C.

TERPILLAR® SEBU8146-06
August 2009

• w
Operation and
Maintenance
Manual
D6T Track-Type Tractor
• JHB1-Up (Machine)
ZEB1-Up (Machine)
SMC1-Up (Machine)
JWD1-Up (Machine)
LBD1-Up (Machine)
LAE1-Up (Machine)
DJG1-Up (Machine)
WCG1-Up (Machine)
WFH1-Up (Machine)
LKJ1-Up (Machine)
KJL 1-Up (Machine)
SKL 1-Up (Machine)
GCT1-Up (Machine)
RLW1 -Up (Machine)
LAY1-Up (Machine)
PEZ1-Up (Machine)

• SAFETY.CAT.COM
 i03602780

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 identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

AWARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard .
The warnings in this publication and on the product are, therefore, not ali inclusive. Vou must
not use this product in any manner different from that considered by this manual without first •
satisfying yourself that you have considered ali safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. Vou should also ensure that the product will not be damaged or beco me unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
T e information , specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written . The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These chang es can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

AWARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

•
 SEBU8146-06 3
Table of Contents

• Table of Contents Engine Starting ............ ...... ...... ........ ... .. ......... ... .... 75

. Tih
Operatlng '
ec niques ... .. ......... ... ... .............. .. ...... . 77
Foreword ....... ......... .... .. ......................... .... .............. 4
Adjustments ...... .... ......... ... .. ... .. ...... ....................... 83
Safety Section
Parking ... ... ........... .. ....... ... ... ..... ... .......... ... ............ . 84
Safety Messages ................................. ... .. ........ .. .... 6
Transportation Information ..... ... .... .............. .. ........ 87
Additional Messages ..... ........................ ............. ... 13
Towing Information ... ............. ...... .... ..... ......... ........ 89
General Hazard Information ...... ..... ..... ... ......... ... .. 15
Engine Starting (Alternate Methods) ..................... 94
Crushing Prevention and Cutting Prevention .... .... 17
Maintenance Section
Burn Prevention ............ ............ ............................ 18
Lubricant Viscosities and Refill Capacities ........... 96
Fire Prevention and Explosion Prevention ...... ...... 18
Maintenance Support .. .. ......... .......... ..... ........... ... 101
Fire Extinguisher Location ... .... ........ ..... ................ 21
Maintenance Interval Schedule ........... .. ...... ....... 102
Track Information ......... ........... .. .......... .. ........... .. ... 22
Reference Information Section
Electrical Storm Injury Prevention ..... ..... ..... .... .. .... 22
Reference Materiais .. ....................... ..... ... ....... .... 161
Before Starting Engine ... .... .......... ............ ..... ... ..... 22
Index Section
Engine Starting ......... ................. ..... ... ...... ....... ... ... 22
Index ..... ..... ......... ..... .. ......... ... .. ...... ..... ................ 163
Before Operation ......................... ......................... 23

Visibility Information ... ........... ..... ......... .................. 23

Restricted Visibility ................ ............ ....... ...... ....... 23

Operation ... .. ..... ........... ...... ... .... .............. .... .. ... ..... 24

Parking ......................... ... .. .... ................. ... ... ..... .... 24

Slope Operation ..... .............. .. ... ....... ... ... ...... .. ...... . 25

Equipment Lowering with Engine Stopped .. ......... 26

Sound Information and Vibration Information ... ... . 26

Operator Station .... ....................... ........ ..... ........... 28

Guards (Operator Protection) ..... ...... ......... ........... 28

Product Information Section

General Information ........ .. ......... .... ......... .............. 30

Identification Information .... .... ...... ................ ..... .... 34

• Operation Section
Before Operation ........... ................................. .... .. 42

Machine Operation ........ .... ....... ...... ............... .... ... 44

4 SEBU8146-06
Foreword

Foreword
Literature Information
This manual should be stored in the operator's
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
•
compartment in the literature holder or seat back under the "When Required" service interval. The
literature storage area. Maintenance Interval Schedule lists the page
number for the step-by-step instructions requ ired to
This manual contains safety information , operation accomplish the scheduled maintenance. Use the
instructions, transportation information , lubrication Maintenance Interval Schedule as an index or "one
information and maintenance information . safe source" for ali maintenance procedures.
Some photographs or illustrations in this publication
show details or attachments that can be different Maintenance Intervals
from your machine. Guards and covers might have
been removed for illustrative purposes. Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
Continuing improvement and advancement of monthly, etc.) can be used instead of service hour
product design might have caus~d c~anges. to your meter intervals if they provide more conven ient
machine which are not included ln thls publlcatlon . servicing schedules and approximate the i ndicat~d
Read , study and keep this manual with the machine. service hour meter reading . Recommended servlce
should always be performed at the interval that
Whenever a question arises regarding your machine, occurs first.
or this publication , please consult your Caterpillar
dealer for the latest available information . Under extremely severe, dusty or wet operating
conditions, more frequen t lubrication tha n is .
specified in the maintenance intervals chart mlght
Safety be necessary.

The safety section lists basic safety precautions: ln Perform service on items at multiples of the original
addition , this section identifies the text and locatlons requirement. For example, at every 500 service
of warning signs and labels used on the machine. hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
Read and understand the basic precautions listed 10 service hours or daily.
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
California Proposition 65 Warning
IOperation Diesel engine exhaust and some of its co nstituents
are known to the State of Californ ia to cause cancer,
The operation section is a reference for the new birth defects, and other reproductive harm .
operator and a refresher for the e~perie~ced
operator. This section includes a dlscusslon of Battery posts, terminais and related accessories
gauges , switches, machine con~rol~ , attach.ment contain lead and lead compounds. Wash hands
controls, transportation and towlng Informatlon. after handling.

Photographs and illustrations guide the operator

through correct procedures of checking , starting , Certified Engine Maintenance
operating and stopping the machine.
Proper maintenance and repair is essential to keep
Operating techniques outlined in this publication are the engine and machine systems operati ng correctly.
basic. Skill and techniques develop as the operator As the heavy duty off-road diesel engine owner,. you
~ains knowledge of the machine and its capabilities.
are responsible for the performance of the reqUlr~d
maintenance listed in the Owner Manual, Operatlon
and Maintenance Manual , and Service Manual.

•
 SEBU8146-06 5
Foreword

• 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
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.

(40 CFR Part 89). Certain elements of the machine Machines and generator sets produced before First
and engine such as the exhaust system, fuel system, Quarter 2001 will maintain their 8 character PIN
electrical system, intake air system and cooling format.
system may be emission related and should not be
altered unless approved by Caterpillar. Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Machine Capacity Serial Number (S/N).

Additional attachments or modifications may exceed

machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering , and rollover protective structures (ROPS) .
Contact your Caterpillar dealer for further information.

Caterpillar Product Identification

Number

-.
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) has changed from 8 to 17
characters. ln an effort to provide uniform equipment
identification , Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261 . The new PI N format will apply
to ali 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 :

*CAT 0789BG 6SL12345*

IT~
IlIustration 1 g00751314

•
Where:

1. Caterpillar's World Manufacturing Code (characters

1-3)

