-by-step instructions required to accomplish the
scheduled maintenance. Use the Maintenance Interval Schedule as an
index or "one safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing intervals. Calendar
intervals shown (daily, weekly, monthly, etc.) can be used instead of
service hour meter intervals if they provide more convenient servicing
schedules and approximate the indicated service hour meter reading.
Recommended service should always be performed at the interval that
occurs rst.
Under extremely severe, dusty or wet operating conditions, more frequent
lubrication than is specied in the maintenance intervals chart might be
necessary.
Perform service on items at multiples of the original requirement. For
example, at every 500 service hours or 3 months, also service those
items listed under every 250 service hours or monthly and every 10
service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds. Wash hands after handling.
SEBU7892-07 7
Foreword
Certied Engine Maintenance
Proper maintenance and repair is essential to keep the engine and
machine systems operating correctly. As the heavy duty off-road diesel
engine owner, you are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation and Maintenance
Manual, and Service Manual.
It is prohibited for any person engaged in the business of repairing,
servicing, selling, leasing, or trading engines or machines to remove,
alter, or render inoperative any emission related device or element of
design installed on or in an engine or machine that is in compliance with
the regulations (40 CFR Part 89). Certain elements of the machine and
engine such as the exhaust system, fuel system, electrical system, intake
air system and cooling system may be emission related and should not
be altered unless approved by Caterpillar.
Machine Capacity
Additional attachments or modications may exceed machine design
capacity which can adversely affect performance characteristics. Included
would be stability and system certications such as brakes, steering, and
rollover protective structures (ROPS). Contact your Caterpillar dealer for
further information.
Caterpillar Product Identication Number
Effective First Quarter 2001 the Caterpillar Product Identication Number
(PIN) has changed from 8 to 17 characters. In an effort to provide uniform
equipment identication, Caterpillar and other construction equipment
manufacturers are moving to comply with the latest version of the product
identication numbering standard. Non-road machine PINs are dened
by ISO 10261. The new PIN format will apply to all Caterpillar machines
and generator sets. The PIN plates and frame marking will display the 17
character PIN. The new format will look like the following:
8 SEBU7892-07
Foreword
g00751314
Illustration 1
Where:
1. Caterpillar's World Manufacturing Code (characters 1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product Sequence Number
(characters 10-17). These were previously referred to as the Serial
Number.
Machines and generator sets produced before First Quarter 2001 will
maintain their 8 character PIN format.
Components such as engines, transmissions, axles, etc. and work tools
will continue to use an 8 character Serial Number (S/N).
SEBU7892-07 9
Safety Section
Safety Messages
Safety Section
i03239202
Safety Messages
SMCS Code: 7000
There are several specic safety messages on this machine. The exact
location of the hazards and the description of the hazards are reviewed in
this section. Please become familiarized with all safety messages.
Make sure that all of the safety messages are legible. Clean the safety
messages or replace the safety messages if you cannot read the words.
Replace the illustrations if the illustrations are not legible. When you
clean the safety messages, use a cloth, water and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen the adhesive that
secures the safety message. Loose adhesive will allow the safety
message to fall.
Replace any safety message that is damaged, or missing. If a safety
message is attached to a part that is replaced, install a safety message
on the replacement part. Any Caterpillar dealer can provide new safety
messages.
10 SEBU7892-07
Safety Section
Safety Messages
g01379082
Illustration 2
g01379087
Illustration 3
SEBU7892-07 11
Safety Section
Safety Messages
Do Not Operate (1)
This warning is located on the rewall above the ROPS/FOPS plate.
g01370904
Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to followthe instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
12 SEBU7892-07
Safety Section
Safety Messages
No Ether (2)
This warning is located near the rain cap for the engine air intake. This
warning is located near the engine air precleaner (if equipped).
g01372254
Explosion hazard! Do not use ether! This machine
is equipped with an air inlet heater. Using ether
can create explosions or res that can cause per-
sonal injury or death. Read and follow the starting
procedure in the Operation and Maintenance Man-
ual.
SEBU7892-07 13
Safety Section
Safety Messages
Water Cleaning System Under Pressure (3)
This warning label is located near the ller plug on the water tank on the
top of the cab.
g01379094
Do not remove the ll plug until the pressure in the
water tank has been relieved. Personal injury may
result.
This ll plug has a cross drilled hole that allows
the pressure to be relieved without disengaging
the threads.
Do not replace this ll plug with any other plug.
For more information, refer to Operation and Maintenance Manual, Water
Cleaning System (Pressurized).
14 SEBU7892-07
Safety Section
Safety Messages
Seat Belt (4)
This warning is located on the left ROPS post.
g01371636
A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
SEBU7892-07 15
Safety Section
Safety Messages
ROPS/FOPS Structure (5)
This warning is located on the LH structural beam under the dash.
g01211895
Structural damage, an overturn, modication, al-
teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certication. Do not weld on or drill holes in the
structure. This will void the certication. Consult
a Caterpillar dealer to determine this structure's
limitations without voiding its certication.
This machine has been certied to the standards that are listed on the
certication plate. The maximum mass of the machine, which includes
the operator and the attachments without a payload, should not exceed
the mass on the certication plate.
16 SEBU7892-07
Safety Section
Safety Messages
Compressed Spring (6)
This warning is located on the parking brake actuator.
g01379131
Do not attempt to remove spring(s), they are not
serviceable. Do not cut, saw, torch or modify this
chamber, serious injury or death may result.
SEBU7892-07 17
Safety Section
Safety Messages
No Clearance (7)
This warning is located on both sides of the machine near the articulation
joint.
g01371644
Crushing Hazard! Stay back a safe distance. There
is no clearance for a person in this area when the
machine turns. Failure to followthese instructions
could cause serious injury or death.
18 SEBU7892-07
Safety Section
Safety Messages
Pressurized System (8)
This warning is located on the top surface of the hydraulic tank near the
ller cap.
g01371640
Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system ller cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling systempressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.
SEBU7892-07 19
Safety Section
Safety Messages
Pressurized System (9)
This warning is located on the bottom of the radiator access door.
g01371640
Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system ller cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling systempressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.
20 SEBU7892-07
Safety Section
Safety Messages
Crushing hazard (10)
This warning is located near the articulation joint on the right side of the
machine.
g01371647
Connect the steering frame lock between the front
and the rear frames before lifting, transporting, or
servicing the machine in the articulation area. Dis-
connect the steering frame lock and secure the
steering frame lock before resuming operation.
Severe injury or death could occur.
SEBU7892-07 21
Safety Section
Safety Messages
High Pressure Cylinder (11)
This warning is located on the mounting bracket of the brake
accumulators.
g01372252
High Pressure Cylinder!
Do not remove any valve, hydraulic tting, or valve
core, nor disassemble any parts until pressure
has been relieved, or personal injury may occur.
To relieve pressure:
1. Refer to the Service Manual for the correct
method of dissipating hydraulic system
pressure.
2. Relieve gas pressure in the accumulator
cylinder by opening the charging valve one
turn only.
Charge the cylinder with dry nitrogen gas.
See your Caterpillar dealer for tools and detailed
information required for charging cylinders.
22 SEBU7892-07
Safety Section
Safety Messages
Battery (12)
This warning is located on the right side of the radiator guard.
g01370909
Explosion Hazard! Improper jumper cable connec-
tions can cause an explosion resulting in serious
injury or death. Batteries may be located in sep-
arate compartments. When using jump start ca-
bles, always connect the positive (+) cable from
the source to the positive (+) terminal of the bat-
tery that is connected to the starter solenoid. Con-
nect the negative () cable from the source to the
negative () terminal of the starter. If the machine
is not equipped with a starter negative terminal,
connect the negative () cable to the engine block.
Follow the procedure in the Operation and Main-
tenance Manual.
SEBU7892-07 23
Safety Section
Additional Messages
Product Link (13)
If your machine is equipped with the product link system, this warning
is located in the cab.
g01370917
This machine is equipped with a Caterpillar Prod-
uct Link communication device which must be de-
activated within 12 m(40 ft) of a blast zone. Failure
to do so could result in serious injury or death.
i03991610
Additional Messages
SMCS Code: 7000
There are several additional messages on this machine. Please become
familiarized with all messages.
24 SEBU7892-07
Safety Section
Additional Messages
g02170833
Illustration 4
Make sure that all of the additional messages are legible. Clean the
messages or replace the messages if you cannot read the words. Replace
the illustrations if the illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the messages. Solvents, gasoline, or
harsh chemicals could loosen the adhesive that secures the message.
Loose adhesive will allow the message to fall.
Replace any message that is damaged, or missing. If a message is
attached to a part that is replaced, install a message on the replacement
part. Any Caterpillar dealer can provide new messages.
Winch (1)
SEBU7892-07 25
Safety Section
Additional Messages
g01102562
Illustration 5
This additional message is located next to the controls for the winch on
the RH console.
Reference: Refer to Operation and Maintenance Manual, Operator
Controls for more information on the operation of the winch.
Window Cleaning (2)
g01102567
Illustration 6
This additional message is located on the bottom left corner of all cab
windows.
Clean the windows with a wet cloth or a wet sponge. A dry cloth or a dry
sponge may scratch the windows.
26 SEBU7892-07
Safety Section
Additional Messages
Reference: For more information, refer to Operation and Maintenance
Manual, Windows - Clean.
Product Link (3)
g01418953
Illustration 7
If your machine is equipped with the Product Link System, this additional
message is located in the cab.
The Product Link System is a satellite communication device that
transmits information regarding the machine back to Caterpillar and
Caterpillar dealers and customers. All logged events and diagnostic
codes that are available to the Caterpillar Electronic Technician (ET) on
the CAT data link can be sent to the satellite. Information can also be sent
to the Product Link System. The information is used to improve Caterpillar
products and Caterpillar services.
Refer to Operation and Maintenance Manual, Operator Controls for
more information.
Fire Points (Engine) (4)
SEBU7892-07 27
Safety Section
Additional Messages
g02095974
Illustration 8
This message is located in two places on each side of the engine
compartment.
This message describes the re points that are available on the engine
compartments. Use the apertures in order to suppress re hazards in
the engine compartment.
Do not use an unsafe method in order to suppress re hazards in the
engine compartment.
28 SEBU7892-07
Safety Section
General Hazard Information
i04010649
SMCS Code: 7000
g00104545
Illustration 9
Attach a Do Not Operate warning tag or a similar warning tag to the
start switch or to the controls. Attach the warning tag before you service
the equipment or before you repair the equipment. These warning tags
(Special Instruction, SEHS7332) are available from your Cat dealer.
Operating the machine while distracted can result
in the loss of machine control. Use extreme cau-
tion when using any device while operating the
machine. Operating the machine while distracted
can result in personal injury or death.
Know the width of your equipment in order to maintain proper clearance
when you operate the equipment near fences or near boundary obstacles.
Be aware of high voltage power lines and power cables that are buried.
If the machine comes in contact with these hazards, serious injury or
death may occur from electrocution.
SEBU7892-07 29
Safety Section
g00702020
Illustration 10
Wear a hard hat, protective glasses, and other protective equipment,
as required.
Do not wear loose clothing or jewelry that can snag on controls or on
other parts of the equipment.
Make sure that all protective guards and all covers are secured in place
on the equipment.
Keep the equipment free from foreign material. Remove debris, oil, tools,
and other items from the deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools, and other items that
are not a part of the equipment.
Know the appropriate work site hand signals and the personnel that
are authorized to give the hand signals. Accept hand signals from one
person only.
Do not smoke when you service an air conditioner. Also, do not smoke if
refrigerant gas may be present. Inhaling the fumes that are released from
a ame that contacts air conditioner refrigerant can cause bodily harm
or death. Inhaling gas from air conditioner refrigerant through a lighted
cigarette can cause bodily harm or death.
Never put maintenance uids into glass containers. Drain all liquids into
a suitable container.
Obey all local regulations for the disposal of liquids.
30 SEBU7892-07
Safety Section
Use all cleaning solutions with care. Report all necessary repairs.
Do not allow unauthorized personnel on the equipment.
Unless you are instructed otherwise, perform maintenance with the
equipment in the servicing position. Refer to Operation and Maintenance
Manual for the procedure for placing the equipment in the servicing
position.
When you perform maintenance above ground level, use appropriate
devices such as ladders or man lift machines. If equipped, use the
machine anchorage points and use approved fall arrest harnesses and
lanyards.
Pressurized Air and Water
Pressurized air and/or water can cause debris and/or hot water to be
blown out. The debris and/or hot water could result in personal injury.
When pressurized air and/or pressurized water is used for cleaning, wear
protective clothing, protective shoes, and eye protection. Eye protection
includes goggles or a protective face shield.
The maximum air pressure for cleaning purposes must be reduced to
205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used
with an effective chip deector and personal protective equipment. The
maximum water pressure for cleaning purposes must be below 275 kPa
(40 psi).
Trapped Pressure
Pressure can be trapped in a hydraulic system. Releasing trapped
pressure can cause sudden machine movement or attachment movement.
Use caution if you disconnect hydraulic lines or ttings. High-pressure
oil that is released can cause a hose to whip. High-pressure oil that
is released can cause oil to spray. Fluid penetration can cause serious
injury and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has
been stopped. The pressure can cause hydraulic uid or items such as
pipe plugs to escape rapidly if the pressure is not relieved correctly.
SEBU7892-07 31
Safety Section
Do not remove any hydraulic components or parts until pressure has been
relieved or personal injury may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved or personal injury
may occur. Refer to the Service Manual for any procedures that are
required to relieve the hydraulic pressure.
g00687600
Illustration 11
Always use a board or cardboard when you check for a leak. Leaking uid
that is under pressure can penetrate body tissue. Fluid penetration can
cause serious injury and possible death. A pin hole leak can cause severe
injury. If uid is injected into your skin, you must get treatment immediately.
Seek treatment from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that uids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the equipment. Prepare to collect the uid with suitable containers
before opening any compartment or disassembling any component that
contains uids.
Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool
Catalog for the following items:
Tools that are suitable for collecting uids and equipment that is suitable
for collecting uids
Tools that are suitable for containing uids and equipment that is
suitable for containing uids
32 SEBU7892-07
Safety Section
Obey all local regulations for the disposal of liquids.
Inhalation
g02159053
Illustration 12
Exhaust
Use caution. Exhaust fumes can be hazardous to your health. If you
operate the machine in an enclosed area, adequate ventilation is
necessary.
Asbestos Information
Cat equipment and replacement parts that are shipped from Caterpillar
are asbestos free. Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when you handle any
replacement parts that contain asbestos or when you handle asbestos
debris.
Use caution. Avoid inhaling dust that might be generated when you
handle components that contain asbestos bers. Inhaling this dust can
be hazardous to your health. The components that may contain asbestos
bers are brake pads, brake bands, lining material, clutch plates, and
some gaskets. The asbestos that is used in these components is bound in
a resin or sealed in some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there are several guidelines
that should be followed:
SEBU7892-07 33
Safety Section
Never use compressed air for cleaning.
Avoid brushing materials that contain asbestos.
Avoid grinding materials that contain asbestos.
Use a wet method in order to clean up asbestos materials.
A vacuum cleaner that is equipped with a high efciency particulate

air lter (HEPA) can also be used.
Use exhaust ventilation on permanent machining jobs.
Wear an approved respirator if there is no other way to control the dust.
Comply with applicable rules and regulations for the work place. In
the United States, use Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements can be found in
29 CFR 1910.1001.
Obey environmental regulations for the disposal of asbestos.
Stay away from areas that might have asbestos particles in the air.
Dispose of Waste Properly
g00706404
Illustration 13
Improperly disposing of waste can threaten the environment. Potentially
harmful uids should be disposed of according to local regulations.
34 SEBU7892-07
Safety Section
Crushing Prevention and Cutting Prevention
Always use leakproof containers when you drain uids. Do not pour waste
onto the ground, down a drain, or into any source of water.
i01359664
Crushing Prevention and Cutting
Prevention
SMCS Code: 7000
Support the equipment properly before you perform any work or
maintenance beneath that equipment. Do not depend on the hydraulic
cylinders to hold up the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
Do not work beneath the cab of the machine unless the cab is properly
supported.
Unless you are instructed otherwise, never attempt adjustments while the
machine is moving or while the engine is running.
Never jump across the starter solenoid terminals in order to start the
engine. Unexpected machine movement could result.
Whenever there are equipment control linkages the clearance in the
linkage area will change with the movement of the equipment or the
machine. Stay clear of areas that may have a sudden change in clearance
with machine movement or equipment movement.
Stay clear of all rotating and moving parts.
If it is necessary to remove guards in order to perform maintenance,
always install the guards after the maintenance is performed.
Keep objects away from moving fan blades. The fan blade will throw
objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable. Wear gloves when
you handle wire cable.
When you strike a retainer pin with force, the retainer pin can y out. The
loose retainer pin can injure personnel. Make sure that the area is clear of
people when you strike a retainer pin. To avoid injury to your eyes, wear
protective glasses when you strike a retainer pin.
SEBU7892-07 35
Safety Section
Burn Prevention
Chips or other debris can y off an object when you strike the object. Make
sure that no one can be injured by ying debris before striking any object.
i01329099
Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine. Allow the engine to cool
before any maintenance is performed on the engine. Relieve all pressure
in the air system, in the oil system, in the lubrication system, in the fuel
system, or in the cooling system before any lines, ttings or related items
are disconnected.
Coolant
When the engine is at operating temperature, the engine coolant is hot.
The coolant is also under pressure. The radiator and all lines to the
heaters or to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause severe burns. Allow
cooling system components to cool before the cooling system is drained.
Check the coolant level only after the engine has been stopped.
Ensure that the ller cap is cool before removing the ller cap. The ller
cap must be cool enough to touch with a bare hand. Remove the ller cap
slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can cause personal
injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot components can cause personal injury. Do not allow hot oil
to contact the skin. Also, do not allow hot components to contact the skin.
Remove the hydraulic tank ller cap only after the engine has been
stopped. The ller cap must be cool enough to touch with a bare hand.
Follow the standard procedure in this manual in order to remove the
hydraulic tank ller cap.
36 SEBU7892-07
Safety Section
Fire Prevention and Explosion Prevention
Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not
allow electrolyte to contact the skin or the eyes. Always wear protective
glasses for servicing batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i03863998
SMCS Code: 7000
g00704000
Illustration 14
General
Much of the material that is found in forestry applications is highly
ammable. This includes the following pieces: limbs, bark, leaves,
sawdust, small wood chips, and pine tree's needles. When this debris
from forestry applications is soaked with fuel or lubricants, the risk of
re is greatly increased. Perform a daily inspection before every shift or
more often when the amount of work output and buildup of debris is the
best way to prevent a machine re. Frequent inspections and thorough
cleanings of the machine are critical when the machine is engaged in
forestry applications. Even minor leaks or electrical malfunctions should
be repaired as soon as possible.
All fuels, most lubricants, and some coolant mixtures are ammable.
SEBU7892-07 37
Safety Section
To minimize the risk of re or explosion, Caterpillar recommends the
following actions.
Always perform a Walk-Around Inspection, which may help you identify a
re hazard. Do not operate a machine when a re hazard exists. Contact
your Caterpillar dealer for service.
Understand the use of the primary exit and alternative exit on the
machine. Refer to Operation and Maintenance Manual, Alternative Exit.
Do not operate a machine with a uid leak. Repair leaks and clean up
uids before resuming machine operation. Fluids that are leaking or
spilled onto hot surfaces or onto electrical components can cause a re. A
re may cause personal injury or death.
Keep the access doors to major machine compartments closed and
access doors in working condition in order to permit the use of re
suppression equipment, in case a re should occur.
Highly ammable debris can collect on equipment and in equipment that
is used in forestry applications. This debris includes the following pieces:
leaves, twigs, sawdust, small wood chips, , and pine tree's needles. If
the debris is allowed to accumulate, the debris can rapidly become the
fuel agent of a machine re. Clean all accumulations of forest debris in
the engine compartment or around other hot areas and hot parts on the
machine at the completion of each work shift. Perform this activity more
frequently when working in conditions with large amounts of forest debris
are present.
Clean all accumulations of ammable materials such as fuel, oil and
debris from the machine.
Do not operate the machine near any ame.
Keep shields in place. Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of a break in a line, in a
hose, or in a seal. Exhaust shields must be installed correctly.
Do not weld or ame cut on tanks or lines that contain ammable uids
or ammable material. Empty and purge the lines and tanks. Then clean
the lines and tanks with a nonammable solvent prior to welding or ame
cutting. Ensure that the components are properly grounded in order to
avoid unwanted arcs.
38 SEBU7892-07
Safety Section
Dust that is generated from repairing nonmetallic hoods or fenders
may be ammable and/or explosive. Repair such components in a well
ventilated area away from open ames or sparks. Use suitable Personal
Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration. Replace damaged
lines and hoses. The lines and the hoses should have adequate support
and secure clamps. Tighten all connections to the recommended torque.
Damage to the protective cover or insulation may provide fuel for res.
Store fuels and lubricants in properly marked containers away from
unauthorized personnel. Store oily rags and ammable materials in
protective containers. Do not smoke in areas that are used for storing
ammable materials.
g00704059
Illustration 15
Use caution when you are fueling a machine. Do not smoke while you
are fueling a machine. Do not fuel a machine near open ames or sparks.
Always stop the engine before fueling. Fill the fuel tank outdoors. Properly
clean areas of spillage.
SEBU7892-07 39
Safety Section
Follow practices for safe fueling that are described in the Operation
section of the Operation and Maintenance Manual section and follow local
regulations. Never store ammable uids in the operator compartment
of the machine.
Battery and Battery Cables
g00704135
Illustration 16
Caterpillar recommends the following in order to minimize the risk of re
or an explosion related to the battery.
Do not operate a machine if battery cables or related parts show signs of
wear or damage. Contact your Caterpillar dealer for service.
Follow safe procedures for engine starting with jump start cables.
Improper jumper cable connections can cause an explosion that may
result in injury. Refer to Operation and Maintenance Manual, Engine
Starting with Jump Start Cables for specic instructions.
Do not charge a frozen battery. This may cause an explosion.
Gases from a battery can explode. Keep any open ames or sparks away
from the top of a battery. Do not smoke in battery charging areas.
40 SEBU7892-07
Safety Section
Never check the battery charge by placing a metal object across the
terminal posts. Use a voltmeter in order to check the battery charge.
Daily inspect battery cables that are in areas that are visible. Inspect
cables, clips, straps, and other restraints for damage. Replace any
damaged parts. Check for signs of the following, which can occur over
time due to use and environmental factors:
Fraying
Abrasion
Cracking
Discoloration
Cuts on the insulation of the cable
Fouling
Corroded terminals, damaged terminals, and loose terminals

Replace damaged battery cable(s) and replace any related parts.
Eliminate any fouling, which may have caused insulation failure or related
component damage or wear. Ensure that all components are reinstalled
correctly.
An exposed wire on the battery cable may cause a short to ground if the
exposed area comes into contact with a grounded surface. A battery cable
short produces heat from the battery current, which may be a re hazard.
An exposed wire on the ground cable between the battery and the
disconnect switch may cause the disconnect switch to be bypassed if
the exposed area comes into contact with a grounded surface. This
may result in an unsafe condition for servicing the machine. Repair
components or replace components before servicing the machine.
SEBU7892-07 41
Safety Section
Fire on a machine can result in personal injury
or death. Exposed battery cables that come into
contact with a grounded connection can result in
res. Replace cables and related parts that show
signs of wear or damage. Contact your Caterpillar
dealer.
Wiring
Check electrical wires daily. If any of the following conditions exist, replace
parts before you operate the machine.
Fraying
Signs of abrasion or wear
Cracking
Discoloration
Cuts on insulation
Other damage
Make sure that all clamps, guards, clips, and straps are reinstalled
correctly. This will help to prevent vibration, rubbing against other parts,
and excessive heat during machine operation.
Attaching electrical wiring to hoses and tubes that contain ammable
uids or combustible uids should be avoided.
Consult your Caterpillar dealer for repair or for replacement parts.
Keep wiring and electrical connections free of debris.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high pressure lines. Do not
install any lines that are bent or damaged. Use the appropriate backup
wrenches in order to tighten all connections to the recommended torque.
42 SEBU7892-07
Safety Section
g00687600
Illustration 17
Check lines, tubes and hoses carefully. Wear Personal Protection
Equipment (PPE) in order to check for leaks. Always use a board or
cardboard when you check for a leak. Leaking uid that is under pressure
can penetrate body tissue. Fluid penetration can cause serious injury and
possible death. A pin hole leak can cause severe injury. If uid is injected
into your skin, you must get treatment immediately. Seek treatment from
a doctor that is familiar with this type of injury.
Replace the affected parts if any of the following conditions are present:
End ttings are damaged or leaking.
Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are swelling or ballooning.
Flexible parts of the hoses are kinked.
Outer covers have exposed embedded armoring.
End ttings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly.
During machine operation, this will help to prevent vibration, rubbing
against other parts, excessive heat, and failure of lines, tubes and hoses.
SEBU7892-07 43
Safety Section
Do not operate a machine when a re hazard exists. Repair any lines
that are corroded, loose or damaged. Leaks may provide fuel for res.
Consult your Caterpillar dealer for repair or for replacement parts. Use
genuine Caterpillar parts or the equivalent, for capabilities of both the
pressure limit and temperature limit.
Ether
Ether (if equipped) is commonly used in cold weather applications. Ether
is ammable and poisonous.
Follow the correct cold engine starting procedures. Refer to the section in
the Operation and Maintenance Manual with the label Engine Starting.
Do not spray ether manually into an engine if the machine is equipped
with a thermal starting aid for cold weather starting.
Use ether in well ventilated areas. Do not smoke while you are replacing
an ether cylinder or while you are using an ether spray.
Do not store ether cylinders in living areas or in the operator compartment
of a machine. Do not store ether cylinders in direct sunlight or in
temperatures above 49 C (120.2 F). Keep ether cylinders away from
open ames or sparks.
Dispose of used ether cylinders properly. Do not puncture an ether
cylinder. Keep ether cylinders away from unauthorized personnel.
Fire Extinguisher
As an additional safety measure, keep a re extinguisher on the machine.
Be familiar with the operation of the re extinguisher. Inspect the re
extinguisher and service the re extinguisher regularly. Follow the
recommendations on the instruction plate.
Consider installation of an aftermarket Fire Suppression System, if the
application and working conditions warrant the installation.
44 SEBU7892-07
Safety Section
Fire Extinguisher Location
i02399496
Fire Extinguisher Location
SMCS Code: 7000
Make sure that a re extinguisher is on the machine. Make sure that you
are familiar with the operation of the re extinguisher. Inspect the re
extinguisher and service the re extinguisher. Obey the recommendations
on the instruction plate.
g01198463
Illustration 18
The recommended location for mounting the re extinguisher is the inside
of the left cab door.
The re extinguisher may be mounted on the Rollover Protective
Structure (ROPS) instead. Do not weld the ROPS in order to install the
re extinguisher. Also, do not drill holes in the ROPS in order to mount
the re extinguisher on the ROPS.
Strap the mounting plate to a leg of the ROPS in order to mount the re
extinguisher. If the weight of the re extinguisher is more than 4.5 kg
(10 lb), mount the re extinguisher as low as possible on one leg. Do not
mount the re extinguisher on the upper one-third area of the leg.
SEBU7892-07 45
Safety Section
Tire Information
i04160129
Tire Information
SMCS Code: 7000
Explosions of air inated tires have resulted from heat-induced gas
combustion inside the tires. Explosions can be caused by heat that is
generated by welding, by heating rim components, by external re, or
by excessive use of brakes.
A tire explosion is much more violent than a blowout. The explosion can
propel the tire, the rim components, and the axle components from the
machine. Stay out of the trajectory path. Both the force of the explosion
and the ying debris can cause property damage, personal injury, or
death.
g02166933
Illustration 19
Typical example of tire is shown
Do not approach a hot or an apparently damaged tire.
Caterpillar recommends against using water or calcium as a ballast for
the tires except in machines designed for this additional mass. For those
applicable machines, the maintenance section will contain instructions on
the correct tire ination and lling procedures. Ballast, such as uid in the
tires, increases overall machine weight and may affect braking, steering,
power train components, or the certication of the protective structure
such as the ROPS. The use of tire/rim rust preventatives or other liquid
additives is not required.
46 SEBU7892-07
Safety Section
Electrical Storm Injury Prevention
Dry nitrogen gas is recommended for ination of tires. If the tires were
originally inated with air, nitrogen is still preferred for adjusting the
pressure. Nitrogen mixes properly with air.
Nitrogen inated tires reduce the potential of a tire explosion because
nitrogen does not aid combustion. Nitrogen helps to prevent oxidation of
the rubber, deterioration of rubber, and corrosion of rim components.
To avoid overination, proper nitrogen ination equipment and training in
the usage of the equipment are necessary. A tire blowout or a rim failure
can result from improper equipment or from misused equipment.
When you inate a tire, stand behind the tread and use a self-attaching
chuck.
Servicing tires and rims can be dangerous. Only trained personnel that
use proper tools and proper procedures should perform this maintenance.
If correct procedures are not used for servicing tires and rims, the
assemblies could burst with explosive force. This explosive force can
cause serious personal injury or death. Carefully obey the specic
instructions from your tire dealer.
i01122596
Electrical Storm Injury Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the machine, the operator
should never attempt the following procedures:
Mount the machine.
Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the
operator's station. If you are on the ground during an electrical storm, stay
away from the vicinity of the machine.
SEBU7892-07 47
Safety Section
Before Starting Engine
i00934890
Before Starting Engine
SMCS Code: 1000; 7000
The steering frame lock must be in the unlocked position in order to steer
the machine.
Start the engine only from the operator compartment. Never short across
the starter terminals or across the batteries. Shorting could bypass the
engine neutral start system. Shorting could also damage the electrical
system.
Inspect the condition of the seat belt and the condition of mounting
hardware. Replace any parts that are worn or damaged. Regardless of
the appearance, replace the seat belt after three years of use. Do not use
a seat belt extension on a retractable seat belt.
Adjust the seat so that there is full pedal travel while the operator's back
is against the back of the seat.
Make sure that the machine is equipped with a lighting system that is
adequate for the job conditions. Make sure that all lights are working
properly.
Before you start the engine or before you move the machine, make sure
that no one is on the machine, underneath the machine, or around the
machine. Make sure that there are no personnel in the area.
i03162317
Visibility Information
SMCS Code: 7000
Before you start the machine, perform a walk-around inspection in order
to ensure that there are no hazards around the machine.
While the machine is in operation, constantly survey the area around the
machine in order to identify potential hazards as hazards become visible
around the machine.
48 SEBU7892-07
Safety Section
Engine Starting
Your machine may be equipped with visual aids. Some examples of visual
aids are Closed Circuit Television (CCTV) and mirrors. Before operating
the machine, ensure that the visual aids are in proper working condition
and that the visual aids are clean. Adjust the visual aids using the
procedures that are located in this Operation and Maintenance Manual.
If equipped, the Work Area Vision System shall be adjusted according
to Operation and Maintenance Manual, SEBU8157, Work Area Vision
System.
It may not be possible to provide direct visibility on large machines to all
areas around the machine. Appropriate job site organization is required
in order to minimize hazards that are caused by restricted visibility. Job
site organization is a collection of rules and procedures that coordinates
machines and people that work together in the same area. Examples of
job site organization include the following:
Safety instructions
Controlled patterns of machine movement and vehicle movement
Workers that direct trafc to move when it is safe
Restricted areas
Operator training
Warning symbols or warning signs on machines or on vehicles
A system of communication
Communication between workers and operators prior to approaching

the machine
Modications of the machine conguration by the user that result in a
restriction of visibility shall be evaluated.
i03690423
Engine Starting
SMCS Code: 1000; 7000
If a warning tag is attached to the engine start switch or to the controls, do
not start the engine and do not move any controls.
SEBU7892-07 49
Safety Section
Before Operation
Move all hydraulic controls to the HOLD position before you start the
engine.
Move the transmission control to the NEUTRAL position.
Engage the parking brake.
Diesel engine exhaust contains products of combustion which can be
harmful to your health. Always operate the engine in a well ventilated
area. If you are in an enclosed area, vent the exhaust to the outside.
Briey sound the horn before you start the engine.
Check for the presence of personnel. Ensure that all personnel are clear
of the machine.
i01360271
Before Operation
SMCS Code: 7000
Make sure that there are no personnel on the machine or in the area
around the machine.
Perform a walk-around inspection. Check all of the uid levels. Look for
loose bolts, leaks, and parts that are worn or broken. Inspect the condition
of the attachments and the condition of the hydraulic components.
Clear all obstacles from the path of the machine. Beware of hazards such
as wires, ditches, etc.
Make sure that all windows are clean. Secure the doors and the windows
in the shut position.
Adjust the rear view mirrors (if equipped) for the best vision of the
areanear the machine.
Make sure that the horn, the backup alarm (if equipped), and all other
warning devices are working properly.
Fasten the seat belt securely.
50 SEBU7892-07
Safety Section
Operation
i04329851
Operation
SMCS Code: 7000
Machine Operating Temperature Range
The standard machine conguration is intended for use within an
ambient temperature range of 40 C (40 F) to 43 C (110 F).
Special congurations for different ambient temperatures may be
available. Consult your Cat dealer for additional information on special
congurations of your machine.
Operation
Only operate the machine while you are sitting in a seat. The seat belt
must be fastened while you operate the machine. Only operate the
controls while the engine is running.
While you operate the machine slowly in an open area, check for proper
operation of all controls and all protective devices.
Before you move the machine, make sure that no one will be endangered.
Do not allow riders on the machine unless the machine has the following
equipment:
additional seat
additional seat belt
Rollover Protective Structure (ROPS)

Never use the work tool for a work platform.
Note any needed repairs during machine operation. Report any needed
repairs.
Carry work tools at approximately 40 cm (15 inches) above ground level.
Do not go close to the edge of a cliff, an excavation, or an overhang.
If the machine begins to sideslip, perform the following procedure:
Discard the load.