2. Machine Descriptor (characters 4-8)

 6 . SEBU8146-06
Safety Sectlon
\ Safety Messages

I Safety Section

I Safety Messages
i03647228
•
SMCS Code: 7000; 7405

-
-
I
@
& ®Iw
2

~~3 IAlml
I~~~
•

1~141
~~~~~~~g01957731 •
IlIustration 2
. ==~
SEBU8 146-06

__________ ~
7
Safety Section
sare~tyMes~sages

1~1@,1
5

••

g01957734
IlIustration 3

•
8 SEBU8146-06
Safety Section
Safety Messages

Do Not Operate 1
Safety message (1) is positioned on the upper ledge
of the left hand console of the operator's station . Vou
should be able to read the message from the right
side of the tractor.
•
--

IIlustration 4
g01957779 - -
There are several specific safety messages on this
machine. The exact location of the hazards and
I the description of the hazards are reviewed in this
section. Please beco me familiarized with ali safety
messages. g01370904

IMake sure that ali of the safety messages are legible. AWARNING
Clean the safety messages or replace the safety
messages if Vou cannot read the words. Replace Do not operate or work on this machine unless
~he illustrations if the illustrations are not visible. Vou have read and understand the instructions
When Vou clean the safety messages, use a cloth , and warnings in the Operation and Maintenance •
water, and soap. Do not use solvent, gasoline , or Manuais. Failure to follow the instructions or heed
pther harsh chemicals to clean the safety messages. the warnings could result in injury or death. Con-
polvents, gasoline, or harsh chemicals could loosen tact any Caterpillar dealer for replacement manu-
~ he adh esive that secures the safety message. Loose ais. Proper care is your respons ibility.
adhesive will allow the safety message to falI.

lReplace any safety message that is damaged or

rrissing . If a safety message is attached to a part of
the machine that is replaced , install a safety message
9n the replacement partoAny Caterpillar dealer can
provide new safety messages.

•
 SEBU8146-06 9
Safety Section
Safety Messages

• Do Not Weld on the ROPS (2) Improper Connections for Jump

Safety message (2) is positioned on the vertical
Start Cables (3)
support of the outside left ROPS post. Safety message (3) is located on the bottom side of
the battery box cover.

1t0fl'1. IAl'JltU,X MAYU.

~o XJt.luu ....

1"0'1: SALJ,II$OXXD ArMa

Lrvfl. M,
LSOXXU. 1M2 LE~L ..

);.0". no..
.0.0.. ltIOU(
"
XII lU "".0."
LI

UJU.. llU lU. XU 11l.lU

- -
g01212952

g01370909
AWARNING
Structural damage, an overturn, modificatlon, al- AWARNING
teration, or improper repair can impair this struc- Explosion Hazardllmproper jumper cable connec-
ture's protection capability thereby voiding this tions can cause an explosion resulting ln serious
certification. Do not weld on or drill holes in the

•
injury or death. Batteries may be located in sep-
structure. This will void the certification. Consult arate compartments. Refer to the Operation and
a Caterpillar dealer to determine this structure's Maintenance Manual for the correct jump starting
limitations without voiding its certification. procedure.

This machine has been certified to the standards that

are listed on the certification plate. The maximum Seat Belt (4)
mass of the machine, which includes the operator
and the attachments without a payload, should not Safety message (4) is located on the right console to
exceed the mass on the certification plate. the right of the dozer control.

A typical example of the certification plate is shown

above.

Refer to Operation and Maintenance Manual,

"Guards (Operator Protection)" for more information .

g01370908

AWARNING

• A seat belt should be worn at ali 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.
10 SE BU8 146-06
Safety Section
Safety Messages

Hot Fluid Under Pressure (5)

Safety message (4) is located on the bottom side of
the radiator access cover.
High Pressure Recoil Spring (6)
Safety message (6) is located inside the cover for the
twister resister on both track roller frames.
•

g01371640 g01379131

AWARNING AWARNING
preSSUrized systeml Hot coolant can cause seri- Recoil spring force, if not relieved , can result in
\ous burns, injury or death. To open the cooling personal injury or death. Relieve spring force be-
system filler cap, stop the engine and wait until fore removing the threaded reta iner, performing
the cooling system components are coo I. Loosen repairs on the recoil spring housing, or removing
I the cooling system pressure cap slowly in order to the recoil spring. Consult a Caterpillar dealer for •
\r elieve the pressure. Read and understand the Op- disassembly instructions.
~ ration and Maintenance Manual before perform-
ing any cooling system maintenance.
!

•
 SEBU8146-06 11
Safety Section
Safety Messages

• High Pressure Cylinder (7) Compressed Recoil Spring (8)

Safety message (7) is located on the access cover Safety message (8) is located inside both track roller
on both track roller frames. frames. The safety message is located on the front
frame of the rear track roller frame .

g01371642
g01065909

AWARNING
AWARNING
Personal injury or death can result from grease
under pressure. Personal injury or death can result from a com-
pressed recoil spring being released suddenly us-
Grease coming out of the relief valve under pres- ing incorrect disassembly procedures.

•
sure can penetrate the body causing injury or
death. A recoil spring that is still held in compression
can result in the recoil spring being released un-
Do not watch the relief valve to see if grease is es- expectedly with extreme force which could cause
caping. Watch the track or track adjustment cylin- serious injury or death.
der to see if the track is being loosened.
Make sure that the correct disassembly procedure
Loosen the relief valve one turn only. is used, if a front track roller frame that has a crack
in the parent metal or weld connection (or a tubu-
If track does not loosen, close the relief valve and lar section that has separated from the front of
contact your Caterpillar dealer. the frame assembly) when the recoil spring is still
held in compression.

Refer to Special Instruction, SMHSB273 which

contains the disassembly procedure that must be
used to decrease the possibility of injury while
performing service on the track roller frame .

•
12 SEBU8146-06
Safety Section
Safety Messages

Hydraulic System Accumulator (9)

Safety message (9) is located beneath the fender on
the right hand platform .
Product Link (10) (If Equipped)
Safety message (10) is located on the console to the
right of the operator seat. Refer to Operation and
Maintenance Manual, SEBU7351, .. Product Link" for
information about th is service tool.
•

g01 372252

g01370917
AWARNING
Hydraulic accumulator contains gas and oi! under AWARNING
high pressure. Improper removal or repair proce-
dures could cause severe injury. To remove or re- This machine is equipped with a Caterpillar
pair, instructions in the service manual must be Product Link communication device. When elec-
followed. Special equipment is required for test- tric/electronic detonators are used, this com- •
ing and charging. munication device should be deactivated within
12 m (40 ft) of a blast site, or within the distance
mandated under applicable legal requirements.
Failure to do so could cause interference with
blasting operations and result in serious injury or
death.

•
 SEBU8146-06 13
Safety Section
Add itional Messages

• Hydraulic System Accumulator (11)

Safety message (11) is located below the dozer
control on the right console in the cabo

g01372252

AWARNING
Hydraulic accumulator contains gas and oil under
high pressure. Improper removal or repair proce-
dures could cause severe injury. To remove or re-
pair, instructions in the service manual must be

•
followed. Special equipment is required for test-
ing and charging.

i02BB0306

Additional Messages
SMCS Code: 7405

There are several specific messages on th is machine.

The exact location of the hazards and the description
of the hazards are reviewed in th is section . Please
beco me familiarized with ali messages.

Make sure that ali of the messages are leg ible.

Clean the messages or replace the messages if
you cannot read the words. Replace the illustrations
if the iIIustrations 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 fal I.

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 partoAny
Caterpillar dealer can provide new messages.
14 SEBU8146-06
Safety Section
Additional Messages

•
g01433716
IlIustration 5

Air Conditioner (1)

!his message is located in the cab on the left side

bf the instrument paneI.
Orbcomm Type Approval: 148KME-CAT

((0888(1)
IC: 216701105A
Q R134a O. Okg
Ó PAG 4C-2959

IlIuslralion 7
g01213010
•
Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a
IIlustration 6
g01213009 specific country.

his message for the air conditioner has the Product Link (3)
II

. ppropriate information for the following services: the

~ir conditioner lubricant, the refrigerant charge, and This message is located on the window inside the
the refrigerant capacity. Also, this safety message cabo
ihstructs the usage of the proper safety information.

Follow instruction in order to avoid engine damage.

~ CC Compliance (2)

this message is located on the product link module

on the back right ROPS of the cab o

IlIuslralion 8
g01418953

•
 SEBU8146-06 15
Safety Section
General Hazard Information

• The Product Link System is a satellite communication

device that transmits information regarding the
machine back to Caterpillar and Caterpillar dealers
and customers. Alllogged events and diagnostic
codes that are available to the Caterpillar Electronic
Q, . ~
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
(i) 'd
improve Caterpillar products and Caterpillar services.

Refer to Operation and Maintenance Manual,

~ ~
"Product Link" for more information.

Reference: See Operation and Maintenance Manual ,

m ~
"Maintenance Interval Schedule" for ali maintenance g00702020
recommendations. IIlustration 10

Wear a hard hat, protective glasses, and other

i03559343 protective equipment, as required .
General Hazard Information Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
SMCS Code: 7000
Make sure that ali protective guards and ali 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 allloose items such as lunch boxes tools

and other items that are not a part of the eq~ipme~t.

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.

lIIustration 9 g00104545 Do not smoke when you service an air conditioner.

Also, do not smoke if refrigerant gas may be present.
Attach a "Do Not Operate" warning tag or a similar Inhaling the fumes that are released from a flame that
warning tag to the start switch or to the controls contacts air conditioner refrigerant can cause bodily
before you service the equipment or before you harm or death. Inhaling gas from air conditioner
repair the equipment. These warning tags (Special refrigerant through a lighted cigarette can cause
Instruction , SEHS7332) are available from your bodily harm or death.
Caterpillar dealer.
Never put maintenance fluids into glass containers.
Know the width of your equipment in order to maintain Drain ali liquids into a suitable container.
proper clearance when you operate the equipment
near fences or near boundary obstacles. Obey ali local regulations for the disposal of liquids.

Be aware of high voltage power lines and power Use ali cleaning solutions with care. Report ali
cables that are buried . If the machine comes in necessary repairs.
contact with these hazards, serious injury or death
may occur from electrocution . 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 .
 16 SEBU8146-06
I Safety Section
General Hazard Information

When you perform maintenance above ground levei

use appropriate devices such as ladders or man lift
machines. If equipped, use the machine anchorage
points and use approved fali arrest harnesses and
lanyards.
•
I Pressurized Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This 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 IIlustration 11
900687600
goggles or a protective face shield .
Always use a board or cardboard when you check
~he maximum air pressure for cleaning purposes for a leak. Leaking fluid that is under pressure can
must be reduced to 205 kPa (30 psi) when the penetrate body tissue. Fluid penetration can cause
rozzle is deadheaded and the nozzle is used with serious injury and possible death. A pin hole leak can
an effective chip deflector and personal protective cause severe injury. If fluid is injected into your skin,
equipment. The maximum water pressure for you must get treatment immediately. Seek treatment
çleaning purposes must be below 275 kPa (40 psi). from a doctor that is familiar with this type of injury.

Trapped Pressure Containing Fluid Spillage

Pressure can be trapped in a hydraulic system. Care must be taken in arder to ensure that fluids •
~eleasing trapped pressure can cause sudden are contained during performance of inspection,
rjnachine movement or attachment movement. Use maintenance, testing, adjusting and repair of the
caution if you disconnect hydraulic lines ar fittings . equipment. Prepare to collect the fluid with suitable
Iil igh pressure oi! that is released can cause a hose to containers before opening any compartment or
whip. High pressure oil that is released can cause oil disassembling any component that contains fluids.
tb spray. Fluid penetration can cause serious injury
~nd possible death. Refer to Special Publication, NENG2500, "Caterpillar
Dealer Service Tool Catalog" for the following items:
Fluid Penetration
• Tools that are suitable for collecting fluids and
F'ressure can be trapped in the hydraulic circuit long equipment that is suitable for collecting fluids
after the engine has been stopped . The pressure can
c~use hydraulic fluid or items such as pipe plugs to • Tools that are suitable for containing flu ids and
escape rapidly if the pressure is not relieved correctly. equipment that is suitable for containing fluids
I

do not remove any hydraulic components or parts Obey ali local regulations for the disposal of liquids.

~
til pressure has been relieved or personal injury
ay occur. Do not disassemble any hydraulic
c mponents 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.

•
 SEBU8146-06 17
Safety Section
Crushing Prevention and Cutting Prevention

• Asbestos Information • Comply with applicable rules and regulations

for the work place. ln the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. lhese 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

g00702022
IlIustration 12

Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

Use caution . Avoid inhaling dust that might be

generated when you handle components that contain

•
asbestos fibers. Inhaling this dust can be hazardous
to your health. lhe components that may contain g00706404
asbestos fibers are brake pads, brake bands, lining IIlustration 13
material , clutch plates, and some gaskets. lhe
asbestos that is used in these components is usually Improperly disposing of waste can threaten the
bound in a resin or sealed in some way. Normal environment. Potentially harmful fluids should be
handling is not hazardous unless airborne dust that disposed of according to local regulations.
contains asbestos is generated .
Always use leakproof containers when you drain
If dust that may contain asbestos is present, there fluids . Do not pour waste onto the ground , down a
are several guidelines that should be followed : drain, or into any source of water.

• Never use compressed air for cleaning . i01359664

• Avoid brushing materiais that contain asbestos. Crushing Prevention and

• Avoid grinding materiais that contain asbestos. Cutting Prevention
• Use a wet method in order to clean up asbestos SMCS Code: 7000
materiais.
Support the equipment properly before you perform
• A vacuum cleaner that is equipped with a high any work or maintenance beneath that equipment.
efficiency particulate air filter (HEPA) can also be Do not depend on the hydraulic cylinders to hold
used. up the equipment. Equipment can fali if a control is
moved , or if a hydraulic line breaks.
• Use exhaust ventilation on permanent machining
jobs. Do not work beneath the cab of the machine unless
the cab is properly supported.

• • Wear an approved respirator if there is no other

way to control the dust. Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while
the engine is running .
18 SEBU8146-06
Safety Section
Burn Prevention

Never jump across the starter solenoid terminais Ensure that the filler cap is cool before removing the •
in order to start the engine. Unexpected machine filler cap. The filler cap must be cool enough to touch
movement could result. with a bare hand . Remove the filler cap slowly in
order to relieve pressure.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the Cooling system cond itioner contains alkali. Alkali can
movement of the equipment or the machine. Stay cause personal injury. Do not allow alkali to contact
clear of areas that may have a sudden change in the skin , the eyes, or the mouth .
clearance with machine movement or equipment
movement.
Oils
Stay clear of ali rotating and moving parts.
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also ,
If it is necessary to remove guards in order to perform
do not allow hot components to contact the skin .
maintenance, always install the guards after the
maintenance is performed .
Remove the hydraulic tank fi ller cap only after the
engine has been stopped . The filler cap must be
Keep objects away from moving fan blades. The fan
cool enough to touch with a bare hand. Follow the
blade will throw objects or cut objects. standard procedure in this manual in order to remove
the hydraulic tank filler cap.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
Batteries
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure Electrolyte is an acid oElectrolyte can cause personal
personnel. Make sure that the area is clear of people injury. Do not allow electrolyte to contact the skin or
when yo strike a retainer pin oTo avoid injury to the eyes. Always wear protective glasses for servicing
your eyes, wear protective glasses when you strike batteries. Wash hands after touching the batteries •
a retainer pin o and connectors. Use of gloves is recommended.

Chips or other debris can fly off an object when you

i03659986
strike the object. Make sure that no one can be
Injured by flying debris before striking any object. Fire Prevention and Explosion
Prevention
I i01329099
SMCS Code: 7000
Burn Prevention
~MCS Code: 7000

IDo not touch any part of an operating engine.

Allow the engine to cool before any maintenance is
performed on the engine. Relieve ali pressure in the
air system, in the oil system, in the lubrication system,
in the fuel system, or in the cooling system before
any lines, fittings or related items are disconnected.

Çoolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under g00704000
pressure . The radiator and ali lines to the heaters or IIlustration 14
to the engine contain hot coolant.

•
General
/lIny contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to Ali fuels , most lubricants, and some coolant mixtures
c~ol before the cooling system is drained. are flammable .

Check the coolant levei only after the engine has To minimize the risk of fire or explosion , Caterpillar
been stopped . recommends the following actions.
 SEBU8146-06 19
Safety Section
Fire Prevention and Explosion Prevention

• Always perform a walk-Around Inspection, which

may help you identify a fire hazard . Do not operate
a machine when a fire hazard exists. Contact your
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 fluid leak. Repair

leaks and clean up fluids before resuming machine
operation . Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire . A tire may cause personal injury or death.
•
Remove flammable material such as leaves, twigs,
papers, trash , etc. These items may accumulate in
the engine compartment or around other hot areas
and hot parts on the machine.

Keep the access doors to major machine

compartments closed and access doors in working lIIustration 15
g00704059
condition in order to permit the use of fire suppression
equipment, in case a fire should occur. Use caution when you are fueling a machine. Do not
smoke while you are fueling a machine. Do not fuel
Clean ali accumulations of flammable materiais such a machine near open flames or sparks. Always stop
as fuel , oil and debris from the machine. the engine before fueling . Fill the fuel tank outdoors.
Properly clean areas of spillage.
• Do not operate the machine near any flame .
Follow practices for safe fueling that are described
Keep shields in place. Exhaust shields (if equipped) in the "Operation" section of the Operation and
protect hot exhaust components from oil spray or fuel Maintenance Manual section and follow local
spray in case of a break in a line, in a hose, or in a regulations. Never store flammable fluids in the
seal. Exhaust shields must be installed correctly. operator compartment of the machine.
Do not weld or flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and Battery and Battery Cables
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding
or flame cutting . Ensure that the components are
properly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallic

hoods or fenders may be flammable and/or explosive.
Repair such components in a well ventilated area
away from open flames or sparks. Use suitable
Personal Protection Equipment (PPE) .

Inspect alllines and hoses for wear or deterioration.

Replace damaged lines and hoses. The lines and
the hoses should have adequate support and secure
clamps. Tighten ali connections to the recommended
torque. Damage to the protective cover or insulation
may provide fuel for fires .

• Store fuels and lubricants in properly marked

containers away from unauthorized personnel. Store
oily rags and flammable materiais in protective
containers. Do not smoke in areas that are used for
storing flammable materiais.
IIlustration 16 g00704135
20 SEBU8 146-06
Safety Section
Fire Prevention and Explosion Prevention

Caterpillar recommends the following in order to An exposed wire on the ground cable between the •
minimize the risk of fire or an explosion related to battery and the disconnect switch may cause the
the battery. disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surface. This
Do not operate a machine if battery cables or related may result in an unsafe condition for servicing the
parts show signs of wear or damage. Contact your machine . Repa ir components or replace components
Caterpillar dealer for service. before servicing the machine.

Follow safe procedures for engine starting with jump

start cables. Improper jumper cable connections can AWARNING
cause an explosion that may result in injury. Refer to
Operation and Maintenance Manual, "Engine Starting Fire on a machine can res ult in personal injury
with Jump Start Cables" for specific instructions. or death. Exposed battery cables that come into
contact with a grounded connection can result in
Do not charge a frozen battery. This may cause an fires. Replace cables and related parts that show
explosion. signs of wear or damage. Contact your Caterpillar
dealer.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas. Wiring
Never check the battery charge by placing a metal Check electrical wires daily. If any of the following
object across the terminal posts. Use a voltmeter in conditions exist, replace parts before you operate
order to check the battery charge. the machine.

Daily inspect battery cables that are in areas that • Fraying

are visible. Inspect cables, clips, straps, and other

•
restraints for damage. Replace any damaged parts. • Signs of abrasion or wear
Check for signs of the following , which can occur
over time due to use and environmental factors : • Cracking

• Fraying • Discoloration

• Abrasion • Cuts on insulation

• Other damage
• Cracki 9

.. Discoloration Make sure that ali clamps, guards , clips, and straps
are reinstalled correctly. This will help to prevent
• Cuts o the insulation of the cable vibration , rubbing against other parts , and excessive
heat during machine operation.
• Fouling
Attaching electrical wiring to hoses and tubes that
• Corroded terminais, damaged terminais, and loose conta in flammable fluids or combustible fl uids should
terminais be avoided .

Replace damaged battery cable(s) and replace Consult your Caterpillar dealer for repair or for
any related parts. Eliminate any fouling , which may replacement parts.
have cau sed insulation failure or related component
clamage or wear. Ensure that ali components are Keep wiring and electrical connections free of debris.
~i nstalle d correctly.
Unes, Tubes and Hoses
4-n exposed wire on the battery cable may cause
a short to ground if the exposed area comes into Do not bend high pressure lines. Do not strike high
contact with a grounded surface. A battery cable pressure lines. Do not install any lines that are bent or •
short produces heat from the battery current, which damaged . Use the appropriate backup wrenches in
rnay be a fire hazard . order to tighten ali connection s to the recommended
torque.
 SESU8146-06 21
Safety Section
Fire Extinguisher Location

• Ether
Ether (if equipped) is commonly used in cold weather
applications. Ether is flammable and poisonous.

,.;e. 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

900687600 while you are replacing an ether cylinder or while you
IlIustration 17 are using an ether spray.
Check lines, tubes and hoses carefully. Wear Do not store ether cylinders in living areas or in the
Personal Protection Equipment (PPE) in order to operator compartment of a machine. Do not store
check for leaks. Always use a board or cardboard ether cylinders in direct sunlight or in temperatures
when you check for a leak. Leaking fluid that is under above 49° C (120.2° F). Keep ether cylinders away
pressure can penetrate body tissue. Fluid penetration from open flames or sparks.
can cause serious injury and possible death. A pin
hole leak can cause severe injury. If fluid is injected Dispose of used ether cylinders properly. Do not
into your skin , you must get treatment immediately. puncture an ether cylinder. Keep ether cylinders
Seek treatment from a doctor that is familiar with this away from unauthorized personnel.
type of injury.

• Replace the affected parts if any of the following

conditions are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

Fire Extinguisher
As an additional safety measure, keep a fire
extinguisher on the machine.

Se familiar with the operation of the fire extinguisher.

Inspect the tire extinguisher and service the fire
• Wires are exposed . extinguisher regularly. Follow the recommendations
on the instruction plate.
• Outer coverings are swelling or ballooning .
Consider installation of an aftermarket Fire
• Flexible parts of the hoses are kinked . Suppression System, if the application and working
conditions warrant the installation.
• Outer covers have exposed embedded armoring .
i02051589
• End fittings are displaced.
Fire Extinguisher Location
Make sure that ali clamps, guards, and heat shields
are installed correctly. During machine operation , this SMCS Code: 7419
will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes and Make sure that a fire extinguisher is available. Se
hoses. familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
Do not operate a machine when a fire hazard extinguisher. Obey the recommendations on the
exists. Repair any lines that are corroded, loose instruction plate.
or damaged. Leaks may provide fuel for fires .

•
Consult your Caterpillar dealer for repair or for Mount the fire extinguisher in the accepted location
replacement parts. Use genuine Caterpillar parts or per local regulations .
the equivalent, for capabilities of both the pressure
limit and temperature limit. Do not weld the ROPS structure in order to install the
fire extinguisher. Also, do not drill holes in the ROPS
structure in order to mount the fire extinguisher on
the ROPS.
22 SEBU8146-06
Safety Section
Track Information

If your machine is equipped with a ROPS structure, i01896223 •

strap the mounting plate to a leg of the ROPS in
order to mount the fire extinguisher, as needed . If Before Starting Engine
the weight of the fire extinguisher exceeds 4.5 kg
(10 Ib), mount the tire extinguisher near the bottom of SMCS Code: 1000; 7000
the ROPS . Do not mount the fire extinguisher at the
upper one-third area of the ROPS. Start the engine only from the operator's
compartment. Do not short across the battery
Consult your Caterpillar dealer for the proper terminais and do not short across the batteries.
procedure for mounting the fire extinguisher. Bypassing the engine neutral start system can
damage the electrical system .

i01329108 Inspect the condition of the seat belt and mounting

hardware. Replace any damaged parts or worn parts.
Track Information Regardless of appearance, replace the seat belt after
three years of use. Do not use an extension for a
SMCS Code: 7000 seat belt on a retractable seat belt.
Track adjusting systems use either grease or oil Adjust the seat so that full pedal travei can be
under high pressure to keep the track under tension. achieved . Make sure that the operator's back is
against the back of the seat.
Grease ar oil under high pressure coming out of the
relief valve can penetrate the body causing injury or Make sure that the machine is equipped with a
death. Do not watch the relief valve to see if grease lighting system that is adequate for the job conditions.
or oil is escaping. Watch the track or track adjustment Make sure that ali lights are working properly. Before
cylinder to see if the track is being loosened . you start the engine or before you move the machine,
make sure that no one is working on the machine,
The pins and bushings in a dry track pin joint working underneath the machine or working close •
can beco me very hot. It is possible to burn the to the machine. Make sure that the area is free of
fingers if there is more than brief contact with these personnel.
components.

i03560481
i01122596

I Electrical Storm Injury Engine Starting

Prevention SMCS Code: 1000; 7000

SMCS Code: 7000 If a warning tag is attached to the start switch or

attached to the controls, do not start the engine. Also,
When lightning is striking in the vicinity of the do not move any controls.
machine, the operator should never attempt the
following procedures: Move ali hydraulic controls to the HOlD position
before starting the engine. Move the transmission
• Mount the machine. control to NEUTRAL position .

• Dismount the machine. Engage the parking brake switch .

If you are in the operator's station during an electrical Diesel engine exhaust contains products of
storm, stay in the operator's station . If you are on the combustion. These products can be harmful to your
ground during an electrical storm, stay away from health. Always start the engine and always operate
the vicin ity of the machine. the engine in a well ventilated area . If you are in an
enclosed area, vent the exhaust to the outside .

Briefly sound the horn before you start the engine .

•
 SEBU8146-06 23
Safety Section
Before Operation

• Before Operation
SMCS Code: 7000
i01896559 • Safety instructions

• Controlled patterns of machine movement and

vehicle movement

• Workers that direct traffic to move when it is safe

Clear ali personnel from the machine and from the
area. • Restricted areas
Remove ali obstacles from the path of the machine. • Operator training
Beware of hazards such as wires, ditches, etc.
• Warning symbols or warning signs on machines
Be sure that ali windows are clean . Secure the doors or on vehicles
and the windows in either the open position or the
shut position. • A system of communication
Adjust the rearview mirrors (if equipped) for best • Communication between workers and operators
vision close to the machine. Make sure that the prior to approaching the machine
machine horn, the backup alarm (if equipped) and ali
other warning devices are working properly. Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
Reference: Refer to Operation and Maintenance evaluated .
Manual, "Walk-Around Inspection" in this manual.

Fasten the seat belt securely. i03633193

Restricted Visibility

•
i0316231 7
SMCS Code: 7000
Visibility Information
The size and the configuration of this machine may
SMCS Code: 7000 result in areas that can not be seen when the operator
is seated . IlIustration 18 provides an approximate
Before you start the machine, perform a walk-around visual indication of areas of significant restricted
inspection in order to ensure that there are no visibility. IlIustration 18 indicates restricted visibility
hazards around the machine. areas at ground levei inside a radius of 12 m (40 ft)
from the operator on a machine without the use of
While the machine is in operation, constantly survey optional visual aids. This illustration does not provide
the area around the machine in order to identify areas of restricted visibility for distances outside a
potential hazards as hazards beco me visible around radius of 12 m (40 ft) .
the machine.
This machine may be equipped with optional visual
Your machine may be equipped with visual aids. aids that may provide visibility to some areas with
Some examples of visual aids are Closed Circuit restricted visibility. Refer to this Operation and
Television (CCTV) and mirrors. Before operating the Maintenance Manual , "Mirror" for more information on
machine, ensure that the visual aids are in proper additional visibility. If your machine is equipped with
working condition and that the visual aids are clean . cameras, refer to this Operation and Maintenance
Adjust the visual aids using the procedures that are Manual, "Camera" for more information on additional
located in this Operation and Maintenance Manual. visibility. For areas that are not covered by the
If equipped, the Work Area Vision System shall be optional visual aids, the job site organization must be
adjusted according to Operation and Maintenance utilized to minimize hazards of this restricted visibility.
Manual, SEBU8157, "Work Area Vision System". See Operation and Maintenance Manual, "Visibility
Information" for more information regarding job site
It may not be possible to provide direct visibility on organization .
large machines to ali 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 :
24 SEBU8146-06
Safety Section
Operation

• additional seat belt

• Rollover Protective Structure (ROPS)

Report any repairs that are needed and noted during

operation .
•
Carry attachments elose to the ground , approximately
40 cm (15 inches) above ground leveI. Do not go
elose to the edge of a eliff, an excavation, or an
overhang .

If the machine begins to sideslip, perform the

following procedure:

• Discard the load .

• Turn the machine downhi ll.

Be careful to avoid any condition which could lead

to tipping . Tipping can occur when you work on
IlIustratlon 18
g01949336 hills, banks and slopes. Also, tipping can occur
Top view of the machine
when you cross ditches, ridges or other unexpected
obstructions.
Note: The shaded areas indicate the approximate
Whenever it is possible, operate the machine up the
location of areas with significant restricted visibility.
slopes and down the slopes. Avoid operating the

Operation
SMCS Code: 7000
i02293406
machine across the slope, when possible.

Keep the machine under control. Do not overload the

machine beyond capacity.

Towing devices and eyes that are not part of machine

must be adequate.
•
Note: The "Machine Operating Temperature Range"
is noted in the following information. Connect trailing equipment to a drawbar or to a hitch
only.
The standard machine configuration is intended
for use within an ambient temperature range of Never straddle a wire cable or allow other personnel
-32 °C (-25.0 °F) to 50 °C (122.0 °F) . Special to straddle a wire cable.
configurations for different ambient temperatures
may be available. Consult your Caterpillar dealer for When you maneuver to connect the equipment, make
additional information on special configurations of sure that no personnel are between the machine
your machine. and trailing equipment. Block the hitch of the trailing
equipment in order to align the equipment with the
Only operate the machine while you are in a seat. drawbar.
The seat belt must be fastened while you operate
the machine. Only operate the controls while the Know the maximum dimensions of your machine.
engine is running . On machines that are disabled , the
controls may be used when the engine is not running . Always keep the Rollover Protective Structure
(ROPS) installed during machine operation.
Check for proper operation of ali controls and
protective devices while you operate the machine
slowl y in an open area. i01 492258

Before moving the machine, the operator must

ensu re that no one will be endangered .

Do not allow riders on the machine unless the

machine has the following equipment:
Parking
SMCS Code: 7000

Park on a levei surface. If you must park on a grade,

use blocks to prevent the machine from rolling .
•
• additional seat
 SEBU8146-06 25
Safety Section
Slope Operation

• Apply the service brake in order to stop the machine.

Move the transmission control to NEUTRAL position
and the speed control to LOW IOLE position . Engage
the parking brake switch.

Lower ali attachments to the ground .

Direction of travei - 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

Stop the engine. may be impeded by the following components:
equipment that is mounted on the machine, machine
Turn the engine start switch key to OFF position and configuration, weights, and counterweights.
remove the key.
Nature of surface - Ground that has been newly
Turn the key for the battery disconnect switch to the filled with earth may collapse from the weight of the
OFF position . Remove the key when you exit the machine.
machine for an extended period of time.
Surface material - Rocks and moisture of the
Turning the battery disconnect switch to the OFF surface material may drastically affect the machine's
position will provide the following benefits: traction and machine's stability. Rocky surfaces may
promote side slipping of the machine.
• Prevent battery discharge that is caused by a
battery short circuit. Slippage due to excessive loads - This may cause
downhill tracks or downhill tires to dig into the ground ,
• Prevent battery discharge that is caused by some which will increase the angle of the machine.
of the components.
Width of tracks or tires - Narrower tracks or
• Prevent battery discharge that is caused by narrower tires further increase the digging into the
vandalism. ground which causes the machine to be less stable .

• Slope Operation
SMCS Code: 7000
i02780235
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.

Machines that are operating safely in various Height of the working load of the machine -
applications depend on these criteria: the machine When the working loads are in higher positions, the
model, configuration , machine maintenance, stability of the machine is reduced .
operating speed of the machine, conditions of the
terrain, fluid leveis, and tire inflation pressures. The Operated equipment - Be aware of performance
most important criteria are the skill and judgment of features of the equipment in operation and the effects
the operator. on machine stability.

A well trained operator that follows the instructions Operating techniques - Keep ali attachments or
in the Operation and Maintenance Manual has pulled loads low to the ground for optimum stability.
the greatest impact on stability. Operator training
provides a person with the following abilities: Machine systems have limitations on slopes -
observation of working and environmental conditions, Slopes can affect the proper function and operation
feel for the machine, identification of potential of the various machine systems. These machine
hazards, and operating the machine safely by making systems are needed for machine control on slopes.
appropriate decisions.
Note: Safe operation on steep slopes may require
When you work on side hills and when you work on special machine maintenance. Excellent skill of
slopes, consider the following important points: the operator and proper equipment for specific
applications are also required . Consult the Operation

•
Speed of travei - At higher speeds, forces of inertia and Maintenance Manual sections for the proper fluid
tend to make the machine less stable. levei requirements and intended machine use.

Roughness of terrain or surface - The machine

may be less stable with uneven terrain .
26 SEBU8146-06
Safety Section
ffquipment Lowering with Engine Stopped

~quipment Lowering with

Engine Stopped
i01329161 Sound levei Information for
Machines in European Union
Countries and in Countries that
Adopt the "EU Directives"
•
SMCS Code: 7000
The dynamic operator sound pressure levei is 73
lBefore lowering any equipment with the engine dB(A) when "ISO 6396:1992" is used to measure the
stopped, clear the area around the equipment of value for an enclosed caboThe cab was properly
ali personnel. The procedure to use will vary with installed and maintained. The test was conducted
tihe type of equipment to be lowered. Keep in mind with the cab doors and the cab windows closed .
fost systems use a high pressure fluid or ~ir to
~aise or lower equipment. The procedure wllI cause
high pressure air, hydraulic, or some other media "The European Union Physical
to be released in order to lower the equipment. Agents (Vibration) Directive
'{Vear appropriate personal protec.tive equipme~t and
tollow the established procedure ln the Operatlon
2002/44/EC"
and Maintenance Manual , "Equipment Lowering with
~ngine Stopped" in the Operation Section of the Vibration Data for Track-Type Tractors
manual.
Information Concerning Hand/Arm Vibration
levei
i02614366
When the machine is operated according to the
Sound Information and intended use, the hand/arm vibration of th is mach ine
Vibration Information is below 2.5 meter per second squared .

SMCS Code: 7000 Information Concerning Whole Body Vibration •

levei
Sound levei Information This section provides vibration data and a method for
estimating the vibration levei for track-type tractors.
The operator Equivalent Sound Pressure Levei
(Leq) is 73 dB(A) when "ANSI/SAE J1166 OCT 98" Note: Vibration leveis are influenced by many
is used to measure the value for an enclosed cabo different parameters. Many items are listed below.
This is a work cycle sound exposure leveI. The cab
was properly installed and maintained . The test was • Operator training, behavior, mode, and stress
conducted with the cab doors and the cab windows
closed . • Job site organization , preparation , environment,
weather, and material
Hearing protection may be needed when the
machine is operated with an open operator station for • Machine type, quality of the seat, quality Df the
extended periods or in a noisy environment. Hearing suspension system, attachments, and condition Df
protection may be needed when the machine is the equipment
operated with a cab that is not properly maintained or
when the doors and windows are open for extended It is not possible to get precise vibration leveis for
periods Dr in a noisy environment. this machine. The expected vibration leveis can be
estimated with the information in Table 1 in order
The average exterior sound pressure levei is 73 to calculate the daily vibration exposure. A simple
dB(A) when the "SAE J88Apr95 - Constant Speed evaluation Df the machine application can be used .
Moving Test" procedure is used to measure the value
for the standard machine. The measurement was Estimate the vibration leveis for the three vibration
conducted under the following conditions: distance of directions. For typical operating conditions, use the
15 m (49.2 ft) and "the machine moving forward in an average vibration leveis as the estimated leveI. With
intermediate gear ratio". an experienced operator and smooth terrain , subtract
the Scenario Factors from the average vibration levei •
in order to obtain the estimated vibration leveI. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration levei in
order to obtain the estimated vibration leveI.
 SEBU8146-06 27
Safety Section
Sound Information and Vibration Information

• Note: Ali vibration leveis are in meter per second

squared .

Table 1

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

Machine Typical Operating Vibration Leveis 5cenarlo Factors

Type Activity X axis Yaxis Z axis X axis Yaxis Z axis
dozing 0,74 0,58 0,70 0,31 0,25 0,31
Track-Type
ripping 1,25 1,19 1,02 0,40 0,41 0,28
Tractors
transfer 0,87 0,80 0,97 0,43 0,40 0,34

Note: Refer to "ISO/TR 25398 Mechanical Vibration - 3. Keep the terrain in good condition .
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving a. Remove any large rocks or obstacles.
machines" for more information about vibration .
This publication uses data that is measured b. Fill any ditches and holes.
by international institutes, organizations and
manufacturers. This document provides information c. Provide machines and schedule time in order
about the whole body exposure of operators of to maintain the conditions of the terrain .
earthmoving equipment. Refer to Operation and
Maintenance Manual, SEBU8257, "The European 4. Use a seat that meets "ISO 7096". Keep the seat
Union Physical Agents (Vibration) Directive maintained and adjusted .
2002/44/EC" for more information about machine
vibration leveis. a. Adjust the seat and suspension for the weight

• The Caterpillar suspension seat meets the criteria of

"ISO 7096". This represents vertical vibration levei
under severe operating conditions. This seat is tested
with the input "spectral class EM6". The seat has a
transmissibility factor of "SEAT<O.7".
and the size of the operator.

b. Inspect and maintain the seat suspension and

adjustment mechanisms.

5. Perform the following operations smoothly.

The whole body vibration levei of the machine varies. a. Steer

There is a range of values. The low value is 0.5
meter per second squared. The mach ine meets the b. Brake
short term levei for the design of the seat in "ISO
7096". The value is 1.61 meter per second squared c. Accelerate.
for this machine.
d. Shift the gears.
Guidelines for Reducing Vibration leveis on
Earthmoving Equipment 6. Move the attachments smoothly.

Properly adjust machines. Properly maintain 7. Adjust the machine speed and the route in order
machines. Operate machines smoothly. Maintain the to minimize the vibration leveI.
conditions of the terrain. The following guidelines can
help reduce the whole body vibration levei: a. Drive around obstacles and rough terrain .

1. Use the right type and size of machine, equipment, b. Slow down when it is necessary to go over
and attachments. rough terrain .

2. Maintain machines according to the manufacturer's 8. Minimize vibrations for a long work cycle or a long
recommendations. travei distance .

• a. Tire pressures

b. Brake and steering systems

c. Controls, hydraulic system and linkages

a. Use machines that are equipped with
suspension systems.

b. Use the ride control system on Track-Type

Tractors.
28 SEBU8146-06
Safety Section
Operator Station

C. If no ride control system is available, reduce

speed in order to prevent bounce.

d. Haul the machines between workplaces.

Caterpillar, Inc.
www.cat.com

i03634321
•
9. Less operator comfort may be caused by other risk
factors. The following guidelines can be effective
Operator Station
in order to provide better operator comfort: SMCS Code: 7000
a. Adjust the seat and adjust the controls in order Any modifications to the inside of the operator station
to achieve good posture. should not project into the operator space or into
the space for the companion seat (if equipped) .
b. Adjust the mirrors in order to minimize twisted The addition of a radio, fire extinguisher, and other
posture. equipment must be installed 50 that the defined
operator space and the space for the companion seat
C. Provide breaks in order to reduce long periods
(if equipped) is maintained . Any item that is brought
of sitting . into the cab should not project into the defined
operator space or the space for the companion seat
d. Avoid jumping from the cab o (if equipped). A lunch box or other loose items must
be secured . Objects must not pose an impact hazard
e. Minimize repeated handling of loads and lifting in rough terrain or in the event of a rollover.
of loads.

f. Minimize any shocks and impacts during sports i03656846

and leisure activities.
Guards
Sources (Operator Protection)
The vlbration information and calculation procedure SMCS Code: 7000; 7150; 7325 •
is based on "ISOITR 25398 Mechanical Vibration
- Guideline for the assessment of exposure There are different types of guards that are used to
to whole body vibration of ride on operated protect the operator. The machine and the machine
earthmoving machines". Harmonized data is application determines the ty pe of guard that should
measured by international institutes, organizations be used .
and manufacturers.
A daily inspection of the guards is requ ired in order to
This literature provides information about assessing check for structures that are bent, cracked or loose.
the whole body vibration exposure of operators of Never operate a machine with a damaged structure.
earthmoving equipment. The method is based on
measured vibration emission under real working The operator becomes exposed to a hazardous
cond itions for ali machines. situation if the machine is used improperly or if poor
operating techniques are used . This situation can
Vou should check the original directive. This occur even though a machine is equipped with an
document summarizes part of the content of the appropriate protective guardo Follow the established
applicable law. This document is not meant to operating procedures that are recommended for you r
substitute the original sources. Other parts of these machine.
documents are based on information from the United
Kingdom Health and Safety Executive.

Refe r to Operation and Maintenance Manual ,

SEBU8257 , "The European Union Physical
Agents (Vibration) Directive 2002/44/EC" for more
information about vibration .

Consult you r local Caterpillar dealer for more

information about machine features that minimize
vibration leveis. Consult your local Caterpillar dealer
about safe machine operation .

Use the following web site in order to find your local

dealer:
•
 SEBU8146-06 29
Safety Section
Guards

• Rollover Protective Structure

(ROPS), Falling Object Protective
Structure (FOPS) or Tip Over
Protection Structure (TOPS)
• Rock quarries

• Forestry products

Additional guards may be required for specific

applications or work tools. The Operation and
The ROPS/FOPS Structure (if equipped) on your Maintenance Manual for your machine or your
machine is specifically designed , tested and work tool will provide specific requirements for the
certified for that machine. Any alteration or any guards. Consult your Caterpillar dealer for additional
modification to the ROPS/FOPS Structure could information.
weaken the structure. This places the operator
into an unprotected environment. Modifications or
attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
structure can be caused by an overturn , a falling
object, a collision , etc.

Do not mount items (fire extinguishers, first aid

kits, work lights, etc) by welding brackets to the
ROPS/FOPS Structure or by drilling holes in the

•
ROPS/FOPS Structure. Welding brackets or drilling
holes in the ROPS/FOPS Structures can weaken
the structures. Consult your Caterpillar dealer for
mounting guidelines.

The Tip Over Protection Structure (TOPS) is

another type of guard that is used on mini hydraulic
excavators. This structure protects the operator in
the event of a tipover. The same guidelines for the
inspection , the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.

Other Guards (If Equipped)

Protection from flying objects and/or falling objects is
required for special applications. Logging applications
and demolition applications are two examples that
require special protection .

A front guard needs to be installed when a work tool

that creates flying objects is used. Mesh front guards
that are approved by Caterpillar or polycarbonate
front guards that are approved by Caterpillar are
available for machines with a cab or an open canopy.
On machines that are equipped with cabs, the
windows should also be closed. Safety glasses are

•
recommended when flying hazards exist for machines
with cabs and machines with open canopies .

If the work material extends above the cab, top

guards and front guards should be used. Typical
examples of this type of application are listed below:

• Demolition applications
30 SEBU8146-06
Product Information Section
General Information

Product Information
Section
Table 2

D6T Track-Type Tractor

Weight without Implements
Weight with 6S Bulldozer
16397 kg (36150 Ib)
18997 kg (41881 Ib)
•
General Information Weight with 6S Bulldozer 20653 kg (45531 Ib)
and Ripper

i03653169
Table 3
Specifications D6T LGP Track-Type Tractor

SMCS Code: 1000; 7000 Weight without Implements 18915 kg (41701 Ib)
Weight with 6S Bulldozer 21717 kg (47877 Ib)
Weight with 6S Bulldozer 22910 kg (50507 Ib)
and Winch

Table 4

D6T LGP VPAT BULLDOZER

Weight without Implements 19112 kg (42135 Ib)
Weight with 6S Bulldozer 22900 kg (50485 Ib)
Weight with 6S Bulldozer 24093 kg (53115 Ib)
and Winch

IlIustratlon 19 901138146
Table 5

D6T XL Track-Type Tractor

Weight without Implements
Weight with 6SU Bulldozer
Weight with 6SU Bulldozer
16771 kg (36974 Ib)
19750 kg (43541 Ib)
21406 kg (47191 Ib)
•
and Ripper

Table 6

D6T XL VPAT BULLDOZER

Weight without Implements 17247 kg (38022 Ib)
Weight with 6SU Bulldozer 20875 kg (46022 Ib)
Weight with 6SU Bulldozer 22531 kg (49672 Ib)
901138255 and Ripper
IIlustration 20
(1) Operator's Compartment
(2) Ra diator Table 7
(3) Bulldozer D6T XW Track-Type Tractor
(4) Engine Compartment
(5) Hydraulic Tank Weight without Implements 17432 kg (38431 Ib)
(6) Bat1eries
(7) Fuel Tank Weight with 6SU Bulldozer 20411 kg (44998 Ib)
(8) Transmission
(9) Ripper Weight with 6SU Bulldozer 22066 kg (48648 Ib)
(10) Winch and Ripper

•
 SEBU8146-06 31
Product Information Section
General Information

• Table8
06T XW VPAT BULLOOZER
Weight without Implements 17784 kg (39208 Ib)
Weight with 6SU Bulldozer 21468 kg (47328 Ib)
Weight with 6SU Bulldozer 23123 kg (50978 Ib)
and Ripper

~--------8--------~
g00768969
IIlustration 21

•
g00768976
IlIustration 22

The basic machine specifications are listed below.

Table 9

06T Track-Type Tractor

VPAT VPAT VPAT
STO LGP XL XW LGP XL XW
Engine Power 185 hp std 200 hp std 200 hp std 185 hp std 200 hp std 200 hp std 185 hp std
Engine (Make and Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar
Caterpillar C9
Model) C9 C9 C9 C9 C9 C9
Engine 9.1 L 9.1 L 9.1 L 9.1 L 9.1 L 9.1 L
9.1 L (555 in')
Displacement (555 in') (555 in' ) (555 in' ) (555 in') (555 in 3) (555 in' )

•
Engine Rated
1850 RPM 1850 RPM 1850 RPM 1850 RPM 1850 RPM 1850 RPM 1850 RPM
Speed
Engine (No. of
6 6 6 6 6 6 6
Cylinders)
(continued)
32 SEBU8146-06
Product Information Section
General Information

(Table 9, conld)

Height (Top of
ROPS) (A)

Length of the
3183 mm
(125.3 inch)

4089 mm
3233 mm
(127.3 inch)

4089 mm
3183 mm
(125.3
inch)
4089 mm
3183 mm
(125.3 inch)

4089 mm
3233 mm
(127.3 inch)

4089 mm
3183 mm
(125.3 inch)

4089 mm
3183 mm
(125.3 inch)

4089 mm
•
Machine(1) (161 .0
(161 .0 inch) (161 .0 inch) (161 .0 inch) (161.0 inch) (161 .0 inch) (161 .0 inch)
(B) inch)
3143 mm
Height to Top of 3143 mm 3193 mm 3143 mm 3193 mm 3143 mm 3143 mm
(123.8
Rain Cap (C) (123.8 inch) (125.7 inch) (123.8 inch) (125.7 inch) (123.8 inch) (123.8 inch)
inch)
Gro nd Clearance 383 mm 396 mm 383 mm 383 mm 396 mm 383 mm 383 mm
(O) (15.1 inch) (15.6 inch) (15.1 inch) (15.1 inch) (15.6 inch) (15.1 inch) (15.1 inch)
1880 mm 2286 mm 2133 mm 2286 mm 2286 mm 2133 mm 2286 mm
Track Gauge (E)
(74.02 inch) (90.0 inch) (84.0 inch) (90.0 inch) (90.0 inch) (84.0 inch) (90.0 inch)
2640 mm 2640 mm
Width Ove r 3479 mm 2939 mm 1358 mm 1358 mm 1358 mm
(103.94 (103.94
Trun nions (F)(2) (137.0 inch) (115.7 inch) (53.5 inch) (53.5 inch) (53.5 inch)
inch) inch)
Height of the 511 mm 511 mm 511 mm 511 mm 511 mm 511 mm 511 mm
Orawbar (20.1 inch) (20.1 inch) (20.1 inch) (20.1 inch) (20.1 inch) (20.1 inch) (20.1 inch)
Width of Track 560 mm 914 mm 560 mm 760 mm 812 mm 560 mm 762 mm
Shoe (22 inch) (36.0 inch) (22 inch) (29.9 inch) (32.0 inch) (22 inch) (30.0 inch)
2821 mm
Length ofTrack on 2610 mm 3243 mm 2821 mm 3243 mm 2821 mm 2821 mm
(111 .06
Ground (102.8 inch) (127.7 inch) (111 .06 inch) (127.7 inch) (111 .06 inch) (111.06 inch)

•
inch)
Operating
Weight(3)
(The ripper with a
22450 kg 24950 kg 22850 kg 24150 kg 25650 kg 24150 kg 24350 kg
single shank and (53680Ib)
(49493Ib) (55005Ib) (50375Ib) (53240Ib) (56550Ib) (53240Ib)
the SU-Blade are
included in the
weight.)
165 mm 165 mm 165 mm 165 mm 165 mm 165 mm 165 mm
Orawbar (Length)
(6.5 inch) (6.5 inch) (6.5 inch) (6.5 inch) (6.5 inch) (6.5 inch) (6.5 inch)
Ripper with
single shank
(Length)(4) (Length
is measured from
1403 mm 1403 mm 1403 mm 1403 mm 1403 mm 1403 mm 1403 mm
the grouser tip with (55.2 inch) (55.2 inch)
(55.2 inch) (55.2 inch) (55.2 inch) (55.2 inch) (55.2 inch)
the ripper shank in
a ve rtical position
and the ripper tip
at the ground.)
(1) The lenglh of lhe machine is measured frem lhe fronl of lhe machine lo lhe end of lhe drawbar. Add 145 mm (5.7 inch) for long drawbar
assembly.
(2) VPAT Irunnions are allached aI lhe case and frame .
(3) The weighl includes lhe machine and lhe following ilems: fulllank of fuel , alllubricanls , coolanl, SU-Blade wilh lill cylinde rs, single shank
ripper, hydraulic conlrols, air condilioner, 560 mm (22 inch) Irack (MS) , cab wilh EROPS , and operalor.
(4) Add lo lenglh of lhe machine .

The basic machine specifications are listed below.

•
 SEBU8146-06 33
Product Information Section
General Information

• Table 10
To obtain the proper lubrication , a maximum slope
should not exceed a grade of 100 percent or 45
D6T Series II Track-Type Tractor Bulldozer Blades
degrees.
Type of Blade
Width Capacity
Undercarriage Reference: See "Slope Operation" in this manual
VPAT 3880 mm 4.73 m 3 for more information .
XL (152.7 inch) (6.1 yd 3)
Do not use the machine in explosive environments.
VPAT 4160 mm 5.10 m3
XW (163.7 inch) (6.6 yd 3) Special attachments and operating instructions are
VPAT 4160 mm 4.32 m3 required for waste handling applications, forestry
LGP (163.7 inch) (5.6 yd 3) applications and other custom configurations.
S 3360 mm 3.89 m3
Winch (Applications)
"StdIXR" (132.3 inch) (5.09 yd 3)
S 4063 mm 3.78 m3 Winch speeds that are standard or slow speed can
LGP (160.0 inch) (4.94 yd 3) exert a bare drum line pull force of 311 kN (70000 Ib).
SU 3260 mm 5.61 m3
XL (128.3 inch) (7.34 yd 3)
SU 3260 mm 5.61 m3
"StdIXR" (128.3 inch) (7.34 yd 3)
SU 3556 mm 5.62 m3
XW (140 inch) (7.40 yd 3)
A 4166 mm 3.18 m3
"StdIXR" (164 inch) (4.16 yd 3)

• A 4166 mm 3.93 m3
XL (164 inch) (5.14 yd 3)
A 4200 mm 4.30 m3
XW (165.4 inch) (5.63 yd 3)

Intended Use
This machine is a track-type tractor that is classified
as a Tractor Oozer. The machine is earthmoving
equipment that is described in "ISO 6165:2006". The
machine propels the track forward . Also, the machine
propels the track rearward . This allows the machine
to move independently. The machine uses equipment
for dozing that cuts material. The material is moved
or graded through the forward motion of the machine.
A mounted attachment can be used to exert a push
or a pull force such as a ripper or towing winch .

Restrictions to Application and

Config u ration
Maximum approved operating weight is 26200 kg
(57761 Ib).

Maximum towing force of a drawbar is 320 kN

•
(71940Ib).

Maximum vertical load for a drawbar is 137 kN

(30800Ib).

The capability of the brake is equal to the ROPS

capability of 26200 kg (57761 Ib) when the slope is
less than 45 degrees.
34 SEBU8146-06
Product Information Section
Identiflcation Information

Identification Information

Plate Locations and Film

i03668580
SERIAL
NU W8 [R

~~~~~(
I
I
Im'EIIPlllAII O
I
1
AI"U,NGE-I
W[N1
NUNB(R 1
mo •
""' ''-DE lN V .S . A "l.AY$ ~V[ All NUWa rft$
Locations
g00880164
SMCS Code: 1000; 7000 IIlustration 25

The Product Identification Number (PI N) will be used The Serial Number Plate is located on the left side of
to identify a powered machine that is designed for the cylinder block near the rear of the engine.
an operator to ride.
The following information is stamped on the Serial
Caterpillar products such as engines, transmissions Number Plate : engine serial number, model , and
and major attachments that are not designed for an arrangement number.
operator to ride are identified by Serial Numbers.
Engine Serial Number _ _ _ _ _ _ _ _ _ __
For quick reference, record the identification numbers
in the spa ces that are provided below the illustration .
el
CJ.T SER. NO. ENCI NE .oon
MU ALT
fUll lOAO
RP . ROTAlION
UI'" ClJERPlUAII" Dr fun puwp ICOV
CAI- CATERPILLAR- AR NO.

I INJECTOR

•
BAR E ENC
"I 10lE RP. TURBO

I
r - - - - - - - - - - - - - - - - - - - CA'IUN.1AIIINC. POW[R HP
I I PEOIIIA, L I1Ia
l UlA ......
I .... CIfIXIt

I
~ __________________ J
1___ [J
__ ,

g00755014
IlIustration 26

g01140726
IlIustrat on 23 The Information Plate is on the engine valve
cover. The following information is stamped on
The PI N plate is attached to the ROPS mounting pad the Information Plate: engine's maximum altitude,
on th e transmission . horsepower, high idle, full load rpm , fue l settings, and
other information .
Machine PIN _ _ _ _ __ __ _ __ _ __

MOOEl

IlIustration 24

Tran smission Serial Number _ _ _ _ _ _ _ __

g0 11 407 59
IIlustration 27

The serial number plate for the dozer blade is

attached to the back side of the dozer.

Bulldozer Serial Number _ _ _ _ _ _ _ _ __

g01140774

•
 SEBU8146-06 35
Product Information Section
Identification Information

• Certification
CE Mark
This plate is positioned on the PIN plate on the left
side of the front frame .

For mach ines that are compliant to "2006/42/EC", the

following information is stamped onto the "CE" plate.

1.-
,
u_u ___u_____u__ u___ .,
g01147880 : '
IlIustration 28 ,,
""""''''''''''''''- ~
Ripper Serial Number _ _ _ _ _ _ _ _ _ __ :
:u... __ u\ ___ : -- ~ u~

The serial number plate for the ripper is located on

the ripper frame .
IC€-O
_O"-"'-I
g01883459
lIIustration 31
CE plate

• For quick reference , record this information in the

spaces that are provided below.

• Engine Power of primary engine (kW) _ _ _ __

• Engine Power for additional engine (kW) (if

equipped) _ _ _ _ _ _ _ _ _ _ __ _

g01209622 • Typical operating weight of machine for European

IlIustration 29
market (kg)._ _ _ _ _ _ _ _ _ _ _ __

• Year of construction _ _ _ _ _ _ _ _ _ _ __

• Machine Type_ _ _ _ _ _ _ _ _ _ _ __
SERIAL NUMBER

For machines that are compliant to "1998/37/EC", the

MODEL
) following information is stamped onto the "CE" plate.

'MNCH

ur UTEIIPILUr Dr
CAI- CATERPILLAR-

g01209629
IlIustration 30

r - - - - - - - - - - - - - - - - - - - CA~IIIC.
The serial number plate for the winch is located on I ~LI1"

•
.:.....100.. 1
':""'"JI"" I UIA
the right side of the winch case. J . ._ ::::.

I
I
I
I
D
Winch Serial Number _ _ _ _ __ _ _ __ _ _ ~--------- - -- --- - -- J --- __ l

IlIuslralion 32 g01140750
36 SEBU8146-06
Product Information Section
Identiflcation Information

For quick reference, record this information in the

spaces that are provided below.

• Engine Power of primary engine (kW) _ _ _ __

• Typical operating weight of machine for European

Structure certification (FOPS)

AWARNING
Structural damage, an overturn, modification, al-
•
market (kg) _ _ _ _ _ _ _ _ _ _ _ __ teration, or improper repair, can impair this struc-
ture's protective capability thereby voiding this
• Yea r___________________ certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
Structure certification (ROPS) its certification.

AWARNING The protective structure certification is located on

the cab o
Structural damage, an overturn, modification, al-
teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. This wlll void the certification. Consult
a Caterpillar dealer to determine this structure's FOPS: 8AEJ.II803448 APR98 LEVEL n
limitations without voiding its certification. 1503448:1992 LEVEL II

The protective structure certification is located on the

outside of the left post. DeR SERIES III, 07R SERlES •

&.IWI

IIlustration 35
ZlMH)1741

This machine has been certified to the standards that

are listed on the certification plate. The maximum
g0196891 7
•
mass of the machine, which includes the operator
and the aUachments without payload, should not
exceed the mass on the certification pia te.

Refer to Operation and Maintenance Manual,

"Guards (Operator Protection)" for more information.
g01968913
IlIustrallon 33
(A) Film on ROPS support assembly ISO 5ymbols (Model Usage)
(6) Film on FOPS cab
The following list contains ali of the ISO Symbols
that appear in this publication . The symbols are in
the order of appearance.
ROPS: SAEJ1 D40 MAY94, 1503471 :1994
On or Start
CD
DeR SERIES III, LB Off or Stop
D6R SERIES .. Xl, 57,7111
DeR SERIES .. XW,

•
DeR SERI9 III LGP

&.Iw l Electrical Oisconnect Switch - Engine

On
g01968914
IlIustralion 34
 SEBU8146-06 37
Product Information Section
Identification Information

•® Engine - Start

Ether Starting Aid - Eng ine Starting Aid

@
Engine Coolant - Temperature

Torque Converter Oil - Temperature

® @)
Electric Engine Preheat Hydraulic Oil - Temperature
@ @
Engine Service
Battery - Charging Condition
@)
ª
@
Fuel Levei Indicator
®) Engine - RPM

~
Parking Brake Ripper
@)
Rear Work Light

®
•
Implement Control Shutoff
@
Panei Lights Switch
@
Engine - Failure/Malfunction
@)
Transmission - Failure/Malfunction Flood Lights
@ Q)
Braking System - Failure/Malfunction Front Work Light
@) @
Engine Filter Element Indicator Dome Light
@ 9
Transmission Filter Indicator Front Wiper/Washer
@ @
Engine Oil - Pressure Left Door Wiper/Washer
@ @)
• @
Engine Temperature
@)
Right Door Wiper/Washer
38 SEBU8146-06
Product Information Section
Identification Information

@
Rear Wiper/Washer

Horn
®
Lumbar Support - Adjustment
•
Defogging

9 @)
Backup Alarm Transmission - Forward
@
,
~0 -
.... \'
®
Circulation Fan Control Switch Transmission - Reverse

® ®
Low Speed Transmission - Neutral

CD @
Medium Speed Bulldozer Blade - Hold
® ©
Medium High (Speed)
@)
•
Bulldozer Blade - Raise

®
High Speed Bulldozer Blade - Lower
([® ®
Bulldozer Blade - Float

~
Air Conditioner
@
Heater Bu lldozer Blade - Tilt Hold

® ©
Temperature Variable Control Bulldozer Blade - Tilt Left

O @
Bulldozer Blade - Tilt Right
@ Seat Back Angle Adjustment
@)
Ripper - Hold

~
Seat Adjustment - Fore and Aft
@
@ Seat Adjustment - Height
G
Ripper - Raise

•
 SEBU8146-06
Product Informar .39
Identification ;ofn Sectlon
_~ n ormation

• R·Ipper - Lower

W·meh - Brake On (Neutral)

W·meh - Reei-ln

W·meh - Brake Off

W·meh - Reei Out

®
Fuses

8
Alternator

@ Power Train ECM

G EngineECM

® Blower Motor

@ Panei Test Switeh

@ Window Washer

•
40 SEBU8146-06
Product Information Section
Identification Information

Declaration of Conformity
SMCS Code: 1000
i03637976

•
Table 11

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

EC DECLARATION OF CONFORMITY OF MACHINERY

Manufacturer: Caterpillar Inc., 100 N.E. Adams Street, Peoria, IL 61629 USA
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the
Authorities of European Union Member States on request:
Standards & Regulations Manager,Caterpillar France SAS 40,
Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France
I, the undersigned, _ _ _ _ , hereby certify that the construction equipment specified hereunder
Description: Generic Denomination : Earthmoving equipment
Function:
Model/Type:
Serial Number:
Commercial Name:
Steel track dozer
D6T

Caterpillar
•
Fulfils ali the relevant provisions of the following Directives

Directives Notified Body Document No.

2006/42/EC
2000/14/EC amended by 2005/88/EC ,
Note (1)
2004/108/EC

Note (1) Annex -_ _ Guaranteed Sound Power Level -_ _ dB (A)

Representative Equipment Type Sound Power Levei - _ _dB (A)
Engine Power per __-__ kW Rated engine speed - _ _ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File

Done at: Signature

Date: Name/Position

Note : The above information was correct as of August 2009, but may be subject to change , please refer to the individual
declaration of conformity issued with the machine for exact details.
•
 SEBU8146-06 41
Product Information Section
Identification Information

• Emissions Certification Film

SMCS Code: 1000; 7000; 7405
i02279469

Note: lhis information is pertinent in the United

States, in Canada , and in Europe.

A typical example is shown.

CATERPlllAR lHe . IMPORTANT ENG INE IHFORMATIO H

2000 5XDOO252
CIT ENGINE MOOEl : 3408 • OISPlAC EMENT : 18.01.. • VALVE lASH : O. ~ INTAKE 0.76mm EKHAUST

-I
F-.Y
YCPJQlaDH!K
nu
TlU _
MAXI_
AOVERTlSEO
.W (11')
~59 (750)
MAXI_
RATEO
SPEEII fRPMl
2100

J40I EII01IIE CONFORMS TO DllECT1YEll,u,{C FOR _ ·ROAD E _S.

M_
LOWIllE
SPEEO (APM)
750
MAlI. FUEL RATE

=:.:,
301

ECTYPEAPPIlOYAL NO. oIRl'll"W '.J8'"

EII01IIE CONFIIIIIIII TO 2000 U.I . El'A ANO C.lLI_ REIllUTIOMS LAROE NOII.fIGAO COMPRESSIOH~ONTIOH ENGINES.
MAXIIIUI
IITIAI. T.IIO
DEGREES BTDC
(lE CTRONIC
IXHAUST
IJIISSlON
CONTROl SYSTEM
EJ.4,DI.1 C, ECN,CAC

TlU EIIl1I1E II ClIITIFIEOTO OI'fIIATE ON C_ClW.Y AYAllAIU DIESEL FUEl.