SEBU7892-07 51
Safety Section
Engine Stopping
Turn the machine downhill.

Avoid operating the machine across the slope. When possible, operate
the machine up the slopes and down the slopes.
Avoid any conditions that can lead to tipping the machine. The machine
can tip when you work on hills, on banks and on slopes. Also, the machine
can tip when you cross ditches, ridges, or other unexpected obstructions.
Maintain control of the machine. Do not overload the machine beyond
the machine capacity.
Never straddle a wire cable. Never allow other personnel to straddle a
wire cable.
Know the maximum dimensions of your machine.
Always keep the Rollover Protective Structure (ROPS) installed during
machine operation.
i02624835
Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine immediately after the machine has been operated
under load. This can cause overheating and accelerated wear of engine
components.
After the machine is parked and the parking brake is engaged, allow the
engine to run for two minutes before shutdown. This allows hot areas of
the engine to cool gradually.
i03907830
Parking
SMCS Code: 7000
Park the machine on a level surface. If you must park the machine on a
downgrade, block the tires.
Apply the service brake in order to stop the machine. Move the
transmission control to the NEUTRAL position.
52 SEBU7892-07
Safety Section
Slope Operation
Engage the parking brake.
Lower all work tools to the ground. Activate any control locks.
Stop the engine.
Turn the engine start switch to the OFF position and remove the key.
Always turn the battery disconnect switch to the OFF position before
leaving the machine.
If the machine will not be operated for a month or more, remove the
battery disconnect switch key.
i03745198
Slope Operation
SMCS Code: 7000
Machines that are operating safely in various applications depend on
these criteria: the machine model, conguration, machine maintenance,
operating speed of the machine, conditions of the terrain, uid levels,
and tire ination pressures. The most important criteria are the skill and
judgment of the operator.
A well trained operator that follows the instructions in the Operation
and Maintenance Manual has the greatest impact on stability. Operator
training provides a person with the following abilities: observation of
working and environmental conditions, feel for the machine, identication
of potential hazards, and operating the machine safely by making
appropriate decisions.
When you work on side hills and when you work on slopes, consider the
following important points:
Speed of travel At higher speeds, forces of inertia tend to make the
machine less stable.
Roughness of terrain or surface The machine may be less stable
with uneven terrain.
SEBU7892-07 53
Safety Section
Slope Operation
Direction of travel Avoid operating the machine across the slope.
When possible, operate the machine up the slopes and operate the
machine down the slopes. Place the heaviest end of the machine uphill
when you are working on an incline.
Mounted equipment Balance of the machine may be impeded by
the following components: equipment that is mounted on the machine,
machine conguration, weights, and counterweights.
Nature of surface Ground that has been newly lled with earth may
collapse from the weight of the machine.
Surface material Rocks and moisture of the surface material may
drastically affect the machine's traction and machine's stability. Rocky
surfaces may promote side slipping of the machine.
Slippage due to excessive loads This may cause downhill tracks
or downhill tires to dig into the ground, which will increase the angle of
the machine.
Width of tracks or tires Narrower tracks or narrower tires further
increase the digging into the ground which causes the machine to be
less stable.
Implements attached to the drawbar This may decrease the weight
on the uphill tracks. This may also decrease the weight on the uphill tires.
The decreased weight will cause the machine to be less stable.
Height of the working load of the machine When the working loads
are in higher positions, the stability of the machine is reduced.
Operated equipment Be aware of performance features of the
equipment in operation and the effects on machine stability.
Operating techniques Keep all attachments or pulled loads low to
the ground for optimum stability.
Machine systems have limitations on slopes Slopes can affect the
proper function and operation of the various machine systems. These
machine systems are needed for machine control.
Note: Safe operation on steep slopes may require special machine
maintenance. Excellent skill of the operator and proper equipment
for specic applications are also required. Consult the Operation and
Maintenance Manual sections for the proper uid level requirements and
intended machine use.
54 SEBU7892-07
Safety Section
Work Tools
i04159629
Work Tools
SMCS Code: 6700
Only use work tools that are recommended by Caterpillar for use on
Cat machines.
Use of work tools, including buckets, which are outside of Caterpillar's
recommendations or specications for weight, dimensions, ows,
pressures, and so on. may result in less-than-optimal vehicle performance,
including but not limited to reductions in production, stability, reliability,
and component durability. Caterpillar recommends appropriate work
tools for our machines to maximize the value our customers receive
from our products. Caterpillar understands that special circumstances
may lead a customer to use tools outside of our specications. In these
cases, customers must be aware that such choices can reduce vehicle
performance and will affect their ability to claim warranty in the event of
what a customer may perceive as a premature failure.
Work tools and work tool control systems, that are compatible with your
Cat machine, are required for safe machine operation and/or reliable
machine operation. If you are in doubt about the compatibility of a
particular work tool with your machine, consult your Cat dealer.
Make sure that all necessary guarding is in place on the host machine
and on the work tool.
Keep all windows and doors closed on the host machine. A polycarbonate
shield must be used when the host machine is not equipped with windows
and when a work tool could throw debris.
Do not exceed the maximum operating weight that is listed on the ROPS
certication.
If your machine is equipped with an extendable stick, install the transport
pin when you are using the following work tools: hydraulic hammers,
augers, and compactors
Always wear protective glasses. Always wear the protective equipment
that is recommended in the operation manual for the work tool. Wear any
other protective equipment that is required for the operating environment.
To prevent personnel from being struck by ying objects, ensure that all
personnel are out of the work area.
SEBU7892-07 55
Safety Section
Equipment Lowering with Engine Stopped
While you are performing any maintenance, any testing, or any
adjustments to the work tool stay clear of the following areas: cutting
edges, pinching surfaces, and crushing surfaces.
Never use the work tool for a work platform.
i01329161
SMCS Code: 7000
Before lowering any equipment with the engine stopped, clear the area
around the equipment of all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind most systems use a
high pressure uid or air to raise or lower equipment. The procedure will
cause high pressure air, hydraulic, or some other media to be released
in order to lower the equipment. Wear appropriate personal protective
equipment and follow the established procedure in the Operation and
Maintenance Manual, Equipment Lowering with Engine Stopped in the
Operation Section of the manual.
i00457455
Sound Information and Vibration
Information
SMCS Code: 7000
The operator sound exposure Leq (equivalent sound pressure level)
measured according to the work cycle procedures specied in ANSI/SAE
J1166May90 is 85 dB(A). This applies to the cab offered by Caterpillar,
when properly installed and maintained and tested with the doors and
windows closed.
The operator sound pressure level measured according to the procedures
specied in SAE J919Jun86 is 85 dB(A), for the cab offered by
Caterpillar, when properly installed and maintained and tested with the
doors and windows closed and with the machine in middle gear range
and moving.
56 SEBU7892-07
Safety Section
Sound Information and Vibration Information
The exterior sound pressure level for the standard machine measured at
a distance of 15 m (49.2 ft) according to the test procedures specied in
SAE J88Jun86, with the machine in middle gear range and moving,
is 88 dB(A).
Sound Performance for Machines Offered in
European Union Countries and in Countries that
Adopt the EU Directives
The operator sound pressure level is 85 dB(A) measured according
to the static test procedures and conditions specied in ISO 6394 or
86/662/EEC.
As manufactured by Caterpillar, this machine's exterior sound power level
meets the criteria specied in the European Directives noted on the
certicate of conformance and the accompanying labels.
The operator sound pressure level is 85 dB(A) measured according
to dynamic test procedures and conditions specied in ISO 6396 or
95/27/EC.
As manufactured by Caterpillar, this machine's exterior sound power level
meets the criteria specied in the European Directives noted on the
certicate of conformance and the accompanying labels.
Vibration Level
The hands and arms are exposed to a weighted root mean square
acceleration that is less than 2.5 m/sec
2
.
The whole body is exposed to a weighted root mean square acceleration
that is less than 0.5 m/s
2
.
Measurements are obtained on a representative machine using the
procedures in the following standards:
ISO 2631/1
ISO 5349
SAE J1166
SEBU7892-07 57
Safety Section
Operator Station
i03634321
Operator Station
SMCS Code: 7000
Any modications to the inside of the operator station should not project
into the operator space or into the space for the companion seat (if
equipped). The addition of a radio, re extinguisher, and other equipment
must be installed so that the dened operator space and the space for
the companion seat (if equipped) is maintained. Any item that is brought
into the cab should not project into the dened operator space or the
space for the companion seat (if equipped). A lunch box or other loose
items must be secured. Objects must not pose an impact hazard in rough
terrain or in the event of a rollover.
58 SEBU7892-07
General Information
General Information
i02207491
Specications
SMCS Code: 7000
Specications for the 525C
Three sizes of grapple are available for the 525C Wheel Skidder.
The 525C is equipped with a C7 Engine.
g01228876
Illustration 20
Bunching and Thinning Grapple
The bunching head is primarily used when the diameters of the logs are
consistent or when the diameters of the logs are under 305 mm (12 inch).
The bunching head is suited for operations that use a feller buncher.
SEBU7892-07 59
General Information
g01228970
Illustration 21
Sorting Grapple
Table 1
525C Grapple Continuous Rotation
Sorting Bunching Thinning
A
Grapple
Capacity
0.83 m
2
(9 ft
2
)
1.16 m
2
(12.5 ft
2
)
1.34 m
2
(14.4 ft
2
)
B
Tip to Tip
Height
2045 mm
(80.5
inch)
1920 mm
(75.6
inch)
1981 mm
(78 inch)
C
Tong
Opening
2540 mm
(100 inch)
3050 mm
(120 inch)
3124 mm
(123 inch)
D
Full Open
Height
1590 mm
(62.6
inch)
1677 mm
(66 inch)
1832 mm
(72.1 inch)
E
Minimum
Stem
Diameter
76 mm
(3 inch)
155 mm
(6 inch)
190 mm
(7.5 inch)
F
Fully
Closed
Height
1829 mm
(72 inch)
1285 mm
(50.6
inch)
1371 mm
(54 inch)
60 SEBU7892-07
General Information
g01228892
Illustration 22
Dual Function
SEBU7892-07 61
General Information
g01229060
Illustration 23
Single Function
62 SEBU7892-07
General Information
Table 2
525C Function Arch
Single
Function
Dual Funtion
A
Lift Highest,
Retracted
2212 mm
(87.1 inch)
2623 mm
(103.3 inch)
B
Lift Highest,
Farthest
1944 mm
(76.5 inch)
C
Lift Maximum
Reach
1336 mm
(52.6 inch)
D
Lift Lowest,
Retracted
752 mm
(29.6 inch)
E
Lift Lowest,
Farthest
600 mm
(23.6 inch)
259 mm
(10.2 inch)
F
Loaded Tire
Radius
(1)
843 mm
(33 inch)
843 mm
(33.2 inch)
G
Reach
Highest,
Retracted
1630 mm
(64.2 inch)
1513 mm
(59.6 inch)
H
Reach Lowest,
Retracted
1469 mm
(57.8 inch)
I
Reach Lowest,
Farthest
2521 mm
(99.3 inch)
2488 mm
(98 inch)
J
Reach
Highest,
Farthest
2765 mm
(108.9 inch)
K
Reach
Maximum
2880 mm
(113.4 inch)
(1)
With 30.5 x 32 tires
SEBU7892-07 63
General Information
g01228906
Illustration 24
64 SEBU7892-07
General Information
Table 3
525C Machine Dimensions
Ground Level to Top Boom
(Grapple)
Dual Function
Single Function
4103 mm (161.5 inch)
3760 mm (148 inch)
Ground Level to Top Roller
(Cable)
2794 mm (110 inch)
Ground Level to Axle
Center Line
(1)
843 mm (33.2 inch)
Rear Axle Center Line to Pin 1798 mm (70.8 inch)
Wheel Base 3534 mm (139.2 inch)
Overall Length (Grapple)
Dual Function
Single Function
7626 mm (300.2 inch)
8369 mm (329.4 inch)
Overall Length (Cable) 6945 mm (273.4 inch)
Ground Clearance 581 mm (22.9 inch)
Decking Blade Lift Height 1381 mm (54.4 inch)
Decking Blade Dig Depth 456 mm (17.9 inch)
Height to Top of Cab
(2)
3184.4 mm(125.4 inch)
Decking Blade Width 3138 mm (123.5 inch)
Tread Width 2622 mm (103.2 inch)
Overall Width
Turning Radius Over Tires
(1)
3398mm (133.8 inch)
6000mm (226.2 inch)
Approximate Maximum Weight
with Attachments
18416 kg (40600 lb)
(1)
(2)
Add 188 mm (7.4 inch) if equipped with optional lights or water
tank.
Two sizes of grapple is available for the 535C Wheel Skidder.
The 535C is equipped with a C-7 engine.
SEBU7892-07 65
General Information
g01228876
Illustration 25
66 SEBU7892-07
General Information
Table 4
Bunching Thinning
A
Grapple
Capacity
1.34 m
2
(14.4 ft
2
)
1.54 m
2
(16.6 ft
2
)
B
Tip to Tip
Height
1981 mm
(78 inch)
2108 mm
(83 inch)
C Tong Opening
3124 mm
(123 inch)
3226 mm
(127 inch)
D
Full Open
Height
1832 mm
(72.1 inch)
1905 mm
(75 inch)
E
Minimum
Stem
Diameter
190 mm
(7.5 inch)
183 mm
(7.2 inch)
F
Fully Closed
Height
1371 mm
(54 inch)
1371 mm
(54 inch)
g01228892
Illustration 26
SEBU7892-07 67
General Information
Table 5
535C Dual Function Arches
Standard
Boom
Extended
Boom
A
Lift Highest,
Retracted
2623 mm
(103.3 inch)
2847 mm
(112.1 inch)
B
Lift Highest,
Farthest
1944 mm
(76.5 inch)
2192 mm
(86.3 inch)
C
Lift Maximum
Reach
1336 mm
(52.6 inch)
1336 mm
(52.6 inch)
D
Lift Lowest,
Retracted
752 mm
(29.6 inch)
764 mm
(30.1 inch)
E
Lift Lowest,
Farthest
259 mm
(10.2 inch)
286 mm
(11.3 inch)
F
Loaded Tire
Radius
(1)
843 mm
(33 inch)
843 mm
(33.2 inch)
G
Reach
Highest,
Retracted
1513 mm
(59.6 inch)
1546 mm
(60.9 inch)
H
Reach Lowest,
Retracted
1469 mm
(57.8 inch)
1666 mm
(65.6 inch)
I
Reach Lowest,
Farthest
2488 mm
(98 inch)
2706 mm
(106.5 inch)
J
Reach
Highest,
Farthest
2765 mm
(108.9 inch)
2825 mm
(111.2 inch)
K
Reach
Maximum
2880 mm
(113.4 inch)
3037 mm
(119.6 inch)
(1)
68 SEBU7892-07
General Information
g01228906
Illustration 27
SEBU7892-07 69
General Information
Table 6
(Grapple)
Standard
Extended
4103 mm (161.5 inch)
4304 mm (169.4 inch)
Ground Level to Top Roller
(Cable)
2794 mm (110 inch)
Center Line
(1)
843 mm (33.2 inch)
Overall Length (Grapple)
Standard Boom
Extended Boom
7626 mm (300.2 inch)
7514 mm (295.8 inch)
Ground Clearance 533 mm (21 inch)
(2)
3184.4 mm(125.4 inch)
Overall Width
(1)
3398mm (133.8 inch)
6000mm (226.2 inch)
Approximate Maximum Weight
with Attachments
18689 kg (41200 lb)
(1)
(2)
tank.
Two sizes of grapple are available for the 545C Wheel Skidder.
The 545C is equipped with a C-7 engine.
70 SEBU7892-07
General Information
g01228876
Illustration 28
SEBU7892-07 71
General Information
Table 7
Bunching Thinning
A
Grapple
Capacity
1.54 m
2
(16.6 ft
2
)
1.78 m
2
(19.0 ft
2
)
B
Tip to Tip
Height
2108 mm
(83 inch)
2159 mm
(85 inch)
C Tong Opening
3226 mm
(127 inch)
3429 mm
(135 inch)
D
Full Open
Height
1905 mm
(75 inch)
1880 mm
(74 inch)
E
Minimum
Stem
Diameter
183 mm
(7.2 inch)
241 mm
(9.5 inch)
F
Fully Closed
Height
1371 mm
(54 inch)
1473 mm
(58 inch)
g01228892
Illustration 29
72 SEBU7892-07
General Information
Table 8
545C Dual Function Arch
Continuous Rotation
A Lift Highest, Retracted 2817 mm (111 inch)
B Lift Highest, Farthest 2163 mm (85 inch)
C Lift Maximum Reach 1443 mm (57 inch)
D Lift Lowest, Retracted 1014 mm (40 inch)
E Lift Lowest, Farthest 335 mm (13 inch)
F Loaded Tire Radius
(1)
843 mm (33 inch)
G
Reach Highest,
Retracted
1653 mm (65 inch)
H
Reach Lowest,
Retracted
1775 mm (70 inch)
I
Reach Lowest,
Farthest
2762 mm (109 inch)
J
Reach Highest,
Farthest
2978 mm (117 inch)
K Reach Maximum 3121 mm (123 inch)
(1)
SEBU7892-07 73
General Information
g01228906
Illustration 30
74 SEBU7892-07
General Information
Table 9
(Grapple)
4302 mm (169.4 inch)
Ground Level to Top
Roller (Cable)
2771 mm (109 inch)
Center Line
(1)
843 mm (33.2 inch)
Overall Length (Grapple) 8028 mm (316 inch)
Ground Clearance 533 mm (21 inch)
(2)
3184.4 mm (125.4 inch)
Overall Width
(1)
3398mm (133.8 inch)
6400mm (252 inch)
Approximate Maximum
Weight with Attachments
19913 kg (43900 lb)
(1)
(2)
tank.
SEBU7892-07 75
Identication Information
i03698294
Plate Locations and Film Locations
SMCS Code: 1000; 7000
The Product Identication Number (PIN) will be used to identify a powered
machine that is designed for an operator to ride.
Caterpillar products such as engines, transmissions, and major
attachments that are not designed for an operator to ride are identied
by Serial Numbers.
For quick reference, record the identication numbers in the spaces that
are provided below the illustration.
g00740332
Illustration 31
76 SEBU7892-07
g02033102
Illustration 32
Machine PIN (1)_______________________________________________________________________
CE Plate(2)_____________________________________________________________________________
Year of Manufacture(3)______________________________________________________________
Country of Origin(4)__________________________________________________________________
Year of Manufacture(5)______________________________________________________________
g01228540
Illustration 33
Identication lm for the Software and the ECM ______________________________
SEBU7892-07 77
g00495347
Illustration 34
Transmission Serial Number ______________________________________________________
g01133431
Illustration 35
535C and 545C
Engine Serial Number ______________________________________________________________
78 SEBU7892-07
g01209622
Illustration 36
g01209629
Illustration 37
The serial number plate for the winch is located on the right side of the
winch case.
Winch Serial Number________________________________________________________________
Certication
ROPS/FOPS Structure
This message is positioned on the ROPS on the left side of the machine
above the door.
SEBU7892-07 79
g01211894
Illustration 38
Structural damage, an overturn, modication, al-
teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certication. Do not weld on or drill holes in the
structure. This will void the certication. Consult
a Caterpillar dealer to determine this structure's
limitations without voiding its certication.
This machine has been certied to the standards that are listed on the
certication lm. The maximum mass of the machine, which includes
the operator and the attachments without a payload, should not exceed
the mass on the certication lm.
80 SEBU7892-07
CE Mark
g01880193
Illustration 39
This plate is positioned on the bottom left side of the plate for the PIN.
Note: The CE plate is on machines that are certied to the European
Union requirements that were effective at that time.
For machines compliant to 2006/42/EC, the following information is
stamped onto the CE plate. For quick reference, record this information in
the spaces that are provided below.
Engine Power Primary Engine (kW)___________________________________________
Engine Power for Additional Engine (If Equipped) _________________________
Typical Machine Operating Weight for European Market (kg)____________
Year of Construction_______________________________________________________________
Machine Type ______________________________________________________________________

SEBU7892-07 81
g01120192
Illustration 40
This plate is positioned on the bottom left side of the plate for the PIN.
Note: The CE plate is on machines that are certied to the European
Union requirements that were effective at that time.
For machines compliant to 98/37/EC and 89/392/EEC, the following
information is stamped onto the CE plate. For quick reference, record this
information in the spaces that are provided below.
Engine Power Primary Engine (kW)___________________________________________
Typical Machine Operating Weight for European Market (kg)____________
Year___________________________________________________________________________________
For manufacturer name and address and the country of origin, see the
PIN plate.
82 SEBU7892-07
Sound
g00933634
Illustration 41
A typical example of this lm is shown. Your machine may have a
different value.
If equipped, the certication lm is used to verify the environmental sound
certication of the machine to the requirements of the European Union.
The value that is listed on the lm indicates the guaranteed exterior sound
power level LWA at the time of manufacture for the conditions that are
specied in ISO 6395 and EU 2000/14/EC Annex III A2.1b.
i04019095
Emissions Certication Film
SMCS Code: 1000; 7000; 7405
Note: This information is pertinent in the United States, in Canada and in
Europe.
Consult your Cat dealer for an Emission Control Warranty Statement.
This label is located on the engine.
SEBU7892-07 83
Operation Section
Before Operation
Operation Section
Before Operation
i04021647
Mounting and Dismounting
SMCS Code: 7000
g00037860
Illustration 42
Typical example
Mount the machine and dismount the machine only at locations that have
steps and/or handholds. Before you mount the machine, clean the steps
and the handholds. Inspect the steps and handholds. Make all necessary
repairs.
Face the machine whenever you get on the machine and whenever you
get off the machine.
Maintain a three-point contact with the steps and with the handholds.
Note: Three-point contact can be two feet and one hand. Three-point
contact can also be one foot and two hands.
84 SEBU7892-07
Operation Section
Before Operation
Do not mount a moving machine. Do not dismount a moving machine.
Never jump off the machine. Do not carry tools or supplies when you try
to mount the machine or when you try to dismount the machine. Use a
hand line to pull equipment onto the platform. Do not use any controls as
handholds when you enter the operator compartment or when you exit
the operator compartment.
Machine Access System Specications
The machine access system has been designed to meet the intent of
the technical requirements in ISO 2867 Earth-moving Machinery
Access Systems. The access system provides for operator access to the
operator station and to conduct the maintenance procedures described in
Maintenance section.
Alternate Exit
Machines that are equipped with cabs have alternate exits. For additional
information, see Operation and Maintenance Manual, Alternate Exit.
SEBU7892-07 85
Operation Section
Before Operation
i01993565
Daily Inspection
SMCS Code: 1000; 7000
For a maximum service life of the machine, complete a thorough daily
inspection before you mount the machine and before you start the engine.
Inspect the area around the machine and under the machine. Look for
loose bolts, trash buildup, oil, coolant leakage, broken parts, or worn parts.
Make sure that all covers and guards are securely attached.
Adjust the mirrors for the correct rear view of the machine.
Note: Watch closely for leaks. If you observe a leak, nd the source of
the leak and correct the leak. If you suspect a leak or you observe a leak,
check the uid levels more frequently.
Daily, perform the maintenance requirements that are applicable to your
machine.
Reference: For more information on the daily maintenance requirements,
refer to Operation and Maintenance Manual, Maintenance Interval
Schedule.
Note: Make all necessary repairs before you operate the machine.
86 SEBU7892-07
Operation Section
Before Operation
i02205646
Steering Frame Lock
SMCS Code: 7506
Personal injury or death can result from machine
articulation or movement.
Machine frames can move and a person can be
crushed.
Connect the steering frame lock link between the
front and rear frames before working on machine.
Secure clevis pin with locking pin.
Before operating the machine, fasten the steering
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.
The steering frame lock is located on the right side of the machine.
g01113809
Illustration 43
Stored Position
SEBU7892-07 87
Operation Section
Before Operation
The steering frame lock should be kept in the STORED position, while the
machine is running.
g01113800
Illustration 44
Locked Position
The steering frame lock should be placed in the LOCKED position, before
you perform service work near the articulation joint. Also, the steering
frame lock should be placed in the LOCKED position, when the machine
is being lifted and when the machine is being transported.
88 SEBU7892-07
Operation Section
Machine Operation
Machine Operation
i02127571
Alternate Exit
SMCS Code: 7308
g01095218
Illustration 45
The door on the left side of the machine serves as an alternate exit. Use
this door if the door on the right side is blocked.
The alternate exit can be opened from the inside of the cab and from the
outside of the cab. Both cab doors function in the same manner.
i02119886
Seat
SMCS Code: 7312
The operator's seat that is provided with this machine is in compliance
with the appropriate class of ISO 7096.
Note: This seat is an air suspension seat. Adjust the seat at the beginning
of each shift and for each new operator.
While the operator's back is against the back of the seat, the seat should
be adjusted so that there is full pedal travel.
SEBU7892-07 89
Operation Section
Machine Operation
g01079883
Illustration 46
Swivel Lever (1) Pull up on the lever and hold the lever. Rotate the
seat to the desired position. Release the lever in order to lock the seat into
position. The seat will lock into position at zero degrees, fteen degrees,
and thirty degrees in either direction.
Fore/Aft Lever (2) Pull up on the lever in order to slide the seat forward
or backward to the desired position. Release the lever in order to lock
the seat into position.
Seat Height Adjustment Switch (3) Push down on the switch in order
to lower the height of the seat. Pull up on the switch in order to raise
the height of the seat.
Note: The engine start switch key must be turned to ON or the engine
must be running in order to adjust the height of the seat.
The height must be changed if the seat bottoms out excessively or if the
seat bounces to the maximum height too frequently.
90 SEBU7892-07
Operation Section
Machine Operation
i04200349
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt when the machine was
shipped from Caterpillar. At the time of installation, the seat belt and the
instructions for installation of the seat belt meet the SAE J386 and ISO
6683 standards. Consult your Cat dealer for all replacement parts.
Always check the condition of the seat belt and the condition of the
mounting hardware before you operate the machine.
Seat Belt Adjustment for Non-Retractable Seat
Belts
Adjust both ends of the seat belt. The seat belt should be snug but
comfortable.
Lengthening the Seat Belt
g00100709
Illustration 47
1. Unfasten the seat belt.
SEBU7892-07 91
Operation Section
Machine Operation
g00932817
Illustration 48
2. To remove the slack in outer loop (1), rotate buckle (2). This will free
the lock bar. This permits the seat belt to move through the buckle.
3. Remove the slack from the outer belt loop by pulling on the buckle.
4. Loosen the other half of the seat belt in the same manner. If the seat
belt does not t snugly with the buckle in the center, readjust the seat
belt.
Shortening the Seat Belt
g00100713
Illustration 49
1. Fasten the seat belt. Pull out on the outer belt loop in order to tighten
the seat belt.
92 SEBU7892-07
Operation Section
Machine Operation
2. Adjust the other half of the seat belt in the same manner.
3. If the seat belt does not t snugly with the buckle in the center, readjust
the seat belt.
Fastening The Seat Belt
g00932818
Illustration 50
Fasten the seat belt catch (3) into the buckle (2). Make sure that the seat
belt is placed low across the lap of the operator.
Releasing The Seat Belt
g00100717
Illustration 51
Pull up on the release lever. This will release the seat belt.
SEBU7892-07 93
Operation Section
Machine Operation
Seat Belt Adjustment for Retractable Seat Belts
Fastening The Seat Belt
g00867598
Illustration 52
Pull seat belt (4) out of the retractor in a continuous motion.
Fasten seat belt catch (3) into buckle (2). Make sure that the seat belt is
placed low across the lap of the operator.
The retractor will adjust the belt length and the retractor will lock in place.
The comfort ride sleeve will allow the operator to have limited movement.
Releasing The Seat Belt
g00039113
Illustration 53
94 SEBU7892-07
Operation Section
Machine Operation
Push the release button on the buckle in order to release the seat belt.
The seat belt will automatically retract into the retractor.
Extension of the Seat Belt
When using retractable seat belts, do not use seat
belt extensions, or personal injury or death can
result.
The retractor system may or may not lock up de-
pending on the length of the extension and the
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.
Longer, non-retractable seat belts and extensions for the non-retractable
seat belts are available.
Caterpillar requires only non-retractable seat belts to be used with a seat
belt extension.
Consult your Cat dealer for longer seat belts and for information on
extending the seat belts.
SEBU7892-07 95
Operation Section
Machine Operation
i03266808
Mirror
SMCS Code: 7319
Adjust all mirrors as specied in the Operation
and Maintenance Manual. Failure to heed this
warning can lead to personal injury or death.
g01665194
Illustration 54
Interior mirror
(A-A) Rear view
Make sure that the mirror is in proper working condition and that the
mirror is clean. Adjust the mirror at the beginning of each work period and
adjust the mirror when you change operators.
Mirror Adjustment
Interior Mirror
The interior mirrors can be adjusted to a position in order to allow
the operator to see preferred areas at the rear of the machine during
operations such as loading and unloading.
96 SEBU7892-07
Operation Section
Machine Operation
i04291971
Operator Controls
SMCS Code: 7300; 7301; 7451
Engine Start Switch (1)
g01100951
Illustration 55
OFF (1) When you insert the engine start switch key and
when you remove the engine start switch key, the engine start
switch must be in the OFF position. To disconnect the power to
the electrical circuits in the cab, turn the engine start switch to the OFF
position. Also, turn the engine start switch to the OFF position in order to
stop the engine.
ON (2) To activate the electrical circuits in the cab, turn the
engine start switch clockwise to the ON position.
START (3) To start the engine, turn the engine start switch
clockwise to the START position. When the engine start switch
key is released, the engine start switch will return to the ON
position.
Note: If the engine fails to start, return the engine start switch to the OFF
position. Do not attempt to start the engine again until the engine start
switch is in the OFF position.
SEBU7892-07 97
Operation Section
Machine Operation
Light Switches (2)
g01100875
Illustration 56
The light switches are located above the right side window in the cab.
Rear Floodlights (1) Press the bottom of the switch in order
to turn off the rear oodlights. Move the switch to the center
position in order to turn on the rear oodlights. Press the top of
the switch in order to turn on the attachment lights.
Front Floodlights (2) Press the bottom of the switch in order
to turn off the front oodlights. Move the switch to the center
position in order to turn on the dash lights. Press the top of the
switch in order to turn on the front oodlights.
g00489242
Illustration 57
98 SEBU7892-07
Operation Section
Machine Operation
The dome light is on the left side of the cab.
Press either side of the lens in order to turn on the dome light. Press the
other side of the lens in order to turn off the dome light.
Window Wiper/Washer Switch (3)
Note: Plastic windows may be scratched if the windows are dry during
use of the window wipers.
g01100920
Illustration 58
The switches are located on the right side of the cab above the window.
Front Windshield Wiper (1) Press the top of the switch
for high speed. Move the switch to the center position for low
speed. Press the bottom of the switch in order to turn off the
front windshield wiper.
Window Washers (2) Hold the top of the switch in order
to activate the front windshield washer. Hold the bottom of the
switch in order to activate the rear window washer. The switch
will return to the center position when the switch is released.
Rear Window Wiper (3) Press the top of the switch for high
speed. Move the switch to the center position for low speed.
Press the bottom of the switch in order to turn off the rear
window wiper.
SEBU7892-07 99
Operation Section
Machine Operation
Heating and Air Conditioning Control (4)
g01097920
Illustration 59
Fan Speed Control(1) This switch controls the fan speed for
the heater and for the air conditioner.
Temperature Control (2) Temperature control knob (2) is a
rotary switch. Turn knob (2) clockwise for warmer air. Turn knob
(2) counterclockwise for cooler air.
Air Conditioner (3) This switch turns the air conditioner ON
or OFF.
100 SEBU7892-07
Operation Section
Machine Operation
Blower Fan Switch
g01100931
Illustration 60
Blower Fan Switch (4) The fan switch controls the air circulation
toward the windows and toward the operator. The top position is HIGH.
The middle position is LOW. The bottom position is OFF.
Note: In order to maximize the air circulation toward the operator, close
the defroster vents on the front windows.
Parking Brake Control (5)
g01099293
Illustration 61
SEBU7892-07 101
Operation Section
Machine Operation
Parking Brake The switch for the parking brake control is on
the right side of the dash.
Push the top of the switch in order to engage the parking brake. Push the
bottom of the switch in order to disengage the parking brake.
g01101986
Illustration 62
The indicator light on the dash panel will ash while the parking brake
(secondary brake) is engaged.
Service Brake Control (6)
g01099254
Illustration 63
102 SEBU7892-07
Operation Section
Machine Operation
The service brake pedal is the left pedal on the cab oor.
Depress the service brake pedal in order to slow the machine ground
speed. Use the service brake pedal for normal braking.
Accelerator Control (7)
g01231272
Illustration 64
The accelerator pedal is the right pedal on the cab oor.
Depress the accelerator pedal in order to increase the engine speed.
Release the accelerator pedal in order to decrease the engine speed.
Torque Converter Lockup Control (8)
The torque converter lockup control enables the operation of the
torque converter lockup clutch. When the operator presses the torque
converter lockup switch the power train Electronic Control Module (ECM)
electronically regulates the torque converter lockup clutch according to
the output speed of the transmission.
The torque converter lockup control should be used as much as possible
to maximize speed and efciency.
When the torque converter lockup clutch is engaged, the torque converter
is in direct drive. The engine transfers power directly to the wheels. The
benets are listed below:
More productive
SEBU7892-07 103
Operation Section
Machine Operation
More fuel efcient
High efciency hauling
Faster cycle time
Less shifting by the operator
Greater power range in all working conditions