GATE DF MANUFACTUIlE MONTH : 02

FMT:3500

90071 5940
IlIustration 36

• C..lT
FAIIIIlU
DE MOTEUR' :
YCPXl lBOHlK
X_I"",
MAli
ruIUU :
558 (750)
CATERPlLLM INe.
MOO~lE MOTEUR : 3408

_
MAIl
REGI Mi
INAl IIr",,") :
2100
- otsn : 18.<X.
MAJII
RtCIME
INFORMATIOH IMPORTANTE SUR l E MOlEUR

- JEU SOU PAPES ' O.38mm

RALE.TlIIr""'" :
7!)()
MAli OBIT O'INJ.
bUlS. MAli
1.."l/STROKE I IP1STON) :
301
2000
AOM ISS ION : 0.76 mm

MAli CALAIl E
NnALO·IIJ.
tCHAPPEMENT

IOEGRís) IAVANT PMH) :

ÉLECTRONICl.(
5XD00252

OISI'OSlTIF
ANTI·I'OLLUANT :
FM.OI,l C Sf'l.CAC

ct MOTEUII - IITCONFD_ MIl DIIECTlYU 'l~C I'OUR U I MOTEUIIS _ ROUnE AS. 110 AI'f'IlOIATlON TYPE EC tlRL'91I68AA'OOOI'1O
CE IIOTl1JR ,.... DT CONFORME AIJl R!GLEMENTATlONS 2100 OE L'AGENtE AIIIIRlCAI. OE I'IIOHCTlOH OE rE"VlRO"NEMENT IEPA) ET OE LA tAUFDRHIE POUR LES CROS MOTEURS NOH RDUTlERS ' COIIIPR!SSION-COHTACT.
CE MOTEUR DT HOMOLOGUE POUR fONCTIOHIlER AnC li CNIIURAHT DIESEl ou COMMEfICE .
DATE OE fMRlCA110ll 11IOlS) 01

tll qol111 nOlllolovatlon ant)-ponouo.

90071 5946
IIlustration 37

lhe Emission Certification Film is located on the side

of the engine .

•
42 SEBU8146-06
Operation Section
Before Operation

Operation Section i02906034 •

Daily Inspection
Before Operation SMCS Code: 1000; 7000

For maximum service life of the machine, perform a

i02189821 thorough walk-around inspection before you mount
the machine and before you start the engine.
Mounting and Dismounting
Inspect the area around the machine and under the
SMCS Code: 7000 machine . Look for loose bolts, trash buildup, oilleaks,
coolant leaks, broken parts or worn parts.

Inspect the tracks, track roller frames, idlers, and

rollers for oil leaks, and excessive wear.

Do not operate the machine until ali necessary

repairs have been made.

Note: Watch closely for leaks. If you observe a leak,

find the source of the leak and correct the leak. If you
suspect a leak or if you observe a leak, check the
fluid leveis more frequently.

Inspect the condition of the work tool and of the

hydraulic components. Sound the horn .

•
g00037860
IlIustration 38
Typica l example Check ali oil leveis, coolant leveis, and fuellevels .

Mou t the machine and dismount the machine only Daily, perform ali of the procedures that are applicable
at locations that have steps and/or handholds. Before to your mach ine :
you mount the machine, clean the steps and the
hand holds. Inspect the steps and handholds. Make • Operation and Maintenance Manual , "Backup
ali necessary repairs . Alarm - Test"

Face the machine whenever you get on the machine • Operation and Maintenance Manual, "Brakes,
and whenever you get off the machine. Indicators and Gauges - Test"

Maintain a three-point contact with the steps and with • Operation and Maintenance Manual, "Cab Filter
the handholds. (Fresh Air) - Clean/lnspectlReplace'"

Note: Three-point contact can be two feet and one • Operation and Maintenance Manual, "Cab Filter
hand . Three-point contact can also be one foot and (Recirculation) - Clean/lnspectlReplace'"
two ands.
• Operation and Maintenance Manual, "Cooling
Do not mount a moving machine. Do not dismount a System Coolant Levei - Check"
moving machine . Never jump off the machine. Do
not carry tools or supplies when you try to mount the • Operation and Maintenance Manual, "Engine Air
machine or when you try to dismount the machine. Precleaner - Clean"
Use a hand line to pull equipment onto the platform.
Do not use any controls as handholds when you • Operation and Maintenance Manual, "Engine Oil
enter the operator compartment or when you exit the Levei - Check"
operator compartment.

•
• Operation and Maintenance Manual , "Fuel System
Alternate Exit Water Separator - Drain"

Mach ines that are equipped with cabs have alternate • Operation and Maintenance Manual, "Hydraulic
exits. For additional information , see Operation and System Oil Levei - Check"Operation and
Maintenance Manual, "Alternate Exit". Maintenance Manual, "Brakes, Indicators and
Gauges - Test"
 SEBU8146-06 43
Operation Section
Before Operation

• • Operation and Maintenance Manual, "Seat Belt -

Inspect"

• Operation and Maintenance Manual , "Transmission

System Oil Levei - Check"

• Operation and Maintenance Manual, "Winch Oil

Levei - Check"

•
44 SEBU8146-06
Operation Section
Machine Operation

Machine Operation

Alternate Exit
i01930019
@
~
...
Fore and Aft Adjustment (1) - Pull up
fore and aft lever (1). This will move the
seat forward or this will move the seat back
to the desired position . Release lever (1) in order to
lock the seat in place.
•
SMCS Code : 7254; 7308; 7310
Adjusting the Angle of the Back of the
Mach ines with cabs are equipped with alternate exits. Seat
If a door becomes disabled , the other door can be
used as an alternate exit. Release the latch and open
the door.

i01919945

Seat
SMCS Code: 7312-025; 7324

Adjusting the Seat 2

The operator's seat that is provided with this machine
is in compliance with the appropriate class of "ISO
7096".

•
Note: Adjust the seat for a new operator or at the
begin ning of each shift.

The operator should be seated against the seat

backrest. Adjust the seat so that the operator is g00999313
IIlustration 40
allowed full travei of the pedais .
Back Angle Adjustment (2) - Lift lever
Adjusting the Fore and Aft Position of
the Seat
@ .0..
'CJ . (2) and allow the seat back to tilt forward .
Push the front of the backrest in order to tilt
the seat backward . Release lever (2) at the desired
position .

Adjusting the Bottom Seat Cushion

The bottom seat cushion has two positions.

IIlustration 39
g00999315
•
 SEBU8146-06 45
Operation Section
Machine Operation

• The bottom seat cushion is in the upper position or

the angled position when the end of the rod is in the
top of the groove in bracket (3) . Pull forward and
push down on the bottom seat cushion in order to
chang e the position of the bottom seat cushion back
to the lower position .

Adjusting the Height of the Seat

Seats with Mechanical Suspension

g00999400
lIIustration 41
The bottom seat cushion is shown in the lower or the flattest
position.

g00999908
The bottom seat cushion is in the lower or the flattest IlIustration 43

•
position when the end of the rod is in the bottom
of the groove in bracket (3) . Pull forward and pull Adjustment of the Seat Height (4) - Pull
upward on the bottom seat cushion in order to up on height adjustment lever (4) and pull
change the position of the bottom seat cushion back up on the seat in order to raise the height of
to the upper position . the seat. Pull up on height adjustment lever (4) and
push down on the seat in order to lower the height
of the seat.

Seats with Air Suspension and Toggle Switch

IlIustration 42 g009994 24

•
The botlom seat cushion is shown in the upper position or the 5
angled position .

IIlustration 44 g00999907
46 SEBU8146-06
Operation Section
Machine Operation

Seats With Air Suspension •

Adjustment of the Seat Height (5) -
Remove the weight from the seat. Hold The weight adjustment is automatically controlled by
toggle switch (5) upwardin order to raise adjusting the height of the seat. Observe the gauge
the seat. Hold toggle switch (5) downward in order on the front of the seat suspension (if equipped) in
to lower the seat. Release the toggle switch at the order to obtain the proper adjustment for the weight
preferred height. of the operator.

Seats with Air Suspension and Air Valve Knob Adjusting the Lumbar Support

IlIustration 45 g00999499

Adjustment of the Seat Height (6) - Push

IlIustration 47

Adjustment for the Lumbar Support

g01001077 •
@ in on the air valve knob (6) in order to raise
the height of the seat. Pull out on the air
(9) - Rotate the knob (9) clockwise in order
to increase support for the lower back.
valve knob (6) in order to lower the height of the seat. Rotate the knob (9) counterclockwise in order to
decrease support for the lower back.
Weight Adjustment
Seats with Mechanical Suspension

IlIustratlon 46

Weight Adjustment (7) - Rotate knob (7) and

observe gauge (8) in order to obtain the proper
adjustment for the weight of the operator.
g01001175

•
 SEBU8146-06 47
Operation Section
Machine Operation

• Extension for the Back of the Seat (if

equipped)
Retractable Seat Belt (11) - When the seat has
been adjusted to fit the operator, secure retractable
seat belt (11) .

Storage for the Operation and

10 ------.J.. Maintenance Manual

12

• \llustratian 48
g01001125

Extension for the Back of the Seat (10) - Lift up

on extension (10) in order to remove the extension .
\llustratian 50

The Operation and Maintenance Manual should be

g01001129

stored and secured in the seat storage area (12).

i03415082
When you install extension (10) push the
extension ali the way downward. lhe extension Seat Belt
should touch the top of the seat.
SMCS Code: 7327
Seat Belt
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. See your
Caterpillar dealer for ali replacement parts.

11 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.

g01001128
I\lustratian 49
48 SEBU8146-06
Operation Section
Machine Operation

Lengthening the Seat Belt Shortening the Seat Belt

•

IlIustration 51 g00100709 g00100713

IlIustration 53

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

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

manner.
2
3. If the seat belt does not fit snugly with the buckle
in the center, readjust the seat belt.

g00932817
Fastening lhe Seat Belt

3 •
IlIustration 52

2. To remove the slack in outer loop (1), rota te 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 g00932818
IlIustration 54
manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
Fasten the seat belt cate h (3) into the buckle (2).
Make sure that the seat belt is placed low across the
lap of the operator.

•
 SEBU8146-06 49
Operation Section
Machine Operation

• Releasing The Seat Belt Releasing The Seat Belt

g00100717 900039113
IlIustrati on 55 IIlustration 57

Pull Up on the release lever. This will release the seat Push the release button on the buckle in order to
belt. release the seat belt. The seat belt will automatically
retract into the retractor.
Seat Belt Adjustment for
Retractable Seat Belts Extension of the Seat Belt

Fastening The Seat Belt AWARNING

•
When using retractable seat belts, do not use seat
belt extensions, or personal injury or death can
result.

4 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 requ ires only non-retractable seat belts to

g00867598
be used with a seat belt extension .
IlIustration 56
Consult your Caterpillar dealer for longer seat belts
Pull seat belt (4) out of the retractor in a continuous and for information on extending the seat belts.
motion.

Fasten seat belt catch (3) into buckle (2). Make sure i0334806 1
that the seat belt is placed low across the lap of the
operator. Operator Controls
The retractor will adjust the belt length and the SMCS Code: 7300 ; 7301 ; 7451
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.

•
50 SEBU8146-06
Operation Section
Machine Operation

//
•
~ Ij
9
/1, /

(~
/
8

13
3
14

2 15

16

17
18, 19, 20
21 •
22

901215064
IIlustration 58
(1) Adjustable armrests (9) Gauges and indicators (17) Bulldozer control
(2) Parking brake control (10) Auto kickdown switch (18) ThroUle control switch
(3) Differential steering control (11) Autoshift switch (19) MVP switch
(4) Transmission direction selector (12) Engine start switch (20) Hydraulic lockout control
(5) Speed range selector (13) Window wiper/washer switch (21) Rippe r or winch control
(6) Service brake (14) Heating and air conditioning controls (22) Horn
(7) Decelerator pedal (15) Light switch
(8) Dome light (16) Operator mode select switch

•
 SEBU8146-06 51
Operation Section
Machine Operation

• Adjustable Armrests (1)

~
Parking Brake - Use this knob to engage
<®> the parking brake and lock the transmission
in the NEUTRAL position. When the parking
brake is engaged , the machine should not move.
To engage the parking brake, pull up on the knob.
To release the parking brake, push down on knob
(2). Keyswitch (2A) may be used to lock the parking
brake in the engaged position . Do not use the parking
brake to stop the machine.

Differential Steering Control and

Transmission Control (3)
g01107108
lIIustration 59
Left arrnrest

Use the following procedure in order to adjust the left

armrest and right armrest(1), if necessary.

1. Loosen the two knobs (1A) on the inside of the

armrest.

2. Move armrest (1) to the desired height.

• 3. Tighten the knobs .

Parking 8rake Control (2)

NOTICE
Do not engage the parking brake while the machine is
IIlustration 61
g01015497

The differential steering control (Iever) (3) allows the

steering system and the transmission system to be
simultaneously controlled . Push down on the parking
moving unless an emergency exists. brake switch in order to release the parking brake
and allow movement of the steering and transmission
The use of the parking brake as a service brake in reg- controls. The steering lever is mechanically locked
ular operation causes severe damage to the parking by the parking brake. The transmission contrais are
brake system. electronically disabled .

Transmission Control (4)

Selection of Transmission Speed Range
2A
Bidirectional Shift Mode

Bidirectional Shift - The machine is equipped with

a bidirectional shift function . This function allows
the operator to preset a FORWARD speed and a
REVERSE speed for directional changes.

The bidirectional shift function includes the following

settings:

•
g01150226
IlIustration 60
FIRST SPEEO FORWARO to SECONO
SPEEO REVERSE
52 SEBU8146-06
Operation Section
Machine Operation

SECONO SPEEO FORWARO to SECONO

SPEEO REVERSE
SECONO SPEEO FORWARO to FIRST SPEEO
REVERSE - Push autoshift button (11) three
times. When you shift the transmission to the
FORWARD position , the transmission will always
shift into the second physical gear. When you sh ift
the transmission to the REVERSE position , the
•
SECONO SPEEO FORWARO to FIRST
SPEEO REVERSE transmission will always shift into the first physical
gear. The speed shift mechanism is manual. Use.
the buttons in order to upshift or use the buttons ln
order to downshift. Speed shifts have no effect in
The bidirectional shift function can be selected with NEUTRAL.
push button (11). The current mode of operation is
shown by lights on the upper display module. Auto Kickdown Mode
When the machine is started , the machine is in Auto Kickdown - This feature provides the operator
the manual mode. No light is lighted . When the with an auto kickdown mode of operation . Once
bidirectional shift function is deactivated , the machine the feature has been activated by the operator, the
will return to the same speed that was used prior transmission will automatically downshift to a lower
to the directional shift. Repeatedly push the button speed range when a significant load increase is
(11) for the bidirectional shift functio.n.in o~der to . detected. Once the load on the machine has been
select the modes of shifting . If the bldlrectlonal shlft reduced , the operator can return to the desired speed
function is not desired , the machine can be operated range by manually upshifting. The auto kickdown .
in the manual mode. Push on the button until ali of will only downshift the transmission . The feature wllI
indicators for the bidirectional shift function are off. not automatically upshift the transmission . The auto
The bidirectional shift function will automatically reset kickdown functions in FORWARD and REVERSE
the OFF when the machine is powered down . speed range.
For the best results , change the options with the To activate the auto kickdown mode of operation , •
trans mission in NEUTRAL. push switch (10) that is located in the center of the
dashboard . The current mode of operation is shown
FIRST SPEEO FORWARO to SECONO SPEEO by the light above the switch. Also, an indicator light
REVERSE - Push button (11) once for the autoshift on the upper display module will illuminate when
function . A directional shift to the FORWARD position the auto kickdown is active. The display window wi ll
will always shift to the first physical gear. A directional display "LO" or "HI" when the auto kickdo~n .is a~tive .
shift to the REVERSE position will always shift to the When the machine is started , the transmlsslon IS
second physical gear. With the transmission in the in the previously selected mode. If you start up the
NEUTRAL position , the display for the transmission machine, and the auto kickdown is not selected , push
indicates "N". The speed shift mechanism is manual. switch (10) . If the auto kickdown is active, the light
Use the buttons to upshift or use the buttons to is illuminated . ln order to achieve the best results ,
downsh ift. Speed shifts have no effect in NEUTRAL. select the auto kickdown with the tran smission in
NEUTRAL. If the autoshift function is not desired , the
SECONO SPEEO FORWARO to SECONO SPEEO machine can be operated in the manual mode.
REVERSE - Push autoshift button (11) twice. When
you shift the transmission to the FORWARD position , The auto kickdown can be used in the following
the transmission will always shift into the second modes:
physical gear. When you shift the transmission to
the REVERSE position, the transmlsslon wllI always Manual Shift in Auto Kic kdown Mode - Automatic
shift into the second physical gear. The speed shift auto kickdown mode allows the transm ission to
mechanism is manual. Use the buttons in order downshift automatically. After a manual upshift, the
to upshift or use the buttons in order to downshift. auto kickdown is prevented for two seconds. The
Speed shifts have no effect in NEUTRAL. operator can make manual shifts at any time.

Auto Kickdown OFF - Push switch (18) and

release switch (10) until the auto kickdown indicat<?r

•
is off. The manual sh ift mode is active if no autoshlft
indicators are on .
 SE8U8146-06 53
Operation Section
Machine Operation

• Auto Kickdown LOW - Push switch (10) and

release switch (10) until the display window shows
"LO" and the autoshift indicators are on . The display
window will also show double arrows that point
downward when the LOW setting is selected .
Speed Range Selector (5)

@)
(I)
Speed Range Selector (5) - Press the
transmission upshift switch (5A) in order to
upshift the transmission to the next higher
speed range . Press the transmission downshift
Note: Auto Kickdown LOW utilizes lower downshift switch (58) in order to downshift the transmission to
points. The lower downshift points result in more the next lower speed range . The speed range and the
engine lug under load before the downshift is initiated. direction will show in the upper digital display window.

Auto Kickdown HIGH - Push switch (10) and

release switch (10) until the display window shows Steering Lever
"HI" and the autoshift indicators are on . The display
window will also show double arrows that point The machine can be steered in the NEUTRAL
upward when the HIGH setting is selected . position .

Note: Auto Kickdown HIGH utilizes higher downshift NOTICE

points. The higher downshift points result in a quicker When the steering leve r is moved with the transmis-
response as load is applied . sion in NEUTRAL or in gear. and the engine is running .
the machine will turn oEngage the steering controllock
Transmission Direction Selection by engaging the parking brake in order to prevent ma-
chine movement.

•
g01150227
IlIustration 62
g01103286
IIlustration 63
Rotate control (4) (transmission direction selector)
clockwise or counterclockwise in order to change the When the machine is moving forward . push the
direction of the machine. steering controllever forward for a left turn oWhen
the machine is moving backward . push the steering
Forward (4A) - Rotate the twist handle

® F on the lever forward to the FORWARD

position in order to move the transmission
to FORWARD.
controllever forward for a right tum. When you move
the steering controllever farther in a forward motion .
the machine will turn faster.

ln order to pivot the machine in the clockwise

Reverse (48) - Rotate the twist handle direction. place the transmission in NEUTRAL and

® on the lever backward to the REVERSE

position in order to move the transmission
to REVERSE.
pull the steering lever backward toward the operator.

ln order to pivot the machine in the counterclockwise

direction. place the transmission in NEUTRAL and
Neutral (4C) - Rotate the twist handle on push the steering lever forward .

®
•
the lever to the NEUTRAL position in order
to move the transmission to NEUTRAL.
54 SEBU8146-06
Operation Section
Machi e Operation

Table 12

Machine travei

FORWARD
Lever movement

PUSH
Machine
direction
LEFT
Release pedal (6) in order to allow the machine to
move. Release pedal (6) in order to increase the
ground speed .

Decelerator Pedal (7)

•
FORWARD PULL RIGHT
REVERSE PULL LEFT Engine speed may also be reduced below the
maximum operating speed by pushing down on
REVERSE PUSH RIGHT the decelerator pedal. Push down on pedal (7) in
NEUTRAL PUSH LEFT order to override the throttle control. This will reduce
the engine speed . Use pedal (7) in order to reduce
NEUT RAL PULL RIGHT engine speed for directional shifts. Also, use pedal (7)
in order to reduce engine speed when you maneuver
When the machine is moving forward , pull the in tight locations.
steering control leve r backward toward the operator
for a right turn . When the machine is moving Note: The sensitivity of the decelerator pedal
backward , pull the steering control lever backward changes according to the setting of the throttle
toward the operator for a left turn . When you move switch . At partial throttle settings, the modulation of
the steering control lever farther toward the operator, the pedal is increased . This increase in modulation
the machine will turn faster. allows more precise control of the engine speed .

Multi-Velocity Program (MVP) Cab Dome Light (8)

Your machine is equipped with one of two versions of Push the top part of the rocker switch to turn on the
speed ranges. The first option is MVP. The second light. Push the bottom part of the switch to turn off
option is MVP and the three speed ranges. the light.

The tive speed ranges that are provided by MVP

allow the operator to find the best match between the
following items: machine speed , application , ground
cond itions, and skill of the operator.

The five speed range operation is indicated on the

Gauges and Indicators (9)
Refer to Operation and Maintenance Manual ,
"Monitoring System" for more information.
•
display with the following designations: "1.5", "2.0", Auto Kickdown Switch (10)
"2.5", "3.0", and "3.5". The display also indicates
"F" for FORWARD , "N" for NEUTRAL, and "R" for This switch activates the auto kickdown mode. Refer
REVERSE. The "2.0" speed range is a ground speed to "Auto Kickdown Mode" within the "Transmission
limited version of the "2.5" speed range. For "2.0", the Control" section of this article for more detailed
engine speed is reduced below high idle in order to information.
limit ground speed. There is no 1055 of power when
you operate in "2.0" as compared to "2.5". The same Autoshift Switch (11)
is true for the "3.0" speed range and the "3.5" speed
range. This switch allows the operator to toggle between the
three bidirectional shift modes. Refer to "Bidirectional
The three speed range mode is indicated on the Shift Mode" within the 'Transmission Control" section
display with the following designations: "1", "2", and of this article for more detailed information .
"3". The display also indicates "F" for FORWARD , "N"
for NEUTRAL, and "R" for REVERSE .
Engine Start Switch (12)
Service 8rake Control (6) OFF - Inserting the engine start switch key

Push down on the brake pedal in order to apply the

O
© and removing the key must only be done
from the OFF position. ln the OFF position,
service brakes. Use pedal (6) for slowing the machine there is no power to most electrical circu its in the
and for stopping the machine. Use the service brakes cab oThe cab lights, the panei lights, the tail lights, •
on a downgrade in order to prevent overspeed . The and the dome light are operational even when the
service brakes are especially needed when you start switch is in the OFF position .
change directions on a steep slope.
Turn the start switch key to the OFF position in order
to stop the engine.
 SEBU8146-06 55
Operation Section
Machine Operation

• @
ON - Turn the start switch key clockwise
to the ON position in order to activate ali
cab circuits.
Heating and Air Conditioning
Control (14)

STAR~ - Tum the start switch key

® 6
.
clockwlse to the START position in order to
crank the engine. Release the key after the
engme starts. The key will return to the ON position .

Window Wiper/Washer Switches

(13)

g01150299
IlIustration 65

Temperature Control (14A)

13A
ffR!-- -L- - -
138 13C 130
((((\
~

t(l
Temperature Variable Control - Turn the
control as far as possible, counterclockwise
in order to close the heater valve. The
heater valve controls the amount of hot
~ water that f~ows through the heater coil. As

•
the control IS turned clockwise the heater
valve is opened . Turn the control as far ~s possible
g01150296
IlIustration 64 clockwise for maximum heat. Turn the fan speed '
switch to the desired speed .
~ Front Window Wiper/Washer (13A) -
@ Turn the .knob cl~ckwise in order to turn Note: Turn the control as far as possible,
. on the wmdow wlper. The first position
counterclockwise and turn the blower fan motor ON
actlvates the wipers in low speed . The second
in order to bring outside air into the cab that is the
position activates the wipers in high speed . Push the
same temperature as outside air.
knob in order to activate the window washer. Spring
force returns the knob when you release the knob.
The controls for the wiper/washer operate in the Fan Speed Switch (148)
same manner for ali of the windows .
Fan Speed Switch - The fan speed switch
Left Door Window Wiper/Washer (138) ® controls the four-speed blower fan motor
for the heater, air conditioner, and fresh air.

OFF - Move the switch to this symbol in

Right Door Window Wiper/Washer(13C) order to stop the blower fan o

LOW - Move the switch to this symbol for

Rear Window Wiper/Washer (130) the lowest fan speed .
@
MEDIUM LOW - Move the switch to this
Note: I~ order to fill the reservoir, refer to Operation ® symbol for a higher fan speed .

• and Mamtenance Manual , "Window Washer

Reservoir - Fill".
MEDIUM HIGH - Move the switch to this
symbol for a higher fan speed .
56 SEBU8146-06
Operation Section
Machine Operation

HIGH - Move the switch to this symbol for

the highest fan speed.
Note: The engine start switch key must be in the ON
position in order for the work lights to come on .

Operator Mode Select Switch (16)

•
Air Conditioning System Operation Oisplay mode switch - Press switch (16)

Air Conditioning - Tum control (14A) as

@) briefly in order to change the display mode
on the lower digital display wi ndow (EMS
far as possible, counterclockwise in order III ).
to close the heater valve . Press the top of
switch (14C) in order to activate the air conditioning • Service meter mode
system . If the air is too cold, adjust temperature
control (14A) until the temperature inside the cab is • Travei distance mode
comfortable. Tum the fan speed switch to the desired
speed Press the bottom of switch (14C) in order to • Service code mode
tum off the air conditioning system.
Note: Refer to Operation and Maintenance Manual,
Pressurizing the Cab "Monitoring System" for more information.

When heating or cooling is not desired , pressurize Bulldozer Control (17)

the cab in order to prevent dust from entering . Tum
control (14A) as far as possible, counterclockwise in
order to close the heater valve. Press the bottom of Lift Control
switch (14C) in order to tum the air conditioner to the
OFF position . Tum the fan speed switch to the fan
speed that is needed to keep dust out of the cabo

Oefogging the Cab

Activate both the air conditioning system and the

heating system. Tum the fan speed switch to one of
the fou r speeds. Use the fan speed that is needed
to remove moisture from the air in the cabo This will
•
prevent moisture trom forming on the windshield and
the win dows. Adjust the temperature variable control
clockwise in order to lower the moisture leveI. Adjust
the temperature control until the temperature in the
cab is comfortable. IlIustration 66
g01151762

Light Switch (15) HOlO (17 A) - The lever will retum to

OFF - Move the light switch to this position

in order to tum off the lights.
© ~ the HOlO position , when you release the
lever from the RAISE position and from the
lOWER position .

RAISE (178) - Pull back on the lever in

Gauge Lights - Move the switch to this
position in order to tum on the gauge lights. ® order to raise the blade. Release the lever.
The lever will retum to the HOlO position .

..
®
~5 lOWER (17C) - Push the lever forward in
Oash Panei Lights and Front
@)O~ Floodlights - Move the switch to this
position in order to tum on the dash lights.
order to lower the blade. Release the lever.
The lever will retum to the HOlO position .
The movement of the bulldozer blade stops.
Move the switch to this position in order to tum on

~
the front floodlights.
QUICK OROP (170) - Push the lever •
~ beyond the lower position . The blade will
Work Lights - Move the switch to this be allowed to drop to the ground . Release
position in order to tum on the work lights. the lever. The lever retums to the HOlO position .
 SEBU8146-06 57
Operation Section
Machine Operation

.~
Variable Pitch Angle Tilt (VPAT) Bulldozer
FLOAT (17E) - Push the lever ali the way (If Equipped)
forward. This will move the bulldozer blade
into the FlOAT position . The control will be
held in the FlOAT position until you manually pull the
lever out of the detent position or until you stop the
engine. The lever then returns to HOlO position . ln
the FlOAT position, the blade moves up and down
with the ground contour.

Note: The control moves through the quick drop

range as you go from the lOWER position to the
FlOAT position .

Note: Hydraulic lockout control (20) is designed to

deactivate the control levers. Press the top switch
(20) to the lock position in order to deactivate the
g01317947
control levers. The action indicator for the attachment IlIustration 68
control will ensure that the control is locked.
Oeactivate the control levers before you exit the seat Angle Control
or before you service the machine. The controllevers
should always be deactivated when the machine is " " A ngleLeft(17K)-Rotatethetop
left unattended. @n. control switch (B) toward the right. This
counterclockwise movement produces
Reference: Vou may lower the attachments after you angle left.
stop the engine. Refer to Operation and Maintenance

•
Manual, "Equipment lowering with Engine Stopped" Angle Hold (17J) - When you release
for more information . switch (B), the switch returns to the HOlO
position . The movement of the bulldozer
Tilt Control blade stops.

Angle Right (17H) - Rotate the top control

switch (B) toward the left. This clockwise
movement produces angle right.

Accugrade Controls
For additional information regarding accugrade
controls please refer to Operation and Maintenance
Manual, SEBU8290, "Accugrade® Grade Control
System - C0700 " or Operation and Maintenance
Manual, SEBU8161, "Accugrade® Grade Control
System - C0610 ".
g01151764
IlIustration 67

Hold (17 A) - When you release the lever,

the lever returns to the HOlO position . The
movement of the bulldozer blade stops.

IA TiltLeft(17F)-pullthetiltlevertoward
@
~ the left in order to lower the left side of

•
the bulldozer blade. When you release the
lever, the lever returns to the HOlO position .

lTiltRi9 ht(17G)-pushthetiltlevertoward
@ the right in order to lower the right side of
the bulldozer blade. When you release the
lever, the lever returns to the HOlO position .
58 SEBU8146-06
Operation Section
Machine Operation

Throttle Control Switch (18) Hydraulic Lockout Control (20)

The hydraulic lockout control is designed to
deactivate the control levers. Press the top of switch
(20) to the lock position in order to deactivate the
control levers. Deactivate the control levers before
•
you exit the seat or before you service the machine.
The control levers should always be deactivated
when the machine is left unattended. Press the
bottom of switch (20) to the unlocked position in order
to activate the control levers.

Winch Control (21)

If equipped , the winch controllever provides variable
g01215062 speed control. As you move the REEL-IN position or
IlIustration 69
the REEL-OUT position of the control, the speed of
the winch changes. As the control is moved farther
For high idle, press the top part of switch (18). The from the center BRAKE ON position, the speed is
engine speed immediately moves to high idle. increased proportionally. When the control is released
from the REEL-IN position or the REEL-OUT position ,
For low idle, press the bottom part of switch (18) . The
the control returns to the BRAKE ON position .
engine speed immediately moves to low idle.

Set the maximum operating speed at a point less

than high idle in the following manner:

1. Set the engine speed to high idle. Push on the

decelerator pedal until the desired speed is
reached .

2. When this desired speed is reached , push on the

top of switch (18) and hold for three seconds.
This will electronically set the engine speed as the
•
218
maxlmum operating speed .

3. The decelerator will function normally in order to

I
21A-21C
reduce engine speeds below this maximum speed .

4. ln arder to return to high idle as maximum speed ,

I
210
press the top part of switch (18) .

MVP Switch (19)

g011 50506
IIlustration 70
If equipped , the MVP switch (19) allows the operator
to choose between two versions of speed ranges. Brake On (21A) - The wire rope should
Press the top part of the switch (19) in order to
activate the five speed range configuration. Press the
bottom part of the switch (19) in order to activate the
(@
(@) not move. Use this position when you tow
the machine. Use this position when you
are holding a load and when the winch is not active.
three speed range configuration .

~
Reei-ln (21 B) - Push the control forward
~ in order to reei in the wire rope. The wire
l' rope should move toward the winch under
power. Release the control. The control will return to •
the BRAKE ON position .
 SEBU8146-06 59
Operation Section
Machine Operation

Brake Off (21 C) - Push the control

outward in order to release the winch. The
control will stay in the OETENT position .
The wire rope will reei out by the weight of the load.
The wire rope will reei out as the machine moves
away from the load. Pull the control from the OETENT
position. The control will return to the BRAKE ON
position.

AWARNING
Do not use drum clutch release for controlled
reelout of suspended loads.

Sudden release of load may result in injury or 21B-21A-21C

\~\
death and property damage.

Use only reelout to lower loads.

~
g01151897

~
Reel-Out (210) - Pull the control rearward IIlustration 71
. .J..I" in order to reei out the wire rope. The wire
rope will reei out under power. Release the HOlO (21A) - Release the lever. The
control. The control will return to the BRAKE ON lever will return to HOlO position . Ripper
position . movement stops .

• Press the switch on the control in order to activate

lOW lOCK. The indicator light will come on . The
lOW lOCK position sets the variable displacement
motor to the maximum pull and to the minimum
speed in order to control the load precisely.
RAISE (21 B) - Move the leve r to the left in
order to raise the ripper. Release the lever.
The lever will return to the HOlO position .

lOWER (21 C) - Move the lever to the

right in order to lower the ripper. Release
Release the switch in order to return to full AUTO the lever. The lever will return to the HOlO
speed . The motor will self-adjust between the position .
maximum and the minimum displacement in order
to achieve the best speed and the best pull for the
application . Horn (22)
Ripper Control (21) Horn - Push the knob downward in order

Note: If equipped, the hydraulic lockout control (20)

is designed to deactivate the control levers. Press
9
~ to sound the horn . Use the horn to alert
the personnel. Use the horn to signal the
personnel.
the top switch (20) to the lock position in order to
deactivate the control levers. Oeactivate the control
levers before you exit the seat or before you service
the machine. The control levers should always be
deactivated when the machine is left unattended .

•
60 SEBU8146-06
Operation Section
Machine Operation

Windows 3. Push the doors firmly from the inside in order to

ensure that the doors will remain closed . Do not
operate the machine with faulty door hinges or
latches.

4. Inspect the windows in order to make sure that

•
the windows are not damaged . Do not operate the
machine with a damaged window.

Keep the doors closed while the machine is moving .

B If the doors are open and the machine is moving , the
additional weight of the "Ultra-Strength 40" Glass
may cause structural damage.

i0364821 7
901317934
IlIustration 72
Battery Disconnect Switch
Lift latch (A) in order to si ide the small window.
Squeeze latch (B) in order to move the window from SMCS Code: 1411
the CLOSED position .

"Ultra-Strength 40" Glass

If the cab is equipped with "Ultra-Strength 40"
Glass, the glass will provide additional protection .
Applications that may accidentally bury the machine
may benefit from this protection . The following
marking is located on ali cab windows in the lower
right corner for identification.

188-2904
o

o •
901139266
IlIustration 74
U LTRA STRE N GTH 40 Front view

~.:-. DUPLATE The battery disconnect switch is on the left side of the
'I.Iii'
L~INÂ TID machine in the access door in front of the battery box.

AS2 22 O 1 2
CDI
On - Insert the key, and turn the key
DOT 18 /'Io1460A clockwise in order to activate the electrical
system . The switch must be ON before you
1 2 4 8 start the engine.
900744597
IlIustration 73
Ott - Turn the key counterclockwise in
order to shut off the entire electrical system.
Machines that are equipped with
"Ultra-Strength 40" Glass
Remove the key when you exit the machine overnight
When you perform applications that may bury the or when you exit the machine for an extended period
machine, keep the doors closed. of time. Also , remove the key when you service the
electrical system.
1. Inspect the door hinges and latches in order to
ensure that the hinges and latches are in good
condition . The door latches prevent the operation NOTICE •
of the doors during the operation of the machine. Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
2. Close lhe doors. age to the electrical system could result.
 SEBU8146-06 61
Operation Section
Machine Operation

• Checking the Battery Disconnect

System

NOTICE
To ensure no damage to the engine occurs, verify that
Monitoring System
SMCS Code: 7490
i03648102

the engine is fully operational before cranking the en-

gine. Do not crank an engine that is not fully opera-
tional.

Perform the following procedure in order to check the

battery disconnect system.

1. With the battery disconnect switch in the ON

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

2. Turn the battery disconnect switch to the OFF

position .

3. Verify that the following items are not

functioning : electrical components in the operator
compartment, hour meter, and engine cranking .
If any of the items continue to function with the g01216183
IIlustration 75

•
battery disconnect switch in the OFF position ,
contact your Caterpillar dealer.
The Caterpillar Monitoring System consists of
gauges, alert indicators, status indicators, action
i02712617 lamps, an action alarm and two display windows.
The following list gives the location in the instrument
Backup Alarm paneI.
SMCS Code: 7406 • (1) Gauges
Backup Alarm - The alarm sounds when the • (2) Individual alert indicators and status indicators
transmission direction selector is in the REVERSE (upper panei)
position . The alarm alerts the people behind the
machine that the machine is backing up. • (3) Digital display window (upper panei)
The backup alarm is on the rear of the machine on • (4) Individual alert indicators and status indicators
the right side of the machine. (Iower panei)

• (5) Digital display window (Iower panei)

• (6) Action lamp

•
62 SEBU8146-06
Operation Section
Machine Operation

During the self test, gauge indicators (1 ) indicate in •

the foliowing sequence:

• Upward

• Left

• Right
7
• Current value

During the self test, digital display window (3) in

the upper panei shows readouts in the following
sequence:
gOl1 50098
IlIustration 76
• ''''888888888888''''
Auxilia ry action lamp (7) is located on the right • "O RPM lN"
console. The auxiliary action lamp is near the right
elbow of the operator. During the self test, digita l display window (5) in
the lower panei shows readouts in the following
The Caterpiliar Monitoring System shows the status sequence:
of the machine systems. The monitoring system
also alerts the operator of a faulty machine system • "Deg C", "kPa", "miles", "kilometers", "rpm", and
or of an impending problem. The gauge panei and "Iiters"
the alert indicators are designed to communicate
machine conditions to the operator.
• "X10"

Functional Test
The self testing feature verifies that the modules of
the monitoring system operate properly.

Observe the self testing feature when you turn the

• Hourglass symbol for the service meter

• "888.8.8.8"

• "Current service meter value"

•
ign ition switch to the RUN position . After the self test, the monitori ng panei is in the
normal operating mode.
The inter ai circuits are automatically checked. The
outputs (displays, action lamps, alert indicators, Status Indicators
status indicators, and the action alarm) are
automatically checked .

The operator must observe the outputs in order to

determine if the modules are operating properly. This
self testing feature is approximately two seconds
long .

During the self test, the warn ing indicators should act
in the following manner:

• Indicator lights (2) in the upper panei come on

briefly.

• Action lamp (6) comes on briefly.

g01216186
IlIustration 77
• The auxiliary action lamp comes on briefly.
~ Parking Brake (8) - Th is statu s indicator •
• Indicator lights (4) in the lower panei flash briefly. ~ indicates that the parki ng bra ke is engaged.

• The action alarm sounds briefly.

 SEBU8146-06 63
Operation Section
Machine Operation

•@ Bidirectional Shift (9) - This status

indicator indicates that a bidirectional shift
mode is activated for first speed forward
and second speed reverse .
Alert Indicators

Bidirectional Shift (10) - This status

(§)
tJ'21
~
indicator indicates that a bidirectional shift
mode is activated for second speed forward
and second speed reverse .

Bidirectional Shift (11) - This status

(§)
B-~ indicator indicates that a bidirectional shift
mode is activated for second speed forward
and first speed reverse .
g012161 90
lIIustration 79
Auto Kickdown (12) - This status
Engine Oi! Pressure (15) - This alert
indicator indicates that the auto kickdown
mode is activated . @
~ indicator indicates low oil pressure. If this
alert indicator and the action lamps flash ,
and the alarm sounds, stop the mach ine immediately.
Hydraulic Lockout Control (13) - This Stop the engine and investigate the cause.
status indicator indicates that the hydraulic
controls for the work tools are locked out.
Charging System (16) - This panei

ªU indicates a malfunction in the charging

system. The alert indicator will flash if the

• system voltage is too high or if the system voltage is

too low.

Increase the engine speed to high idle, if the electrical

loads are high . The electric loads consist of the air
conditioning and/or the lighting . An alternator will
generate more output when the engine is at high
idle. If the alert indicator for the charg ing system
1--------------------------1 stops flash ing , the charging system is operating
normally. During extended periods of low engine
~ ------_ . _----- - ----_ . _- - -- ~ speeds with high electrical loads, the alternator may
be overloaded .
IlIustration 78 g01957975
Vou can also reduce the load on the electrical system.
Electric Engine Preheat(14) - This status ln order to reduce the load on the electrical system,

® indicator indicates that the preheat mode is

activated.
you can shut off some lights or accessories, or you
can reduce the fan speed of the blower.

Run the engine speed at normal rpm. Run the

electrical system at a light load . Ifthe light remains on ,
drive the machine to a convenient stop. Investigate
the cause of the problem. The cause may be a loose
alternator belt, a broken alternator belt, a faulty
battery, a faulty alternator, etc.

The alert indicator and the action lamps will flash ,

and the action alarm will sound if the system voltage

•
is too high or if the system voltage is too low. Stop
the engine and investigate the cause.
64 SEBU8146-06
Operation Section
Machine Operation

@
ôi Inlet Manifold Temperature (17) -
This alert indicator indicates excessive
temperature in the engine inlet manifold .
If this alert indicator flashes and the action lamps
flash , change the machine operation or perform
@
~
~ ! Implement System (23) - This alert
indicator indicates that a problem exists in
the implement system. Check the system at
the earliest possible time. Check for a service code.
See "Digital Display Window (Lower)" and "Service
•
maintenance to the system. The cause may be a Code Mode" in this article.
radiator that is clogged . The cause may be restricted
air flow due to debris in the engine compartment. Engine System (24) - This alert indicator
A fouled aftercooler core can cause excessive
temperature. A failed water pump can cause @
CD indicates that a problem exists in the engine
system . Take action that is appropriate for
excessive heat. the warning leveI. Check for a service code. See
"Digital Display Window (Lower)" and "Service Code
Fuel levei (18) - When the fuellevel Mode" in this article.
@
t>B1 reaches ten percent of the tank capacity,
this alert indicator will illuminate. Refuel in Transmission System (25) - Th is alert
order to avoid running out of fuel.
@)
<.D indicator indicates that a problem exists
in the transmission system. Take action
that is appropriate for the warn ing leveI. Check for a
22 service code. See "Dig ital Display Window (Lower)"
and "Service Code Mode" in this article.

Brake System (26) - This alert indicator

@)
fi) indicates that a problem exists in the brake
system . Take action that is appropriate for
27 the warning leveI. Check for a service code. See
"Digital Display Window (Lower)" and "Service Code •
[ -------------------------1 Mode" in this article.

~. __._ - --- ---- - --- ---------~

Hydraulic Filter Restriction (27) - This
alert indicator is illuminated when the
g01957995
IlIustration 80 hydrau lic filter is bypassed .

Restriction of Intake Air Filter (19) - The

@~ __ .. alert indicator indicates that the engine air
filter is restricted and that the filter should
Engine Overspeed - The action lamps and the
tacho meter will flash if the engine attains a speed
over 2800 rpm . The tachometer will stick at the
be cleaned or replaced . highest engine speed over 2800 rpm . Slow down
the machine if the action lamps and the tachometer
Fuel Pressure Indicator (20) - The alert flash . The action lamps and the tachometer will flash,
@Q~ indicator indicates that the system fuel
pressure is not correct. Stop the engine and
and the action alarm will sound if the engine attains
a speed ove r 3000 rpm . The tachometer will stick at
investigate the cause. the highest engine speed . Immediately reduce the
engine speed in order to prevent severe damage to
Power Train Oil Filter Bypass (21) - the engine.

®~
O.. This alert indicator indicates that oil flow is
bypassing the transmission oil filter. If this
alert indicator flashes and the action lamps flash,
Warning levei 1
change the transmission oil filter. See Operation The alert indicator will flash . Warning levei 1 alerts
and Maintenance Manual , "Transmission Oil Filter the operator that a machine system needs attention .
- Replace". No immediate action is required . The following alert
indicators can be illuminated with Warni ng Category
Transmission Oil Temperature (22) - 1:
@)
@ This alert indicator indicates excessive oil
temperature in the torque converter. If this • Charging system (16) •
alert indicator and the action lamps flash , and the
alarm sounds, stop the machine immediately. Stop • Fuellevel (18)
the engine and investigate the cause.
• Restriction of intake air filter (19)
 SEBU8146-06 65
Operation Section
Machine Operation

• • Implement system (23) Gauges

• Engine system (24)

• Transmission system (25) 27lC~ ~28

• Brake system (26)

• Hydraulic oil filter bypass (27)

Warning levei 2 30~ ~29

The alert indicator light and the action lamps flash .
Warning levei 2 requires changing the machine
operation or performing a maintenance procedure.
Changing the machine operation can reduce the g0114 161 1
IlIuslralion 81
excessive temperatures in one system or more.
Failure to react to this warning may result to damage
Engine Coolant Temperature (27) -
to the machine components. The following alert
indicators can be illuminated with Warning Category
2:
@
Gi The engine coolant temperature gauge
indicates the temperature of the engine
coolant. If the gauge reaches the red area with a
pressurized cooling system, the gauge indicates that
• Inlet manifold temperature (17)
the temperature is too high . The gauge reaches the
red area at 107 °C (225 °F) .
• Power train oil filter bypass (21)

•
• Engine system (24) Torque Converter Oi! Temperature (28) -

• Transmission system (25)

@)
~ The power train oil temperature gauge
indicates the temperature of the power
train oil at the torque converter outlet. If the gauge
• Brake system (26) reaches the red area , the gauge indicates that the
temperature is too high . The gauge reaches the red
• Engine overspeed area at 129 °C (265 °F).

Warning levei 3 Fuel levei (29) - The fuel levei gauge

indicates the amount of fuel in the fuel tank.
The alert indicator light and the action lamps flash .
Also, the action alarm will sound . Warning levei 3
requires you to immediately shut down the machine. t ~ Hydraulic Oil Temperature (30) - The
Engine overspeed does not require immediate
shutdown . Engine overspeed requires immediate
@~I hydraulic oil temperature gauge indicates
the temperature of the hydraulic oil. If the
reduction in engine speed. Failure to react to this gauge reaches the red area, the gauge indicates
warning may result in injury to the operator and/or that the temperature is too high . The gauge reaches
severe damage to machine components. The the red area at 102 °C (215 °F). Move the cylinders
following alert indicators can be illuminated with without a load on the cylinders in order to reduce
Warning Category 3: excessive temperature.

• Engine oil pressure (15)

• Charging system (16)

• Engine system (24)

•
• Transmission system (25)

• Brake system (26)

• Engine overspeed
66 SEBU8146-06
Operation Section
Machine Operation

Digital Display Window (Upper)

•
31 CD CE) ,® 'O
~ • .@

g01 216198
IIlustration 83
g012161 96
IlIustratio 82
When the engine drops below 2600 rpm , you may
The display window (3) indicates the following : the press operator switch (3 1) in order to stop the display
engine speed , the physical gear of the transmission , from flashing before the th irty second timer expires.
the speed range within the physical gear, and the
direction of the transmission. If the machine is in Digital Display Window (Lower)
MVP mode, the display will show one of the following
speed ranges: "1.5", "2.0", "2.5", "3.0", or "3.5". If the
\
machine is not in MVP mode, the display will show
one of the following speed ranges : "1", "2", or "3".

Engine Speed - The engine speed is

indicated on the left side of the display
window (3).

Physical Gear - The numbers "1", "2",

and "3" indicate the physical gear of the
•
transmission .

(i)
•
Speed Range - If the machine is in MVP
mode , the numbers "O" and "5" indicate IIlustration 84
LU u -=

g01 216201
the speed range within the physical gear.
For example, when the display reads "2.0", the ". 0" Display window (5) provides an information area that
indicates the reduced ground speed mode. When the can be changed to three different display modes.
display reads "2.5", the ".5" indicates the full ground
speed mode. • Service meter mode

n Direction - The display window will also • Travei distance mode

('-U~ ) show the direction of the transmission . This
-Y indicator is located immediately after the • Service code mode
speed display. "F" indicates the forward direction and
"R" indicates the reverse direction. Press the switch briefly in order to change the display
mode, as shown .
The digital tachometer and the speed range are
displayed continuously. An engine speed that is
greater than 2800 rpm will activate an indication of

•
engine overspeed.