g01231269
Illustration 65
Torque Converter Lockup Control (8A) The torque
converter lockup control is located on the right side of the dash
panel. Pressing the switch will enable the lockup clutch. The
torque converter will lock up, when the output speed of the transmission
is in the correct speed range.
This feature provides more efcient operation for high speeds and for
transporting loads.
When the torque converter lockup clutch is engaged, lamp (8B) is
illuminated.
104 SEBU7892-07
Operation Section
Machine Operation
Operation
When the operator enables the torque converter lockup control, the
operator should use lamp (8B) as an indicator to shift to the next gear.
The operator should select a low gear before applying full throttle.
While the machine is moving and lamp (8B) is illuminated, the operator
should shift to the next gear. The operator should maintain full throttle.
The operator should observe lamp (8B) during each gear change. The
green light should be on. Keep the machine in the safest highest speed
possible. This will increase efciency and speed.
If the green light goes off, then the lockup clutch is no longer engaged.
Downshift to the next lower gear. This will keep the lockup clutch engaged,
if the output speed of the transmission is in the correct speed range. The
machine is more efcient and faster in this mode. Staying in a higher gear
is less efcient and slower with the lockup clutch disengaged.
Turn off torque converter lockup control (1) only when the operating
conditions require the machine to stay in torque converter drive.
The torque converter lockup control should be placed in the disabled
position when traveling downhill. With the torque converter lockup control
disabled the transmission will be in torque converter drive mode. Shifting
to a lower gear will provide maximum machine retarding and will minimize
the need to use the service brakes to retard the machine. This will result
in lower axle oil temperature and extended service brake life.
Service
If the following CID 0709 FMI 13 diagnostic code is recorded on the
Caterpillar Monitoring System, the modulating valve (torque converter
lockup clutch) needs to be calibrated.
Note: The CID 0709 FMI 13 diagnostic code is also recorded whenever
the power train ECM is replaced or whenever new software is ashed to
the power train ECM.
In order to clear the CID 0709 FMI 13 diagnostic code, the modulating
valve for the torque converter lockup clutch must be calibrated. Once the
calibration of the modulating valve for the torque converter lockup clutch
has been performed successfully, this diagnostic code will disappear.
Reference: For additional information on calibrating the modulating valve
for the torque converter lockup clutch, refer to Testing and Adjusting,
Calibration for the machine that is being serviced.
SEBU7892-07 105
Operation Section
Machine Operation
Transmission Control (9)
Direction Selector
g01099298
Illustration 66
The transmission direction control switch is located on the steering wheel.
REVERSE (1) Move the top of the trigger switch to R
(REVERSE). The machine will move in the reverse direction.
NEUTRAL (2) The middle position of the trigger switch is N
(NEUTRAL). The machine should not move.
FORWARD (3) Move the bottom of the trigger switch to F
(FORWARD). The machine will move in the forward direction.
Speed Selector
Note: This machine is equipped with a transmission that has ve forward
speeds and three reverse speeds.
106 SEBU7892-07
Operation Section
Machine Operation
g01099300
Illustration 67
The upshift gear speed switch and the downshift gear speed switch are
located on the steering wheel.
Upshift Gear Speed Switch (4) Push the upshift gear speed switch in
order to shift the machine into the next highest gear.
Downshift Gear Speed Switch (5) Push the downshift gear speed
switch in order to shift the machine into the next lowest gear.
g01099301
Illustration 68
The gear speed and the direction will be displayed on the digital display.
SEBU7892-07 107
Operation Section
Machine Operation
Action Indicator
g01366825
Illustration 69
Transmission System This indicator indicates that a
problem exists in the electronic system of the transmission. If
the indicator continues to ash, reduce the load on the machine.
Check the system at the earliest possible time.
Reference: For a complete list of diagnostic codes that may cause this
warning to be activated, refer to the Service Manual Troubleshooting,
RENR8952, Troubleshooting Diagnostic Codes for the machine that is
being serviced.
Differential Lock Control (10)
g01097963
Illustration 70
108 SEBU7892-07
Operation Section
Machine Operation
g00674468
Illustration 71
Lock (1) Move the switch to the ON position in order to
engage the differential lock.
Unlock (2) Move the switch to the OFF position in order to
disengage the differential lock.
g01101993
Illustration 72
The alert indicator light on the dash panel will ash while the differential
lock is engaged.
SEBU7892-07 109
Operation Section
Machine Operation
When the differential lock is activated, both wheels on each axle will turn
at the same speed. This helps to prevent wheel slippage on soft ground.
If the wheels continue to slip, reduce the engine speed.
The differential lock is automatically disengaged by the power train ECM
at high ground speed. The alert indicator light on the dash will turn off.
Steering Control (11)
Note: The steering frame lock must be in the unlocked position in order
to steer the machine.
g01099304
Illustration 73
Turn the steering wheel clockwise in order to turn the machine to the right.
Turn the steering wheel counterclockwise in order to turn the machine to
the left. As the steering wheel is turned farther, the radius of the turn is
more acute.
110 SEBU7892-07
Operation Section
Machine Operation
Steering Column Tilt Control (12)
g01099305
Illustration 74
To adjust the steering column, push the steering column tilt control inward
and move the steering column to the desired position. When you release
the steering column tilt control, the steering wheel will remain in the
desired position.
Telescoping Steering Wheel Control (13)
g01100177
Illustration 75
Rotate the lever counterclockwise in order to adjust the height of the
steering wheel. Rotate the lever clockwise in order to lock the steering
wheel in the desired position.
SEBU7892-07 111
Operation Section
Machine Operation
Note: The lever is shown in the LOCKED position.
Decking Blade Control (14)
g01097216
Illustration 76
LOWER (1) Push the control lever forward in order to lower
the decking blade.
HOLD (2) The control lever will automatically return to the
HOLD position when the control lever is released. The decking
blade will remain in the selected position.
RAISE (3) Pull back on the control lever in order to raise
the decking blade.
Hydraulic Retrieval Winch Control (15)
NOTICE
Do not deactivate the winch Freespool function while
the drum is rotating. Deactivating the winch Freespool
function while the drum is rotating will cause serious
damage to the winch gear train.
112 SEBU7892-07
Operation Section
Machine Operation
NOTICE
Do not activate the winch Freespool function with a
load on the cable. Use the Reel out to lower the load to
the ground before the freespool function is activated.
If the winch Freespool function is activated with a load
on the cable, damage to the winch may occur.
g01097218
Illustration 77
Reel In (1)
Reel In High Push switch (1) to the bottom in order to reel
in the cable. The engine speed controls the speed of the winch
drum.
Reel In Slow Push switch (1) to the top in order to slowly
reel in the cable. The engine speed controls the speed of the
winch drum.
In order to turn the winch to the OFF position, press the Reel In switch
(1) to the center position.
Reel Out (2)
Reel Out High Push the switch (2) to the bottom in order
to reel out the cable. The engine speed controls the speed of
the winch drum.
SEBU7892-07 113
Operation Section
Machine Operation
Reel Out Slow Place the switch (2) to the top in order to
slowly reel out the cable. The engine speed controls the speed
of the winch drum.
In order to turn the winch to the OFF position, press the Reel Out switch
(2) to the center position.
Freespool (3)
Freespool Push the switch (3) to the bottom in order to
disengage the winch drum from the drive train. This allows the
cable to unwind freely. The FREESPOOL will not engage if the
machine is moving. The FREESPOOL position will disconnect the spool
drum from the winch drive. The FREESPOOL position should only be
used when the spool drum is not rotating. The FREESPOOL position
should only be used when the spool drum is not under a load.
Place the control for the winch into the FREESPOOL position. Adjust the
drag on the winch drum if the winch cable cannot be turned by hand.
Reference: Refer to Operation and Maintenance Manual, Winch Drum
Drag Adjustment.
Mechanical Winch Control (16)
NOTICE
Do not deactivate the winch Freespool function while
the drum is rotating. Deactivating the winch Freespool
function while the drum is rotating will cause serious
damage to the winch gear train.
NOTICE
Do not activate the winch Freespool function with a
load on the cable. Use the winch Brake Off function
to lower the load to the ground before the freespool
function is activated.
If the winch Freespool function is activated with a load
on the cable, damage to the winch may occur.
114 SEBU7892-07
Operation Section
Machine Operation
NOTICE
Freespool function will work only with the parking
brake applied.
Apply the parking brake and activate the winch
Freespool function only after lowering the load with
the winch Brake Off function. When the parking brake
is released, the winch control will instantly engage the
freespool clutch and activate Brake Off.
g01242274
Illustration 78
(1) Winch control lever. (2) FREESPOOL position. (3) Winch
BRAKE OFF position. (4) Winch BRAKE ON position. (5) REEL
IN position.
When control lever (1) is in the BRAKE ON position (3), the spring-applied
brake that is splined to the clutch shaft rmly holds the entire gear train
and the load on the winch. The bevel pinion, the bevel gear, and the reel
in clutch friction discs are turning freely on the roller bearings.
Moving the control lever (1) to the REEL IN position (5) shifts the spool in
the control valve, sending oil pressure to both the winch brake and the
clutch. The brake is released and the clutch is applied. The bevel gear
now rotates the clutch shaft and the gear train. This will pull the cable to
the winch drum. When the control lever (1) is returned to the BRAKE ON
position (4), the clutch releases and the brake engages. This causes the
gear train to stop and the load is held in place.
SEBU7892-07 115
Operation Section
Machine Operation
Moving the control lever (1) to the BRAKE OFF position (3) activates the
brake solenoid valve on the winch control valve. This sends control oil
pressure to the winch brake in order to release the brake. The drum can
be rotated at this time, but considerable force is required since the gear
train is still engaged and the gear train must be backdriven by the drum.
Note: Apply the parking brake before activating the winch freespool
control.
To activate the winch freespool, control lever (1) must rst be placed
in the full BRAKE OFF position (3), then placed into the FREESPOOL
position (2). Be sure to pause in the BRAKE OFF position (3) until any
load on the drum is released and the drum has come to a complete stop.
Control oil pressure is sent to the freespool cylinder. When the piston
moves, the drum is mechanically disengaged from the gear train. This
allows the cable to be pulled off the drum by hand.
Note: When the parking brake is disengaged, the brake off function will
be immediately activated and the freespool mechanical clutch will be
engaged.
Grapple Tong Control (17)
Note: The grapple control lever is being viewed from the operator seat.
g01099311
Illustration 79
Grapple CLOSE (16A) Push the top left switch in order to
close the grapple arms (tong). The grapple arms (tong) will
close until the switch is released.
116 SEBU7892-07
Operation Section
Machine Operation
Grapple OPEN (16B) Push the bottom left switch in order to
open the grapple arms (tong). The grapple arms (tong) will open
until the switch is released.
Grapple AUTOMATIC (16C) Push the switch in the front
of the control in order to turn on the automatic grab function.
When the switch is activated the light on the gauge cluster
will illuminate. The automatic grab switch will provide the appropriate
pressure on the load. The load will not slip with the appropriate pressure.
Grapple Rotator Control (18)
Note: The grapple control lever is being viewed from the operator seat.
g01099314
Illustration 80
Rotate COUNTERCLOCKWISE (1) Push the top right switch
in order to rotate the grapple in the counterclockwise direction.
Rotate CLOCKWISE (2) Push the bottom right switch in
order to rotate the grapple in the clockwise direction.
SEBU7892-07 117
Operation Section
Machine Operation
Grapple Boom and Arch Control (19)
g01099315
Illustration 81
Grapple Arch IN (1) Push the grapple control lever forward
in order to move the grapple arch inward.
Grapple Boom DOWN (2) Move the grapple control lever to
the right in order to lower the grapple boom.
HOLD (3) When the grapple control lever is in this position, movement
is stopped. The control lever will automatically return to the HOLD position
when the control lever is released.
Grapple Boom UP (4) Move the grapple control lever to the
left in order to raise the grapple boom.
Grapple Arch OUT (5) Pull the grapple control lever
backward in order to move the grapple arch outward.
118 SEBU7892-07
Operation Section
Machine Operation
i02127486
Battery Disconnect Switch
SMCS Code: 1411
g01098016
Illustration 82
To access the battery disconnect switch (1), open the access door to the
engine compartment on the front left side of the machine.
Disconnect Switch ON To activate the electrical system,
insert the battery disconnect switch key and turn the key
clockwise. The battery disconnect switch must be turned to the
ON position before you can start the engine.
Disconnect Switch OFF To deactivate the electrical system,
turn the battery disconnect switch key counterclockwise to the
OFF position.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
The battery disconnect switch and the engine start switch perform
different functions. The entire electrical system is disabled when you turn
off the battery disconnect switch. The battery remains connected to the
electrical system when you only turn off the engine start switch.
SEBU7892-07 119
Operation Section
Machine Operation
Turn the battery disconnect switch to the OFF position and remove the key
when you service the electrical system or any other machine components.
Turn the battery disconnect switch to the OFF position and remove the
key when the machine will not be used for an extended period of a month
or more. This will prevent drainage of the battery.
i02253482
Backup Alarm
SMCS Code: 7406
g01134891
Illustration 83
The backup alarm is mounted on the rear of the machine.
Backup Alarm The alarm will sound when the transmission
direction control switch is in the R (REVERSE) position. The
alarm is used to alert people behind the machine when the
machine is backing up.
120 SEBU7892-07
Operation Section
Machine Operation
g00930005
Illustration 84
A three-position switch at the rear of the backup alarm regulates the
sound of the alarm (HIGH, LOW, and MEDIUM).
The alarm is set at the maximum sound level when the machine is
shipped from the factory. The setting should remain on HIGH unless the
job site requires a lower sound level.
SEBU7892-07 121
Operation Section
Machine Operation
i04054871
Monitoring System
SMCS Code: 7451; 7490
Gauges
g01101018
Illustration 85
Hydraulic Oil Temperature (1) This gauge indicates the
temperature of the hydraulic oil. If the needle is in the red zone,
the hydraulic oil temperature is excessive.
Coolant Temperature (2) This gauge indicates the
temperature of the coolant. If the needle is in the red zone, the
coolant temperature is excessive.
Engine RPM (3) This gauge indicates the speed of the
engine.
Transmission Oil Temperature (4) This gauge indicates the
temperature of the transmission oil. If the needle is in the red
zone, the transmission oil temperature is excessive.
Fuel Level (5) This gauge indicates the amount of fuel that
is in the fuel tank. If the needle is in the red zone, the fuel tank
is almost empty.
122 SEBU7892-07
Operation Section
Machine Operation
Alert Indicators
g01101597
Illustration 86
g01101097
Illustration 87
No function (6) This alert indicator is not used.
Transmission Oil Filter (7) When this alert indicator is on,
the ow of transmission oil is being restricted or the transmission
oil lter is plugged.
Differential Lock (8) When this alert indicator is on, the
differential lock is activated.
SEBU7892-07 123
Operation Section
Machine Operation
Torque Converter Lockup Clutch (9) When this indicator
light is on, the torque converter lockup clutch is engaged.
Engine Oil Pressure (10) When this alert indicator is on, the
engine oil pressure is low.
Parking Brake (11) When this alert indicator is on, the
parking brake is engaged.
Action Light (12) When the action light ashes, a change
in machine operation is required or the machine must be shut
down in order to correct a problem.
Brake Oil Pressure (13) When this alert indicator is on, the
brake oil pressure is low.
Machine Security System (14) When this alert indicator is
on, the machine security system is active.
Electrical System (15) When this alert indicator is on, there
is a malfunction in the electrical system.
Air Inlet Heater Starting Aid (16) When this alert indicator
is on, the air inlet heater is activated.
Engine (17) When this alert indicator is on, there is a problem
with the engine. This alert indicator will come on if there is a
problem with the fuel system.
Winch Freespool (18) When this alert indicator is on, the
winch is in FREESPOOL.
124 SEBU7892-07
Operation Section
Machine Operation
Automatic Grapple (19) When this alert indicator is on,
the automatic CLOSE feature of the grapple arms (tongs) is
activated.
Work Lights (20) When this alert indicator is on, the work
lights are in the ON position.
Transmission System (21) When this alert indicator is on,
a problem exists in the electronic system of the transmission. If
Secondary Steering (22) When this alert indicator is on,
the secondary steering is activated.
Note: This indicator is for machines that are equipped with the secondary
steering attachment, only.
Primary Steering Malfunction (23) When this alert indicator
is on, the pressure in the steering system is low.
Note: This indicator is for machines that are equipped with the secondary
steering attachment, only.
g01101956
Illustration 88
SEBU7892-07 125
Operation Section
Machine Operation
Diagnostic Service Tool Connector (24) The connector is use by
service personnel.
Warning Categories
The Caterpillar Monitoring System provides three warning categories for
the operator. Each warning category is a different level of severity and
each warning category requires different actions by the operator.
Warning Category 1
For this warning category, only the alert indicator will ash. This warning
category only requires the operator to be aware of a condition.
Differential Lock (8) When this alert indicator is on, the
differential lock is activated. Both wheels on each axle will turn
at the same speed.
parking brake is engaged. The alert indicator should ash during
engine start-up. After the parking brake is released, the alert
indicator should go off.
Electrical System (15) When this alert indicator is on, there
is a malfunction in the electrical system. If this alert indicator
ashes, the system voltage is too high for normal machine
operation or too low for normal machine operation.
If the electrical loads are too high and the engine speed is low, increase
the engine speed to high idle. This operation will generate more output
from the alternator. If the alert indicator goes off within one minute, the
electrical system is functioning normally. However, the electrical system
becomes overloaded, only during periods of low engine speed.
Modify the operating cycle in order to avoid overloading the electrical
system and discharging the batteries. Using lower fan speeds, turning off
the air conditioner, and/or using fewer lights may also help by reducing
electrical loads.
Low idle must be corrected. Adjust low idle to the high side of the
specication while the most commonly used electrical loads are turned on.
126 SEBU7892-07
Operation Section
Machine Operation
If the alert indicator does not go off, stop the machine and investigate
the cause of the problem. If the alert indicator still ashes near normal
operating speeds and with a light electrical load, stop the machine.
Investigate the cause of the problem. The alternator belt may be loose or
broken. The batteries or the alternator may be faulty.
Automatic Grapple (19) When this alert indicator is on,
the automatic CLOSE feature of the grapple arms (tongs) is
activated.
Secondary Steering (22) (if equipped) When you turn the
engine start switch to the ON position, the alert indicator for the
secondary steering will come on for three seconds. Then, the
alert indicator will go off. If the alert indicator for the secondary steering
does not come on, investigate the cause of the fault. Do not operate the
machine until the fault has been corrected.
Warning Category 2
For this warning category, action light (12) will ash. This warning
category requires a change in machine operation in order to lower the oil
temperature or the engine coolant temperature.
You may need to stop the machine in order to investigate the cause of the
problem. If the action light continues to ash, do not operate the machine
until the cause of the problem has been xed.
Hydraulic Oil Temperature (1) This gauge indicates the
temperature of the hydraulic oil. If the needle is in the red zone,
the hydraulic oil temperature is excessive. Reduce the load
on the hydraulic system. If the needle remains in the red zone and the
action light continues to ash, stop the machine and investigate the cause
of the problem.
Coolant Temperature (2) This gauge indicates the
temperature of the coolant. If the needle is in the red zone,
the coolant temperature is excessive. Stop the machine and
investigate the cause of the problem.
SEBU7892-07 127
Operation Section
Machine Operation
Transmission Oil Temperature (4) This gauge indicates the
temperature of the transmission oil. If the needle is in the red
zone, the transmission oil temperature is excessive. Reduce the
load on the machine. If the needle remains in the red zone and the action
light continues to ash after ve minutes, stop the machine. Investigate
the cause of the problem.
Transmission Oil Filter (7) When this alert indicator is on,
the ow of transmission oil is being restricted or the transmission
oil lter is plugged. Stop the machine immediately. Stop the
engine and investigate the cause of the problem.
Transmission System (21) When this alert indicator is on,
a problem exists in the electronic system of the transmission. If
Warning Category 3
For this warning category, the alert indicator and action light (12) will ash
and an action alarm will sound. This warning category requires immediate
shutdown in order to prevent severe damage to a system and/or to the
machine.
Do not operate the machine until the cause of the problem has been xed.
Engine Oil Pressure (10) When this alert indicator is on, the
engine oil pressure is low. Stop the machine immediately. Stop
the engine and investigate the cause of the problem.
parking brake is engaged while the transmission is in gear. Stop
the machine immediately. Stop the engine and investigate the
cause of the problem.
Brake Oil Pressure (13) When this alert indicator is on, the
brake oil pressure is low. Stop the machine immediately. Stop
the engine and investigate the cause of the problem.
128 SEBU7892-07
Operation Section
Machine Operation
Electrical System (15) When this alert indicator is on,
there is a severe malfunction in the electrical system. Stop
the machine immediately. Stop the engine and investigate the
cause of the problem.
Secondary Steering (22) (if equipped) When the engine is
running and the alert indicator comes on, the secondary steering
is activated. Steer the machine immediately to a convenient
location and stop the machine. Stop the engine and investigate the cause
of the failure. Do not operate the machine until the cause of the failure
has been corrected.
Primary Steering Malfunction (23) (if equipped) When this
alert indicator is on, the pressure in the steering system is low.
The secondary steering is automatically activated. If this alert
indicator ashes during operation, stop the machine immediately and
engage the parking brake. Stop the engine and investigate the cause of
the fault. Do not operate the machine until the fault has been corrected.
Digital Display
g01101493
Illustration 89
SEBU7892-07 129
Operation Section
Machine Operation
g01099301
Illustration 90
Press the switch on the left side of the dash panel in order to change the
data that is being displayed on the digital display. The digital display is a
six-digit display area which shows the total service hours of the engine,
the currently selected gear, the rpm of the engine, or diagnostic codes
for troubleshooting. Hold the switch down for 5 seconds in order to get
the diagnostic codes. Once the diagnostic codes are displayed, press the
switch on the left side in order to step through the available displays.
Service Hour Meter The digital display shows the total
service hours of the engine. Use this reading to determine
maintenance intervals.
Note: When the parking brake is engaged, the service hour meter is
shown. When the parking brake is not engaged, the gear readout is
shown.
Gear Readout The digital display shows the selected gear speed and
the selected direction.
Engine RPM The digital display shows the engine RPM.
Diagnostic Code The digital display shows the diagnostic code that is
currently active. Diagnostic information is available in the service mode.
Reference: Refer to Service Manual, SENR1394, Caterpillar Monitoring
System for information about using diagnostic codes for troubleshooting.
130 SEBU7892-07
Operation Section
Machine Operation
i03992269
Product Link
(If Equipped)
SMCS Code: 7490; 7606
The Product Link PL121SR is a satellite communication device that
transmits information regarding the machine to Caterpillar, Caterpillar
dealers, and Caterpillar customers. The unit contains a Global Positioning
System receiver (GPS receiver) and a satellite transceiver.
The Product Link PL121SR is two-way communication between the
machine and a remote user. The remote user can be a dealer or a
customer. At any time, a user can request updated information from a
machine such as hours of use or the location of the machine. Also, the
system parameters for Product Link PL121SR can be changed. Data is
transmitted from the machine to a satellite. Next, the data is transmitted to
a ground station. The receiving station transmits the data to Caterpillar
Inc. The data can then be sent to a Caterpillar dealer and to the customer.
Data Broadcasts
Machine data about the machine condition and operation is being
transmitted by Product Link. This data is transmitted to Caterpillar and/or
Cat dealers in order to serve the customer better. Also, this machine
data will improve Caterpillar products and services. The information that
is transmitted may include the following data: machine serial number,
location of the machine, fault codes, emissions data, fuel usage, service
meter hours, version numbers for software and hardware, and installed
attachments.
Caterpillar and/or Caterpillar dealers may use this information for various
purposes: providing services to the customer and/or the machine,
checking or maintaining Product Link equipment, monitoring the machine
health or performance, helping to maintain the machine, improving the
machine efciency, evaluating or improving Caterpillar products and
services, complying with legal requirements and valid court orders,
performing market research, and offering the customer new products
and services.
SEBU7892-07 131
Operation Section
Machine Operation
Caterpillar may share some or all of the collected information with
Caterpillar afliated companies, dealers, and authorized representatives.
Caterpillar will not sell or rent collected information to any other third
party and will exercise reasonable efforts to keep the information
secure. Caterpillar recognizes and respects customer privacy. For more
information, please contact your local Caterpillar dealer.
Operation in a Blast Site
If the machine is required to work within 12 m (40 ft) of a blast site, then
Product Link PL121SR must be disabled. In order to disable theProduct
Link PL121SR install a Product Link Disconnect Switch in the machine
cab. This disconnect switch will allow the Product Link PL121SR module
to be shut off. Refer to Special Instruction, REHS2365, An Installation
Guide for the Product Link PL121SR and for the PL300 for more details
and installation instructions. You may also disconnect the Product Link
PL121SR module from the main power source by disconnecting the wiring
harness at the Product Link module.
This blast site warning does not supersede the published requirements or
regulations found in Title 30 of the Code of Federal Regulations (CFR).
This warning does not allow deviation from the published requirements
or regulations found in Title 30 of the Code of Federal Regulations
(CFR). A hazard assessment should be conducted by each customer.
Every customer should meet all of the requirements of Title 30 of the
Code of Federal Regulations (CFR) in order to ensure the safe storage,
transportation, loading, and blasting of any explosive.
The following Product Link PL121SR specications are provided in order
to aid in conducting any related hazard assessment. These specications
help to ensure compliance with all local regulations:
The transmit power rating for the Product Link PL121SR transmitter
is 5 to 10 w
The operating frequency range for the Product Link PL121SR module
is 148 MHz to 150 MHz.
Consult your Caterpillar dealer if there are any questions.
Information for the initial installation of the Product Link PL121SR is
available in Special Instruction, REHS2365, Installation Guide for the
Product Link PL121SR.
132 SEBU7892-07
Operation Section
Machine Operation
Operation, conguration, and troubleshooting information for the Product
Link PL121SR can be found in System Operation Troubleshooting Testing
and Adjusting, RENR7911.
Regulatory Compliance
g01131982
Illustration 91
NOTICE
Transmission of information using Product Link is sub-
ject to legal requirements that may vary from location
to location, including, but not limited to, radio frequen-
cy use authorization. The use of Product Link must be
limited to those locations where all legal requirements
for the use of the Product Link communication network
have been satised.
In the event that a machine outtted with Product Link
is located in or relocated to a location where (i) le-
gal requirements are not satised or (ii) transmitting
or processing of such information across multiple lo-
cations would not be legal, Caterpillar disclaims any
and all liability related to such failure to comply and
Caterpillar may discontinue the transmission of infor-
mation from that machine.
Consult your Caterpillar dealer with any questions that concern the
operation of the Product Link in a specic country.
SEBU7892-07 133
Operation Section
Machine Operation
g02171578
Illustration 92
Note: A translated extract of the above document is provided below.
Table 10
DECLARATION OF CONFORMITY
We, Quake Global, Inc (Previously Quake Wireless, Inc up to January
2001)
of 9765 Clairemont Mesa Blvd, Suite A (Previously 5575 Rufn Road,
Suite 100 up to March 2002)
San Diego
(continued)
134 SEBU7892-07
Operation Section
Machine Operation
(Table 10, contd)
CA 92124, Usa
(Previously 92123)
declare under our sole responsibility that the product
QHE2500, Q2000,Q1500, Q1400, Q1200S, Q1200SG, Q1200SH,
Q1200SM and Q1200SV
to which this declaration relates, is in conformity with the following standards
and / or other normative documents.
EN 301 721 V1.2.1 (June 2001)
EN 300 489-20V1.2.1
(November 2002)
EN 60950-1/A11:2004, 1st
Edition
We hereby declare that all essential radio test suites have been carried out and
that the above named product is in conformity to all the essential requirements
of Directive 1999/5/EC.
The conformity assessment procedure referred to in Article 10 and detailed in
Annex [IV] of Directive 1999/5/EC has been followed with the involvement of
the following Notied Body:
BABT, Claremont House, 34 Molesey Foad, Walton-on-
Thames, KT12 4RQ, UK
Identication mark: 0168 The equipment will
also carry the Class 2
Equipment identier.
The technical documentation relevant to the above equipment will be held at:
Quake Global Inc (Previously Quake Wireless, Inc. up to January 2001)
9765 Clairemont Mesa Blvd, Suite A
San Diego, CA 92124, USA
Polina Braunstein
President
(continued)
SEBU7892-07 135
Operation Section
Machine Operation
(Table 10, contd)
(signature of authorized person) (date)
Class 2 equipment identier
i02467298
Operation Information
SMCS Code: 7000
NOTICE
Do not operate the machine with the cab doors open.
Large tires can contact the doors when the front axle
is oscillated.
The cab doors can be damaged.
Note: To prevent injury, make sure that no one is working on the machine
or near the machine. Always maintain control of the machine.
Reduce the engine speed when you maneuver in tight quarters and when
you are going over a hill.
Select the necessary gear range before you begin to move downhill. Do
not change speeds while you travel downhill.
When you drive downhill, use the same gear range that is used for driving
uphill.
Do not allow the engine to overspeed while you travel downhill. Apply
the service brake in order to reduce engine overspeed while you travel
downhill.
Note: For operator comfort and maximum service life of power train
components, deceleration and/or braking is recommended before any
directional shifts are made.
1. Adjust the operator's seat.
2. Fasten the seat belt.
136 SEBU7892-07
Operation Section
Machine Operation
3. Raise all lowered work tools in order to negotiate any obstacles.
4. Depress the service brake pedal in order to prevent the machine from
moving.
5. Push in the parking brake switch in order to release the parking brake.
6. Move the transmission control to the desired travel direction and to
the desired speed.
7. Release the service brake pedal.
8. Push the accelerator pedal downward in order to achieve the desired
engine speed.
9. Drive the machine forward for best visibility and for best control.
i02173654
Parking Brake
SMCS Code: 7000
Personal injury could result from the sudden stop
of the machine. The parking brake is automatically
engaged when brake oil pressure drops below an
adequate operating pressure.
g01101739
Illustration 93
SEBU7892-07 137
Operation Section
Machine Operation
If the brake loses oil pressure, the alert indicator (1) for the brakes will
ash and the action alarm will sound. The alert indicator for the brakes is
on the dash panel. Loss of oil pressure will cause the parking brake to
automatically engage. This will stop the machine.
Anticipate a sudden stop. Correct the cause of the loss of oil pressure. Do
not operate the machine without normal brake oil pressure.
The action light will also ash when the lights on the monitoring system
ash.
NOTICE
Moving the machine with the parking brake engaged
can cause excessive wear or damage to the brake.
If necessary, have the brake repaired before operating
the machine.
i02262460
Secondary Steering
(If Equipped)
SMCS Code: 7000
A low charge condition, or any defect in the bat-
tery, battery cells, or electrical circuit can cause
loss of the secondary steering.
The machine's batteries must have a normal
charge and the secondary steering electrical sys-
tem must be in working order.
The loss of the secondary steering could result in
personal injury and/or damage to the machine.
138 SEBU7892-07
Operation Section
Machine Operation
NOTICE
The alarm system indicates that the primary steering
system has failed.
Use the secondary steering system to steer the ma-
chine to the nearest convenient location. When the
machine comes to a complete stop, turn the start
switch key to the OFF position.
Continuing to operate the machine may result in dam-
age to the system.
The secondary steering system provides temporary steering control in the
event of primary steering failure. Primary steering failure is the result of
low oil pressure in the steering system. Primary steering failure can occur
for any of the following reasons:
Hydraulic pump failure
Engine failure
Pressure loss in the hydraulic system