The tachometer flashes as an indication of engine

overspeed . The highest engine speed that is greater
than 2800 rpm will stick in the display window for
thirty seconds.
 SEBU8146-06 67
Operation Section
Machine Operation

• Service Meter Mode Service Code Mode

The service code mode displays codes that are used
by service technicians in order to diagnose problems
of machine systems. Service codes are generated
when system faults occur.

Each service code consists of three parts:

• Module identifier (MIO)

• Component identifier (CID)

• Failure mode identifier (FMI)

g01037507
A module identifier (MIO) is acode that identifies the
IlIustration 85 electronic control module that has diagnosed a fault.

The service meter mode displays an hourglass A component identifier (CID) is acode that informs
symbol (30). This mode indicates the total operating the service personnel of specific component or
hours of the engine. Use the display in order to system failure .
determine the maintenance intervals. When the
engine start switch is turned to the OFF position , the A failure mode identifier (FMI) is acode that informs
display defaults back to the service meter mode. the service personnel of the type of failure that has
occurred .
The "SERV CODE" indicator (31) will be displayed in
the display window when there is an active service The service code mode will continuously scroll

•
code. An action indicator will be flashing . See through ali of the service codes. If there are no
"Service Code Mode"in this article. service codes, a series of dashes will be displayed.

Travei Distance Mode Two sequential displays are required to show a single
service code. The first display shows three digits and
The travei distance mode displays the distance the second display shows six digits.
of travei in reverse and in forward , and the total
distance of traveI. These values are displayed in
display window (5).

The travei distance mode will continuously scroll

through the above tive displays in the following
sequence:

• reverse direction

• miles of travei in reverse speed ranges

• forward direction

• miles of travei in forward speed ranges g00759546

IlIustration 86
• total miles of travei
The three digit number is the "MIO".
Note: Your Caterpillar dealer can set the units of
travei to miles or to kilometers.

•
The "SERV CODE" indicator will be displayed in the
display window when there is an active service code.
An action indicator will be flashing . See "Service
Code Mode" in this article.
68 SEBU8146-06
Operation Section
Machine Operation

• Restriction of intake air filter

• Engine coolant flow

• Power train oil filter bypass

•
• Hydraulic oil filter bypass

• Engine overspeed

Electrical Connector Location

.........
a
IlIustration 87
900759385 , , "'"
The six digit number is the "CID" and the "FMI ". The
first four digits before the decimal point are the "CID". A __ --~

The last two digits after the decimal point are the
"FMI ".

There are two categories of service codes that may

be displayed . One category is "active" service codes.
The second category is "Iogged" service codes.

An active service code indicates that a fault condition 9011 50137

•
IlIustration 88
is occurring now. The "SERV CODE" indicator is
displayed in the display window when the code that Location of service connectors for th e D6T Track-Type Tractor
is being displayed is active.
(A) Two connectors are 12 volt power outlets.
A logged service code is a record of a fault condition
that has occurred in the past. A logged service (B) This service connector is for the 4C - 8195
code is no longe r active. When the code that is Control Service Tool.
being displayed is logged , the "SERV CODE" is not
displayed . (C) This data link connector is for use with the
Caterpillar Electronic Technician (ET). Also , this
ln the example that is shown above, the active connector is used for the flash programming of
service code is "036 0273 .03". software.

036 "MIO" - Engine control module These electronic connectors are located behind the
operator's seat on the left side of the compartment.
0273 "CID" - Turbocharger outlet pressure sensor
Refer to Service Manual , SENR8367 , "Electrical
03 "FMI" - Voltage that is above normal or shorted Component And Connector Locations" for additional
high information about these service tools.

"SERV COOE" - Active fault Note: The eng ine start switch must be in the ON
position in order for the electrical connectors to be
When there is a problem that generates a service activated .
code you need to report ali of the numbers to your
Caterpillar dealer. Vou need to report if the code is Reporting a Problem
active or logged .
Report ali of the information about problems to your

•
The following indicators do not result in an active Caterpillar dealer. Report ali of the service code
service code or in a logged service code: information and indicate if the codes are active or
logged . Report an action indicator that lights but does
• Engine oil pressure not create a service code. Report if an action lamp is
flashing or the action alarm is sound ing .
• Inlet manifold temperature
Your Caterpillar dealer can re move the service codes.
• Fuellevel
 SEBU8146-06 69
Operation Section
Machine Operation

• Consult your Caterpillar dealer for more information.

Refer to Special Instruction, REHS0126 , "Caterpillar

Electronic Controls".
Caterpillar may share some or ali of the collected
information with Caterpillar affiliated companies,
dealers, and authorized representatives. Caterpillar
will not sell or rent collected information to any other
third party and will exercise reasonable efforts to
keep the information secure. Caterpillar recognizes
i03555467
and respects customer privacy. For more information ,
Product Link please contact your local Caterpillar dealer.

(If Equipped) Operation in a Blast Site

SMCS Code: 7606
If the machine is required to work within 12 m (40 ft)
The Product Link PL 121 SR is a satellite of a blast site, then Product Link PL 121 SR must
communication device that transmits information be disabled. ln order to disable theProduct Link
regarding the machine to Caterpillar, Caterpillar PL 121SR install a Product Link Disconnect Switch
in the machine cab that will allow the Product Link
dealers, and Caterpillar customers. The unit contains
a Global Positioning System receiver (GPS receiver) PL 121SR module to be shut off. Refer to Special
and a satellite transceiver. Instruction, REHS2365, "An Installation Guide for the
Product Link PL 121 SR and for the PL300" for more
The Product Link PL 121SR is capable of two-way details and installation instructions. Vou may also
communication between the machine and a remote disconnect the Product Link PL 121SR module from
the main power source by disconnecting the wiring
user. The remote user can be a dealer or a customer.
At any time, a user can request updated information harness at the Product Link module .
from a machine such as hours of use or the location
of the machine. Also, the system parameters for This blast site warning does not supersede the
Product Link PL 121SR can be changed. Data is published requirements or regulations found in "Títle

•
transmitted from the machine to a satellite. Next, the 30 of the Code of Federal Regulations (CFR)" . This
warning does not allow deviation from the published
data is transmitted to a ground station . The receiving
station transmits the data to Caterpillar Inc. The data requirements or regulations found in "Títle 30 of
can then be sent to a Caterpillar dealer and to the the Code of Federal Regulations (CFR)". A hazard
customer. assessment should be conducted by each customer.
Every customer should meet ali of the requirements
of "Títle 30 of the Code of Federal Regulations (CFR)"
Data Broadcasts in order to ensure the safe storage, transportation ,
loading , and blasting of any explosive.
Machine data about the machine's condition and
operation is being transmitted by Product Link to The following Product Link PL 121 SR specifications
Caterpillar and/or Caterpillar dealers in order to are provided in order to aid in conducting any related
better serve the customer and to improve Caterpillar hazard assessment and to ensure compliance with
products and services. The information that is ali local regulations:
transmitted may include the following data: machine
serial number, location of the machine, fault codes, • The transmit power rating for the Product Link
emissions data, fuel usage, service meter hours, PL 121 SR transmitter is five to ten watts
version numbers for software and hardware, and
installed attachments. • The operating frequency range for the Product Link
PL 121SR module is 148 MHz to 150 MHz.
Caterpillar and/or Caterpillar dealers may use this
information for various purposes: providing services Consult your Caterpillar dealer if there are any
to the customer and/or the machine, checking or questions.
maintaining Product Link equipment, monitoring the
machine's health or pertormance, hei ping to maintain Information for the initial installation of the Product
the machine, improving the machine's efficiency, Link PL 121 SR is available in Special Instruction,
evaluating or improving Caterpillar products and REHS2365 , "Installation Guide for the Product Link
services, complying with legal requirements and PL 121SR".

•
valid court orders, pertorming market research , and
offering the customer new products and services. Operation , configuration , and troubleshooting
information for the Product Link PL 121SR can be
found in System Operation Troubleshooting Testing
and Adjusting , RENR7911 .
70 SEBU8146-06
Operation Section
Machine Operation

Regulatory Compliance

ORBCOMM TYPE
•
APPROV AL: 801 QWI
IC:4650A-Q121415

(€ (j)
901131 982
IlIustration 89

NOTICE
Transmlssion 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 ali legal requirements
for the use of the Product Link communication network
have been satisfied .

ln the event that a machine outfitted with Product Link

is located in or relocated to a location where (i) le-
gai req uirements are not satisfied or (ii) transmitting
or processing of such information across multiple 10-
cations would not be legal , Caterpillar disclaims any
and ali 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
specific country.

•
 SEBU8146-06 71
Operation Section
Machine Operation

•
DECLARATION OF CONFORMITY
We. Quake Globallne (previously Quake Wireless, loe. up to J.nury 2001 )

of 9765 CI.iremont M ••• Blvd, S uite A (Previou.ly !I!I7S RufOo Road , Suite 100 up to M»rch
2(02)

San Di~o

CA 92124, USA (Previou.ly 92123)

declare IInder o ur sole respon, ihil il) Ihal lhe producI

QHE2Soo, Q20oo. Q15oo. Q 14oo. Q1200S, Q1200SG. Q12ooSH, Q1200SM an d QI200SV

to which th is declaratinn rdates. is in confonnity wilh lhe fo llowing standards andio r other nom18tive
docwnents.
EN 301721 Vl.l.1 (June 2001 )

EN 300 489-20 VI.2.1 C'lovcmbcr 2002)

EN 609SO- IIA I I:2004, I " Editioo

We hereby declare Ihal ali esscnlial radio Icsl suiles ha\e been carricd oul and Ihal lhe ahove namt:d
prodUCI is in confo rmil)' lo 011 lhe . s",olial rcquiremenl' of DireClive 1999/51EC.
The confomlil)' assessmenl procedure rcfer""lto in Anicle 10 nnd detailed in Annex [IV J of Dirocti"
I 99915/EC has bccn follo\\cd wilh lhe invo l,.rncnl of,he foll owing Nolified Sod)'
tlADT t Clare monl Hou"ie. 34 MoJnty Road, Wallon --on- Thlm~ KT12 4R«J, lJ K

•
ldenlification mark: 0168 The C<juipmenl \ViII 01'0 carl)' lhe
e lass :! equipmenl idenlifier

The lechnical documen lalion rC ICyanlto lhe abov. eqllipmcnl will be held aI :
Quak. Globllllnc (Previously Quake Wir.I .... IDC. up l O January 200 1)

9765 Cloiremont M ... Bh'd, Suile A

SaD Die1/o, CA 92124. USA

(tU/e)

(d(l!t:.)

IlIuslralion 90 901435306

Note: A translated extract of the above document

is provided below.

•
72 SEBU8146-06
Operation Section
Machine Operation

Table 13

DECLARATION OF CONFORMITY
•
We, Quake Global, Inc (Previously Quake Wireless, Inc up to January 2001)

of 9765 Clairemont Mesa Blvd, Suite A (Previously 5575 Ruffin Road, Suite 100 up to March 2002)
San Diego
CA 92124, Usa (Previously 92123)
declare under our sole responsibility that the product
QHE2500, Q2000,Q1500, Q1400, Q1200S, Q1200SG, Q1200SH, Q1200SM and Q1200SV
to whic 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 ali essential radio test suites have been carried out and that the above named product is in conformity
to ali 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 Notified Body:
BABT, Claremont House, 34 Molesey Foad, Walton-on-Thames, KT12 4RQ, UK

Identification mark: 0168 The equipment will also carry the

Class 2 Equipment identifi er.

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

(signatu re of authorized person) (date)

CD
Class 2 equipment identifier

•
 SEBU8146-06 73
Operation Section
Machine Operation

• Camera
SMCS Code: 7347; 7348
i03638523

Operation Information
SMCS Code: 7000
i02605992

To prevent injury, make sure that no maintenance

Video Camera (If Equipped) work is being performed on the machine or near the
machine. Keep the machine under control at ali times
in order to prevent injury.
r. . - . - ..-.:L-:-:..
,L, ..
~
-- ~ ~ ..-.....-.... _ .. _'I !
-:-: .. - .. -:-: ~-:-: .:..:.p- .• - .. - .. ' "
.. Reduce the engine speed when you maneuver the
., J --~i\'
i • O • machine in tight quarters or when you break over a
\ : " ,q i
: ...-- " - " - " - ' - " - " -"-. mi '
,. . :/ .' ,:" -rr.=~= ==
/ rise.
.. /: ,: I! ( J- :1' : \. \ :
ILJ,/
fn: /: '/ ' /lU
r' ~ ::
I:::
:111
\
::,'
\! .I \: Select the speed range that is necessary before you
:I start the downgrade. Do not change speeds when
I ' ,:
', I /' :8/1:
;/ I:' ~ I: \:,'11 : Iã" \
,:,: :,
/'
,'I: : /I /I
I / ::::
i:: :
'~ I
li: ' I:"I i'
\
you are going downhill.

:: ' ;i=~L i::: ~

\ : \ When you drive down a grade, use the same speed
~ ~
_. : ~" --..
"- "-
_ .. _ ..-=~. _ .. _ .. _ ... . . .'
S::' ''';;'~;~===_'
" _ •• ~~~..::::::::::= ::
:
.. . ' that is used for driving up a grade.

IlIuslralion 91
g01952674
Operating The Machine
Rear view of cab
Video camera on lhe rear of lhe machine 1. Adjust the operator's seat.

2. Fasten the seat belt.

•
2

g01952662
IlIuslralion 92
Fronl console g01136721
lIIuslralion 93
WAVS display in lhe cab

3. Push down on service brake pedal (1) in order to

The video camera is provided for visibility behind the prevent the machine from moving ,
machine.
4. Start the engine.
Reference: Refer to Operation and Maintenance
Manual, SEBU8157 for information about operation 5. Raise ali attachments enough to clear any
of the video camera.
unexpected obstacles .

•
74 SEBU8146-06
Operation Section
Machine Operation

5
11. Select an intermediate speed in the following
manner:

a. Set the engine speed to high idle.

b. Select the desired engine speed with the

•
decelerator (1) .

C. Push in on the switch of the engine speed

control and hold for three seconds in order to
lock in the engine speed . This speed is now
the maximum operating speed .

12. Change an intermediate speed in the following

901108809
manner:
IlIustratio 94
Differenlial steering control and transmission direction selector a. To return to high idle from an intermediate
engine speed, push in and release the top part
6. Release the parking brake by pushing down on of the engine speed control switch .
parking brake knob (3). This unlocks the parking
brake, the transmission control, and the steering b. To return to low idle from an intermediate
lever. speed, push in and release the bottom part of
the engine speed control switch .
Note: When the parking brake is set, the transmission
defaults to NEUTRAL. When the parking brake is 13. Use the differential steering control in order to
released the transmission will stay in NEUTRAL. To turn the machine.
select the direction of machine travei, return direction

•
selector (4) to neutral. 14. Drive the machine forward for best visibility and
for control.
7. Then, move direction selector (4) to the desired
direction. Use speed range selector (5) to select
the desired speed . Changing Direction and Speed
8. Release service brake pedal (1) in order to allow NOTICE
the machine to move. For operator comfort and maximum service life of pow-
er train components, deceleration and/or braking is
recommended before any directional shifts are made.

Speed changes and directional changes at full engine

speed are possible.

1. ln order to decrease engine speed , push down on

the decelerator pedal (2) .

:;....-- "
::;;..--
~,,
-- . ~' .. ,
.... ~" .~
'
2. When the machine slows, shift the transmission to
the desired direction with direction selector (4).

3. Increase the engine speed by releasing the

~ --~
decelerator pedal (1).
901138803
IIlustration 95
Engine speed control 4. Select the desired speed with speed range
selector (5). Push button (6) for upshift. Push
9. To select high idle, push in on the top of the engine button (7) for downshift.

•
speed control switch and release . The engine
speed immediately moves to high idle .

10. To select low idle, push in on the bottom of the

engine speed control switch and release. The
engine speed immediately moves to low idle .
 SEBU8146-06 75
Operation Section
Engine Starting

• Engine Starting The indicator light for the parking brake will stay
on until the parking brake is released . If the
attachment contrais are locked out the indicator
i026B0961 light for the hydraulic lockout control will stay on
until the controls are unlocked. The indicator light
Engine Starting for the auto kickdown will stay on until the function
is unselected .
SMCS Code: 1000; 7000
If the system detects a fault, check the electrical
system. Make ali of the necessary repairs before
vou start the engine.

5. Before Vou start the engine, check for the presence

of bystanders or maintenance personnel. Ensure
that ali personnel are clear of the machine. Briefly
sound the forward horn before Vou start the
engine.

6. Turn start switch key (3) to the START position .

Crank the engine. Release the key when the
engine starts.

IlIustration 96 g01141130 NOTICE

Do not crank the engine for more than 30 seconds. AI-
1. Tum the battery disconnect switch to the ON low the starter to cool for two minutes before cranking
position . The battery disconnect switch is inside of again . Turbocharger damage can result if the engine

•
an access door in the battery compartment on the rpm is not kept low until the oil gauge display verifies
left side of the machine. that the oil pressure is sufficient.

Ether Starting Aid

(k\ Ether Starting Aid - The machine is
\{;2J equipped with an ether starting aid. The
ether starting aid is continuously available
to the engine for the purpose of cold weather starting .
The engine ECM will determine automatically when
the premeasured amount of ether injects the engine
air intake. This will occur during the engine starting
procedure. The indicator light indicates that the relay
for the ether aid is being activated .

g01150613 For starting below the appraximate temperature

IlIustration 97
of -1 °C (30 °F), the use of the ether starting aid
is automatic. Continue the pracedure for Engine
2. Move direction selector (2) to the NEUTRAL
Starting .
position .
For starting below -18°C (O°F), the use of the cold
3. Engage parking brake (1).
weather starting aids is recommended . A fuel heater,
a jacket water heater, and extra battery capacity may
4. Turn key start switch (3) to the ON position. The
be required.
monitoring system performs an automatic self test.
The action alarm sounds and ali of the indicator
At temperatures below -23°C (-1Q°F), consult your
lights come on briefly.

•
Caterpillar dealer. For information on starting the
engine in cold weather, refer to the Operation and
Maintenance Manual, SEBU5898, "Cold Weather
Recommendations for ali Caterpillar Machines".
76 SEBU8146-06
Operation Section
Engine Starting

Subsequent Engine Starting

Procedures
NOTICE
Keep engine speed low until the engine oil pressure
Engine and Machine Warm-Up
SMCS Code: 1000; 7000
10227985 5

•
registers on the gauge or the engine oil indicator light After the engine has been started , allow the
goes out. monitoring system to complete the self test.

If it does not register or the light does not go out 1. Allow a cold engine to warm up at LOW
within ten seconds, stop the engine and investigate IDLE for at least five minutes. To help the
the cause before starting again . Failure to do so, can hydraulic components to warm up faster, engage
cause engine damage. the attachment contrais and disengage the
attachment controls.
1. Allow a cold engine to warm up at low idle for at 2. You can begin to operate the machine with a
least five minutes. reduced load.
2. You can begin to operate the machine with a 3. When the engine coolant temperature reaches the
reduced load. normal operating range and no faults are present,
you may operate the machine at fullload .
3. Whe the oil pressure reaches the normal
operating range and the temperature gauge 4. Look at the indicators and the gauges frequently
begins to move, you may operate the machine at during operation . Refer to Operation and
fullload . Maintenance Manual, "Monitoring System".
4. Monitor lights (4) and gauges (5) frequently during 5. Check oillevels in the power train, the engine, and
operation . the hydraulic systems when the oil is at operating •
temperature. Maintain the oil leveis to the FULL
5. Check oillevels in the power train , the engine, and marks.
the hydraulic systems when the oil is at operating
temperature. Maintain the oillevels to the FULL The hydraulic oil will warm up faster, if the dozer
marks. blade control is held in the CLOSE position for short
periods of ten seconds or less. This will allow the
hydraulic oil to reach relief pressure, wh ich causes
the hydraulic oil to warm up more rapidly.

Cycle ali controls in order to allow warm hydraulic

oil to circulate through ali hyd raulic cylinders and
thraugh ali hydraulic lines.

Idling
When you idle the engine in order to warm up the
engine, observe the following recommendations:

• Allow the engine to warm up for approximately 15

minutes when the temperature is higher than O°C
(32°F) .

• Allow the engine to warm up for approximately 30

minutes or more when the temperature is below
O°C (32°F) .

• More time may be required if the temperature is

less than -18°C (O°F). More time may also be •
required if the hydraulic functions are sluggish .
 SEBU8146-06 77
Operation Section
Operating Techniques

• Operating Techniques Angle Blade

i02680933

Operating Technique
Information
SMCS Code: 7000

Selection of Speed Range

Selection of Speed Range - Maximize the amount
of work that is accomplished by selecting the best
speed range for the load .
900522781
IIluslralion 99
With certain loads, the machine will move faster in
the first speed range instead of a higher speed range . Angle bulldozers are excellent for widening fills,
See the chart in IIlustration 98 . backfilling ditches, or windrowing material in one
direction and maintaining forward motion at the same
time.

Straight Dozing
50000
45000
1""-

•
40000
35000
30000 .'\.
"\
:l! 25000
X- --.........
>- 20000
15000
"'
~
"" ~ -...,

---
...........
10000
~
5000
.........
o
o 3 5 8
D6RIII X mph

900040620
IlIustration 100
g01150544
IlIuslralion 98
Straight Dozing - Maintain a levei cut for the best
(X) Ground speed of lhe machine performance. Fill the bulldozer blade. Carry the load
(Y) Load on lhe machine
to the dump.
(1) Firsl speed range
(2) Second speed range
(3) Third speed range • Avoid lugging or stalling the machine.

The General Rule For Selection of a Speed Range • Avoid excessive spinning of the track.
As Vou Are Dozing - If the transmission is shifted
into a higher speed range and the machine slows • If turning the machine with a loaded blade is
down , return to the previous speed range. necessary, use the bulldozer tilt cylinders instead
of the steering lever in order to steer the machine.

When you are performing levelling work, a full

• bulldozer blade manages better than a partially

loaded bulldozer blade.
78 SEBU8146-06
Operation Section
Operating Techniques

Slot Dozing
•
g00040628
IIlustration 103
g00040626
IlIustration 101
When you are digging parallel slots, the center should
Slot Dozing - When you trap material in a slot, you be removed from the rear. This procedure permits
can carry larger loads in front of the bulldozer blade. the operator to maintain a slot until the center is
removed . The center berm should be wide enough to
The depth of the slot should not be deeper than the stand up without collapsing. Maximum width should
top cor er of the bulldozer blade. be approximately 1/3 of the bulldozer blade.

Machine on a Slope

•
Machine on a Side Slope

g00040622
IIlustra tio n 102

Start the slot at the dump or the spoil end and work
rearward . See Figure (A) in IlIustration 102. Vou
can load the blade as you are moving downhill. IIlustration 104
g00040630
Also, yo u can then carry the load on a levei surface.
The technique that is shown in Figure (B) is not as When possible, work on a slope vertically. This
effi~ient as the technique that is shown in Figure (A) .
method is better than working horizontally.
ln figure (B), the machine is pushing a load uphill
and the operator does not utilize the slot. Dozing When you are working on banks, use caution. When
levei through the entire pit is inefficient because the you are working on slopes, use caution. Avoid tipping
average distance for pushing the material to the the machine .
dump will be greater.
If the machine starts to sideslip on a slope, lighten
the load and turn the machine downhill.

If you are working horizontally on a slope, start at the •

top of the slope . Work downhill. Maintain a windrow
of material on the low side of the machine in order
to provide stability.

Use caution in order to not undercut the slope.

Undercutting the slope will increase the slope .
 SEBU8146-06 79
Operation Section
Operating Techniques

• Machine on an Up Slope or Down Slope Backfilling

g00641146 g00040635
IlIustration 105 IlIustration 107

Reduce ground speed of the machine to an Backfilling - Push the material at a 90 degree angle
acceptable levei by using the service brake prior to in order to fill a trench . When you are cutting material
initiating a steering correction . with the side of the blade, use caution so that the
remaining material does not fali on the machine.
Do not allow the engine to overspeed when you
are unloaded and moving down a slope. Watch the
tachometer and use the service brakes. Use the
land Clearing
service brakes near the top of the slope to prevent
excessive engine speed .