g01101919
Illustration 94
Secondary Steering (1) When this alert indicator is on, the
secondary steering is activated.
SEBU7892-07 139
Operation Section
Machine Operation
Primary Steering Malfunction (2) When this alert indicator
is on, the pressure in the steering system is low.
Alert indicator (2) indicates a failure of the primary steering. When alert
indicator (1) ashes, the secondary steering system is active. When
the alert indicators come on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the machine. Stop
the engine and investigate the cause of the failure. Do not operate the
machine until the cause of the failure has been corrected.
g01136250
Illustration 95
Test Switch (3)
The secondary steering system can be tested when the machine is
operating. Press test switch (3) in order to activate the secondary steering.
Release test switch (3) in order to disengage the secondary steering.
When test switch (3) is pushed, the secondary steering motor will run.
Alert indicator (1) and the action light will come on and the action alarm
will sound. If alert indicator (1) does not come on or the action alarm does
not sound, do not operate the machine.
140 SEBU7892-07
Operation Section
Machine Operation
i02467154
Winch Warm-Up Procedure
SMCS Code: 5163
Personal injury or death can result from improper
wire rope use.
Always wear gloves when handling wire rope.
NOTICE
Do not move the winch control lever out of the
FREESPOOL position while the drum is rotating. This
will cause serious damage to the winch gear train.
Note: The following procedure only applies to the mechanical winch C500.
A warm-up for the winch is recommended when the engine is started and
especially when the ambient temperature is below 4 C (40 F).
1. Start the engine and run the engine at low idle for ve minutes.
2. Cycle the winch control lever between the Winch Brake ON position
and the FREESPOOL position. Then, place the winch control lever in
the FREESPOOL position and pull out approximately 30 m (100 ft)
of wire rope.
3. Make sure that the area is clear of personnel. While the engine is
running at low idle, reel in the wire rope.
4. Repeat this operation in order to circulate the warm oil throughout
the gear train.
SEBU7892-07 141
Operation Section
Machine Operation
i02391191
Water Cleaning System (Pressurized)
(If Equipped)
SMCS Code: 5612
Note: The water cleaning system is used to clean the cab oor. Do not
use the water cleaning system for re suppression.
The controls for the water cleaning system are located on the oor of the
cab next to the seat. The water tank is located on top of the cab.
g00868210
Illustration 96
(1) Water Tank
(2) Relief Valve
(3) Filler Plugs
(4) Air Valve
(5) Ball Valve
(6) Water Spray Nozzle
Ball valve (5) controls the ow of water to the water hose and water spray
nozzle (6). When the water cleaning system is not being used, ball valve
(5) should be shut off. After ball valve (5) is shut off, the pressure in the
water hose should be released through water spray nozzle (6).
142 SEBU7892-07
Operation Section
Machine Operation
Fill
result.
the threads.
1. In order to ll water tank (1), release pressure in the system through
water spray nozzle (6).
2. Unscrew ller plugs (3) for two turns counterclockwise. After the
pressure is completely relieved, remove the ller plugs.
3. Fill water tank (1) with water.
The total volume of water tank (1) is 34 L (9 US gal). Water tank (1) will
hold 25.5 L (6.75 US gal) of water and 8.5 L (2.2 US gal) of air.
Note: If the outside temperature is below freezing, use a propylene glycol
based antifreeze in the water tank. The antifreeze should be a non-toxic
antifreeze that is used in recreational vehicles.
4. Install ller plugs (3) and pressurize water tank (1).
Pressurize the Water Tank
Water tank (1) is pressurized to 345 kPa (50 psi). In order to pressurize
water tank (1), connect an air hose to air valve (4). Relief valve (2) limits
the tank pressure to 345 kPa (50 psi).
SEBU7892-07 143
Operation Section
Engine Starting
Engine Starting
i02391204
Engine Starting
SMCS Code: 1000; 7000
1. Make sure that the transmission control is in the NEUTRAL position.
2. Move the steering column to the desired position.
3. Engage the parking brake.
4. Fasten the seat belt.
5. Make sure that the control levers are in the HOLD position.
6. Turn the engine start switch to the START position in order to start the
engine. Release the engine start switch key after the engine starts.
NOTICE
Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display veries
that the oil pressure is sufcient.
If equipped with an air inlet heater (AIH) for cold
weather starting, do not use aerosol types of start-
ing aids such as ether. Such use could result in an
explosion and personal injury.
144 SEBU7892-07
Operation Section
Engine Starting
g01102202
Illustration 97
Turn the ignition switch into the ON position. The alert indicator (1) will
come on during the heating process prior to starting the engine. The
machine can be started after the alert indicator turns off.
Note: The preheat time varies between 10 seconds and 30 seconds.
Release the ignition switch when the engine starts.
i02173657
Engine and Machine Warm-Up
SMCS Code: 1000; 7000
NOTICE
Keep engine speed low until the engine oil pressure
alert indicator goes out. If the alert indicator does not
go out within ten seconds, stop the engine and inves-
tigate the cause before starting again. Failure to do so
can cause engine damage.
SEBU7892-07 145
Operation Section
Engine Starting
g01101736
Illustration 98
Note: The monitoring system will perform a self test when the engine is
started. Always allow the monitoring system to complete the self test
before you begin operating the machine.
1. Allow a cold engine to warm up at low idle for at least ve minutes.
To help the hydraulic components to warm up faster, engage the
attachment controls and disengage the attachment controls.
2. Cycle all controls in order to allow warm hydraulic oil to circulate
through all hydraulic cylinders and through all hydraulic lines.
3. Look at the indicators and the gauges frequently during operation.
While you idle the engine, observe the following recommendations:
Allow the engine to warm up for approximately 15 minutes when the

outside temperature is higher than 0C (+32F).
Allow the engine to warm up for approximately 30 minutes when the

outside temperature is below 0C (+32F).
More time may be required if the outside temperature is less than

18C (0F). More time may also be required if the hydraulic functions
are sluggish.
146 SEBU7892-07
Operation Section
Adjustments
Adjustments
i03009978
Winch Drum Drag Adjustment
SMCS Code: 5163
Mechanical Winch Adjustment
g01524123
Illustration 99
This is the location of the mechanical winch.
SEBU7892-07 147
Operation Section
Adjustments
g01524143
Illustration 100
This is the adjustment bolt for the mechanical winch (1).
The adjustment screw is on the right side of the winch.
Remove the protective cover from the right side of the winch.
Turn the screw inward in order to increase the drag. Turn the screw
outward in order to decrease the drag.
Adjust the drag so that the cable can be unreeled by hand. The winch
drum will stop when the cable is released.
Note: The drag may need to be adjusted when a cable of a different
size is being installed.
148 SEBU7892-07
Operation Section
Adjustments
Hydraulic Winch Adjustment
g01524162
Illustration 101
This is the location of the hydraulic winch.
g01524163
Illustration 102
This is the adjustment bolt for the mechanical winch (2).
The adjustment screw is on the left side of the winch.
Remove the protective cover from the left side of the winch.
SEBU7892-07 149
Operation Section
Adjustments
Turn the screw inward in order to increase the drag. Turn the screw
outward in order to decrease the drag.
Adjust the drag so that the cable can be unreeled by hand. The winch
drum will stop when the cable is released.
Note: The drag may need to be adjusted when a cable of a different
size is being installed.
150 SEBU7892-07
Operation Section
Parking
Parking
i01358133
Stopping the Machine
SMCS Code: 7000
NOTICE
Do not engage the secondary brake while the machine
is moving unless the primary service brake fails.
The use of the secondary brake as a service brake
in regular operation will cause severe damage to the
brake system.
1. Park the machine on a level surface. If it is necessary to park on a
grade, block the wheels.
2. Apply the service brakes in order to stop the machine.
3. Move the transmission control to the NEUTRAL position.
5. Lower the work tool to the ground and apply slight downward pressure.
SEBU7892-07 151
Operation Section
Parking
i02173658
Stopping the Engine
SMCS Code: 1000; 7000
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
celerated wear of the engine components.
Refer to the following procedure, to allow the engine
to cool, and to prevent excessive temperatures in the
turbocharger housing (if equipped), which could cause
oil coking problems.
1. While the machine is stopped, operate the engine for ve minutes at
low idle. This allows hot areas in the engine to cool gradually. Also, this
will allow the turbocharger shaft to slow down.
g01100951
Illustration 103
(1) OFF position. (2) ON position. (3) START position.
2. Turn the engine start switch to the OFF position in order to stop the
engine.
152 SEBU7892-07
Operation Section
Parking
i02164117
Stopping the Engine if an Electrical
Malfunction Occurs
SMCS Code: 1000; 7000
Turn the engine start switch into the OFF position. If the engine does not
stop, an electrical malfunction exists.
g01097538
Illustration 104
An emergency engine shutdown switch (2) is located at the left front of
the machine under access door (1).
g01097543
Illustration 105
SEBU7892-07 153
Operation Section
Parking
Open the access door (1). Move the switch (2) upward in order to stop
the engine.
i02157029
SMCS Code: 7000
Personal injury can result from hydraulic oil pres-
sure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Seri-
ous injury can be caused if this pressure is not re-
leased before any service is done on the hydraulic
system.
Make sure all of the work tools have been lowered
to the ground, and the oil is cool before removing
any components or lines. Remove the oil ller cap
only when the engine is stopped, and the ller cap
is cool enough to touch with your bare hand.
The machine is equipped with an accumulator in the hydraulic system to
control the lowering of the boom and/or the arch and the blade when
the engine is stopped.
154 SEBU7892-07
Operation Section
Parking
g01102146
Illustration 106
The accumulator is located in the compartment behind the right door of
the cab. In order to gain access to the accumulator, open the compartment
door.
g00710946
Illustration 107
The bladder type accumulator is mounted to a block manifold. The
accumulator stores potential energy by accumulating a quantity of
pressurized hydraulic oil. The pressurized uid is stored in a bladder type
accumulator. A bag that contains gas is located within the accumulator.
The medium that is used for charging is dry nitrogen.
The pressurized oil enters the accumulator and the uid creates pressure
within the accumulator. Energy is stored as the bag that is within the
accumulator is compressed by the oil.
SEBU7892-07 155
Operation Section
Parking
The accumulator supplies pressurized oil to the pilot valve when the
engine is stopped.
Before you lower the attachments, make sure that no one is in the area
around the machine.
1. Turn the engine start switch to the ON position.
2. Push each control lever to the LOWER position in order to lower the
attachments to the ground. The control levers will return to the HOLD
position when the control levers are released.
After the attachments are lowered relieve the pressure in the accumulator
by moving the handle of the grapple control several times in different
directions.
Reference: For more information about the accumulator, refer to the
Service Manual module Systems Operation (Hydraulic and Steering
System) for the machine that is being serviced.
156 SEBU7892-07
Operation Section
Parking
i00936884
Leaving the Machine
SMCS Code: 7000
1. Make sure that the steps are free of debris. Use the steps and the
handholds when you dismount the machine.
Reference: Refer to Operation and Maintenance Manual, Mounting
and Dismounting for more information.
2. Inspect the engine compartment for debris. Remove any debris from
the engine compartment in order to avoid a re hazard.
3. Remove all ammable debris from the bottom guard on the front of the
machine. Removing the debris will prevent a re hazard. Remove this
debris through the access doors and dispose of the debris properly.
4. Turn the battery disconnect switch to the OFF position and remove the
key when the machine will not be used for an extended period of time
(a month or more). This will prevent the battery from being drained.
Drainage of the battery can be caused by a short circuit, by a current
draw from certain components, or by vandalism.
5. Install all vandalism covers, all guards and all locks.
SEBU7892-07 157
Operation Section
Transportation Information
i02467779
Shipping the Machine
SMCS Code: 7000; 7500
Investigate the travel route for overpass clearances. Make sure that
there will be adequate clearance if the machine that is transported has a
ROPS, a cab, or a canopy.
Remove ice, snow, or other slippery material from the loading dock and
from the transport machine before you load the machine. This will help
to prevent slippage of the machine. This will also help to prevent a shift
while the machine is moving in transit.
Obey the appropriate laws that govern the parameters of the load (weight,
width, and length).
g01096801
Illustration 108
Properly chocked trailer wheels
1. Chock the trailer wheels or the rail car wheels before you load the
machine.
2. After the machine is positioned, connect the steering frame lock in
order to hold the front frame and the rear frame in place.
3. Lower the bucket or the work tool to the oor of the transport vehicle.
Move the transmission control to the NEUTRAL position.
158 SEBU7892-07
Operation Section
5. Turn the engine start switch to the ON position. The engine does not
need to be on, but power must be available through the system.
6. Move all of the control levers in order to relieve any trapped pressure.
7. Turn the engine start switch to the OFF position. Remove the engine
start switch key.
8. Turn the battery disconnect switch to the OFF position. Remove the
battery disconnect switch key.
9. Lock the door and the access covers. Attach any vandalism protection.
10. Secure the machine, any equipment, and any tools with adequate
tie-downs in order to prevent movement during shipping.
11. Cover the exhaust opening. The turbocharger (if equipped) should not
rotate when the engine is not operating. Damage to the turbocharger
can result.
SEBU7892-07 159
Operation Section
i01998604
Roading the Machine
SMCS Code: 7000
Check with the proper ofcials in order to obtain the required licenses and
other similar items before roading the machine.
Complete a thorough daily inspection before you mount the machine
and before you start the engine.
Manual, Daily Inspection.
Carry the work tool as low to the ground as possible. Disable the controls
for the work tool when the machine is roaded.
Limitations for TON-kilometer per hour (TON-mile per hour) must be
obeyed. Before roading, consult your tire dealer for recommended tire
pressures and for speed limitations of the tires.
Inate the tires to the correct pressure. Use a self-attaching ination
chuck in order to inate the tire. Stand behind the tire tread while you
inate the tires.
Reference: For more information, refer to the Operation and Maintenance
Manual, Tire Ination Information.
When you road for long distances, schedule stops in order to allow the
tires and the components to cool. Stop for 30 minutes after every 40 km
(25 miles) or after every hour.
160 SEBU7892-07
Operation Section
i02216077
Lifting and Tying Down the Machine
SMCS Code: 7000; 7500
A machine may shift if improper procedures or
equipment are used for lifting and tying down for
transport. Ensure that proper equipment and pro-
cedures are used for lifting and tying machines
down for transport. If a machine shifts it could
cause personal injury or death.
NOTICE
Improper lifting or tie-downs can allow the load to shift
and cause injury or damage. Install the steering frame
lock link before lifting.
g01118386
Illustration 109
This notice is located on the rear RH lower exterior of platform.
Lifting Point This lm identies a lifting point that may be
used in order to lift the machine.
SEBU7892-07 161
Operation Section
Tie Down Point This lm identies a tie-down point that may
be used in order to tie down the machine.
Check all of the laws that govern the load characteristics (height, weight,
width, and length).
The machine shipping weight that is listed is the weight of the most
common conguration of the machine. If attachments have been installed
on your machine, the weight of your machine and the center of gravity
of your machine may vary.
Reference: For the dimensions and the weight of the machine, refer to
Operation and Maintenance Manual, Specications.
1. Engage the parking brake before you sling the machine and before
you secure the machine with tie-downs.
2. Install the steering frame lock pin.
3. There are two lifting points at the rear of the machine. Attach a lifting
cable to each lifting point. Each lifting point should be identied as a
lifting point.
Note: Use properly rated cables and properly rated slings to lift the
machine.
4. There are two lifting points at the front of the machine. Attach a lifting
cable to each lifting point. Each lifting point should be identied as a
lifting point.
5. Connect the four lifting cables to the spreader bars. The spreader bars
must be centered over the machine.
Note: The width of the spreader bar must be sufcient to prevent the
lifting cables or the lifting straps from contacting the machine.
6. If equipped, secure any attachments.
7. Position the crane or the lifting device in order to lift the machine in
a level position.
8. Lift the machine. Move the machine to the desired position.
162 SEBU7892-07
Operation Section
9. When the machine is positioned, place blocks behind the tires.
10. Secure the machine at the tie-down points. Each tie-down point should
be identied as a tie-down point.
Reference: For shipping instructions, refer to Operation and Maintenance
Manual, Shipping the Machine.
SEBU7892-07 163
Operation Section
Towing Information
Towing Information
i02163070
Towing the Machine
SMCS Code: 7000
Personal injury or death could result when towing
a disabled machine incorrectly.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if
it is not blocked.
In order to properly perform the towing procedure, use the following
recommendations.
This machine is equipped with spring applied parking brakes that are
released by oil pressure. If the engine is inoperable or if the brake oil
system is inoperable, the parking brakes are applied. The machine can
not be moved.
Use these towing instructions for moving a disabled machine over a short
distance. Do not move the machine faster than 2 km/h (1.2 mph). Move
the machine to a convenient location for repair. Use these instructions
for emergency situations only. Always haul the machine if long distance
moving is required.
Shielding must be provided on the towing machine in order to protect the
operator in case the tow line breaks or the tow bar breaks.
Do not allow riders on the machine which is being towed unless the
operator can control the steering and/or the braking.
164 SEBU7892-07
Operation Section
Towing Information
Before you tow the machine, inspect the condition of the tow line or of
the tow bar. Make sure that the tow line or the tow bar is sturdy enough
to tow the disabled machine. The tow line or the tow bar must have a
strength that is equal to 1.5 times the gross weight of the machine that
is being towed. Use a tow bar with this strength or a tow line with this
strength to tow a disabled machine that is stuck in the mud. Also, use a
tow bar with this strength or a tow line with this strength to tow a disabled
machine up a grade.
Do not use a chain for pulling. A chain link may break. This can cause
personal injury. Use a wire cable with cable loops or end rings. Position
an observer at a safe location. The observer should stop the pulling
procedure if the cable starts to break or the cable starts to unravel. If
the towing machine moves without the pulled machine, stop the pulling
procedure.
Keep the tow line angle to a minimum. Do not exceed a 30 angle from
the straight ahead position.
Quick machine movement could overload the tow line or the tow bar.
This could cause the tow line or the tow bar to break. Gradual, smooth
machine movement works better.
Normally, the towing machine should be as large as the disabled machine.
The towing machine must have enough brake capacity, enough weight,
and enough power for the grade that is involved and for the distance
that is involved.
It may be necessary to connect a larger machine or additional machines
to the machine that is disabled. This will provide sufcient control for
moving a disabled machine downhill and sufcient braking for moving a
disabled machine downhill. This will prevent the disabled machine from
rolling away out of control.
The requirements for different situations cannot be specied. Minimal
towing machine capacity is required on smooth, level surfaces. Maximum
towing machine capacity is required on inclines or on poor surface
conditions.
Any towed machine with a load must be equipped with a brake system
that can be operated from the operator's compartment.
Consult your Caterpillar dealer for more information about towing a
disabled machine.
SEBU7892-07 165
Operation Section
Towing Information
Towing with the Engine Running
If the engine is running, the machine can be towed for a short distance
under certain conditions. The power train and the steering system must
be operable. Tow the machine for a short distance only. For example,
pull the machine out of mud or pull the machine to the side of the road.
The operator on the towed machine must steer the machine in the
direction of the tow line.
Carefully obey all of the instructions that are outlined in this topic.
Towing with the Engine Stopped
Perform the following steps before you tow the machine.
g01096802
Illustration 110
(A) Rod end. (B) Head end.
166 SEBU7892-07
Operation Section
Towing Information
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
NOTICE
Be sure the cylinder hoses are connected correctly be-
fore operating the machine. With the hoses reversed,
the steering system will not function.
1. Reverse the hydraulic steering hose connections on one cylinder only.
This will allow the steering cylinders to move freely.
NOTICE
Release the parking brake to prevent excessive wear
and damage to the parking brake systemwhen towing
the machine.
Note: For information about the manual release of the parking brake, see
Operation and Maintenance Manual, Parking Brake Manual Release.
2. Release the parking brake.
3. Fasten the tow bar.
4. Remove the wheel blocks. Tow the machine slowly. Do not exceed
2 km/h (1.2 mph).
SEBU7892-07 167
Operation Section
Towing Information
Personal injury or death can result from brake
malfunction.
Make sure all necessary repairs and adjustments
have been made before a machine that has been
towed to a service area, is put back into operation.
i02719558
Parking Brake Manual Release
SMCS Code: 4267; 7000
g00493183
Illustration 111
The parking brake drum is located on the lower back side of the
transmission.
Note: Place blocks in front of the tires and behind the tires in order to
prevent the machine from rolling.
Turn swivel nut (1) in order to move rod (2) downward. Brake lever (3) will
move downward and the parking brake will be released.
168 SEBU7892-07
Operation Section
Engine Starting (Alternate Methods)
i02407539
Engine Starting with Jump Start Cables
SMCS Code: 1000; 7000
Failure to properly service the batteries may cause
personal injury.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
machine.
Do not smoke when checking battery electrolyte
levels.
Electrolyte is an acid and can cause personal in-
jury if it contacts the skin or eyes.
Always wear eye protection when starting a ma-
chine with jump start cables.
Improper jump start procedures can cause an ex-
plosion resulting in personal injury.
When using jumper cables, always connect the
positive (+) jumper cable to the positive (+) bat-
tery terminal rst. Next, connect the negative (-)
jumper cable to the frame away from the batteries.
Follow the procedure in the Operation and Main-
tenance Manual.
Jump start only with an energy source of the same
voltage as the stalled machine.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the
energy source is connected.
SEBU7892-07 169
Operation Section
Do not attempt to charge a battery that has ice in
any of the cells.
Charging a battery in this condition can cause an
explosion that may result in personal injury or
death.
Always let the ice melt before attempting to
charge.
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
This machine has a 24 volt starting system. Use only
the same voltage for jump starting. Use of a higher
voltage damages the electrical system.
Use of Jump Start Cables
1. Place the transmission control on the stalled machine in the NEUTRAL
position. Engage the parking brake. Lower all attachments to the
ground. Move all controls to the HOLD position.
2. On the stalled machine, turn the engine start switch to the OFF
position. Turn off the accessories.
3. On the stalled machine, turn the battery disconnect switch to the ON
position.
170 SEBU7892-07
Operation Section
4. Move the machine or the auxiliary power source close to the stalled
machine so that the cables can reach. DO NOT ALLOW THE
MACHINE OR THE AUXILIARY POWER SOURCE TO CONTACT
THE STALLED MACHINE.
5. Stop the engine on the machine that is the electrical source. (If you are
using an auxiliary power source, turn off the charging system.)
6. Check the battery caps for correct placement and for correct tightness.
Make these checks on both machines. Make sure that the batteries
in the stalled machine are not frozen. Check the batteries for low
electrolyte.
7. Connect the positive jump start cable to the positive cable terminal
of the discharged battery.
Do not allow positive cable clamps to contact any metal except for
battery terminals.
Note: Batteries in series may be in separate compartments. Use the
terminal that is connected to the starter solenoid. This battery is normally
on the same side of the machine as the starter.
8. Connect the positive jump start cable to the positive terminal of the
electrical source. Use the procedure from Step 7 in order to determine
the correct terminal.
9. Connect one end of the negative jump start cable to the negative
terminal of the electrical source.
10. Make the nal connection. Connect the negative cable to the frame
of the stalled machine. Make this connection away from the battery,
away from the fuel, away from the hydraulic lines, and away from all
moving parts.
11. Start the engine of the machine that is the electrical source. (If you are
using an auxiliary power source, energize the charging system on the
auxiliary power source.)
12. Allow the electrical source to charge the batteries for two minutes.
13. Attempt to start the stalled engine.
Manual, Engine Starting.
SEBU7892-07 171
Operation Section
14. Immediately after the stalled engine starts, disconnect the jump start
cables in reverse order.
i02180048
Engine Starting with Auxiliary Start
Receptacle
(If Equipped)
SMCS Code: 1463
NOTICE
Ensure that the machine that is used as an electrical
source does not touch the stalled machine. This could
prevent damage to engine bearings and electrical cir-
cuits.
Turn on the disconnect switch on the electrical source.
This will help to prevent damage to electrical compo-
nents on the stalled machine.
This machine has a 24 volt starting system. Use only
equal voltage for jump starting. Use of a higher voltage
will damage the electrical system.
Severely discharged maintenance free batteries will
not fully recharge from the alternator alone after
you jump start the machine. The batteries must be
charged to the proper voltage with a battery charger.
Many batteries that are considered to be unusable
can still be recharged.
Refer to Special Instruction, SEHS7633, Battery Test
Procedure for complete information about testing and
about charging. This document is available from your
Caterpillar dealer.
NOTICE
In order to jump start this machine, a jump start recep-
tacle must be used.
Failure to do so could cause damage to the electrical
system of the machine.
172 SEBU7892-07
Operation Section
There are two cable assemblies that can be used to jump start the stalled
machine. You can jump start the stalled machine from another machine
that is equipped with an auxiliary start receptacle or with an auxiliary
power pack. Your Caterpillar dealer can provide the correct cable lengths
for your application.
The auxiliary start receptacle is located next to the battery disconnect
switch.
1. Place the transmission control on the stalled machine in NEUTRAL.
Engage the parking brake. Lower all work tools to the ground. Move
all controls to the HOLD position.
2. On a stalled machine, turn the engine start switch key to OFF. Turn
off all accessories.
3. On a stalled machine, turn the battery disconnect switch to ON.
4. Open the engine access door on the right side of the machine in order
to access the auxiliary start receptacle.
5. Move the machine or the auxiliary power source close to the stalled
machine so that the cables can reach. DO NOT ALLOW THE
MACHINE OR THE AUXILIARY POWER SOURCE TO CONTACT
THE STALLED MACHINE.
6. Stop the engine on the machine that is the power source. If you are
using an auxiliary power source, turn off the charging system.
7. Check the battery caps for correct placement and for correct tightness.
Make these checks on both machines. Make sure that the batteries
in the stalled machine are not frozen. Check the batteries for low
electrolyte.
8. Connect the appropriate jump start cable to the auxiliary start
receptacle on the stalled machine.
9. Connect the other end of the jump start cable to the auxiliary start
receptacle of the machine that is being used as a power source.
10. Start the engine on the machine that is being used as a power source
or energize the charging system on the auxiliary power source.
11. Allow the machine that is being used as the power source to charge
the batteries for two minutes.
SEBU7892-07 173
Operation Section
12. Attempt to start the stalled engine.
13. Immediately after the stalled engine starts, disconnect the jump start
cables from the power source.
174 SEBU7892-07
Maintenance Section
Tire Ination Information
Maintenance Section
i04129751
Tire Ination Pressure
SMCS Code: 4203
The tire ination pressures in the following table are cold ination
pressures.
Table 11
Standard Tires
Size
Ply Rating or
Strength Index
Ination
Pressure
24.5 32 16
210 kPa
(30 psi)
30.5 32 20
276 kPa
(35 psi)
30.5 32 26
310 kPa
(45 psi)
35.5 32 20
210 kPa
(30 psi)
35.5 32 24
276 kPa
(35 psi)
68 50 32 16
241 kPa
(35 psi)
73 44 32 16
276 kPa
(40 psi)
The ination pressure is based on the weight of a ready-to-work
machine without attachments, at rated payload, and in average operating
conditions. Pressures for each application may vary. Always obtain the
proper pressures from your tire supplier.
SEBU7892-07 175
Maintenance Section
Wheel and Tire Arrangement
The machines can be equipped with different types of tires. The type of
tire will depend on the application. The tables below listed the tires that
are available. The mark (X) indicates the tires that are recommended. For
more information, consult your Caterpillar dealer.
Table 12
Wheel and Tire Arrangement
Size 525C
525C
H.D. 535C 545C
28L 26
(1)
N/A N/A N/A N/A
24.5 32 X N/A N/A N/A
30.5 32 X X X X
35.5 32 N/A X X X
73 44
x 32
N/A X X X
68 50
x 32
N/A X X X
(1)
This tire is approved for the 525C. These tires are not
recommended as the tires will slip on the rims.
Note: The letters (N/A) in the above table signify that the tires are not
approved for this machine.
Table 13
Wheel and Tire Arrangement (With Chains)
Size 525C
525C
H.D. 535C 545C
28L 26
(1)
N/A N/A N/A N/A
24.5 32 X N/A N/A N/A
30.5 32 N/A X X X
35.5 32 N/A X X X
73 44 x
32
N/A X X X
68 50 x
32
N/A N/A N/A N/A
(1)
This tire is approved for the 525C. These tires are not
recommended as the tires will slip on the rim.
176 SEBU7892-07
Maintenance Section
Table 14
Dual Tire Conguration
Size 525C
525C
H.D. 535C 545C
30.5 x 24.5 N/A X X X
i01909274
Tire Ination Pressure Adjustment
SMCS Code: 4203
The tire pressure in a warm shop area (18 to 21C (65 to 70F) average
temperature) will signicantly change when you move the machine into
freezing temperatures. If you inate the tire to the correct pressure in a
warm shop, the tire will be underinated in freezing temperatures. Low
pressure shortens the life of a tire.
When you operate the machine in freezing temperatures, see Special
Publication, SEBU5898, Cold Weather Recommendations For All
Caterpillar Machines.
SEBU7892-07 177
Maintenance Section
Lubricant Viscosities and Rell Capacities
Lubricant Viscosities and Rell
Capacities
i03993329
Lubricant Viscosities
SMCS Code: 7581
Selecting the Viscosity
The proper oil viscosity grade is determined by the minimum outside
temperature. This is the temperature when the machine is started and
while the machine is operated. In order to determine the proper oil
viscosity grade, refer to the Min column in the table. This information
reects the coldest ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer to the Max column in
the table in order to select the oil viscosity grade for operating the machine
at the highest temperature that is anticipated. Use the highest oil viscosity
that is allowed for the ambient temperature when you start the machine.
Machines that are operated continuously should use oils that have the
higher oil viscosity in the nal drives and in the differentials. The oils that
have the higher oil viscosity will maintain the highest possible oil lm
thickness. Consult your dealer if additional information is needed.
Lubricant Viscosities for Ambient Temperatures
Table 15
C F
Compartment
or System
Oil Type and
Classication
Oil
Viscosities
Min Max Min Max
(continued)
178 SEBU7892-07
Maintenance Section
(Table 15, contd)
C F
Compartment
or System
Oil Type and
Classication
Oil
Viscosities
Min Max Min Max
SAE 0W20 40 10 40 50
SAE 0W30 40 30 40 86
SAE 0W40 40 40 40 104
SAE 5W30 30 30 22 86
SAE 5W40 30 40 22 104
SAE
10W30
20 40 4 104
SAE
10W40
20 50 4 122
Engine
Crankcase
Cat DEO
Multigrade
CatDEO-ULS
CatDEO-ULS
SYN
Cat Cold
Weather
DEO-ULS
(1)
Cat ECF-1-a,
ECF-2, ECF-3
(2)
SAE
15W40
15 50 5 122
SAE 0W20
(3)
40 10 40 50
SAE 0W30
(3)
40 20 40 68
SAE 5W30
(3)
30 20 22 68
SAE 10W 20 10 4 50
SAE 30
(4)
0 35 32 95
SAE 50
(4)(5)
10 50 50 122
Power Shift
Transmissions
and Winch Gear
Case
Cat TDTO
Cat Cold
Weather TDTO
Cat TDTO-TMS
Cat TO-4
TDTO-TMS
(6)
10 43 14 110
(continued)
SEBU7892-07 179
Maintenance Section
(Table 15, contd)
C F
Compartment
or System
Oil Type and
Classication
Oil
Viscosities
Min Max Min Max
SAE 0W20 40 40 40 104
SAE 0W30 40 40 40 104
SAE 5W30 30 40 22 104
SAE 5W40 30 40 22 104
SAE 10W 20 40 4 104
SAE 30 10 50 50 122
SAE
10W30
20 40 4 104
SAE
15W40
15 50 5 122
Cat MTO 25 40 13 104
Hydraulic
Systems
Cat HYDO
Advanced 10
(7)
Cat DEO
Cat MTO
(8)
Cat TDTO
Cat TDTO-TMS
Commercial
TO-4
Commercial
BF-2
(9)
TDTO-TMS
(6)
20 50 -4 122
SAE 0W20
(3)
40 0 40 32
SAE 0W30
(3)
40 10 40 50
SAE 5W30
(3)
35 10 31 50
SAE 10W 25 15 13 59
SAE 30 20 43 4 110
SAE 50 10 50 50 122
Drive Axles
Cat TDTO
Cat TDTO-TMS
Cat Cold
Wether TDTO
Commercial
TO-4
TDTO-TMS
(6)
30 43 22 110
(1)
Cat DEO-ULS SYN and Cat DEO SYN are SAE 5W-40 viscosity grade oils.
(2)
API CI-4, API CI-4 PLUS, and API CH-4 oils are acceptable if the requirements of
Caterpillar's ECF-1-a or ECF-2 are met. API CI-4, API CI-4 PLUS, and API CH-4 oils
that have not met the requirements of Caterpillar's ECF-1 or ECF-2 specication may
cause reduced engine life. Refer to Special Publication, SEBU6250, Caterpillar Machine
Fluid Recommendations for more information to the CAT ECF specications and other
commercial oils.
(continued)
180 SEBU7892-07
Maintenance Section
(Table 15, contd)
(3)
First Choice: Oils of full synthetic base stock without viscosity index improvers that
meet the performance requirements of the TO-4 specication for the SAE 30 viscosity
grade. Typical viscosity grades are SAE 0W20, SAE 0W30, and SAE 5W30. Second
Choice: Oils with a TO-4 type additive package and a lubricant viscosity grade of SAE
0W20, SAE 0W30, or of SAE 5W30.
(4)
Except for the hydraulic drive winch gear case. Do not use SAE 50 viscosity grade for
the hydraulic drive winch gear case. Instead, use SAE 30 viscosity grade for 0C (32F)
to 43C (110F) or TMS for 10C (14F) to 50C (122F).
(5)
Do not use SAE 50 viscosity grade oil in ICM controlled transmissions. Do not use SAE
50 viscosity grade oil for the hydraulic drive winch case.
(6)
TDTO-TMS Transmission Multi-Season (exceeds the TO-4/TO-4M multigrade
specication requirements).
(7)
Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic
and hydrostatic transmission systems when ambient temperature is between 20 C
(4 F) and 40 C (104 F). Cat HYDO Advanced 10 has an SAE viscosity grade of 10W.
Cat HYDO Advanced 10 has a 50% increase in the standard oil drain interval for
machine hydraulic systems (3000 hours versus 2000 hours) over second and third
choice oils - when following the maintenance interval schedule for oil lter changes
and for oil sampling that is stated in the Operation and Maintenance Manual for your
particular machine. 6000 hour oil drain intervals are possible when using SOS Services
oil analysis. Contact your Cat dealer for details. In order to gain the most benet from
the improved performance designed into Cat HYDO Advanced 10, when switching to
Cat HYDO Advanced 10, cross contamination with the previous oil should be kept to
less than 10%.
(8)
Second choice oils are Cat MTO, Cat DEO, Cat DEO-ULS, Cat TDTO, Cat Cold
Weather TDTO, Cat TDTO-TMS, Cat DEO-ULS SYN, Cat DEO SYN, Cat Cold Weather
DEO-ULS . Third choice oils are commercial oils that meet Cat ECF-1-a, Cat ECF-2,
Cat ECF-3, Cat TO-4, or the Cat TO-4M performance requirements, and that have
a minimum zinc additive level of 0.09 percent (900 ppm). Commercial biodegradable
hydraulic oil must meet the Cat BF-2 specication.
(9)
Commercial Biodegradable Hydraulic Oil (HEES) must meet the Caterpillar BF-2
specication.
SEBU7892-07 181
Maintenance Section
i02211819
Capacities (Rell)
SMCS Code: 7560
Table 16
525CWheel Skidder
Approximate Rell Capacities
Component or System Liters US gal
Engine Crankcase 27 7.1
Transmission 54 14.3
Hydraulic Tank 54 14.3
Hydraulic Tank with Grapple 115 25.3
Cooling System 57 15
Fuel Tank 303 80
Front Differential and Final Drive 52 13.7
Rear Differential and Final Drive 52 13.7
Mechanical Winch 24.5 6.5
Hydraulic Winch 6.6 1.7
182 SEBU7892-07
Maintenance Section
Table 17
535CWheel Skidder
Fuel Tank 303 80
SEBU7892-07 183
Maintenance Section
Table 18
545CWheel Skidder
Fuel Tank 379 100
i04311449
SOS Information
SMCS Code: 1348; 3080; 4070; 4250; 4300; 5050; 7542
SOS Services is a highly recommended process for Cat customers to
use in order to minimize owning and operating cost. Customers provide
oil samples, coolant samples, and other machine information. The dealer
uses the data in order to provide the customer with recommendations
for management of the equipment. In addition, SOS Services can help
determine the cause of an existing product problem.
Refer to Special Publication, SEBU6250, Caterpillar Machine Fluid
Recommendations for detailed information concerning SOS Services.
Refer to the Operation and Maintenance Manual, Maintenance Interval
Schedule for a specic sampling location and a service hour maintenance
interval.
Consult your Cat dealer for complete information and assistance in
establishing an SOS program for your equipment.
184 SEBU7892-07
Maintenance Section
Maintenance Support
Maintenance Support
i03636245
Welding on Machines and Engines with
Electronic Controls
SMCS Code: 1000; 7000
Do not weld on any protective structure. If it is necessary to repair a
protective structure, contact your Caterpillar dealer.
Proper welding procedures are necessary in order to avoid damage to
the electronic controls and to the bearings. When possible, remove the
component that must be welded from the machine or the engine and then
weld the component. If you must weld near an electronic control on the
machine or the engine, temporarily remove the electronic control in order
to prevent heat related damage. The following steps should be followed in
order to weld on a machine or an engine with electronic controls.
1. Turn off the engine. Place the engine start switch in the OFF position.
2. If equipped, turn the battery disconnect switch to the OFF position. If
there is no battery disconnect switch, remove the negative battery
cable at the battery.
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
3. Clamp the ground cable from the welder to the component that will be
welded. Place the clamp as close as possible to the weld. Make sure
that the electrical path from the ground cable to the component does
not go through any bearing. Use this procedure in order to reduce the
possibility of damage to the following components:
Bearings of the drive train
Hydraulic components
Electrical components
SEBU7892-07 185
Maintenance Section
Maintenance Support
Other components of the machine

4. Protect any wiring harnesses and components from the debris and the
spatter which is created from welding.
5. Use standard welding procedures in order to weld the materials
together.
186 SEBU7892-07
Maintenance Section
Maintenance Interval Schedule
i04328700
SMCS Code: 7000
When Required
Battery - Recycle ................................................................................. 195
Battery or Battery Cable - Inspect/Replace ......................................... 197
Circuit Breakers - Reset ....................................................................... 206
Engine Air Filter Primary Element - Clean/Replace ............................. 228
Engine Air Filter Secondary Element - Replace .................................. 232
Engine Air Precleaner - Clean ............................................................. 237
Ether Starting Aid Cylinder - Replace .................................................. 249
Fuel System - Prime ............................................................................ 251
Fuses - Replace ................................................................................... 261
Oil Filter - Inspect ................................................................................. 295
Radiator Core - Clean .......................................................................... 296
Water Cleaning System (Pressurized) - Purge .................................... 316
Winch Wire Rope - Install .................................................................... 333
Window Washer Reservoir - Fill ........................................................... 335
Window Wiper - Inspect/Replace ......................................................... 336
Windows - Clean .................................................................................. 337
Every 10 Service Hours or Daily
Air Cleaner Dust Valve - Clean/Inspect ............................................... 190
Backup Alarm - Test ............................................................................. 193
Cooling System Coolant Level - Check ............................................... 214
Engine Air Filter Service Indicator - Inspect ......................................... 234
Engine Oil Level - Check ..................................................................... 240
Fuel System Primary Filter (Water Separator) - Drain ......................... 252
Grapple Boom and Arch (Dual Function) - Lubricate ........................... 266
Grapple Boom and Arch (Single Function) - Lubricate ........................ 267
Grapple Head (Bunching) - Lubricate .................................................. 268
Grapple Head (Continuous Rotation) - Lubricate ................................ 268
Grapple Head (Sorting) - Lubricate ...................................................... 272
Grapple Snubber - Inspect/Adjust ........................................................ 274
Hydraulic System Oil Level - Check .................................................... 289
Seat Belt - Inspect ............................................................................... 300
Transmission Oil Level - Check ........................................................... 313
Winch Oil Level - Check ...................................................................... 331
SEBU7892-07 187
Maintenance Section
Every 50 Service Hours or Weekly
Articulation Bearings - Lubricate .......................................................... 191
Axle Oscillation Bearings - Lubricate ................................................... 192
Cab Air Filter - Clean/Replace ............................................................. 204
Differential and Final Drive Oil Level - Check ...................................... 225
Fairlead Rollers - Lubricate .................................................................. 251
Fuel Tank Water and Sediment - Drain ................................................ 260
Steering Cylinder Bearings - Lubricate ................................................ 303
Tire Ination - Check ............................................................................ 305
Winch Drive Shaft Spline - Lubricate ................................................... 319
Initial 100 Service Hours
Transmission Oil Filter - Replace ......................................................... 311
Every 100 Service Hours or 2 Weeks
Secondary Steering - Test ................................................................... 302
Every 250 Service Hours
Cooling System Coolant Sample (Level 1) - Obtain ............................ 215
Engine Oil Sample - Obtain ................................................................. 241
Every 250 Service Hours or Monthly
Battery - Clean ..................................................................................... 194
Belt - Inspect/Adjust/Replace ............................................................... 199
Brake Accumulator - Check ................................................................. 200
Braking System - Test .......................................................................... 202
Engine Air Filter Service Indicator - Inspect/Replace .......................... 235
Water Cleaning System (Pressurized) - Test ....................................... 318
Winch Drive Shaft Support Bearing - Lubricate ................................... 319
Winch Drive Shaft Universal Joint - Lubricate ..................................... 320
Initial 500 Hours (for New Systems, Relled Systems, and
Converted Systems)
Differential and Final Drive Oil Sample - Obtain .................................. 226
Hydraulic System Oil Sample - Obtain ................................................ 292
Transmission Oil Sample - Obtain ....................................................... 314
Winch Oil Sample - Obtain .................................................................. 332
188 SEBU7892-07
Maintenance Section
Every 500 Service Hours or 3 Months
Engine Crankcase Breather - Clean .................................................... 238
Engine Oil and Filter - Change ............................................................ 243
Fuel System Primary Filter (Water Separator) Element - Replace ...... 253
Fuel System Secondary Filter - Replace ............................................. 256
Fuel Tank Cap and Strainer - Clean .................................................... 259
Grapple Head Rotator (Continuous Rotation) - Lubricate .................... 273
Hydraulic System Oil Filter - Replace .................................................. 287
Winch Oil Filter - Replace .................................................................... 330
Engine Valve Lash - Check .................................................................. 248
Every 1000 Service Hours or 6 Months
Battery Hold-Down - Tighten ................................................................ 195
Rollover Protective Structure (ROPS) - Inspect ................................... 299
Transmission Oil - Change .................................................................. 306
Winch Drum Bearing - Lubricate .......................................................... 321
Winch Oil - Change .............................................................................. 322
Every 2000 Service Hours or 1 Year
Brake Discs - Check ............................................................................ 201
Cooling System Water Temperature Regulator - Replace ................... 218
Differential and Final Drive Oil - Change ............................................. 221
Hydraulic System Oil - Change ............................................................ 281
Hydraulic Tank Breaker Relief Valve - Clean ....................................... 294
Refrigerant Accumulator (With Desiccant) - Replace .......................... 298
Every Year
Every 3 Years After Date of Installation or Every 5 Years After
Date of Manufacture
Seat Belt - Replace .............................................................................. 301
Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add ................................... 211
SEBU7892-07 189
Maintenance Section
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ............................................ 207
190 SEBU7892-07
Maintenance Section
Air Cleaner Dust Valve - Clean/Inspect
i03239585
Air Cleaner Dust Valve - Clean/Inspect
SMCS Code: 1051-571-VL
1. Open the right side engine compartment.
2. The air lter housing is located on the right side of the machine. The
air cleaner dust valve is located below the air lter housing.
g01645293
Illustration 112
3. Check the air cleaner dust valve after every ten service hours or at the
end of each day. Actuate the valve by squeezing the lips of the valve
in order to remove any accumulated debris.
4. Close the engine compartment.
SEBU7892-07 191
Maintenance Section
Articulation Bearings - Lubricate
i02354839
Articulation Bearings - Lubricate
SMCS Code: 7057-086-BD; 7065-086-BD; 7066-086-BD
g01176013
Illustration 113
g01176016
Illustration 114
Place the steering frame lock into the LOCKED position before lubricating
the articulation bearings.
Wipe the ttings before you apply lubricant.
Apply lubricant through one tting on the upper hitch and through one
tting on the lower hitch.
192 SEBU7892-07
Maintenance Section
Axle Oscillation Bearings - Lubricate
There is a total of two ttings.
i02155797
Axle Oscillation Bearings - Lubricate
SMCS Code: 3278-086-BD
g01093280
Illustration 115
g01097093
Illustration 116
Open the engine access door on the right side of the machine.
Wipe off the ttings before you apply any lubricant.
Apply lubricant through two remote ttings (1) and (2) in order to grease
the bearings for the oscillating axle.
SEBU7892-07 193
Maintenance Section
Backup Alarm - Test
i02261741
Backup Alarm - Test
SMCS Code: 7406-081
1. Turn the engine start switch to the ON position. Do not start the engine.
2. Move the transmission direction control switch to the REVERSE
position.
3. The backup alarm should immediately sound. The backup alarm
will continue to sound until the transmission control is moved to the
NEUTRAL position or to the FORWARD position.
g00930005
Illustration 117
The backup alarm is mounted on the rear of the machine.
A three-position switch at the rear of the backup alarm regulates the
sound of the alarm (HIGH, LOW, and MEDIUM).
The alarm is set at the maximum sound level when the machine is
shipped from the factory. The setting should remain on HIGH unless the
job site requires a lower sound level.
194 SEBU7892-07
Maintenance Section
Battery - Clean
i02146969
Battery - Clean
SMCS Code: 1401-070
g01089244
Illustration 118
Before you can clean the battery terminals, you must open the radiator
grill. The radiator grill is hinged in two places in the front of the machine.
Use the following procedure to open the radiator grill.
Remove bolts (1) and (2) from the left side of the radiator grill. This will
allow you to open the grill.
g01089245
Illustration 119
SEBU7892-07 195
Maintenance Section
Battery - Recycle
Clean the battery terminals and the surfaces of the batteries with a clean
cloth. Coat the battery terminals with petroleum jelly. Make sure that the
battery cables are installed securely.
i02039199
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery. Return used batteries
to one of the following locations:
A battery supplier
An authorized battery collection facility
A recycling facility
i02467359
Battery Hold-Down - Tighten
SMCS Code: 7257-527
g01089245
Illustration 120
Before you can tighten the hold-downs for the batteries, you must open
the radiator grill. The radiator grill is hinged in two places in the front of
the machine. Use the following procedure to open the radiator grill:
196 SEBU7892-07
Maintenance Section
Battery Hold-Down - Tighten
g01089244
Illustration 121
Remove bolts (1) and (2) from the left side of the radiator grill. This will
Over time, the vibration of an operating machine can cause the battery
retainers to loosen. To help to prevent loose batteries and the possibility
of loose cable connections, tighten the three locknuts to a torque of
8 2 Nm (71 18 lb in).
Note: Do not operate the blade while the radiator door is open.
SEBU7892-07 197
Maintenance Section
Battery or Battery Cable - Inspect/Replace
i03657099
SMCS Code: 1401-040; 1401-510; 1402-040; 1402-510
Personal injury may occur from failure to properly
service the batteries.
Batteries give off ammable fumes that can ex-
plode. Electrolyte is an acid and can cause per-
sonal injury if it contacts the skin or eyes.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
proper jumper cable connections can cause an ex-
plosion.
Always wear protective glasses when working
with batteries.
1. Turn the engine start switch key OFF. Turn all of the switches OFF.
2. Turn the battery disconnect switch OFF. Remove the key.
3. Disconnect the negative battery cable from the disconnect switch.
Note: Do not allow the disconnected battery cable to contact the
disconnect switch.
4. Disconnect the negative battery cable at the battery.
5. Disconnect the positive battery cable at the battery.
6. Inspect the battery terminals for corrosion. Inspect the battery cables
for wear or damage.
7. Make any necessary repairs. If necessary, replace the battery cables
or the battery.
8. Connect the positive battery cable at the battery.
198 SEBU7892-07
Maintenance Section
9. Connect the negative battery cable at the battery.
10. Connect the battery cable at the battery disconnect switch.
11. Install the key and turn the battery disconnect switch ON.
Recycle the Battery
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following locations:
A battery supplier
An authorized battery collection facility
Recycling facility
SEBU7892-07 199
Maintenance Section
Belt - Inspect/Adjust/Replace
i02216078
Belt - Inspect/Adjust/Replace
SMCS Code: 1397-025; 1397-040; 1397-510
g01090698
Illustration 122
(1) Air conditioner compressor
(2) Alternator
(3) Belt tensioner
Your engine is equipped with a serpentine belt that drives the alternator
(2) and the air conditioner compressor (1).
For maximum engine performance and maximum utilization of your
engine, inspect the belt for wear and for cracking. Replace the belt, if
necessary.
Insert a ratchet with a square drive into the square hole that is located
in the belt tensioner (3). Rotate the belt tensioner (3) in order to relieve
tension on the belt. Remove the belt.
Install the new belt correctly, as shown. The correct tension will
automatically be applied. Be sure that the belt is fully seated on the
pulleys.
200 SEBU7892-07
Maintenance Section
Brake Accumulator - Check
i02173659
Brake Accumulator - Check
SMCS Code: 4263-535
1. Start the engine and run the engine at low idle.
g01101739
Illustration 123
Note: The brake oil pressure indicator light (1) should come on when the
engine is started. The indicator light should turn off when the braking
system reaches normal operating pressure.
2. Allow the engine to idle for at least 30 seconds in order to fully charge
the accumulators.
3. Turn the engine start switch to the OFF position.
4. Turn the engine start switch to the ON position but do not start the
engine.
5. Depress the service brake pedal for at least eight applications until the
indicator light comes on.
6. If the indicator light comes on after less than eight applications, check
the nitrogen precharge pressure of the brake accumulator. Consult
your Caterpillar dealer for the proper tools.
Note: To completely discharge the brake accumulator, depress the
service brake pedal for at least 30 applications.
SEBU7892-07 201
Maintenance Section
Brake Discs - Check
i02127658
Brake Discs - Check
SMCS Code: 4255-535
Personal injury or death can result if two persons
are not used in the following procedure.
NOTICE
products.
mandates.
Brake service life can vary greatly because of the different applications.
The following conditions can lead to premature brake failure:
The axle housing breather is damaged or plugged.
Excessive heat is generated.
Oil leaks at the yoke and the drive axles

A leak can also allow contamination from water and debris to occur. Water
and debris can enter the axle through the lip seal at the drive yoke. The
water and debris can mix with the oil. This water and debris can lead
to premature brake failure.
Inspect wear on the brake discs in order to determine the remaining life of
the brake discs.
202 SEBU7892-07
Maintenance Section
Braking System - Test
Reference: For the procedure, refer to the Testing and Adjusting service
manual of the braking system or consult your Caterpillar dealer.
i02391229
SMCS Code: 4251-081; 4267-081
Park the machine on a dry, level surface.
Check the area around the machine. Make sure that the machine is
clear of personnel and clear of obstacles.
Make sure that the steering frame lock is in the unlocked position.
Fasten the seat belt before you test the brakes.