• Note: When you approach engine overspeed the

action lamps will flash . If the engine overspeeds, the
action lamps will flash and the warning alarm will
sound.

V-Ditching

g00040067
IlIustration 108

• Beware of ali dead limbs. Beware of ali limbs that

are hanging overhead.

• Cut the roots of the tree in order to fell a large tree.

g00040633
IlIustration 106

V-Dltching - Tilt the bulldozer blade in order to start

the desired slope. Position the corner of the bulldozer
blade in the center of the ditch. Cut to the desired

•
depth.

,'I/III
. ..... ~ --==-
II

900040073
IlIustration 109
80 SEBU8146-06
Operation Section
Operating Techniques

• If additional leverage is needed, you can doze a The multishank ripper is intended for high production . •
small ramp near the base of the tree. The ramp Use the multishank ripper in hard, packed soi! and
allows the machine to make higher contact on the loosened, embedded rock. The multishank ripper is
tree . Push the tree in the direction of the intended for use in material that can be ripped with AT LEAST
falI. Advance cautiously. The ball of the root may two shanks. Use the multishank ripper with a single
hang up under the bulldozer blade. This could drag center shank less than 20 percent of the time.
the machine off the ramp.
The multishank ripper is NOT intended for high
production in rock with a single center shank.
Stump Removal
A single ripper shank in an outside pocket of lhe
ripper is NOT recommended . If necessary, locate the
shank in the highest position. Operate the machine
at reduced speed . The frame of the ripper is not
designed for ripping with a single outside shank at
full horsepower.

The multishank ripper is NOT intended for ripping in

deep applications. Only use shanks of the specified
length.

Use a single shank ripper when deep ripping is

required .

IlIuslralion 110
g00561004
Packed Soil, Hardpan, Clay, Shale
or Cemented Gravei

•
Stump Removal - Make sure that roots are cut or
loosened . Remove the stump by pushing or digging .

Ripping
Use FIRST speed range for ripping operations. Use
additional shanks instead of increasing the speed
or higher speed ranges .

Use the decelerator in order to match the drawbar

pull. Also, use the decelerator in order to prevent
spinning the track.

Rip the ground as deep as possible. Sometimes, you

may rip at partial depth. Vou can remove the material g00040571
in natural layers. IlIuslration 111
Mullishank ripper wilh Ihree shanks
The sizing of the material is controlled by the depth of
the pass and by the wid th of the pass oIf the material Three shanks work well in these materiais. Use the
is loaded with a wheel dozer, the size of the material greatest possible number of shanks to break the
should be smaller. Finally, the material should be material to the desired size. However, the number of
!)maller if the material is loaded into a scraper. shanks that are used should not cause the machine
to stall.
NOTICE
Do not turn or back the machine while shanks are in
the ground . Twisting stra in on the shanks and tips may
cause fai lure.

NOTICE
Inspect the ripper tips frequently for excessive wear.
•
 SEBU8146-06 81
Operation Section
Operating Techniques

• Rock with Fractures, Faults and

Planes of Weakness

g00040595
IIlustration 114

g00040576 Insert the ripper into the material that is being ripped .
lIIustration 112
Adjust the angle of the shank slightly beyond the
Multishank ripper with two shanks vertical position . This will give you the correct tip
angle for entering the material. The angle will change
The use of two shanks will cause the rocks to break because of the different materiais that need to be
out in smaller pieces. , Then , the machine can ripped .
manage the job easily. When the machine begins to
stall, use only the center shank. If the tracks spin ,
use only the center shank.

•
Single Shank Ripper (Solid Rock,
Granite, or Hard Spots)

..
g00040600
IIlustration 115

Lower the ripper into the material while you move

the machine forward . When you reach the desired
ripping depth, move the shank forward in order to
achieve the correct angle for best pertormance. This
g00562861 angle is usually between the vertical position of the
IlIustration 113
shank and the forward position of the shank.
Use one shank in material that tends to break out in
large slabs or in large pieces.

Adjustable Ripper
The shank on the ripper has angle adjustments and
length adjustment features.

• The angle of the shank must be varied in order to

achieve the maximum pertormance throughout each
ripping passo

IlIustration 116 g00040603

82 SEBU8146-06
Operation Section
Operating Techniques

Move l he ripper shank forward to the shank in

position when you pry out the lodged material.
Push Loading
•

900040056
IIlustration 118
900040607
IIlustration 117
1. Contact the push block squarely.
Adjust the length of the shank according to the
following procedure. 2. The machine should not be moving more than
5 km/h (3 mph ).
1. Maintain a length of the shank so that the machine
can efficiently pull the shank through the material. 3. When possible, maintain a straight push .

2. Mai tain sufficient clearance under the lower 4. Do not allow the rear of the scraper off the ground .
ripper frame. This will prevent the machine from
catching on large slabs or on large rocks that are 5. When the cut is complete , upshift the machine in •
brought to the surface. order to help the scraper get out of the cut.

3. Keep the lower frame assembly as parallel to the

ground as possible. This will evenly distribute the
stress.

4. When you remove material with a scraper or with

a loader, shallow ripping is recommended .

5. When you are ripping for a scraper, rip in the same

direction as the scraper that is being loaded.

6. Never rip to a deeper depth than the depth of the

material that is being removed .

7. When you are removing material with an excavator

or with a bulldozer, deep ripping is recommended .

•
 SEBU8146-06 83
Operation Section
Adjustments

• Adjustments 6. Stop the engine. Align the holes in the tilt brace
and in the push arm bracket. Reassemble the pin ,
the retainer, and the bolts in the desired location.
i027 12811

Bulldozer Blade Pitch i01373627

SMCS Code: 6060; 7000

Tracks
Note: The following procedure is only for the SMCS Code: 4170; 7000
SU-BLAOE.
NOTICE
If tracks are too tight or loose, wear of components is
accelerated .
2
If they appear too tight or too loose, adjust the track.

Follow the procedures in the Maintenance Section for

adjustment.

g00101105
IlIustration 119

• The bulldozer blade can be placed in several

positions. Position (1) is the pitch forward position .
Position (2) is the pitch neutral position . Position (3)
is the pitch back position .

1. Lower the bulldozer blade to the ground. Place the

control for the lift cylinder in the FLOAT position.

2. Actuate the tilt cylinder in order to remove ali force

from the tilt brace. The rear pin between the tilt
brace and the push arm must be loose. The rear
pin must move freely. Stop the engine.

3. Place wooden strips under the edges of the tabs

of the tilt brace. Maintain the holes in the tilt brace
and the push arm bracket at the same elevation.
Reassembly will be easier.

4. Remove the retainer bolts, the retainer, and the

pin at the tilt brace in order to move the push arm o
Start the engine.

NOTICE
Keep fingers clear. Do not place your fingers into the
pin holes in the tilt brace and/or push arm bracket at
any time during the adjustment procedure .

• 5. ln order to slide the tilt brace forward , actuate the

tilt cylinder. ln order to slide the tilt brace rearward ,
actuate the tilt cylinder. If you extend the tilt
cylinder, the brace will slide forward . If you retract
the tilt cylinder, the brace will slide rearward .
84 SE BU8146-06
Operation Section
Parking

Parking i022B0076 •

Stopping the Engine

i02021512
SMCS Code: 1000; 7000
Stopping the Machine
NOTICE
SMCS Code: 7000 Stopping the engine immediately after it has been
working under load can result in overheating and ac-
NOTICE celerated wea r of engine components.
Park on a levei surface. If it is necessary to park on a
grade, block the tracks securely. Refer to the following procedure to allow the engine
to cool and to prevent excessive temperatures in the
Do not engage the parking brake while the machine is turbocharger housing, which could cause oil cokin g
moving unless an emergency exists. problems.

1. Apply the service brakes in order to stop the 1. While the machine is stopped , run the engine fo r
machine. five minutes at low idle.

901043954
. ~~
--' g01141200
•
IlIuslralion 120 IIluslralion 121

2. Move the transmission control to NEUTRAL. 2. Turn the start switch key to the OFF position .
Remove the start switch key.
3. Engage the parking brake.

4. Lower the bulldozer blade and lower ali of the

Idling the Engine for Extended
attachments to the ground . Apply slight downward Periods
pressure.
If the machine is parked and left runn ing for extended
periods of time, set the engine speed at an RPM that
is slightly higher than low idle. Idling the engine at a
higher RPM ensures good eng ine lubrication .

•
 SEBU8146-06 85
Operation Section
Parking

• Stopping the Engine if an

Electrical Malfunction Occurs
SMCS Code: 1000; 7000
i02280396 Bleed Down the Accumulator
When the engine is running , the bulldozer blade
can be lowered by pushing the implement control
lever forward . For a short period of time, after the
engine has been stopped , the bulldozer blade can
be lowered by pushing the implement control leve r
If the engine does not stop after turning the engine forward . Release the control lever. The controllever
start switch key to the OFF position , perform the will return to the HOlO position .
following procedure.
The ripper can be lowered by moving the ripper
1. Apply the parking brake. control lever to the right. Release the control lever.
The controllever will return to the HOlO position .
2. lower the dozer blade or the ripper, if necessary.
Bleed Down the Pilot Oil System
3. Oismount the machine.
Mechanically
After the engine has been stopped for a short
period of time the control levers will not lower the
implements to the ground .

There is a mechanical method that can be used to

lower the attachments.
o

•
o

g01 141130
IlIustration 122

4. locate the battery disconnect switch . The battery

disconnect switch is inside of the access door in
the battery compartment on the left side of the
machine.

5. Turn the key counterclockwise to the OFF position g01144052

in order to stop the engine. Remove the key. IIlustration 123

Note: Do not operate the machine until the There is an access cover for the dozer/ripper valves
malfunction has been corrected . behind the molding inside the operator module.
Remove the molding .

i02285779 Remove the access cover. A bolt is stored inside the

access cover. This bolt may be used to lower the
Equiprnent Lowering with implements.
Engine Stopped
SMCS Code: 7000

Make sure that no one is endangered before you

lower the attachments .

•
86 SEBU8146-06
Operation Section
Parking

i026B0944 •

Leaving the Machine

SMCS Code: 7000

1. Park on a levei surface. If you must park on a

grade , block the machine.
2
2. Apply the service brake in order to stop the
machine. Move the speed range selector to the
NEUTRAL position. Use the throttle switch to
reduce the engine speed to low idle. Engage the
parking brake.
g01144053
IlIuslralion 124 3. Lower ali implements to the ground .

Remove fitting (1) and slowly insert the bolt in order 4. Stop the engine by turning the engine start switch
to lower the ripper. key to the OFF position. Remove the key.

Remove fitting (2) and slowly insert the bolt in order 5. Turn the key for the battery disconnect switch to
to lower the bulldozer. the OFF position . Remove the key when you exit
the machine for an extended period of time.
Install the fittings, the access cover, and the molding .
6. When you dismount, use the steps and the
handholds. Use both hands and face the machine.

7. Inspect the engine compartment for debris. Clean •

out any debris and paper in order to avoid a fire .

8. Install ali the vandalism protection covers and

install ali the locks.

Padlocks are provided for the following areas:

• Engine Enclosures

• Radiator Cap

• Oil Filler Cover

• Battery Box and Master Switch Cover

• Compartment for Washer Fluid Bottle

• Fuel Cap

• Fuel Drain

• Hydraulic Tank Cap

• Lid for Hydraulic Compartment

• Compartment on Back of Seat for Operation

•
and Maintenance Manual

9. Lock the cab doors and the windows, if equipped .

 SEBU8146-06 87
Operation Section
Transportation Information

• Transportation Information 6. Turn the battery disconnect switch to the OFF

position. Remove the key.

i02713607 7. Lock the door and lock the access covers. Attach
any vandalism protection .
Shipping the Machine
8. Install the tie-downs at severallocations and block
SMCS Code: 7000; 7500 the tracks in the front and in the rear.

Investigate the travei route for overpass clearances. 9. Cover the opening for the engine exhaust. Rotation
Make sure that there is adequate clearance for of the turbocharger without engine operation can
the machine that is being transported. This is result in damage to the turbocharger.
especially true for machines that are equipped with a
ROPS/FOPS structure, a cab, or a canopy. Consult your Caterpillar dealer for shipping
instructions for your machine.
Remove ice, snow, or other slippery material from the
loading dock and from the truck bed before loading .
Removing ice, snow, or other slippery material will i02614365
prevent the machine from slipping as you load the
machine. Removing ice, snow, or other slippery Lifting and Tying Down the
material will prevent the machine from slipping in Machine
transit.
SMCS Code: 7000; 7500
NOTICE
Obey ali state and local laws governing the weight,
width and length of a load.

• Observe ali regulations governing wide loads .

~
rJ]2~
111 1

g00040011
IlIustration 125
g00040000
IIlustration 126
1. Place blocks under the trailer wheels or under the
rail car wheels before loading , as shown . NOTICE
Improper lifting or tiedowns can allow load to shift and
2. Lower ali attachments to the floor of the transport can cause injury and damage.
machine. Move the transmission control lever to
the NEUTRAL position .
Note: Do not use handles or steps in order to lift or
3. Engage the parking brake switch . tie down the machine.

•
4. Stop the engine by turning the engine start switch 1. The approximate machine shipping weights are
key to the OFF position. Remove the key. found in the Operation and Maintenance Manual,
"Specifications". The instructions that are listed
5. Pull up on the parking brake knob in order to lock below describe the units that are manufactured
the parking brake. by Caterpillar Inc.
88 SEBU8146-06
Operation Section
Tran sportation Information

Note: Significant deviations can affect shipping the

machine, or significant deviations can affect lifting
the machine. Some examples of these deviations are
listed below:

• Different implements
•
• Additional fuel

• Wider track shoes

• Tracks with accumu lated mud

2. The parking brake must be engaged before you

sling the machine. Engage the parking brake
before you secure the machine with tie-downs.

3. Use properly rated cables and use properly rated

slings for lifting . For a machine without a ripper,
position the slings beneath the front of the track
and beneath the rear of the track. For a machine
with a ripper, position the slings beneath the front
of the track and under the ripper at the rear of
th e machine.

4. On sharp corners, use corner protectors. The

crane should be positioned so that the machine
may be lifted in a levei plane. The spreader bars
should be wide enough to prevent contact with
th e mach ine.

5. Locations for Tie-downs

• Use the eye of the front tie-down .

•
• Use the inside edge of the track shoe for the
side tie-downs.

• Use the drawbar, the ripper, or the outer edge of

the track shoe for the rear tie-downs.

Check the state laws and the local laws that

govern the following load characteristics.

• Weight

• Width

• Length

• Height

Consult your Caterpillar dealer for sh ipping

instructions for your machine .

•
 SEBU8146-06 89
Operation Section
Towing Information

• Towing Information Do not allow an operator to be on the machine that

is being towed unless the operator can control the
steering and/or the braking . Do not attempt to tow
i02712797 a machine without reading and understanding the
following procedures.
Towing the Machine
These towing instructions are for moving a disabled
SMCS Code: 7000 machine for a short distance at low speed . Move the
machine at a speed of 2 km/h (1 .2 mph) or less to a
AWARNING convenient location for repair. These instructions are
only for emergencies.
Personal injury or death could result when towing
a disabled machine incorrectly. Always haul the machine if long distance moving is
required. When any towed machine is loaded, the
Block the machine to prevent movement before machine must be equipped with a brake system that
releasing the brakes. The machlne can roll free if is operable from the operator's compartment.
it is not blocked.
Normally, the towing machine should be as large as
the disabled machine, or larger than the disabled
AWARNING machine. Make sure that the towing machine has
enough brake capacity, enough weight, and enough
Personal injury or death can result from worn wire power. The towing machine must be able to control
rope cable. both machines for the grade that is involved and for
the distance that is involved.
Worn or frayed cable could break causing injury.
Do not use a chain for pulling a disabled machine.
Check the wire rope cable. If cable is worn or is A chain link can break. This may cause possible

• frayed Install a new cable. personal injury. Use a wire cable with ends that have
loops or rings. Put an observer in a safe position in
order to watch the pulling procedure. A safe position
AWARNING would be at a distance away from either machine that
is greater than two times the length of the towing
When the final drive sun gears are removed, the cable. The observer can stop the procedure, if
machine has NO parking brakes. The machine can necessary. The procedure should be stopped if the
roll and cause personal injury or death. cable starts to break. Also, stop the procedure if the
cable starts to unravel. Stop pulling whenever the
Block the tracks securely so that the machine can- towing machine moves without moving the towed
not move. machine.

The towing connection must be rigid, or towing Shields must be provided on both machines. This
must be done by two machines of the same size will protect the operator if either the tow line or the
or larger than the towed machine. Connect a ma- bar breaks.
chine on each end of towed machine.
Before towing , make sure that the tow line or the
Be sure ali necessary repairs and adjustments bar is in good condition . Make sure that the tow
have been ma de before a machine that has been line or the bar has enough strength for the towing
towed to a service area, is put back into operation. procedure that is involved. The strength of the towing
line or of the bar should be at least 150 percent of the
gross weight of the towing machine. This is true for
Note: Consult your Caterpillar dealer for towing a a disabled machine that is stuck in the mud and for
disabled machine. towing on a grade.
This machine is equipped with spring applied brakes. For towing , only attach the tow line to the tow eyes
These brakes are also oil pressure released brakes. on the frame , if equipped .
If the power train oil system for pressure oil is

• inoperable, the brakes are applied and the machine

cannot be moved.
Keep the tow line angle to a minimum. Do not exceed
a 30 degree angle from the straight ahead position.
90 SEBU8146-06
Operation Section
Towing Information

Quick machine movement could overload the tow If you are towing a machine without axle shafts, •
line or the bar. This could cause the tow line or the you may not be able to use the implements to stop
bar to break. Gradual, steady machine movement will the machine. The implement hydraulic system is
be more effective. pilot controlled. With an inoperable engine or an
inoperable hydraulic pump, the accumulator pressure
Ali situation requirements cannot be listed . Minimal will bleed off rapidly. The implement controls will
towing machine capacity is required on smooth, not operate when there is no pressure in the
levei surfaces. Maximum towi ng machine capacity is accumulator. The implements can not be lowered
required on inclines or on surfaces that are in poor with the implement control lever in order to stop a
condition . towed machine when there is no pressure in the
accu mu lator.
Consult your Caterpillar dealer for the equipment that
is necessary for towing a disabled machine. One or more towing machines must provide sufficient
control and sufficient braking when you are moving a
Running Engine disabled machine downhill. This may require a larger
towing machine and additional machines that are
connected to the rear. This will prevent the machine
If the engine is running , the machine can be towed for
a short distance under certain conditions. The power from rolling away out of control.
train and the steering system must be operable.
Tow the machine for a short distance only. For Consult your Caterpillar dealer or refer to the
example, pull the machine out of mud or pull the machine's Service Manual for axle shaft removal and
machine to the side of the road. installation procedures.

The operator on the towed machine must steer the For the second method, use a brake release
machine in the direction of the tow line. pump. If a brake release pump is used to tow the
machine, the brakes can not be applied with the
Carefully follow ali instructions that are outlined in service brake pedal or with the parking brake control.
the Towing Information. Ensure that the instructions If the brake release pump is used and you need to •
are followed exactly. apply the brakes, the brakes must be applied with the
brake release pump that is being used.

Stopped Engine or Drive Une Note: The axles must not be removed when you use
Defect a brake release pump.

Vou can move the machine when the engine is not Connection of 8rake Release Pump
operable. Vou must use a brake release pump or you
must remove the axle shafts. Note: This machine is free to move. This machine is
free to roll away. This machine has no braking ability
Vou can use a brake release pump or you can remove with the parking brake or with the service brake when
the axle shafts in order to tow the machine, if the both brakes have been released .
engine is stopped and if the driveline is not damaged.
The pressure hoses from the pump connect to the
If an internal transmission or a driveline failure is brake valve. The pump takes oil from the sump of the
suspected , remove the axle shafts. brake release pump. Then , the pump pressurizes the
brake piston cavity in order to release the brake.
For the first method, remove the axle shafts.You
may remove the axle shafts from the final drives in
order to tow the machine. This will make the machine
brakes inoperable and the machine can move freely.
The towed machine will be totally dependent on the
towi 9 machine for control and for braking .

•
 SEBU8146-06 91
Operation Section
Towing Information

• 4

J}
6

IlIustration 127 g00775200 g00775222

IIlustration 128
(1) FT1973 Adapter Gp
(2) 8T - 0855 Pressure Gauge 1. The main pressure hose connects to 9J - 6190
(3) 8T - 0477 Relief Valve Adapter Union, 04 - 6683 Nipple, 5P - 8018
(4) Handle
(5) 6V - 5016 Ball Valve
Adapter Union, 8M - 0547 Elbow, and 5P - 2909

•
(6) FT1 845 Brake Release Pump Plug . Plug the pressure hose at the connection
(7) 123 - 0525 Brake Release Adapter with a 5P - 2909 Plug . The components are
(Not shown) 5P - 2909 Plug indicated by shaded area (A).

The machine brakes can be released for towing . Use 2. Turn the handle of bypass valve (5) to the closed
FT1973 Adapter Gp (1), two 123 - 0525 Adapters position .
(7), and FT1845 Brake Release Pump (6).
3. While you are pumping handle (4), observe the
Relief Valve Setting opening pressure of relief valve (3) .

4. Adjust the opening pressure of the rel ief valve.

NOTICE Set the pressure to 3030 ± 70 kPa (440 ± 10 psi) .
Possible brake piston seal damage could result with-
out checking relief valve. Opening pressure must be 5. Turn the handle on bypass valve (5) to the open
checked and adjusted before connection is made. position in order to relieve the pressure in the
pump and in the hose .

•
92 SEBU8146-06
Operation Section
Towing Information

Connection for the Pum p

8
•
9

g00545389
IlIuslralion 131
(8) Brake conlrol valve
(9) Brake valve ports

3. Remove the seat and the floorplate from the

operator's station .

4. Remove the pressure test fittings from the top of

g00775205
IlIuslralion 129 brake va lve ports (9).

1. Remove the components that were used to plug 5. Install one 123 - 0525 Adapter (7) into each of the
the pressure hose. The components are 9J - 6190 brake va lve ports.
Adapter Union, 04 - 6683 Nipple, 5P - 8018
Adapter Union, 8M - 0547 Elbow, and 5P - 2909 6. Connect the FT 1973 Adapter to the 123 - 0525 •
Plug . The components are indicated by shaded Adapters.
area (A) .
7. Route the pressure hose through the rear, around
the side, and through the door of the cabo Connect
the pressure hose to the pump. Install the pump
temporarily on the platform .

8. Replace the floorplate and the seat.

9. Place the brake release pump in front of the

operator.

10. Fasten the seat belt. Continue to the next topic.

g00775209
IlIuslratio n 130
(1) Pump adapler

•
(7) 8rake release adapler

2. Connect FT1973 Adapter (1) to the pump

pressure hose. The adapter will be downstream
from the relief valve.
 SEBU8146-06 93
Operation Section
Towing Information

• 8rake Release 8rake Engagement

5 5

g00775217 g00775217
IlIustration 132 IIlustration 133
(5) Bypass valve (5) Bypass valve

1. Tum bypass valve handle (5) to the closed Open bypass valve (5) in order to apply the brakes.

•
position . This will completely dump the oil.

2. Initially, rapidly move the pump handle. This will The brake system can only be applied by turning
produce a large volume of oil flow. the bypass valve. The service brake pedal and the
steering levers do not function .
3. The brake piston seal must be fully seated . The
seating of the seal is evident by a sudden rise in After towing , remove the brake release pump. Repair
the oil pressure. the machine. Install the floorplate and the seat.

When the seal is properly seated , the pressure

rises to the relief valve setting . The setting is
3030 ± 70 kPa (440 ± 10 psi).

4. Now, the machine can be towed .

NOTICE
Do not allow pressure to drop below 2756 kPa
(400 psi) while towing .

Partial brake engagement could occur and can result

in brake damage.

Brakes must be fully released when towed machine is

moving .