The following tests are used to determine whether the braking system is
functional. These tests are not intended to measure the maximum brake
holding effort. The required brake holding effort for sustaining a machine
at a specic engine rpm varies from one machine to another machine.
The variations include differences in the engine setting, the power train
efciency, the brake holding ability, etc.
Service Brake Holding Ability Test
Personal injury can result if the machine moves
while testing.
If the machine begins to move during test, reduce
the engine speed immediately and engage the
parking brake.
This test is performed when the service brakes are engaged. If the
machine begins to move, compare the engine rpm to the engine rpm of a
prior test. This will indicate the amount of system deterioration.
1. Start the engine. Raise the decking blade slightly. Apply the service
brakes. Release the parking brake.
SEBU7892-07 203
Maintenance Section
2. Move the transmission control to THIRD SPEED FORWARD while
the service brakes are applied.
3. Gradually increase the engine speed to high idle. The machine should
not move.
4. Reduce the engine speed to low idle. Move the transmission direction
control to NEUTRAL. Engage the parking brake. Lower the decking
blade to the ground. Stop the engine.
If the machine moved during the test, consult your Caterpillar dealer for
a brake inspection. Make any necessary repairs before the machine is
returned to operation.
Parking Brake Holding Ability Test
Personal injury can result if the machine moves
while testing.
If the machine begins to move, reduce the engine
speed immediately and apply the service brake
pedal.
This test is performed when the parking brake is engaged. If the machine
begins to move, compare the engine rpm to the engine rpm of a prior test.
This will indicate the amount of system deterioration.
2. Move the transmission direction control to the NEUTRAL position.
3. Start the engine. Apply the service brake. Disengage the parking
brake. Press the upshift switch until the display shows 4N.
4. Engage the parking brake. Raise the decking blade slightly. Raise the
grapple slightly. Release the service brake.
5. Move the transmission direction control to FOURTH SPEED
FORWARD. Then move the transmission direction control back to
NEUTRAL position. Then move the transmission direction control back
to FOURTH SPEED FORWARD. The parking brake indicator should
come on.
204 SEBU7892-07
Maintenance Section
Cab Air Filter - Clean/Replace
Note: The transmission will be in FOURTH SPEED FORWARD.
Note: This will cause a level 3 warning, which will activate the alarm.
6. Gradually increase the engine speed to high idle. The machine should
not move.
7. Reduce the engine speed to low idle. Move the transmission direction
control to NEUTRAL. Lower the decking blade. Lower the grapple
to the ground. Stop the engine.
If the machine moved during the test, consult your Caterpillar dealer for
a brake inspection. Make any necessary repairs before the machine is
returned to operation.
i02408600
SMCS Code: 7342-070; 7342-510
Note: When you are operating the machine in dusty conditions, clean the
cab air lters more often.
g00584743
Illustration 124
1. Open the access door on the rear of the cab.
2. Remove the lter element.
3. Replace the lter element. The lter element is disposable.
SEBU7892-07 205
Maintenance Section
4. Close the access door on the rear of the cab.
g00584744
Illustration 125
5. Remove four bolts and the lter cover behind the seat inside the cab.
Remove the lter element.
6. Clean the lter element with pressure air or wash the lter elements
in warm water with a nonsudsing household detergent. Rinse the
lter element with clean water and allow the lter elements to air dry
thoroughly.
7. Install the lter element. Install the lter cover.
206 SEBU7892-07
Maintenance Section
Circuit Breakers - Reset
i02205736
Circuit Breakers - Reset
SMCS Code: 1420-529
g01097660
Illustration 126
The circuit breakers are located on the right side of the machine in the
engine compartment. Open the access panel on the right side of the
machine.
g01097663
Illustration 127
Press the reset button in order to reset circuit breaker (1). Circuit breaker
(1) is the breaker for the thermal starting aid. The thermal starting aid
is an air inlet heater.
SEBU7892-07 207
Maintenance Section
Cooling System Coolant (ELC) - Change
(2) is for the breaker for the alternator.
(3) is the main breaker for the electrical system.
(4) is for the unswitched circuits.
If the button remains depressed, the electrical circuit is functioning
properly. If the button does not remain depressed, check the appropriate
electrical circuit.
i02216952
SMCS Code: 1350-044
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specications reduces
the effectiveness of the coolant and shortens coolant
service life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specication for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
Failure to follow these recommendations can result in
shortened cooling system component life.
If an Extended Life Coolant was previously used, ush the cooling system
with clean water. No other cleaning agents are required. Use the following
procedure to change the cooling system coolant (ELC):
208 SEBU7892-07
Maintenance Section
g01118819
Illustration 128
1. Remove bolts (1) and the access door (2) on the top front part of the
machine.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
g01118820
Illustration 129
2. Slowly loosen the cooling system pressure cap (3) in order to relieve
system pressure.
SEBU7892-07 209
Maintenance Section
g01180997
Illustration 130
3. Remove the bottom guard at the front of the machine. Pull out the
drain hose through the opening.
4. Open the engine access door on the left side of the machine.
NOTICE
products.
mandates.
210 SEBU7892-07
Maintenance Section
g01204097
Illustration 131
5. Open the drain valve at the bottom of the radiator. Allow the coolant
to drain into a suitable container.
6. Flush the cooling system with clean water until the draining water is
clean. Close the drain valve.
7. Replace the water temperature regulator.
Reference: For the correct procedure, refer to Operation and
Maintenance Manual, Cooling System Water Temperature Regulator
- Replace.
8. Add the Extended Life Coolant (ELC).
Reference: For the capacity of the cooling system, refer to Operation
and Maintenance Manual, Capacities (Rell).
9. Start the engine. Run the engine without the cooling system pressure
cap until the water temperature regulator opens and the coolant level
stabilizes.
10. Stop the engine.
11. Install the cooling system pressure cap (3).
12. Install the access door (2) and the bolts (1).
13. Check the cooling system coolant level.
SEBU7892-07 211
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Reference: For the correct procedure, refer to Operation and
Maintenance Manual, Cooling System Coolant Level - Check.
14. Reinstall the bottom guard.
i02216953
Cooling System Coolant Extender (ELC) -
Add
SMCS Code: 1352-544-NL
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specications reduces
the effectiveness of the coolant and shortens coolant
service life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specication for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
Failure to follow these recommendations can result in
shortened cooling system component life.
When a Caterpillar Extended Life Coolant (ELC) is used, an Extender
must be added to the cooling system.
Use a coolant test kit in order to check the concentration of the coolant
solution.
212 SEBU7892-07
Maintenance Section
NOTICE
products.
mandates.
g01118819
Illustration 132
1. Remove bolts (1) and the access door (2) on the top front part of the
machine.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
SEBU7892-07 213
Maintenance Section
g01118820
Illustration 133
2. Slowly remove the cooling system pressure cap (3) in order to relieve
system pressure.
g00671272
Illustration 134
3. If necessary, drain enough coolant into a suitable container in order
to allow the addition of the Extender to the cooling system. Open
the engine access door on the left side of the machine. The coolant
drain valve is located at the bottom of the radiator on the left side of
the machine.
4. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of
the ller pipe.
5. Install the cooling system pressure cap. Close the access door.
214 SEBU7892-07
Maintenance Section
Cooling System Coolant Level - Check
i02164357
Cooling System Coolant Level - Check
SMCS Code: 1350-535-FLV
g01097780
Illustration 135
1. Open the engine access door (1).
g01097787
Illustration 136
2. Maintain the coolant level between the FULL and the LOW marks on
the coolant reservoir (3).
Note: If it is necessary to add coolant daily, check for leaks.
3. If more coolant is needed open engine access door (2).
SEBU7892-07 215
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
4. Open the cap on the top of the coolant reservoir (3) and add coolant
until the coolant level is between the FULL and LOW marks on the
coolant reservoir (3).
i02251419
Cooling System Coolant Sample (Level 1) -
Obtain
SMCS Code: 1350-008; 1395-008; 7542
Note: It is not necessary to obtain a Coolant Sample (Level 1) if
the cooling system is lled with Cat ELC (Extended Life Coolant).
Cooling systems that are lled with Cat ELC should have a Coolant
Sample (Level 2) that is obtained at the recommended interval that is
stated in the Maintenance Interval Schedule.
Note: Obtain a Coolant Sample (Level 1) if the cooling system is
lled with any other coolant instead of Cat ELC. This includes the
following types of coolants.
Commercial long life coolants that meet the Caterpillar Engine Coolant
Specication -1 (Caterpillar EC-1)
Cat Diesel Engine Antifreeze/Coolant (DEAC)
Commercial heavy-duty coolant/antifreeze

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for Level 2 Analysis.
216 SEBU7892-07
Maintenance Section
g01195489
Illustration 137
1. Obtain the sample of the coolant as close as possible to the
recommended sampling interval. In order to receive the full effect
of SOS analysis, you must establish a consistent trend of data.
In order to establish a pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for collecting samples can
be obtained from your Caterpillar dealer.
Use the following guidelines for proper sampling of the coolant:
Complete the information on the label for the sampling bottle before
you begin to take the samples.
Keep the unused sampling bottles stored in plastic bags.
Obtain coolant samples directly from the coolant sample port. You
should not obtain the samples from any other location.
Keep the lids on empty sampling bottles until you are ready to
collect the sample.
Place the sample in the mailing tube immediately after obtaining the
sample in order to avoid contamination.
Never collect samples from expansion bottles.
Never collect samples from the drain for a system.

2. Submit the sample for Level 1 analysis.
SEBU7892-07 217
Maintenance Section
For additional information about coolant analysis, refer to Special
Publication, SEBU6250, Caterpillar Machine Fluids Recommendations
or consult your Caterpillar dealer.
i02471396
Cooling System Coolant Sample (Level 2) -
Obtain
SMCS Code: 1350-008; 1395-008; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
g01195489
Illustration 138
1. Obtain the sample of the coolant as close as possible to the
recommended sampling interval. Supplies for collecting samples can
be obtained from your Caterpillar dealer.
Reference: Refer to Operation and Maintenance Manual, Cooling
System Coolant Sample (Level 1) - Obtain for the guidelines for
proper sampling of the coolant.
218 SEBU7892-07
Maintenance Section
Cooling System Water Temperature Regulator - Replace
2. Submit the sample for Level 2 analysis.
Reference: For additional information about coolant analysis, refer
to Special Publication, SEBU6250, Caterpillar Machine Fluids
Recommendations or consult your Caterpillar dealer.
i04333314
Cooling System Water Temperature
Regulator - Replace
SMCS Code: 1355-510; 1393-010
NOTICE
ing, adjusting, and repair of the product. Be prepared
to collect the uid with suitable containers before
opening any compartment or disassembling any com-
ponent containing uids.
Refer to Special Publication, NENG2500, Dealer Ser-
vice Tool Catalog for tools and supplies suitable to
collect and contain uids on Cat products.
mandates.
Replace the thermostat on a regular basis per the maintenance interval
schedule. This action reduces the chance of unscheduled downtime and
of problems with the cooling system.
A new thermostat should be installed after the cooling system has been
cleaned. Install the thermostat while the cooling system is drained
completely. Or install the thermostat while the cooling system coolant is
drained to a level that is below the thermostat housing.
NOTICE
Failure to replace the engine's thermostat on a regu-
larly scheduled basis could cause severe engine dam-
age.
SEBU7892-07 219
Maintenance Section
Note: If you are only installing a new thermostat, drain the cooling system
coolant to a level that is below the thermostat housing.
g01097799
Illustration 139
1. Open the right engine compartment.
g01097811
Illustration 140
The water temperature regulator housing is located on the front
right side of the engine.
Regulator housing (1). Water temperature regulator (2).
2. Remove the bolts from regulator housing (1). Remove the regulator
housing (1). Remove all of the used gasket from the regulator housing
(1).
3. Remove the water temperature regulator (2).
220 SEBU7892-07
Maintenance Section
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a thermostat.
Depending on load, failure to operate with a thermo-
stat could result in either an overheating or an over-
cooling condition.
NOTICE
If the thermostat is installed incorrectly, it will cause
the engine to overheat.
4. Install a new water temperature regulator (2).
5. Install a new gasket and the two bolts on regulator housing (1). Install
the thermostat housing on the engine cylinder head.
6. Close the right engine compartment.
7. Replace the coolant that was drained from the system. Refer to
Operation and Maintenance Manual, Capacities (Rell).
SEBU7892-07 221
Maintenance Section
Differential and Final Drive Oil - Change
i02338399
SMCS Code: 3278-044; 4011-044
NOTICE
products.
mandates.
Note: The axles on this machine are equipped with ecology drain valves.
g01167201
Illustration 141
Front Axle
1. Remove bolts (1) and plate (2).
222 SEBU7892-07
Maintenance Section
g01167202
Illustration 142
Front Axle
2. Remove the drain plug (3) near the bottom of the differential housing.
3. Attach a hose to a suitable drain adapter. Install the adapter in the
drain valve and allow the oil to drain into a suitable container.
4. Remove the adapter and the hose.
5. Remove the ecology drain valve. Inspect the magnet on the end for
metal particles.
6. Clean the metal particles from the magnet. Install the valve.
g01231823
Illustration 143
Rear Axle
SEBU7892-07 223
Maintenance Section
7. Remove the plate (5) from the rear bottom guard in order to access the
drain plug for the rear differential.
Note: The plate is slotted. Remove two bolts (4), and then loosen the
remaining two bolts. The plate will slide downward. Remove the plate
from the guard.
g01231828
Illustration 144
Rear Axle
8. Remove the drain plug (6) near the bottom of the differential housing.
Note: Remove the dipstick on the right side of the axle, in order to
improve the oil ow while the oil is draining.
9. Attach a hose to a suitable drain adapter. Install the adapter in the
drain valve and allow the oil to drain into a suitable container.
10. Remove the adapter from the drain valve.
11. Clean the drain plug and install the drain plug.
12. Install the plate to the guard underneath the machine.
224 SEBU7892-07
Maintenance Section
g01167247
Illustration 145
Front Axle (Right Side)
g01167248
Illustration 146
Rear Axle (Left Side)
13. Remove the dipstick/ll plugs on the right side of the axle. Add oil
through the opening.
Reference: Refer to Operation and Maintenance Manual, Capacities
(Rell) for the proper amount of oil.
14. Clean the plugs and install the plugs.
15. Check the oil level.
SEBU7892-07 225
Maintenance Section
Differential and Final Drive Oil Level - Check
Reference: Refer to Operation and Maintenance Manual, Differential
and Final Drive Oil Level - Check for the correct procedure.
i02338442
Differential and Final Drive Oil Level -
Check
SMCS Code: 3278-535-FLV; 4011-535-FLV
g01167247
Illustration 147
g01167248
Illustration 148
226 SEBU7892-07
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
1. Remove the dipstick/ll plug on the axle and wipe off the dipstick with a
clean cloth. This will ensure a more accurate measurement. Reinsert
the dipstick/ll plug.
Note: Make sure that the dipstick/ll plug is installed tightly before you
check the oil level. Otherwise, the oil level reading may be incorrect.
2. Remove the dipstick/ll plug again and check the oil level on the
dipstick. The oil level should be between the ADD mark and the
FULL mark. Add oil through the opening, if necessary.
3. Clean the plug and install the plug.
i02338440
Differential and Final Drive Oil Sample -
Obtain
SMCS Code: 3278-008; 4011-008; 4070-008; 7542
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
NOTICE
products.
mandates.
SEBU7892-07 227
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
Operate the machine for a few minutes before you obtain the uid sample.
This will thoroughly mix the uid for a more accurate sample.
g01167247
Illustration 149
g01167248
Illustration 150
The axles are not equipped with sampling valves. Obtaining a sample
of the differential and nal drive oil will require a vacuum pump or an
equivalent. Remove the dipstick/ll plug on the right side of each axle and
withdraw the oil through the ller opening.
Reference: For more information, refer to Special Publication,
SEBU6250, Caterpillar Machine Fluids Recommendations and Special
Publication, PEHP6001, How To Take A Good Oil Sample.
228 SEBU7892-07
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
i02468548
Engine Air Filter Primary Element -
Clean/Replace
SMCS Code: 1054-070-PY; 1054-510-PY
NOTICE
Service the air lter only with the engine stopped. En-
gine damage could result.
NOTICE
Always change the air lter based on the Air Filter Ser-
vice Indicator. Do not based service on the appear-
ance of the lter.
1. The air lter is located on the left side of the machine. Open the engine
access panel.
g01096335
Illustration 151
2. Remove cover (1).
3. Remove air lter element (2).
To avoid personal injury, always wear eye and face
protection when using pressurized air.
SEBU7892-07 229
Maintenance Section
4. Clean the inside of the air lter housing.
5. Install a clean primary air lter element. For more information, refer to
Cleaning the Primary Air Filter Element.
6. Install cover (1).
7. Close the engine access panel.
Cleaning the Primary Air Filter Element
NOTICE
Caterpillar recommends certied air lter cleaning ser-
vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufcient lter life.
Observe the following guidelines if you attempt to
clean the lter element:
Do not tap or strike the lter element in order to re-
move dust.
Do not wash the lter element.
Use low pressure compressed air in order to remove
the dust from the lter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air ow up the
pleats and down the pleats from the inside of the lter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air lters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
The element can be reused up to six times when the element is properly
cleaned and inspected after each use. When the primary air lter element
is cleaned, check for rips or tears in the lter material. The primary air lter
element should be replaced at least one time per year. This replacement
should be performed regardless of the number of cleanings.
230 SEBU7892-07
Maintenance Section
NOTICE
Do not clean the air lter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air lter element before cleaning. Inspect the
air lter element for damage to the seal, the gaskets, and the outer cover.
Discard any damaged air lter elements.
There are two common methods that are used to clean the primary air
lter element:
Pressurized air
Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean a primary air lter element that has
not been cleaned more than two times. Pressurized air will not remove
deposits of carbon and oil. Use ltered, dry air with a maximum pressure
of 207 kPa (30 psi).
g01096212
Illustration 152
Note: When the primary air lter element is cleaned, always begin with
the inside of the lter in order to force dirt particles toward the outside.
SEBU7892-07 231
Maintenance Section
Aim the hose so that the air ows inside the element along the length of
the lter in order to help prevent damage to the paper pleats. Do not
aim the stream of air directly at the primary air lter element. Dirt could
be forced further into the pleats.
Vacuum Cleaning
Vacuum cleaning is another method for cleaning a primary air lter element
which requires daily cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior to vacuum cleaning.
Vacuum cleaning will not remove deposits of carbon and oil.
Inspecting the Primary Air Filter Elements
g01096213
Illustration 153
Inspect the clean, dry primary air lter element. Use a 60 watt blue light in
a dark room or in a similar facility. Place the blue light in the primary air
lter element. Rotate the primary air lter element. Inspect the primary air
lter element for tears and/or holes. Inspect the primary air lter element
for light that may show through the lter material. If it is necessary in
order to conrm the result, compare the primary air lter element to a new
primary air lter element that has the same part number.
Do not use a primary air lter element that has any tears and/or holes in
the lter material. Do not use a primary air lter element with damaged
pleats, gaskets or seals. Discard damaged primary air lter elements.
232 SEBU7892-07
Maintenance Section
Engine Air Filter Secondary Element - Replace
Storing Primary Air Filter Elements
If a primary air lter element that passes inspection will not be used, the
primary air lter element can be stored for future use.
g01096217
Illustration 154
Do not use paint, a waterproof cover, or plastic as a protective covering
for storage. An airow restriction may result. To protect against dirt and
damage, wrap the primary air lter elements in Volatile Corrosion Inhibited
(VCI) paper.
Place the primary air lter element into a box for storage. For identication,
mark the outside of the box and mark the primary air lter element.
Include the following information:
Date of cleaning
Number of cleanings
Store the box in a dry location.
i02468628
Engine Air Filter Secondary Element -
Replace
SMCS Code: 1054-510-SE
1. The air lter is located on the left side of the machine. Open the engine
access panel.
SEBU7892-07 233
Maintenance Section
Engine Air Filter Secondary Element - Replace
g01096209
Illustration 155
2. Remove cover (1) from the air lter housing.
Note: If necessary, unclamp the strap on the air lter housing so that the
air lter housing can be moved for better access.
3. Remove primary element (2) from the air lter housing.
Reference: Refer to Operation and Maintenance Manual, Engine Air
Filter Primary Element - Clean/Replace.
g00882913
Illustration 156
4. Clean the inside of the air lter housing. Then, remove the secondary
element from the air lter housing.
234 SEBU7892-07
Maintenance Section
Engine Air Filter Service Indicator - Inspect
5. Install a new secondary element.
Note: A secondary element should never be cleaned. Always install a
new secondary element lter.
6. Install a clean primary element.
7. Install cover (1).
8. Make sure that the air lter housing is secure.
i02212237
Engine Air Filter Service Indicator - Inspect
SMCS Code: 7452
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
g01095177
Illustration 157
1. Open the engine access door on the LH side of the machine. The air
lter service indicator (1) is located in the engine compartment on the
LH side of the machine.
SEBU7892-07 235
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace
g01116980
Illustration 158
2. If the yellow piston in the air lter service indicator (1) enters the red
zone, service the air cleaner.
3. Check the condition of the air lter service indicator. If the air lter
service indicator is damaged, then replace the air lter service indicator.
4. Close the engine access door.
i02212375
Engine Air Filter Service Indicator -
Inspect/Replace
SMCS Code: 7452-040; 7452-510
The air lter service indicator is an important inexpensive instrument.
The indicator is used to show air lter restriction. The indicator can help
prevent unnecessary servicing. The indicator can also help avoid running
the engine with an excessively plugged air lter. The air lter service
indicator should be the method for determining the lter's life. A dirty lter
can still maintain the required performance. Only, proper use of the air
lter service indicator can determine if the lter can maintain the required
performance.
236 SEBU7892-07
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace
g01116980
Illustration 159
The air lter service indicator (1) is located in the engine compartment on
the LH side of the machine.
In normal dust conditions, the air lter service indicator should be tested
for proper operation at 250 hours. Also, the indicator should be tested
when the air lter elements are serviced. In order to check the operation
of the air lter service indicator, do the following checks.
Stop the engine. Check for ease of resetting the indicator. The indicator
should reset within a maximum of three pushes.
Check for movement of the yellow core when the engine is accelerated
to high idle. When the engine is accelerated to high idle, the yellow core
should latch near the highest position.
If the indicator will not easily reset replace the indicator. When the engine
is accelerated to high idle and the indicator does not latch at the highest
position, replace the indicator.
SEBU7892-07 237
Maintenance Section
Engine Air Precleaner - Clean
i03238081
Engine Air Precleaner - Clean
(If Equipped)
SMCS Code: 1055-070
g01645019
Illustration 160
The engine air precleaner is located on the top of the engine enclosure.
Empty the precleaner bowl whenever the dirt reaches the FULL mark.
g01645093
Illustration 161
1. Loosen wing nut (1) on cover (2). Remove the cover.
2. Empty precleaner bowl (3). Wash the precleaner bowl and the cover
with water.
238 SEBU7892-07
Maintenance Section
Engine Crankcase Breather - Clean
3. Install precleaner bowl (3) and cover (2). Tighten wing nut (1) nger
tight.
i02164487
SMCS Code: 1317
g01095177
Illustration 162
1. Open the access panel on the left side of the machine.
g01097860
Illustration 163
2. Loosen breather outlet hose clamp (3) and remove the hose from
breather cover (1).
SEBU7892-07 239
Maintenance Section
3. Remove bolt (2) that holds the breather assembly onto breather cover
(1). Remove the breather.
4. Check the condition of the cover seal. Replace the seal if the seal
is damaged.
5. Wash the breather cover and the element in a clean, nonammable
solvent. Shake the element dry or use pressure air.
6. Inspect the hose. Replace the hose if the hose is damaged.
7. Install the breather assembly, breather cover (1) and bolt (2).
8. Install the hose and breather outlet hose clamp (3).
240 SEBU7892-07
Maintenance Section
Engine Oil Level - Check
i02145934
Engine Oil Level - Check
NOTICE
Do not under ll or overll engine crankcase with oil.
Either condition can cause engine damage.
1. Open the engine access door on the left side of the machine.
g01089197
Illustration 164
2. Maintain the engine oil within the marks on the correct side of oil level
dipstick (1). Check the oil level while the engine is stopped.
g01089198
Illustration 165
3. Add oil through oil ller tube (2), if necessary.
SEBU7892-07 241
Maintenance Section
Engine Oil Sample - Obtain
i02127839
SMCS Code: 1348-008; 7542
jury.
skin.
NOTICE
products.
mandates.
242 SEBU7892-07
Maintenance Section
g01095579
Illustration 166
The sampling valve for the engine oil is located on the right side of the
engine on the engine oil lter base.
SEBU7892-07 243
Maintenance Section
Engine Oil and Filter - Change
i02340757
SMCS Code: 1318-510
NOTICE
products.
mandates.
g00698957
Illustration 167
535C and 545C
244 SEBU7892-07
Maintenance Section
g01096085
Illustration 168
535C and 545C
g01207506
Illustration 169
525C
The drain valve is located on the left side of the machine.
SEBU7892-07 245
Maintenance Section
g01230416
Illustration 170
525C
1. Remove the plug from the drain valve in order to drain the oil from
the engine.
2. Attach an elbow and hose to the drain valve. Open the drain valve and
allow the oil to drain into a suitable container.
3. Close the drain valve. Remove the elbow and the hose from the drain
valve.
4. Clean the plug and reinstall the plug in the drain valve.
g01096517
Illustration 171
246 SEBU7892-07
Maintenance Section
g01095949
Illustration 172
5. Open the front access door on the right side of the machine. Use a
strap type wrench to remove engine oil lter (1).
6. Clean the housing base. Make sure that the used gasket is completely
removed.
7. Apply a light coat of clean engine oil to the new gasket that is provided
with the new lter.
Note: There are rotation index marks on each engine oil lter that are
spaced 90 degrees or 1/4 of a turn from each other. When you tighten
engine oil lters, use the rotation marks as a guide.
8. Install the engine oil lter hand tight until the seal contacts the base.
Note: Note the position of the index marks on the lter in relation to a
xed point on the lter base.
9. Tighten the lter according to the instructions that are printed on the
lter. Use the index marks as a guide.
SEBU7892-07 247
Maintenance Section
g01095976
Illustration 173
g01095975
Illustration 174
10. Open the engine access door on the left side of the machine. Fill the
crankcase with oil through oil ller tube (3).
(Rell) for the proper amount of oil.
11. Start the engine and allow the oil to circulate. Check for leaks.
12. Check the engine oil level with oil dipstick (2).
Reference: Refer to Operation and Maintenance Manual, Engine Oil
Level - Check for the correct procedure.
13. If the oil level is correct, close the engine access doors.
248 SEBU7892-07
Maintenance Section
Engine Valve Lash - Check
i01181536
Engine Valve Lash - Check
SMCS Code: 1105-535
For the correct procedure, refer to the appropriate Service Manual module
for your machine's engine or consult your Caterpillar dealer.
Note: A qualied mechanic should adjust the engine valve lash because
special tools and training are required.
SEBU7892-07 249
Maintenance Section
Ether Starting Aid Cylinder - Replace
i02391361
(If Equipped)
SMCS Code: 1456-510-CD
Breathing ether vapors or repeated contact of
ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid res.
Do not store replacement ether cylinders in living
areas or in the operator's compartment.
Do not store ether cylinders in direct sunlight or
at temperatures above 49 C (120 F).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.
Keep ether cylinders out of the reach of unautho-
rized personnel.
To avoid possible injury, be sure the brakes are ap-
plied and all controls are in Hold or Neutral when
starting the engine.
NOTICE
Do not manually apply the ether into the intake. The
heating element will incur damage if ether is sprayed
directly into the intake.
250 SEBU7892-07
Maintenance Section
g01095177
Illustration 175
1. Open the access panel on the left side of the engine enclosure.
g01225878
Illustration 176
2. Loosen cylinder retaining clamp (1). Unscrew ether starting aid cylinder
(2).
3. Remove the ether starting aid cylinder and the used gasket. Install the
new gasket that is provided with the new ether starting aid cylinder.
4. Install the new ether starting aid cylinder. Tighten the ether starting aid
cylinder and the cylinder retaining clamp by hand.
5. Install the access panel.
SEBU7892-07 251
Maintenance Section
Fairlead Rollers - Lubricate
i02755946
Fairlead Rollers - Lubricate
SMCS Code: 6306-086
Wipe off all ttings before any lubricant is applied.
g00586884
Illustration 177
On the cable skidder, apply lubricant through the tting on the end of each
fairlead roller. There is a total of four ttings.
i02456550
Fuel System - Prime
SMCS Code: 1258-548
1. Turn the engine start switch to the ON position. Leave the engine start
switch in the ON position for two minutes.
2. Attempt to start the engine. If the engine starts and the engine runs
rough or the engine misres, operate at low idle until the engine is
running smoothly. If the engine cannot be started, or if the engine
continues to misre or smoke, repeat step 1.
Note: The electric fuel pump turns on when the key is turned on. There is
not a separate priming pump.
252 SEBU7892-07
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
i02217093
Fuel System Primary Filter (Water
Separator) - Drain
SMCS Code: 1263-543
NOTICE
products.
mandates.
g01118968
Illustration 178
1. Open the engine access door on the left side of the machine. The
primary fuel lter and water separator (1) is located on the left side
of the machine.
2. Loosen drain valve (2) on the bottom of the water separator bowl.
Allow the water and the sediment to drain into a suitable container.
SEBU7892-07 253
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
3. Tighten drain valve (2).
Note: The water separator is under suction during normal engine
operation. Tightening the drain valve prevents air leakage into the fuel
system.
4. If the engine fails to start or if there is a power loss, change the fuel
lter.
Reference: Refer to Operation and Maintenance Manual, Fuel
System Primary Filter (Water Separator) Element - Replace for the
correct procedure.
i02217164
Fuel System Primary Filter (Water
Separator) Element - Replace
SMCS Code: 1260-510; 1263-510-FQ
Personal injury or death can result from a re.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a re.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel lters.
254 SEBU7892-07
Maintenance Section
NOTICE
products.
mandates.
NOTICE
Do not ll fuel lters with fuel before installing them.
The fuel will not be ltered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
g01119024
Illustration 179
1. Open the engine access door on the left side of the machine. The
primary fuel lter (1) is a spin-on type lter.
SEBU7892-07 255
Maintenance Section
2. Install a hose or a tube onto drain valve (3). Open drain valve (3) on
the bottom of water separator bowl (2). Allow the water and the fuel
to drain into a suitable container.
3. Close drain valve (3). Remove the tube or the hose from the drain
valve.
4. Remove primary fuel lter (1) from the lter base.
5. Remove water separator bowl (2) from primary fuel lter (1). Inspect
the fuel lter element for debris by cutting the lter open. Discard the
used fuel lter element properly. Clean water separator bowl (2).
Note: The water separator bowl is reusable. Do not discard water
separator bowl (2).
6. Inspect the gasket on water separator bowl (2). Replace the gasket, if
necessary.
7. Lubricate the gasket with clean diesel fuel or with engine oil. Place the
gasket in water separator bowl (2).
8. Install water separator bowl (2) onto the new primary fuel lter (1) by
hand until water separator bowl (2) is snug. Do not use tools to tighten
water separator bowl (2).
Note: Remove the cap from the new primary fuel lter before you install
the water separator bowl. Discard the cap.
9. Clean the lter mounting base. Make sure that all of the used seal is
removed from the lter mounting base.
10. Apply a thin coat of diesel fuel or engine oil to the seal on new primary
fuel lter (1).
11. Install the new fuel lter by hand. When the seal contacts the lter
base, tighten primary fuel lter (1) by an additional 3/4 turn. This will
tighten primary fuel lter (1) sufciently. Do not use tools to tighten
primary fuel lter (1).
12. Prime the fuel system in order to ll the water separator element with
fuel.
System - Prime for the correct procedure.
256 SEBU7892-07
Maintenance Section
Fuel System Secondary Filter - Replace
i02252246
Personal injury or death can result from a re.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a re.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel lters.
NOTICE
products.
mandates.
NOTICE
Do not ll fuel lters with fuel before installing them.
The fuel will not be ltered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
SEBU7892-07 257
Maintenance Section
g01098027
Illustration 180
1. Open the left front engine access door. The secondary fuel lter is
located on the left side of the engine.
g01099064
Illustration 181
2. Use a strap type wrench to remove the secondary fuel lter.
3. Clean the lter mounting base. Make sure that all of the used seal is
completely removed.
258 SEBU7892-07
Maintenance Section
g01099018
Illustration 182
4. Install the new lter element by hand. After the gasket contacts the lter
mounting base, tighten the lter elements by an additional 3/4 turn.
5. Prime the fuel system.
System - Prime for the correct procedure.
SEBU7892-07 259
Maintenance Section
Fuel Tank Cap and Strainer - Clean
i02145893
Fuel Tank Cap and Strainer - Clean
SMCS Code: 1273-070-Z2; 1273-070-STR
The fuel tank cap is located on the right side of the machine.
g00702968
Illustration 183
1. Lift lever (5) and turn the lever counterclockwise until the lever stops.
Lift the cap straight up in order to remove the cap.
2. Inspect seal (4) for damage. Replace the seal, if necessary.
3. Remove screws (1), lter assembly (2), valve (3) and the gaskets.
4. Wash the fuel tank cap in a clean, nonammable solvent.
5. Install the new cap lter kit. Install the components in reverse order.
6. Remove the strainer from the tank ller opening. Wash the strainer in a
clean, nonammable solvent. Install the strainer.
7. Install the fuel tank cap.
260 SEBU7892-07
Maintenance Section
Fuel Tank Water and Sediment - Drain
i01408020
Fuel Tank Water and Sediment - Drain
SMCS Code: 1273-543-M&S
g00741044
Illustration 184
The fuel tank drain valve is located in the articulation joint near the drive
shaft.
Note: For better access, turn the machine all the way to the right.
g00587858
Illustration 185
1. Pull the attached hose out of the opening in the hitch. Remove the plug
from the end of the hose.
SEBU7892-07 261
Maintenance Section
Fuses - Replace
g00585242
Illustration 186
2. Open the drain valve. Allow the water and the sediment to drain into
a suitable container for disposal.
3. Close the drain valve. Install the plug in the end of the hose and place
the hose back into the rear frame.
i02206402
Fuses - Replace
SMCS Code: 1417-510
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
Fuses Fuses protect the electrical system from damage that
is caused by overloaded circuits. Replace the fuse if the element
separates. If the element of a new fuse separates, check the
circuit. Repair the circuit, if necessary.
262 SEBU7892-07
Maintenance Section
Fuses - Replace
g01097733
Illustration 187
The fuse panel is located on the left side of the cab.
SEBU7892-07 263
Maintenance Section
Fuses - Replace
g01099172
Illustration 188
(1) Seat Adjustment (Height) 15 Amp
(2) Voltage Converter (24 Volt Power Source) 15 Amp
(3) Defroster Fan 15 Amp
(4) Rear Grapple Lights 15 Amp
264 SEBU7892-07
Maintenance Section
Fuses - Replace
(5) Front Working Lights 15 Amp
(6) Rear Working Lights 15 Amp
(7) Engine Start Switch 10 Amp
(8) Flood Lamp 15 Amp
(9) Electronic Gauges 10 Amp
(10) Engine 15 Amp
(11) Fan Motor 15 Amp
(12) Front Window Wiper and Washer 15 Amp
(13) Engine 10 Amp
(14) Transmission 15 Amp
SEBU7892-07 265
Maintenance Section
Fuses - Replace
(15) Electronic Gauges 10 Amp
(16) Spare Fuse 10 Amp
(17) Interior Lights 10 Amp
(18) Voltage Converter (24 Volt Power Source) 15 Amp
(19) Horn 10 Amp
(20) Spare Fuse 15 Amp
266 SEBU7892-07
Maintenance Section
Grapple Boom and Arch (Dual Function) - Lubricate
i02461972
Grapple Boom and Arch (Dual Function) -
Lubricate
SMCS Code: 6302-086; 6308-086
g01228503
Illustration 189
Apply lubricant through six ttings on each side of the grapple arch. There
is a total of twelve ttings.
SEBU7892-07 267
Maintenance Section
Grapple Boom and Arch (Single Function) - Lubricate
i02462104
Grapple Boom and Arch (Single Function)
- Lubricate
SMCS Code: 6302-086; 6308-086
g01228518
Illustration 190
Apply lubricant through three ttings on each side of the grapple arch.
There is a total of six ttings.
268 SEBU7892-07
Maintenance Section
Grapple Head (Bunching) - Lubricate
i02462202
Grapple Head (Bunching) - Lubricate
SMCS Code: 6307-086
g00954439
Illustration 191
Apply lubricant through seven ttings on the grapple head.
i01906178
Grapple Head (Continuous Rotation) -
Lubricate
SMCS Code: 6307-086
S/N: 5351-Up
S/N: 5451-Up
SEBU7892-07 269
Maintenance Section
Grapple Head (Continuous Rotation) - Lubricate
g00954439
Illustration 192
Apply lubricant through six ttings on the grapple head.
270 SEBU7892-07
Maintenance Section
g00956334
Illustration 193
Grapple Rotator
Apply lubricant through two ttings on the grapple rotator.
SEBU7892-07 271
Maintenance Section
g00992708
Illustration 194
Grapple Snubber
Apply 5P-0960 Molybdenum Grease through seven ttings on the
grapple snubber.
Note: Apply 5P-0960 Molybdenum Grease to the clutch housing until
grease comes out of the reversed grease zerk.
272 SEBU7892-07
Maintenance Section
Grapple Head (Sorting) - Lubricate
i02462227
Grapple Head (Sorting) - Lubricate
SMCS Code: 6307-086
g00954439
Illustration 195
Apply lubricant through seven ttings on the grapple head.
SEBU7892-07 273
Maintenance Section
Grapple Head Rotator (Continuous Rotation) - Lubricate
i01878169
Grapple Head Rotator (Continuous
Rotation) - Lubricate
SMCS Code: 6307-086
g00955879
Illustration 196
Remove cover plate (1) in order to access tting (2). Fill the rotator with
lubricant through tting (2).
274 SEBU7892-07
Maintenance Section
Grapple Snubber - Inspect/Adjust
i01906192
SMCS Code: 6307-025; 6307-040
If the swing dampener (snubber) is not properly
tightened, the grapple can swing freely. This could
cause personal injury to nearby personnel.
Make sure that the area around the grapple is clear
of personnel before you check the swing dampen-
er (snubber).
In order to achieve the longest life of the components for the snubber, the
operation of the snubber should be monitored constantly. The adjustment
should be tight enough to avoid damaging contact with the arch or the
boom while the grapple arms (tongs) are empty.
g00956113
Illustration 197
SEBU7892-07 275
Maintenance Section
g00956038
Illustration 198
View A-A
Upper Joint Assembly
(1) Bolt
(2) Cap
(3) Shims
(4) Reaction plate
(5) Friction plate
276 SEBU7892-07
Maintenance Section
g00956037
Illustration 199
View B-B
Lower Joint Assembly
(1) Bolt
(2) Cap
(3) Shims
(4) Reaction plate
(5) Friction plate
The amount of drag of the snubber is set with shims (3). In order to
increase the drag of the snubber, remove shims. In order to decrease
drag of the snubber, add shims.
1. To adjust the snubber, loosen bolts (1) from cap (2).
Note: Each shim goes halfway around cap (2). Therefore, the shims are
removed in pairs. The machine is shipped with 5 shim thicknesses.
2. Add or remove shims until the desired swing of the grapple is achieved.
Use the shims, as needed.
(3) 203-3956 Shim ....................................... 1.21 mm (.048 inch)
SEBU7892-07 277
Maintenance Section
3. Replace the reaction plates and the friction plates if the drag of the
snubber is not high enough.
Installation Procedure
Upper Joint Assembly
g00956218
Illustration 200
(6) 204-9606 Shim
(7) 204-9607 Shim
(8) Pin
278 SEBU7892-07
Maintenance Section
g00956219
Illustration 201
View A-A
(1) Bolt
(2) Cap
(3) 203-3956 Shim
(4) Reaction plate
(5) Friction plate
(9) O-ring seal
(10) Bushing
(11) Lip seal
(12) Pin
(13) Spring
(14) Retaining ring
(15) Bushing
1. Install one reaction plate (4) and one friction plate (5).
Note: All friction plates should be dipped in 8T-9579 Oil for ve minutes
before assembly.
Note: A total of ve friction plates are required for proper operation.
2. Insert the pin (12) with retaining ring (14) until the retaining ring
touches the rst friction plate (5).
3. Install the rest of the parts.
SEBU7892-07 279
Maintenance Section
Note: Install cap (2) with the reversed grease zerk at the top.
4. Retract the pin (8) far enough in order to slide shims (6,7) between the
lug edge and the clevis end. Insert the shims and assemble pin (8).
(6) 204-9606 Shim ....................................... 2.29 mm (.090 inch)
(7) 204-9607 Shim ....................................... 1.52 mm (.060 inch)
5. Apply 5P-0960 Molybdenum Grease on the bearings and the clutch
housing through the grease ttings that are on the bearing. Apply the
grease to the clutch housing until grease comes out of the reversed
grease zerk.
6. Repeat Step 5 again after one hour of operation after the initial ll.
Lower Joint Assembly
g00956278
Illustration 202
280 SEBU7892-07
Maintenance Section
g00992715
Illustration 203
View B-B
(1) Bolt
(2) Cap
(3) 203-3956 Shim
(4) Reaction plate
(5) Friction plate
(6) 204-9606 Shim
(7) 204-9607 Shim
(8) Pin
(9) O-ring seal
(10) Bushing
(11) Lip seal
(12) Pin
(13) Spring
(14) Retaining ring
1. Install pin (8).
2. Install one reaction plate (4) and one friction plate (5).
Note: All friction plates should be dipped in 8T-9579 Oil for ve minutes
before assembly.
Note: A total of ve friction plates are required for proper operation.
SEBU7892-07 281
Maintenance Section
Hydraulic System Oil - Change
3. Insert the pin (12) with retaining ring (14) to the back of the clutch
housing.
4. Insert shims (6,7) at the back of the clutch housing lug and pass pin
(12) through the shims until retaining ring (14) touches the rst friction
plate (5).
(6) 204-9606 Shim ....................................... 2.29 mm (.090 inch)
(7) 204-9607 Shim ....................................... 1.52 mm (.060 inch)
5. Install the rest of the parts.
Note: Install cap (2) with the reversed grease zerk at the top.
6. Apply 5P-0960 Molybdenum Grease on the bearings and the clutch
housing through the grease ttings that are on the bearing. Apply the
grease to the clutch housing until grease comes out of the reversed
grease zerk.
7. Repeat Step 6 again after one hour of operation after the initial ll.
i02156191
SMCS Code: 5056-044
sure and hot oil.
system.
Make sure all of the attachments have been low-
ered, oil is cool before removing any components
or lines. Remove the oil ller cap only when the en-
gine is stopped, and the ller cap is cool enough
to touch with your bare hand.
282 SEBU7892-07
Maintenance Section
NOTICE
products.
mandates.
When you change the hydraulic oil, be sure to clean the cover for the lter
and the hydraulic ller cap, before you remove these items. Be sure to
plug or cap any lines or hoses that are disconnected. This will prevent
foreign material from contaminating the hydraulic system.
Note: The hydraulic tank supplies oil to the decking blade, to the grapple,
to the differential lock, to the brakes and to the steering system.
1. Operate the machine in order to warm the oil. Then, park the machine
on a level surface.
2. Move the transmission direction switch to the NEUTRAL position.
3. Lower all attachments to the ground. Apply the parking brake and
stop the engine.
SEBU7892-07 283
Maintenance Section
g01093673
Illustration 204
4. Open the access door on the top of the engine enclosure.
g01093664
Illustration 205
5. Slowly loosen the hydraulic tank ller cap (1) in order to release the
pressure from the hydraulic tank (2).
284 SEBU7892-07
Maintenance Section
g01095177
Illustration 206
6. Open the access door on the left side of the engine enclosure.
g01093612
Illustration 207
7. Remove the bolt and the retainer (3) so that hose (5) can be moved.
SEBU7892-07 285
Maintenance Section
g01095187
Illustration 208
8. Route hose (5) through door (6).
9. Remove plug (4) from hose (5).
g01093617
Illustration 209
10. Open drain valve (7). Allow the oil to drain into a suitable container.
11. Close drain valve (7).
12. Install plug (4) into hose (5).
13. Return hose (5) to the original position and install the bolt and the
retainer (3).
286 SEBU7892-07
Maintenance Section
14. Replace the hydraulic oil lters.
Reference: Refer to Operation and Maintenance Manual, Hydraulic
System Oil Filter - Replace for the correct procedure.
15. Remove the strainer from the hydraulic oil ller tube. Clean the
strainer and install the strainer.
16. Fill the hydraulic tank with oil.
(Rell) for the correct amount of oil.
17. Inspect the ller cap gasket. If the gasket is damaged, replace the
gasket.
18. Install the hydraulic tank ller cap.
19. Start the engine and check for leaks. Check the hydraulic oil level.
System Oil Level - Check for the correct procedure.
Note: The oil must be free of bubbles. If bubbles are present in the oil, air
is entering the hydraulic system. Inspect the suction line for leaks.
SEBU7892-07 287
Maintenance Section
Hydraulic System Oil Filter - Replace
i02156638
SMCS Code: 5056-510-FI; 5068-510
sure and hot oil.
system.
Make sure all of the attachments have been low-
ered, oil is cool before removing any components
or lines. Remove the oil ller cap only when the en-
gine is stopped, and the ller cap is cool enough
to touch with your bare hand.
NOTICE
products.
mandates.
When you change the hydraulic lters, be sure to clean the cover for the
lter and the hydraulic ller cap, before you remove these items. Be sure
to plug or cap any lines or hoses that are disconnected. This will prevent
foreign material from contaminating the hydraulic system.
288 SEBU7892-07
Maintenance Section
1. Park the machine on a level surface. Lower all attachments to the
ground. Move the transmission direction switch to the NEUTRAL
position. Apply the parking brake and stop the engine.
g01094632
Illustration 210
2. Open the access door on the top of the engine enclosure and open the
access door on the right side of the engine enclosure.
g01095207
Illustration 211
3. Slowly loosen hydraulic tank ller cap (1) in order to release the
pressure from the tank.
SEBU7892-07 289
Maintenance Section
Hydraulic System Oil Level - Check
4. Use an oil lter strap wrench to remove the hydraulic oil lters (2) and
(3). Dispose of the used lters properly.
5. Clean both of the lter bases. Make sure that all of the used gaskets
are removed.
6. Apply a light coat of clean hydraulic oil on the new gaskets.
7. Install the new hydraulic oil lters (2) and (3). When the lter contacts
the lter base, tighten the lter by an additional 3/4 turn.
8. Tighten hydraulic tank ller cap (1).
9. Start the engine and operate the brakes, the steering and the
attachments. Check the hydraulic oil level.
System Oil Level - Check for the correct procedure.
10. Inspect the lters for leaks.
11. Close the access doors.
i02392258
g01196941
Illustration 212
290 SEBU7892-07
Maintenance Section
1. Lower the decking blade to the ground. Move the grapple tongs
together so the tips of the grapple touch each other. Lower the grapple
to the ground. This position is critical in order to obtain a proper reading
of the hydraulic oil level. Cable machines have only a decking blade
that is hydraulic. Therefore, the decking blade is the only component
that must be on the ground.
g01094632
Illustration 213
2. Open the access door on the top of the engine enclosure and open the
access door on the right side of the engine enclosure.
g01095207
Illustration 214
SEBU7892-07 291
Maintenance Section
3. Slowly loosen the hydraulic ller cap (1) in order to release the
pressure from the tank.
g01095177
Illustration 215
4. Open the access door on the left side of the machine.
5. Check the oil level sight gauge. The oil level should be visible through
the sight gauge.
6. If the oil level is low, open the access door on the top of the engine
enclosure.
g01093664
Illustration 216
7. Slowly loosen the hydraulic cap (1) in order to release the pressure
from the tank (2).
292 SEBU7892-07
Maintenance Section
Hydraulic System Oil Sample - Obtain
8. Remove the hydraulic tank ller cap and add oil, if necessary.
9. Clean the ller cap and install the ller cap. Close the access door.
i02127840
SMCS Code: 5050-008; 5056-008; 7542
jury.
skin.
NOTICE
products.
mandates.
SEBU7892-07 293
Maintenance Section
g01088315
Illustration 217
The hydraulic system is equipped with a sampling valve. The sampling
valve (1) is located on the base of the hydraulic oil lter.
294 SEBU7892-07
Maintenance Section
Hydraulic Tank Breaker Relief Valve - Clean
i02156875
Hydraulic Tank Breaker Relief Valve - Clean
SMCS Code: 5118-070
g01094645
Illustration 218
1. Open the access door on the top of the engine enclosure.
g01093924
Illustration 219
2. Slowly loosen the hydraulic tank ller cap (1) in order to relieve the
pressure in the hydraulic tank (3). Tighten the hydraulic tank ller cap
(1). Remove the hydraulic tank breaker relief valve (2).
SEBU7892-07 295
Maintenance Section
Oil Filter - Inspect
3. Clean the hydraulic tank breaker relief valve (2) in a clean,
nonammable solvent. Shake the relief valve (2) dry or use pressure
air.
4. Install the hydraulic tank breaker relief valve (2).
5. Close the access door.
i02161948
Oil Filter - Inspect
SMCS Code: 1308-507; 3067-507; 5068-507; 5177-507
Inspect a Used Filter for Debris
g01096266
Illustration 220
The element is shown with debris.
Use a lter cutter to cut the lter element open. Spread apart the pleats
and inspect the element for metal and for other debris. An excessive
amount of debris in the lter element can indicate a possible failure.
If metals are found in the lter element, a magnet can be used to
differentiate between ferrous metals and nonferrous metals.
Ferrous metals can indicate wear on steel parts and on cast iron parts.
Nonferrous metals can indicate wear on the aluminum parts of the engine
such as main bearings, rod bearings, or turbocharger bearings.
296 SEBU7892-07
Maintenance Section
Radiator Core - Clean
Small amounts of debris may be found in the lter element. This could
be caused by friction and by normal wear. Consult your Caterpillar dealer
in order to arrange for further analysis if an excessive amount of debris
is found.
Using an oil lter element that is not recommended by Caterpillar can
result in severe engine damage to engine bearings, to the crankshaft,
and to other parts. This can result in larger particles in unltered oil.
The particles could enter the lubricating system and the particles could
cause damage.
i02469270
SMCS Code: 1353-070-KO
Before you can clean the radiator, you must open the radiator grill. The
radiator grill is hinged in two places.
g01089244
Illustration 221
Radiator Grill
1. Remove bolts (1) and (2) from the left side of the radiator grill. This will
SEBU7892-07 297
Maintenance Section
g01096285
Illustration 222
2. Use compressed air, high pressure water, or steam in order to remove
dust and other debris from the radiator core. However, the use of
compressed air is preferred.
g01231388
Illustration 223
3. Remove the cover plates on the left side of the radiator and the right
side of the radiator in order to expose the access hole for the radiator.
The holes will allow easier access in order to clean the radiator.
Reference: For more information on cleaning the radiator core, refer to
Special Publication, SEBD0518, Know Your Cooling System.
298 SEBU7892-07
Maintenance Section
Refrigerant Accumulator (With Desiccant) - Replace
i01701441
Refrigerant Accumulator (With Desiccant)
- Replace
SMCS Code: 7322-510-DSS
Reference: For the correct procedure, refer to Air Conditioning and
Heating Service Manual, SENR5664 or the Disassembly and Assembly
Manual for your machine.
Note: A qualied mechanic should replace the components of the
refrigerant system since special tooling and training are required.
SEBU7892-07 299
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
i02252267
Rollover Protective Structure (ROPS) -
Inspect
SMCS Code: 7323-040; 7325-040
g01133939
Illustration 224
Remove the access panels from both sides of the machine. Tighten the
four cab mounting bolts to a torque of 850 100 Nm (625 75 lb ft).
Replace the mounting supports if the ROPS rattles during machine
operation.
Inspect the ROPS for bolts that are loose, damaged or missing. Replace
any bolts that are damaged or missing with original equipment parts only.
Note: Apply oil to all bolt threads before installation. Failure to apply oil
may result in improper bolt torque.
Do not repair the ROPS by welding reinforcement plates to the ROPS.
Consult your Caterpillar dealer for repair of cracks in welds, in castings, or
in any metal section on the ROPS.
300 SEBU7892-07
Maintenance Section
Seat Belt - Inspect
i02429612
Seat Belt - Inspect
SMCS Code: 7327-040
Always check the condition of the seat belt and the condition of the seat
belt mounting hardware before you operate the machine. Replace any
parts that are damaged or worn before you operate the machine.
g00932801
Illustration 225
Typical example
Check the seat belt mounting hardware (1) for wear or for damage.
Replace any mounting hardware that is worn or damaged. Make sure
that the mounting bolts are tight.
Check buckle (2) for wear or for damage. If the buckle is worn or
damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or frayed. Replace the
seat belt if the seat belt is worn or frayed.
Consult your authorized dealer for the replacement of the seat belt and
mounting hardware.
Note: Within three years of the date of installation or within ve years of
the date of manufacture, replace the seat belt. Replace the seat belt at
the date which occurs rst. A date label for determining the age of the
seat belt is attached to the seat belt, the seat belt buckle, and the seat
belt retractor.
SEBU7892-07 301
Maintenance Section
Seat Belt - Replace
If your machine is equipped with a seat belt extension, also perform this
inspection procedure for the seat belt extension.
i04270251
Seat Belt - Replace
SMCS Code: 7327-510
Within 3 years of the date of installation or within 5 years of the date of
manufacture, Caterpillar recommends replacing the seat belt. Replace
the seat belt at the date which occurs rst. A date label for determining
the age of the seat belt is attached to the seat belt, the seat belt buckle,
and the seat belt retractor.
g01152685
Illustration 226
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended Web)
(4) Date of manufacture (underside) (buckle)
Consult your Cat dealer for the replacement of the seat belt and the
mounting hardware.
If your machine is equipped with a seat belt extension, also perform this
replacement procedure for the seat belt extension.
302 SEBU7892-07
Maintenance Section
Secondary Steering - Test
i02468987
Secondary Steering - Test
Use the following procedure to test the secondary steering system.
1. Park the machine on a hard level surface. Lower the implements and
shut off the engine. Leave the engine start switch in the ON position.
g01136250
Illustration 227
2. Press and hold the top of the test switch for the secondary steering.
This will activate the secondary steering motor.
3. Turn the steering wheel fully from left to right. If the machine responds
to the steering input the secondary steering is operating. If the machine
does not respond to the steering input the secondary steering is not
working.
4. Release the test switch for the secondary steering. Spring force will
return the test switch for the secondary steering to the OFF position.
This will deactivate the secondary steering motor. Do not run the
secondary steering motor longer than 12 seconds while you are testing
the secondary steering.
NOTICE
Do not operate the machine if the secondary steering
is not operating correctly.
SEBU7892-07 303
Maintenance Section
Steering Cylinder Bearings - Lubricate
i02252283
1. Wipe off the ttings before you apply lubricant. There is a total of four
ttings.
g00725258
Illustration 228
2. Apply lubricant through the tting at the rod end of each steering
cylinder.
g01093280
Illustration 229
3. Open the engine access door on right side of the machine.
304 SEBU7892-07
Maintenance Section
g01133957
Illustration 230
4. Apply lubricant through the remote ttings (1) and (2) for the head end
of each steering cylinder.
5. Close the engine access door on right side of the machine.
SEBU7892-07 305
Maintenance Section
Tire Ination - Check
i01110218
Tire Ination - Check
SMCS Code: 4203-535-AI
g00585803
Illustration 231
Remove the valve caps on each tire. Measure the tire pressure on each
tire. Inate the tires, if necessary.
Reference: Refer to the Tire Ination Information section of the
Operation and Maintenance Manual for more information or consult your
Caterpillar dealer.
306 SEBU7892-07
Maintenance Section
Transmission Oil - Change
i02786556
SMCS Code: 3030-044
NOTICE
Dealer Service Tool Catalog for tools and supplies
products.
mandates.
1. Operate the engine in order to warm the oil. Park the machine on a
level surface and lower the decking blade to the ground with slight
down pressure.
2. Engage the parking brake. Stop the engine.
3. Remove the access plate underneath the machine.
4. Remove the transmission drain plug at the bottom of the transmission.
Drain the oil into a suitable container.
Note: The transmission is equipped with an ecology drain valve.
5. Clean the drain plug and install the drain plug. Install the access plate.
6. Remove the transmission guards. The rst guard weighs approximately
45 kg (95 lb). The second guard weighs approximately 20 kg (45 lb).
SEBU7892-07 307
Maintenance Section
g00701384
Illustration 232
g00586353
Illustration 233
7. Remove the magnetic strainer cover.
Note: The rst photo shows a machine that is equipped with a secondary
steering pump and electric motor. The second photo shows a machine
that is not equipped with a secondary steering pump and electric motor.
308 SEBU7892-07
Maintenance Section
g00585943
Illustration 234
8. Remove suction screen (2) and tube (4) from the housing. Remove
three magnets (3) from the tube.
9. Wash the tube and the suction screen in a clean, nonammable
solvent.
10. Use a cloth, a stiff bristle brush or pressurized air to clean the magnets.
NOTICE
Do not drop or rap the magnets against any hard ob-
jects. Replace any damaged magnets.
11. Clean the cover and inspect cover seal (1). Replace the seal, if
necessary.
12. Install three magnets (3) on the tube. Insert suction screen (2) and
tube (4) in the housing.
13. Install the cover and the cover bolts.
14. Replace the transmission oil lter.
Reference: Refer to Operation and Maintenance Manual,
Transmission Oil Filter - Replace for the correct procedure.
SEBU7892-07 309
Maintenance Section
g01135465
Illustration 235
15. Open the access door on the right side of the machine.
g01135488
Illustration 236
16. Pull out the extendable oil ller tube for easier access and ll the
transmission with oil.
(Rell) for the correct amount.
17. Remove the transmission breather from the top of the dipstick tube.
Wash the breather in a clean, nonammable solvent. Install the
breather.
310 SEBU7892-07
Maintenance Section
g01115803
Illustration 237
18. Open the access panel on the left side of the machine.
g01119039
Illustration 238
19. Remove the transfer gear housing breather. Wash the breather in a
clean, nonammable solvent. Install the breather.
Note: The photo shows a machine that is equipped with a secondary
steering arrangement.
20. Start the engine and run the engine at low idle.
21. Disengage the parking brake. Apply the service brakes.
SEBU7892-07 311
Maintenance Section
Transmission Oil Filter - Replace
22. Move the transmission control to FORWARD and to REVERSE in
order to circulate the oil.
23. Move the transmission control to the NEUTRAL position and engage
the parking brake.
24. Check for leaks under the machine.
25. Check the transmission oil level.
Transmission Oil Level - Check for the correct procedure.
26. If transmission oil level is low, add oil. Recheck the transmission oil
level.
27. Close the access door.
28. Stop the engine.
29. Close the access panel on the left side of the machine. Install the
transmission guards underneath the machine.
i02254243
SMCS Code: 3004-510; 3067-510
NOTICE
products.
mandates.
312 SEBU7892-07
Maintenance Section
g01101509
Illustration 239
1. Stop the engine. Engage the parking brake.
2. Remove the step assembly on the left side of the machine.
g01135506
Illustration 240
3. Use an oil lter strap wrench to remove the transmission oil lter.
Dispose of the used lter properly.
4. Clean the lter base. Make sure that all of the used gasket is removed.
5. Apply a light coat of clean transmission oil on the new gasket. Install
the gasket on the new lter.
SEBU7892-07 313
Maintenance Section
Transmission Oil Level - Check
6. Install a new transmission oil lter. When the lter contacts the lter
base, tighten the lter by an additional 3/4 turn.
7. Start the engine. Apply the service brakes.
8. Disengage the parking brake.
9. Move the transmission direction control switch to FORWARD and to
REVERSE in order to circulate the transmission oil.
10. Move the transmission direction control switch to the NEUTRAL
position and engage the parking brake.
11. Inspect the lter for leaks. Check the transmission oil level.
Transmission Oil Level - Check for the correct procedure.
12. Reinstall the step assembly.
i02254945
Transmission Oil Level - Check
g01135465
Illustration 241
314 SEBU7892-07
Maintenance Section
Transmission Oil Sample - Obtain
g01135568
Illustration 242
1. Open the access door on the right side of the machine.
2. Remove the dipstick and wipe off the dipstick with a clean cloth. This
will ensure a more accurate measurement of the oil level.
3. Reinsert the dipstick and remove the dipstick again. Check the oil
level. The oil level should be between the marks on the dipstick while
the engine is running at low idle and the transmission is in neutral.
4. If the oil level is low, remove the oil ller cap and add transmission oil
through the oil ller tube, as needed. Reinstall the oil ller cap.
5. Install the dipstick and close the access door.
i02255100
SMCS Code: 3080-008; 7542
jury.
skin.
SEBU7892-07 315
Maintenance Section
NOTICE
products.
mandates.
g01135571
Illustration 243
The transmission is equipped with a sampling valve. The sampling valve
is located next to the transmission oil lter on the left side of the machine.
Remove the step assembly under the left door in order to gain access.
316 SEBU7892-07
Maintenance Section
Water Cleaning System (Pressurized) - Purge
i02393313
Water Cleaning System (Pressurized) -
Purge
(If Equipped)
SMCS Code: 5612-542; 5613-542
g00868210
Illustration 244
Water Cleaning System
(1) Water Tank
(2) Relief Valve
(3) Filler Plugs
(4) Air Valve
(5) Ball Valve
1. Open ball valve (5).
2. Use water spray nozzle (6) to expel all of the water from water tank (1).
Allow the compressed air to escape through the nozzle also.
SEBU7892-07 317
Maintenance Section
Water Cleaning System (Pressurized) - Purge
result.
the threads.
3. Unscrew ller plugs (3) for two complete turns in order to relieve
pressure.
4. Once the pressure is relieved, remove ller plugs (3).
5. Close ball valve (5). Fill the tank with 60 L (16 US gal) of water.
Note: If the outside temperature is below freezing, use a propylene glycol
based antifreeze in the water tank. The antifreeze should be a non-toxic
antifreeze that is used in recreational vehicles.
6. When water tank (1) is full, install ller plugs (3).
7. Connect an air hose to air valve (4). Pressurize water tank (1) to
345 kPa (50 psi).
8. Open ball valve (5).
9. Expel the water from water spray nozzle (6). If the discharge is not
strong, repeat the purging process. If there is still a problem, remove
the hose and the lines and check for an obstruction.
10. Once the purging process is complete, ll and pressurize the water
tank.
318 SEBU7892-07
Maintenance Section
Water Cleaning System (Pressurized) - Test
i02143406
Water Cleaning System (Pressurized) - Test
SMCS Code: 5612-081; 5613-081
g00868210
Illustration 245
Water Cleaning System
(1) Water Tank
(2) Relief Valve
(3) Filler Plugs
(4) Air Valve
(5) Ball Valve
1. Remove the water hose from behind the seat. Open ball valve (5).
2. Squeeze water spray nozzle (6) in order to expel the water. There
will be pressure as the water is expelled. If there is very little water
pressure, purge the water cleaning system.
3. After you test the water cleaning system, rell water tank (1). Water
tank (1) must also be pressurized.
SEBU7892-07 319
Maintenance Section
Winch Drive Shaft Spline - Lubricate
Reference: For information on purging and pressurizing the system,
refer to Operation and Maintenance Manual, Water Cleaning System
(Pressurized) - Purge.
i02786672
Winch Drive Shaft Spline - Lubricate
(If Equipped)
SMCS Code: 5178-086
Note: This procedure only pertains to machines that are equipped with
a mechanical winch.
Wipe off the tting before you apply any lubricant.
Apply lubricant through one tting on the drive shaft spline.
i02786655
Winch Drive Shaft Support Bearing -
Lubricate
(If Equipped)
SMCS Code: 5178-086
a mechanical winch.
Apply lubricant through one tting on the top of the support.
320 SEBU7892-07
Maintenance Section
Winch Drive Shaft Universal Joint - Lubricate
i02216955
Winch Drive Shaft Universal Joint -
Lubricate
(If Equipped)
SMCS Code: 5178-086
a mechanical winch.
g01118824
Illustration 246
Top View
Wipe the ttings before you apply any lubricant.
Apply lubricant through ttings (1) and (2) on the rear drive shaft.
There is a total of two ttings.
SEBU7892-07 321
Maintenance Section
Winch Drum Bearing - Lubricate
i01367960
Winch Drum Bearing - Lubricate
a Caterpillar C-500 Series winch.
g00721798
Illustration 247
Apply a small amount of lubricant through the tting on the right side of the
winch. Excess lubricant may escape from the vent hole in the cover plate.
322 SEBU7892-07
Maintenance Section
Winch Oil - Change
i02456564
Winch Oil - Change
SMCS Code: 5163-044
Personal injury can result from winch oil pressure
and hot oil.
Oil pressure can remain in the winch system after
the engine has been stopped. Serious injury can
be caused if this pressure is not released before
any service is done on the winch system.
Make sure the engine is stopped, and the oil is
cool, before you remove any components or any
lines.
NOTICE
Dealer Service Tool Catalog for tools and supplies
products.
mandates.
Mechanical Winch
SEBU7892-07 323
Maintenance Section
Winch Oil - Change
g00694842
Illustration 248
1. Remove drain plug (1) on the left side of the winch. Attach a hose to a
suitable drain adapter. Install the adapter in the drain valve and allow
the oil to drain into a suitable container.
g00672642
Illustration 249
2. Remove the protective cover from the right side of the winch.
3. Disconnect the return line from the tting.
324 SEBU7892-07
Maintenance Section
Winch Oil - Change
g00690980
Illustration 250
g00699155
Illustration 251
4. Remove the four bolts and cover (2) on the lower right side of the
winch. Remove the strainer from the winch. Remove the strainer from
the suction tube. Remove the metal band and the magnets from the
strainer.
5. Wash the strainer and the magnets in a clean, nonammable solvent.
Use compressed air to dry the parts.
6. Inspect the strainer. Replace the strainer if the strainer is damaged
or plugged.
7. Install the magnets and the metal band on the strainer. Apply clean
winch oil to the O-ring seal and install the strainer on the suction tube.
SEBU7892-07 325
Maintenance Section
Winch Oil - Change
8. Inspect the cover seal for wear or for damage. Replace the cover seal,
if necessary. Install the cover and the four bolts.
9. Reconnect the return line to the tting.
10. Reinstall the protective cover.
g00694843
Illustration 252
11. Remove vent plug (3) on the left side of the winch. Clean the vent plug
in a clean, nonammable solvent. Install the vent plug.
Note: Do not replace the vent plug with a solid plug. Do not apply paint
over the vent plug. Either condition may cause oil leaks due to increased
internal pressure during operation of the winch.
326 SEBU7892-07
Maintenance Section
Winch Oil - Change
g00694839
Illustration 253
12. Remove ller plug (4) and ll the winch with oil through the opening.
13. Clean the ller plug and install the ller plug. Clean the vent plug and
install the vent plug.
Hydraulic Winch
Note: The line for the hydraulic winch must be extended in order to
expose the drain hole in the center of the winch.
SEBU7892-07 327
Maintenance Section
Winch Oil - Change
g01231645
Illustration 254
1. Remove the cover plate on the right side of the winch.
g01225969
Illustration 255
2. Remove drain plug (1) on the right side of the winch. Attach a hose
to a suitable drain adapter. Install the adapter in the drain valve and
allow the oil to drain into a suitable container.
328 SEBU7892-07
Maintenance Section
Winch Oil - Change
g01231535
Illustration 256
3. Remove drain plug (2) on the center of the winch. Attach a hose to a
suitable drain adapter. Install the adapter in the drain valve and allow
the oil to drain into a suitable container.
4. After you have drained the oil, remove the adapters from the drain
openings.
5. Clean the drain plugs and install the drain plugs.
g01231657
Illustration 257
6. Remove vent plug (3) on the left side of the winch. Clean the vent plug
in a clean, nonammable solvent. Install the vent plug.
SEBU7892-07 329
Maintenance Section
Winch Oil - Change
Note: Do not replace the vent plug with a solid plug. Do not apply paint
over the vent plug. Either condition may cause oil leaks due to increased
internal pressure during operation of the winch.
g01231668
Illustration 258
7. Remove ller plug (4) and ll the winch with oil through the opening.
8. Clean the ller plug and install the ller plug. Clean the vent plug and
install the vent plug.
g01231645
Illustration 259
9. Install the cover plate on the right side of the winch.
330 SEBU7892-07
Maintenance Section
Winch Oil Filter - Replace
i02156039
Winch Oil Filter - Replace
SMCS Code: 5177-510
g01096103
Illustration 260
g00698328
Illustration 261
1. Remove the access panels on the right side of the machine in order to
access the winch oil lter.
2. Use a strap type wrench to remove the oil lter. Clean the lter base
and dispose of the used lter properly.
SEBU7892-07 331
Maintenance Section
Winch Oil Level - Check
3. Apply a thin coat of oil to the seal of a new lter and install the lter by
hand. When the lter contacts the lter base, tighten the lter by an
additional 3/4 turn.
4. Install the access panels.
i01312912
Winch Oil Level - Check
g00694965
Illustration 262
The sight gauge is on the left side of the winch.
Check the oil level of the winch, when the engine is stopped. Maintain the
oil level within the sight gauge. Add oil, if necessary.
332 SEBU7892-07
Maintenance Section
Winch Oil Sample - Obtain
i02127842
Winch Oil Sample - Obtain
SMCS Code: 5163-008; 7542
jury.
skin.
NOTICE
products.
mandates.
SEBU7892-07 333
Maintenance Section
Winch Wire Rope - Install
g00697412
Illustration 263
The winch is not equipped with a sampling valve. Obtaining a sample of
the winch oil will require a vacuum pump or an equivalent. Remove the
ller plug from the left side of the winch and withdraw the oil sample.
i00947128
SMCS Code: 5154-012
Personal injury or death can result from improper
wire rope use.
Always wear gloves when handling wire rope.
334 SEBU7892-07
Maintenance Section
Note: Ferrules are made in various sizes. Make sure that you use the
correct ferrule for the size of the wire rope.
Table 19
Caterpillar C-500 Series Winch
Diameter of Wire Rope Ferrule (Part Number)
19 mm (3/4 inch) 118-6273
22 mm (7/8 inch) 118-6275
25 mm (1 inch) 118-6276
g00483393
Illustration 264
1. Attach a ferrule to the end of the wire rope.
2. Wrap the wire rope once around the drum and slide the ferrule into the
slot in the drum. Make sure that the wire rope is installed so that the
wire rope will be reeled in over the top of the drum.
3. Move the winch control lever to the REEL IN position in order to wind
the wire rope onto the winch drum.
Note: The wire rope will detach if the wire rope is unwound below one full
turn. Applying red paint to the last six coils of the wire rope will help to
serve as a visual warning.
SEBU7892-07 335
Maintenance Section
Window Washer Reservoir - Fill
i02176858
Window Washer Reservoir - Fill
SMCS Code: 7306-544
NOTICE
When operating in freezing temperatures, use
Caterpillar nonfreezing window washer solvent or
equivalent. System damage can result from freezing.
g01102225
Illustration 265
The window washer reservoir is located inside the top engine access
cover on the left side of the hood.
Fill the reservoir with window washer solvent.
336 SEBU7892-07
Maintenance Section
Window Wiper - Inspect/Replace
i02143121
Window Wiper - Inspect/Replace
SMCS Code: 7305-040; 7305-510
Inspect
Inspect the front wiper blade and the rear wiper blade. Replace the wiper
blades if the wiper blades are worn or damaged or if streaking occurs.
The window wiper and/or the wiper motor should be replaced under the
following conditions:
The wiper arm is worn or damaged.
The wiper motor is faulty.

Replace
Use the following procedure in order to install a new wiper and/or a new
wiper motor on the front window and the rear window:
1. Move the transmission direction control switch to NEUTRAL.
3. Place the steering frame lock in the LOCK position.
4. Remove the cover in order to access the wiper arm and the wiper
motor.
5. Remove the wiper arm and the wiper motor.
6. Install the new wiper arm and/or the new wiper motor.
7. Reinstall the cover.
8. Place the steering frame lock in the STORED position.
SEBU7892-07 337
Maintenance Section
Windows - Clean
i01921569
Windows - Clean
SMCS Code: 7310-070
Use commercially available window cleaning solutions in order to
clean the windows. Clean the outside windows from the ground unless
handholds are available.
Note: Use a damp cloth to clean the windows. Using a dry cloth will
damage the surface of the window.
338 SEBU7892-07
Reference Materials
Reference Materials
i03984369
Reference Material
SMCS Code: 1000; 7000
The following literature can be obtained from any Caterpillar dealer:
Cooling System
Special Publication, PMEP5027, Label - ELC Radiator Label
Special Publication, PEHJ0067, Product Data Sheet for Caterpillar ELC
Special Publication, PEHP9554, Product Data Sheet for Caterpillar
DEAC (Diesel Engine Antifreeze/Coolant)
Special Publication, SEBD0518, Know Your Cooling System
Special Publication, SEBD0970, Coolant and Your Engine
Grease
Data Sheet, NEHP6010, Cat Ultra 5Moly Grease (NLGI grade 1 and
grade 2)
Data Sheet, NEHP6011, Cat Arctic Platinum Grease (NLGI grade 0)
Data Sheet, NEHP6012, Cat Desert Gold Grease (NLGI grade 2)
Data Sheet, NEHP6015, Cat High Speed Ball Bearing Grease (NLGI
grade 2)
Special Publication, PEGJ0035, Grease Selection Guide
Data Sheet, PEHJ0088, Cat Multipurpose Grease (NLGI grade 2)
Data Sheet, PEHP0002, Cat Advanced 3Moly Grease (NLGI grade 2)
SEBU7892-07 339
Reference Materials
Hydraulic Oil
Special Publication, PEGP6028, Caterpillar Hydraulic Systems
Management Guide
Special Publication, PEHJ0009, Product Data Sheet for Caterpillar
Hydraulic Oil (HYDO) (SAE 10W)
Biodegradable Hydraulic Oil (HEES)
Miscellaneous Publications
Special Publication, REHS2348, Product Link PL121SR Operation &
Maintenance Manual
System Operations, Test, and Adjustment Guide, RENR7911, Product
Link 121SR/321SR
Special Instruction, REHS2365, An Installation Guide for the Product
Link PL121SR and for the PL300
Power Train Disassembly and Assembly, RENR6422, Tire and Rim -
Remove and Install
Special Publication, PECP9067, One Safe Source
Special Publication, PEDP9131, Fluid Contamination - The Silent Thief
Special Publication, PEWJ0074, Cat Filter & Fluid Application Guide
Special Publication, SEBD0400 , Dictionary of Pictograph Symbols
Special Publication, SEBD0717, Diesel Fuels and Your Engine
Special Publication, SEBF1015, Improving Component Durability - Final
Drives and Differentials
Special Publication, SEBU6250, Caterpillar Machine Fluid
Recommendations
Special Publication, SEBU5898, Cold Weather Recommendations
Special Publication, SENR5664, Air Conditioning and Heater R-134a
for All Caterpillar Machines
340 SEBU7892-07
Reference Materials
Special Publication, SENR9620, Improving Fuel System Durability
Special Publication, SMBU6981, Emissions Control Warranty
Information
Special Instruction, SMHS7867, Nitrogen Tire Ination Group
Oil
Multipurpose Tractor Oil (MTO)
Special Publication, PEHP6001, How to Take a Good Oil Sample
Special Publication, PEHJ0007, Product Data Sheet for Caterpillar Arctic
TDTO (SAE 0W-20) (synthetic blend)
Special Publication, PEHJ0008, Product Data Sheet for Caterpillar Arctic
DEO (SAE 0W-30)
Special Publication, PEHJ0030, Product Data Sheet for Caterpillar
Synthetic Gear Oil (SAE 75W-140)
Special Publication, PEHJ0059, Product Data Sheet for Caterpillar DEO
(SAE 10W-30)
TDTO (SAE 10W, SAE 30, SAE 50)
Special Publication, PEHP7508, Product Data Sheet for Caterpillar Gear
Oil (GO) (SAE 80W-90 and SAE 85W-140)
Special Publication, PEHP7062, Product Data Sheet for Caterpillar DEO
Synthetic (SAE 5W-40)
FDAO (SAE 60)
FDAO Synthetic (Multigrade)
Special Publication, PELJ0179, Caterpillar Engine Crankcase Fluid-1
Specications (Cat ECF-1)
SEBU7892-07 341
Reference Materials
Special Publication, PEHP8035, Product Data Sheet for TDTO
Transmission Multi-Season (TMS)
Special Publication, SEBD0640, Oil and Your Engine
Parts Manuals
Parts Manual, SEBP3855, 525C Wheel Skidder
ROPS/FOPS Structure
Special Publication, SEBD1587, What ROPS/FOPS Certication Means
Special Publication, SEHS6929, Inspection, Maintenance, and Repair of
ROPS and Attachment Installation Guidelines
Safety Information
Operation and Maintenance Manual, SEBU8257, The European Union
Physical Agents (Vibration) Directive 2002/44/EC
SOS Information
Special Publication, PEDP7036, SOS Services
Special Publication, PEHP7052, Making the Most of SOS Services
Special Publication, PEHP7057, SOS Coolant Analysis
Special Publication, PEHP7076, Understanding SOS Services Tests
Specications Manuals
Specications Manual, SENR3130, Torque Specications
Tools
Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog
342 SEBU7892-07
Reference Materials
Additional Reference Material
SAE J183, Classication This reference can normally be found in the
SAE handbook.
SAE J313, Diesel Fuels This reference can be found in the SAE
handbook. Also, this publication can be obtained from your local
technological society, from your local library, or from your local college.
SAE J754, Nomenclature This reference can normally be found in the
SAE handbook.
Engine Manufacturers Association, Engine Fluids Data Book
Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
Chicago, Illinois USA 60602
E-mail: ema@enginemanufacturers.org
(312) 827-8700
Facsimile: (312) 827-8737
The Society of Automotive Engineers (SAE) Specications can be found
in your SAE handbook. This publication can also be obtained from the
following locations: local technological society, local library, and local
college. If necessary, consult SAE at the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
The International Organization for Standardization (ISO) offers information
and customer service regarding international standards and standardizing
activities. ISO can also supply information on the following subjects
that are not controlled by ISO: national standards, regional standards,
regulations, certication, and related activities. Consult the member of
ISO in your country.
SEBU7892-07 343
Reference Materials
International Organization for Standardization (ISO)
1, rue de Varemb
Case postale 56
CH-1211 Genve 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
web site: http://www.iso.ch
i03989612
Decommissioning and Disposal
SMCS Code: 1000; 7000
When the product is removed from service, local regulations for the
product decommissioning will vary. Disposal of the product will vary with
local regulations. Consult the nearest Cat dealer for additional information.
344 SEBU7892-07
Index Section
Index
A
Additional Messages .............................................................................. 23
Adjustments.......................................................................................... 146
Air Cleaner Dust Valve - Clean/Inspect ................................................ 190
Alternate Exit .......................................................................................... 88
Articulation Bearings - Lubricate........................................................... 191
Axle Oscillation Bearings - Lubricate.................................................... 192
B
Backup Alarm....................................................................................... 119
Backup Alarm - Test ............................................................................. 193
Battery - Clean...................................................................................... 194
Battery - Recycle.................................................................................. 195
Battery Disconnect Switch.................................................................... 118
Battery Hold-Down - Tighten ................................................................ 195
Battery or Battery Cable - Inspect/Replace .......................................... 197
Recycle the Battery........................................................................... 198
Before Operation.............................................................................. 49, 83
Before Starting Engine ........................................................................... 47
Belt - Inspect/Adjust/Replace ............................................................... 199
Brake Accumulator - Check.................................................................. 200
Brake Discs - Check............................................................................. 201
Braking System - Test........................................................................... 202
Parking Brake Holding Ability Test .................................................... 203
Service Brake Holding Ability Test .................................................... 202
Burn Prevention...................................................................................... 35
Batteries.............................................................................................. 36
Coolant................................................................................................ 35
Oils...................................................................................................... 35
C
Cab Air Filter - Clean/Replace.............................................................. 204
Capacities (Rell) ................................................................................. 181
Circuit Breakers - Reset ....................................................................... 206
Cooling System Coolant (ELC) - Change............................................. 207
Cooling System Coolant Extender (ELC) - Add.................................... 211
Cooling System Coolant Level - Check................................................ 214
SEBU7892-07 345
Index Section
Cooling System Coolant Sample (Level 1) - Obtain............................. 215
Cooling System Coolant Sample (Level 2) - Obtain............................. 217
Cooling System Water Temperature Regulator - Replace.................... 218
Crushing Prevention and Cutting Prevention ......................................... 34
D
Daily Inspection...................................................................................... 85
Decommissioning and Disposal ........................................................... 343
Differential and Final Drive Oil - Change.............................................. 221
Differential and Final Drive Oil Level - Check....................................... 225
Differential and Final Drive Oil Sample - Obtain................................... 226
E
Electrical Storm Injury Prevention .......................................................... 46
Emissions Certication Film ................................................................... 82
Engine Air Filter Primary Element - Clean/Replace.............................. 228
Cleaning the Primary Air Filter Element............................................ 229
Inspecting the Primary Air Filter Elements........................................ 231
Engine Air Filter Secondary Element - Replace ................................... 232
Engine Air Filter Service Indicator - Inspect ......................................... 234
Engine Air Filter Service Indicator - Inspect/Replace ........................... 235
Engine Air Precleaner - Clean (If Equipped) ........................................ 237
Engine and Machine Warm-Up ............................................................ 144
Engine Crankcase Breather - Clean..................................................... 238
Engine Oil and Filter - Change ............................................................. 243
Engine Oil Level - Check...................................................................... 240
Engine Oil Sample - Obtain.................................................................. 241
Engine Starting............................................................................... 48, 143
Engine Starting (Alternate Methods) .................................................... 168
Engine Starting with Auxiliary Start Receptacle (If Equipped).............. 171
Engine Starting with Jump Start Cables............................................... 168
Use of Jump Start Cables................................................................. 169
Engine Stopping..................................................................................... 51
Engine Valve Lash - Check .................................................................. 248
Equipment Lowering with Engine Stopped..................................... 55, 153
Ether Starting Aid Cylinder - Replace (If Equipped) ............................. 249
F
Fairlead Rollers - Lubricate .................................................................. 251
Fire Extinguisher Location...................................................................... 44
346 SEBU7892-07
Index Section
Fire Prevention and Explosion Prevention ............................................. 36
Battery and Battery Cables................................................................. 39
Ether ................................................................................................... 43
Fire Extinguisher ................................................................................. 43
General ............................................................................................... 36
Lines, Tubes and Hoses ..................................................................... 41
Wiring.................................................................................................. 41
Foreword .................................................................................................. 8
California Proposition 65 Warning ........................................................ 6
Caterpillar Product Identication Number ............................................. 7
Certied Engine Maintenance............................................................... 7
Literature Information............................................................................ 5
Machine Capacity ................................................................................. 7
Maintenance ......................................................................................... 6
Operation.............................................................................................. 5
Safety.................................................................................................... 5
Fuel System - Prime............................................................................. 251
Fuel System Primary Filter (Water Separator) - Drain.......................... 252
Fuel System Primary Filter (Water Separator) Element - Replace....... 253
Fuel System Secondary Filter - Replace.............................................. 256
Fuel Tank Cap and Strainer - Clean..................................................... 259
Fuel Tank Water and Sediment - Drain ................................................ 260
Fuses - Replace ................................................................................... 261
G
General Hazard Information................................................................... 28
Containing Fluid Spillage .................................................................... 31
Dispose of Waste Properly ................................................................. 33
Fluid Penetration................................................................................. 30
Inhalation ............................................................................................ 32
Pressurized Air and Water .................................................................. 30
Trapped Pressure ............................................................................... 30
General Information................................................................................ 58
Grapple Boom and Arch (Dual Function) - Lubricate ........................... 266
Grapple Boom and Arch (Single Function) - Lubricate......................... 267
Grapple Head (Bunching) - Lubricate................................................... 268
Grapple Head (Continuous Rotation) - Lubricate ................................. 268
Grapple Head (Sorting) - Lubricate ...................................................... 272
Grapple Head Rotator (Continuous Rotation) - Lubricate .................... 273
Grapple Snubber - Inspect/Adjust ........................................................ 274
Installation Procedure....................................................................... 277
SEBU7892-07 347
Index Section
H
Hydraulic System Oil - Change ............................................................ 281
Hydraulic System Oil Filter - Replace................................................... 287
Hydraulic System Oil Level - Check ..................................................... 289
Hydraulic System Oil Sample - Obtain ................................................. 292
Hydraulic Tank Breaker Relief Valve - Clean........................................ 294
I
Identication Information ........................................................................ 75
Important Safety Information.................................................................... 2
L
Leaving the Machine ............................................................................ 156
Lifting and Tying Down the Machine..................................................... 160
Lubricant Viscosities............................................................................. 177
Lubricant Viscosities for Ambient Temperatures............................... 177
Selecting the Viscosity...................................................................... 177
Lubricant Viscosities and Rell Capacities........................................... 177
M
Machine Operation ................................................................................. 88
Maintenance Interval Schedule............................................................ 186
Maintenance Section............................................................................ 174
Maintenance Support ........................................................................... 184
Mirror ...................................................................................................... 95
Mirror Adjustment................................................................................ 95
Monitoring System................................................................................ 121
Alert Indicators.................................................................................. 122
Digital Display ................................................................................... 128
Gauges ............................................................................................. 121
Warning Categories .......................................................................... 125
Mounting and Dismounting..................................................................... 83
Alternate Exit....................................................................................... 84
Machine Access System Specications.............................................. 84
348 SEBU7892-07
Index Section
O
Oil Filter - Inspect ................................................................................. 295
Inspect a Used Filter for Debris ........................................................ 295
Operation................................................................................................ 50
Machine Operating Temperature Range............................................. 50
Operation............................................................................................ 50
Operation Information........................................................................... 135
Operation Section................................................................................... 83
Operator Controls................................................................................... 96
Accelerator Control (7)...................................................................... 102
Decking Blade Control (14)............................................................... 111
Differential Lock Control (10) ............................................................ 107
Engine Start Switch (1) ....................................................................... 96
Grapple Boom and Arch Control (19) ............................................... 117
Grapple Rotator Control (18) ............................................................ 116
Grapple Tong Control (17) ................................................................ 115
Heating and Air Conditioning Control (4) ............................................ 99
Hydraulic Retrieval Winch Control (15)............................................. 111
Light Switches (2) ............................................................................... 97
Mechanical Winch Control (16)......................................................... 113
Parking Brake Control (5) ................................................................. 100
Service Brake Control (6).................................................................. 101
Steering Column Tilt Control (12) ..................................................... 110
Steering Control (11)......................................................................... 109
Telescoping Steering Wheel Control (13) ......................................... 110
Torque Converter Lockup Control (8)................................................ 102
Transmission Control (9)................................................................... 105
Window Wiper/Washer Switch (3) ...................................................... 98
Operator Station..................................................................................... 57
P
Parking ........................................................................................... 51, 150
Parking Brake....................................................................................... 136
Parking Brake Manual Release............................................................ 167
Plate Locations and Film Locations........................................................ 75
Certication......................................................................................... 78
Sound.................................................................................................. 82
Product Information Section................................................................... 58
Product Link (If Equipped) .................................................................... 130
Data Broadcasts ............................................................................... 130
Operation in a Blast Site ................................................................... 131
Regulatory Compliance..................................................................... 132
SEBU7892-07 349
Index Section
R
Radiator Core - Clean........................................................................... 296
Reference Information Section............................................................. 338
Reference Material ............................................................................... 338
Additional Reference Material........................................................... 342
Cooling System................................................................................. 338
Grease.............................................................................................. 338
Hydraulic Oil...................................................................................... 339
Miscellaneous Publications............................................................... 339
Oil...................................................................................................... 340
Parts Manuals................................................................................... 341
ROPS/FOPS Structure ..................................................................... 341
SOS Information ............................................................................. 341
Safety Information............................................................................. 341
Specications Manuals ..................................................................... 341
Tools.................................................................................................. 341
Reference Materials ............................................................................. 338
Refrigerant Accumulator (With Desiccant) - Replace........................... 298
Roading the Machine............................................................................ 159
Rollover Protective Structure (ROPS) - Inspect ................................... 299
S
SOS Information................................................................................. 183
Safety Messages...................................................................................... 9
Safety Section .......................................................................................... 9
Seat ........................................................................................................ 88
Seat Belt ................................................................................................. 90
Extension of the Seat Belt................................................................... 94
Seat Belt Adjustment for Non-Retractable Seat Belts......................... 90
Seat Belt Adjustment for Retractable Seat Belts ................................ 93
Seat Belt - Inspect ................................................................................ 300
Seat Belt - Replace............................................................................... 301
Secondary Steering - Test .................................................................... 302
Secondary Steering (If Equipped) ........................................................ 137
Shipping the Machine........................................................................... 157
Slope Operation...................................................................................... 52
Sound Information and Vibration Information......................................... 55
Sound Performance for Machines Offered in European Union Countries
and in Countries that Adopt the EU Directives.................................. 56
Vibration Level .................................................................................... 56
350 SEBU7892-07
Index Section
Specications ......................................................................................... 58
Specications for the 525C................................................................. 58
Steering Cylinder Bearings - Lubricate................................................. 303
Steering Frame Lock .............................................................................. 86
Stopping the Engine............................................................................. 151
Stopping the Engine if an Electrical Malfunction Occurs...................... 152
Stopping the Machine........................................................................... 150
T
Table of Contents...................................................................................... 3
Tire Ination - Check ............................................................................ 305
Tire Ination Information....................................................................... 174
Tire Ination Pressure .......................................................................... 174
Wheel and Tire Arrangement ............................................................ 175
Tire Ination Pressure Adjustment ....................................................... 176
Tire Information ...................................................................................... 45
Towing Information ............................................................................... 163
Towing the Machine.............................................................................. 163
Towing with the Engine Running....................................................... 165
Towing with the Engine Stopped....................................................... 165
Transmission Oil - Change................................................................... 306
Transmission Oil Level - Check............................................................ 313
Transmission Oil Sample - Obtain........................................................ 314
Transportation Information ................................................................... 157
V
Visibility Information................................................................................ 47
W
Water Cleaning System (Pressurized) - Purge (If Equipped) ............... 316
Water Cleaning System (Pressurized) - Test........................................ 318
Water Cleaning System (Pressurized) (If Equipped) ............................ 141
Fill ..................................................................................................... 142
Pressurize the Water Tank................................................................ 142
Welding on Machines and Engines with Electronic Controls................ 184
Winch Drive Shaft Spline - Lubricate (If Equipped) .............................. 319
Winch Drive Shaft Support Bearing - Lubricate (If Equipped) .............. 319
SEBU7892-07 351
Index Section
Winch Drive Shaft Universal Joint - Lubricate (If Equipped)................. 320
Winch Drum Bearing - Lubricate .......................................................... 321
Winch Drum Drag Adjustment .............................................................. 146
Hydraulic Winch Adjustment ............................................................. 148
Mechanical Winch Adjustment.......................................................... 146
Winch Oil - Change .............................................................................. 322
Hydraulic Winch................................................................................ 326
Mechanical Winch............................................................................. 322
Winch Oil Filter - Replace..................................................................... 330
Winch Oil Level - Check ....................................................................... 331
Winch Oil Sample - Obtain ................................................................... 332
Winch Warm-Up Procedure.................................................................. 140
Winch Wire Rope - Install ..................................................................... 333
Window Washer Reservoir - Fill ........................................................... 335
Window Wiper - Inspect/Replace ......................................................... 336
Inspect .............................................................................................. 336
Replace............................................................................................. 336
Windows - Clean .................................................................................. 337
Work Tools.............................................................................................. 54
352 SEBU7892-07
Index Section
Product and Dealer Information
Note: For product identication plate locations, see the section Product Identication
Information in the Operation and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identication Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
2011 Caterpillar
All Rights
Reserved
Cat, Caterpillar, their respective logos,
Caterpillar Yellow and the Power edge trade
dress, as well as corporate and product identity
used herein, are trademarks of Caterpillar and
may not be used without permission.

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SEBU7892-07

Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

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

A vacuum cleaner that is equipped with a high efciency particulate

Use exhaust ventilation on permanent machining jobs.

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

Obey environmental regulations for the disposal of asbestos.

Cuts on the insulation of the cable

Corroded terminals, damaged terminals, and loose terminals

Signs of abrasion or wear

End ttings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are swelling or ballooning.

Flexible parts of the hoses are kinked.

Outer covers have exposed embedded armoring.

End ttings are displaced.

Mount the machine.

Dismount the machine.

Controlled patterns of machine movement and vehicle movement

Workers that direct trafc to move when it is safe

Warning symbols or warning signs on machines or on vehicles

Communication between workers and operators prior to approaching

additional seat belt

Rollover Protective Structure (ROPS)

Discard the load.

Turn the machine downhill.

Engine Power Primary Engine (kW)___________________________________________

Engine Power for Additional Engine (If Equipped) _________________________

Typical Machine Operating Weight for European Market (kg)____________

Machine Type ______________________________________________________________________

Engine Power Primary Engine (kW)___________________________________________

Typical Machine Operating Weight for European Market (kg)____________

More fuel efcient

High efciency hauling

Faster cycle time

Less shifting by the operator

Greater power range in all working conditions

Hydraulic pump failure

Pressure loss in the hydraulic system

Allow the engine to warm up for approximately 15 minutes when the

Allow the engine to warm up for approximately 30 minutes when the

More time may be required if the outside temperature is less than

Bearings of the drive train

Other components of the machine

An authorized battery collection facility

An authorized battery collection facility

The axle housing breather is damaged or plugged.

Excessive heat is generated.

Oil leaks at the yoke and the drive axles

Park the machine on a dry, level surface.

Fasten the seat belt before you test the brakes.

Cat Diesel Engine Antifreeze/Coolant (DEAC)

Commercial heavy-duty coolant/antifreeze

Keep the unused sampling bottles stored in plastic bags.

Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

The wiper arm is worn or damaged.

The wiper motor is faulty.

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