•
94 SEBU8146-06
Operation Section
Engine Starting (Alternate Methods)

Engine Starting (Alternate

Methods)
i02279525
NOTICE
When starting from another machine, make sure that
the machines do not touch . Th is could prevent dam-
age to engine bearings and electrical circuits.
•
Engine Starting with Jump Turn on (elose) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
Start Cables components on the stalled machine.

SMCS Code: 1000; 7000 Severely discharged maintenance free batteries do

not fully recharge from the alternator after jump start-
in~ . The batteries must be charged to proper voltage
AWARNING wlth a battery charger. Many batteries thought to be
unusable are still rechargeable.
Batteries give off f1ammable fumes which can ex-
plode.
This machine has a 24 volt starting system. Use only
the same voltage for jump starting . Use of a welder or
To avoid injury or death, do not strike a match ,
higher voltage damages the electrical system .
cause a spark, or smoke in the vicinity of a battery.
Refer to Special Instruction, Battery Test Procedure,
SEHS7633 , available from your Caterpillar dealer, for
AWARNING complete testing and charging information.
Failure to properly service the batteries may cause
peronal injury.
Use of Jump Start Cables
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump When the auxi.liary start receptacles are not available, •
start cable ends to contact each other or the use the followmg procedure.
machine.
1. Determine the failure of the engine to start.
Do not smoke when checking battery electrolyte
leveis. Reference: Refer to Special Instruction ,
SEHS7768 on the use of 6V - 2150
Electrolyte is an acid and can cause personal in- Starting/Charging Analyzer. Use this procedure if
jury if it contacts skin or eyes. the machine does not have a diagnostic connector.

Always wear eye protection when starting a ma- Reference: Also, refer to Systems Operation ,
chine with jump start cables. SENR2947 , "Starting and Charging Systems for
Machines Equipped with Diagnostic Connector".
Improper jump start procedures can cause an ex-
plosion resulting in personal injury. 2. Place the transmission control on the stalled
machine in the NEUTRAL position . Engage the
Alw~~s connect the battery positive (+) to battery parking brake switch . lower ali attachments to the
positive (+) and the battery negative (-) to battery ground . Move ali controls to the HOlD position .
negative (-).
3. On a stalled machine, turn the start switch key to
Jump start only with an energy source with the the OFF position . Turn off the accessories.
same voltage as the stalled machine.
4. On a stalled machine, turn on the battery
Turn off ali lights and accessories on the stalled disconnect switch .
machine. Otherwise, t hey will operate when the
energy source is connected. 5. Move the machines together in order for the cables
to reach . DO NOT ALLOW TH E MACHINES TO

•
CONTACT EACH OTHER.

6. Stop the engine on the machine that is the

electrical source. When you use an auxiliary
power source , turn off the charging system.
 SEBU8146-06 95
Operation Section
Engine Starting (Alternate Methods)

• 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.
14. Allow the electrical source to charge the batteries
for two minutes.

15. Attempt to start the stalled engine. Refer to

Operation and Maintenance Manual, "Engine
Starting". See the beginning of this topic. Allow
the electrical source to charge the batteries for
two minutes.

16. Immediately after the stalled engine starts,

3 disconnect the jump start cables in reverse order.

: I 17. Conclude with a failure analysis on the starting

charging system. Check the stalled machine, as
! I:FWO) required . Check the machine when the engine is
running and the charging system is in operation.

gO l1 41 042
IIlustration 134
Top view
(1) Negative cable terminal
(2) Negative cable
(3) Battery disconnect switch
(4) Positive cable
(5) Positive cable terminal

• NOTICE
Do not allow positive cable clamps to contact any met-
al except for battery terminais.

Note: Some positive cables and some covers for

positive terminais are red for correct identification .

8. Connect the positive jump start cable to the

positive cable terminal of the discharged battery.

9. Batteries in series may be in separate

compartments. Use the terminal that is connected
to the starter solenoid. Trace this cable in order
to make sure that the cable is connected to the
starter.

10. Connect the positive jump start cable to the

positive terminal of the electrical source. Use the
procedure from Step 8 in order to determine the
correct terminal.

11. Connect one end of the negative jump start cable

to the negative terminal of the electrical source.

12. Make the final connection . Connect the negative

cable to the frame of the stalled machine. Make

• this connection away from the battery, the fuel , the

hydraulic lines, or moving parts.

13. Start the engine on the machine that is the

electrical source. Also, you can energize the
charging system on the auxiliary power source .
96 SEBU8 146-06
Maintenance Section
Lubricant Viscosities and Refill Capacities

Maintenance Section

Lubricant Viscosities and

•
Refi II Capacities
i034 96960

Lubricant Viscosities
SMCS Code: 7581

Selecting the Viscosity

Ambient temperature is the temperature of the air
in the immediate vicinity of the machine. This may
differ due to the machine application from the generic
ambient temperature for a geographic region . When
selecting the proper oil viscosity for use, review both
the regional ambient temperature and the potential
ambient temperature for a given machine application .
Generaliy, use the higher temperature as the criterion
for the selection of the oil viscosity. Generally, use the
highest oil viscosity that is allowed for the ambient
temperatu re when you start the machine. Refer to
the Lubricant Viscosities for Ambient Temperatures
tables and the associated footnotes for guidance. ln
arctic applications, the preferred method is to use
properly sized machine compartment heaters and a
higher viscosity grade oil. Thermostatically controlled
heaters that circulate the oil are preferred .
•
The proper oil viscosity grade is determined by the
minimum outside ambient temperature. This is the
temperature when the machine is started and while
the machine is operated . ln order to determine the
proper oil viscosity grade, refer to the "Min" column
in the ta ble. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer
to the "Max" column in the table in order to select
the oil viscosity grade for operating the machine at
me highest temperature that is anticipated . Unless
specified otherwise in the Lubricant Viscosities for
Ambient Temperatures tables, use the highest oil
viscosity that is allowed for the ambient temperature
w'hen you start the machine.

Machines that are operated continuously should

use oils that have the higher oil viscosity in the final
drives and in the differentials. The oils that have the

•
higher oil viscosity will maintain the highest possible
oi! film th ickness. Consult your dealer if additional
information is needed .
 SEBU8146-06 97
Maintenance Section
Lubricant Viscosities and Refill Capacities

• Lubricant Viscosities for Ambient

Tem peratu res
Table 14

Lubricant Viscosities for Ambient Temperatures

Compartment or Oil Type and °C °F

Application Oil Viscosities
System Classification Min Max Min Max
SAE 60 -7 50 19 122
Cat FOAO(l)(2)
Moderate Usage commercial FO-1 (1) SAE 50 -15 32 5 90
or Intermittent Cat TOTO
Operation Cat TOTO-TMS SAE 30 -25 15 -13 59
commercial TO-4 -35 -31
Cat TOTO-TMS(3) 15 59
Final Drive
Cat FOAO(l)(2) SAE 60 -25(4) 50 -13(4) 122
Severe Usage commercial FO-1 (1)
SAE 50 -33(4) 14 -27(4) 58
or Continuous Cat TOTO
Operation (Multiple Cat TOTO-TMS SAE 30 -40(4) O -40(4) 32
Shifts/Oay) commercial TO-4
Cat TOTO-TMS(3) -40(4) O -40(4) 32
SAE 75W-90 -30 40 -22 104
End Pin Joints for SAE 75W-140 -30 45 -22 113
Cat GO
the Equalizer Bar,
Cat Synthetic GO(5)
Bogie Cartridge Normal SAE 80W-90 -20 40 -4 104
commercial APl
Pins, and Track
GL-5 gear oil SAE 85W-140 -10 50 14 122
Pins

• Power Shift
Transmissions
and Winches Normal
Cat TOTO
commercial TO-4
SAE
SAE 90
OW-20~

SAE OW-30(7)
SAE 5W-30(7)
SAE 10W
O
-40
-40
-30
-20
40
10
20
20
10
32
-40
-40
-22
-4
104
50
68
68
50
Cat TOTO-TMS
(mechanical
Cat Arctic TOTO SAE 30(8) O 35 32 95
drive)
SAE 5Q(8)(8) 10 50 50 122
Cat TOTO-TMS(3)(8) -10 35 14 95
SAE OW-20 -40 40 -40 104

Cat HYOO SAE OW-30 -40 40 -40 104

Cat OEO
SAE 5W-30 -30 40 -22 104
Cat MTO
Cat TOTO SAE 5W-40 -30 40 -22 104
Cat TOTO-TMS
Cat DEO SYN SAE 10W -20 40 -4 104
Cat Arctic OEO SYN
Hydraulic SAE 30 10 50 50 122
Normal Cat Arctic TOTO
Systems
Cat ECF-1 SAE 10W-30 -20 40 -4 104
Cat BIO HYOO
(HEES) SAE 15W-40 -15 50 5 122
APl CG-4
Caterpillar MTO -25 40 -13 104
APICF
commercial TO-4 Cat 810 HYOO
commercial BF_1 (10)(11) -25 43 -13 110

•
(HEES)(lO)(ll)
Cat TOTO-TMS(3) -15 50 5 122
(continued)
98 SEBU8146-06
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 14 , contd)

Compartment or
System
Application
Lubricant Viscosities for Ambient Temperatures

Oil Type and

Classification
Oil Viscosities
Min
°C
Max Min
°F
Max
•
SAE 0W20f,) -40 10 -40 50
SAE OW30(7) -40 20 - 40 68
Cat TOTO SAE 5W30(7) -30 20 -22 68
Winches
Normal Cat TOTO-TMS
(hydraul ic drive) SAE 10W -20 10 -4 50
commercial TO-4
SAE 30(8) O 43 32 110
Cat TOTO-TMS(3)(8) -10 35 14 95
SAE OW-20 -40 10 -40 50
SAE OW-30 -40 30 -40 86
Cat OEO Multigrade
SAE OW-40 -40 40 -40 104
Cat OEO SYN
Cat Arctic OEO SAE 5W-30 -30 30 -22 86
Engine Crankcase Normal SYN (12)
Cat ECF-1 (13) SAE 5W-40 -30 50 -22 122
APl CG-4
SAE 10W-30 -18 40 O 104
Multigrade(14)
SAE 10W-40 -18 50 O 122
SAE 15W-40 -15 50 5 122

•
SAE OW-20f,) -40 O -40 32
SAE OW-30(7) -40 10 -40 50
SAE 5W-20(7) -35 O -31 32
Track Roller
Cat TOTO
Frame SAE 10W -30 O - 22 32
Cat TOTO-TMS
Recoil Spring Normal
Cat Arctic TOTO SAE 30 -20 25 -4 77
Pivot Shaft
commercial TO-4
Beari ngs
SAE 40 -10 40 14 104
SAE 50 O 50 32 122
Cat TOTO-TMS(3) -25 25 -13 77
(contmued)

•
 SEBU8146-06 99
Maintenance Section
Lubricant Viscosities and Refill Capacities

• (Table 14, contd)

Compartment or
System
Application
Lubricant Viscosities for Ambient Temperatures

Oil Type and

Classification
Oil Viscosities
Min
°C
Max Min
°F
Max

Cat DEO SAE 30 -20 25 -4 77

Cat DEO SYN SAE 40 -10 40 14 104
Track Idlers and
Normal Cat ECF-1
Track Rollers
APl CG-4
APl CF SAE 5W-40 -35 40 -31 104

(1) Cat FOAO or commercial FO-1 are the preferred oil types to maximize gear and bearing life. Do not use Cat FOAO or FO-1 in compartments
that contain clutches and/or brakes. Cat TOTO, Cat TOTO-TMS , or commercial TO-4 oil types must be used in any compartment that
contains friction material unless specified otherwise by Caterpillar.
(2) Cat FOAO (Final Drive and Axle Oil) (exceeds the FO-1 specification requirements)
(3) Cat TOTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the TO-4M multigrade specification requirements) .
(4) WARM-UP Required - Exercise the final drives for several minutes with the engine at partial throttle in order to warm up the oil prior to
production operation .
(5) Cat Synthetic GO is an SAE 75W-140 viscosity grade oil.
(6) First Choice: Cat Arctic TOTO - SAE OW-20. Second Choice : Oils of full synthetic base stock that do not have viscosity index improvers and
do meet the performance requirements of the TO-4 specification for the SAE 30 viscosity grade. Typicallubricant viscosity grades are SAE
OW-20, SAE OW-30 , and SAE 5W-30. Third Choice : Oils that conta in a TO-4 additive package and a lubricant viscosity grade of SAE
OW-20, SAE OW-30., or SAE 5W-30
(7) First Choice : Oils of full synthetic base stock that do not have viscosity index improvers and do meet the performance requirements of the
TO-4 specification for the SAE 30 viscosity grade. Typical viscosity grades are SAE OW-20, SAE OW-30, and SAE 5W-30. Second Choice:
Oils with a TO-4 type additive package and a lubricant viscosity grade of SAE OW-20 , SAE OW-30 , or SAE 5W-30.
(8) Except for the hydraulic drive winch gear case. Use SAE 30 viscosity grade for O°C (32°F) to 43°C (110°F) or Cat TOTO-TMS for -20° C
(-4° F) to 50°C (122°F).
(9) 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 .
(10) Commercial biodegradable hydraulic oil must meet the Caterpillar BF-1 specification . The listed ambient temperature range is for
the current Cat BIO HYOO (HEES), not for commercial BF-1 oil.
(11 ) Refer to the machine Operation and Maintenance Manual or contact your local Caterpillar dealer before using Cat BIO HYDO (HEES) or
commercial BF-1 oil.
(12) Cat Arctic OEO SYN is an SAE OW-30 viscosity grade oil.
(13) APl CI-4 , APl CI-4 PLUS , and APl CH-4 oils are acceptable if the requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid
specification - 1) are mel. APl CI-4, APl CI-4 PLUS , and APl CH-4 oils that have not met the requirements of Caterpillar's ECF-1
specification may cause reduced engine life.
(1 4) APl CG-4 oils are acceptable for use in ali Caterpillar machine diesel engines. When APl CG-4 oils are used , the oil change interval
should not exceed 250 hours. APl CG-4 oils that also meet APl CI-4 , APl CI-4 PLUS , or APl CH-4 must also meet the requirements
of the Caterpillar ECF-1 specification .

•
100 SEBU8146-06
Maintenance Section
Lubricant Viscosities and Refill Capacities

i02680952 i01822901 •

Capacities (Refill) S·O·S Information

SMCS Code: 7560 SMCS Code: 7542

Table 15 S·O·S Services is a highly recommended process

APPROXIMATE REFILL CAPACITIES for Caterpillar customers to use in order to minimize
owning and operating cost. Customers provide
Compartment or Imperial oil samples, coolant samples, and other machine
Liters US gal
System gallon information. The dealer uses the data in order to
Cooling System 70 (18.5) (15.4) provide the customer with recommendations for
management of the equipment. ln addition, S·O·S
FuelTa k 424 (112) (93.3) Services can help determine the cause of an existing
product problem.
Engine Crankcase
28.0 (7.4) (6.2) Refer to Special Publication , SEBU6250, "Caterpillar
and Filter
Machine Fluid Recommendations" for detai led
Power rain Oil information concerning S·O·S Services.
148 (39.1) (32.6)
System
Hydraulic Tank Oil 55.5 (14.7) (12.2) Refer to the Operation and Maintenance Manual ,
"Maintenance Interval Schedu le" for a specific
Each Final Drive 13.5 (3.6) (3) sampling location and a service hour maintenance
Each Recoil Spring interval.
25 (6.6) (5.5)
Compartment
Consult your Caterpillar dealer for complete
Pivot Shaft 5 (1.3) (1 .1)
information and assistance in establishing an S·O·S

•
Winch 67.2 (17.8) (14.8) program for you r equipment.

Note: When you are operating on severe slopes, the

quantity of oil in the power train can be increased
up to 10 percent. When you are operating with
the increased oil quantity, prolonged operation in
some machines can cause high power train oil
temperatu res. After the work on the severe slopes
has been completed , drain the excessive oil quantity
from the bevel gear case.

Ecology Orains
Table 16

Ecology Orain Components

Ora in Location Component Needed
12.7 mm (0.5 inch)
Transmission pipe with 1/2-14 NPTH
thread
12.7 mm (0.5 inch)
Torque Converter pipe with 1/2-14 NPTH
thread
19 mm (0.75 inch) pipe
Engine Oil
with 3/4-14 NPTH thread

•
126 -7914 Oil Orain
Coupling
Hydraulic Tank or
25.4 mm (1 inch) pipe with
1-11 1/2 NPTH thread
33 mm (1 .31 inch) pipe with
Bevel Gear Case
1 5/16-12 NPTH thread
 SEBU8146-06 101
Maintenance Section
Maintenance Support

• Maintenance Support 5. Use standard welding procedures in order to weld

the materiais together.

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 ECM sen-
sors) or electronic component grounding points for
grounding 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

• • Other components of the machine

4. Protect any wiring harnesses and components

from the debris and the spatter which is created
from welding .
102 SEBU8146-06
Maintenance Section
Maintenance Interval Schedule

i03629790 Cab Filter (Fresh Air) - Clean/lnspectlReplace ... 109 •

Cooling System Coolant Levei - Check ............... 111
Maintenance Interval Schedule Engine Oil Level- Check ...... .. ............................ 121
Fuel System Water Separator - Drain ................. 133
SMCS Code: 7000 Hydraulic System Oil Levei - Check ........ ........... 140
Seat Belt - Inspect ........................................... ... 146
Ensure that ali safety information, warnings and Transmission Oil Levei - Check .......................... 154
instructions are read and understood before any
operation or any maintenance procedures are Every 50 Service Hours or Weekly
performed .
Cab Filter (Recirculation) - Clean/lnspectl
The user is responsible for the performance of Replace ............................... ... ........ ................... 109
maintenance, including ali adjustments, the use of Ripper Linkage and Cylinder Bearings -
proper lubricants, fluids , filters, and the replacement Lubricate ................................. .. ................. ... .... 145
of components due to normal wear and aging . Failure Track Pins - Inspect .... ........................................ 149
to adhere to proper maintenance intervals and
procedu res may result in diminished performance of Initial 100 service Hours
the product and/or accelerated wear of components.
Trunnion Bearing - Adjust ........................ .. ......... 155
Use mileage, fuel consumption , servi ce hours, or
calendar time, WHICH EVER OCCURS FIRST, Every 250 Servi ce Hours
in order to determine the maintenance intervals.
Products that operate in severe operating conditions Cooling System Coolant Sample (Levei 1) -
may require more frequent maintenance. Obtain ... ... .. .... .. .. ....... .... .............. ...... .............. ... 112

Note: Before each consecutive interval is performed, Every 250 service Hours or Monthly
ali maintenance from the previous interval must be

•
Angle Blade Manual Tilt Brace - Lubricate .......... 104
performed.
Belts - InspectlAdjustlReplace ............................ 104
Bulldozer - Lubricate ........................................... 108
Note: If Cat HYDO Advanced 10 hydraulic oil is
Engine Oil Sam pie - Obtain ........ ........................ 121
used , the hydraulic oil change interval will change.
Equalizer Bar Center Pin - Lubricate .................. 126
The normal interval of 2000 hours is extended to
Equalizer Bar End Pins Oil Levei - Check .......... 126
3000 hours. S·O·S services may extend the oil
Final Drive Oil Levei - Check .. ..... .. ..................... 128
change even longer. Consult your Caterpillar dealer
Fuel Tank Water and Sediment - Drain .. .. ........... 135
for details.
Pivot Shaft Oil Levei - Check .. .................. .......... 142
Track - ChecklAdjust ........................................... 148
When Required Winch Fairlead Rollers - Lubricate ......... .. ........... 156
Camera - Clean/Adjust ............ ...... ... ......... .. .... .. .. 110 Winch Oil Levei - Check ....... .. ....... .. ........... ........ 157
Cutting Edges and End Bits - InspectlReplace .... 117
Engine Air Filter Primary Element - Cleanl Initial 500 service Hours
Replace ................ ....... ............ ........................... 118
Cooling System Coolant Sample (Levei 2) -
Engine Air Filter Secondary Element - Replace .. 119
Obtain ........ .. ................ ............ .......................... 113
Engine Air Precleaner - Clean ............................ 120
Winch Oil and Breather - Change/Clean ............ 157
Ether Starting Aid Cylinder - Replace ....... .. ........ 127
Front Idler Position - Check .. ............... ....... .. .. .... 130
Fuel System - Prime ........................................... 131 Every 500 service Hours
Fuses and Circuit Breakers - Replace/Reset .. .... 136 Final Drive Oil Sample - Obtain .. ........................ 129
Oil Filter - Inspect ...................... .......................... 142 Hydraulic System Oil Sample - Obtain ...... .. ... .... 141
Radiator Core - Clean ........ .. ............ ....... .. .......... 143 Transmission Oil Sam pie - Obtain ...... .............. .. 154
Radiator Pressure Cap - Clean/Replace .... ...... .. 143
Ripper Tip and Shank Protector - Inspectl Every 500 service Hours or 3 Months
Replace ........ ...... .... ....... ...... .. ................. .. ......... 145
Trunnion Bearing - Adjust ............... .................... 155 Engine Crankcase Breather - Clean ................... 120

•
Winch Wire Rope - Install ............ .. ....... ... .. ........ . 158 Engine Oil and Filter - Chang e .. .. ....................... 122
Window Washer Reservoir - Fill .... ...... ..... .... ....... 158 Fuel System Secondary Filter - Replace ..... .. ..... 132
Windows - Clean ........................... .... .................. 159 Fuel System Water Separator Element -
Replace ... ..... ...... .... ................. ... ............... . .. .... 133
Every 10 service Hours or Daily Fuel Tank Cap Filter and Strainer -
Replace/Clean ... ... ...... .. ... ......... ......... .... ... .. ...... 135
Backup Alarm - Test .......... .................................. 104 Hydraulic System Oil Filter - Replace ... ... .... .. .. ... 139
Brakes, Indicators and Gauges - Test .. .. .. .. ...... ... 106 Recoil Spring Compartment Oil Levei - Check ... 144
 SEBU8146-06 103
Maintenance Section
Maintenance Interval Schedule

• Transmission Breather - Clean ...... ..................... 151

Window Wipers - InspectlReplace ....... ...... ......... 159

Initial 1000 Service Hours

Engine Valve Lash - ChecklAdjust ...................... 126

Every 1000 Service Hours or 6 Months

Battery - Inspect ..... ..... ........ .. ....... .... .. ..... ....... ..... 104
Lift Cylinder Yoke Bearings - Lubricate ............... 142
Rollover Protective Structure (ROPS) and Falling
Object Protective Structure (FOPS) - Inspect .. . 146
Torque Converter Scavenge Screen - Clean ...... 147
Transmission Breather - Replace ....... ......... ....... 151
Transmission Oil- Change ...... .................... ....... 151
Transmission Oil Filter - Replace ... .... ................. 153
Transmission Scavenge Screen - Clean ............. 155
Winch Oil and Breather - Change/Clean ............ 157

Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ................................. .... 128
Hydraulic System Oil - Change ... .... ............. ....... 137
Track Roller Frame Guides - Inspect ........ .......... 150

Every Year

• Cooling System Coolant Sample (Levei 2) -

Obtain ......... ....... ... ...................... ............ ........... 113
Engine Air Filter Secondary Element - Replace .. 119
Refrigerant Dryer - Replace ....... ..... ......... ..... .... .. 144

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace .......... .. ................................. 147

Every 6000 Service Hours or 3 Years

Cooling System Extended Life Coolant Extender -
Add ....... .... ...... .... ...................... .................... .. .... 115
Cooling System Water Temperature Regulator -
Replace .. .................... ..... ...... ....................... .. .... 116
Engine Valve Lash - ChecklAdjust .... .... .............. 126

Every 6000 Service Hours or 4 Years

Engine Valve Lash - ChecklAdjust .. ... ................ . 126

Every 12 000 Service Hours or 6 Years

Cooling System Extended Life Coolant -
Chang e ................. ...................................... ....... 114

•
104 SEBU8146-06
Maintenance Section
Angle Blade Manual Tilt Brace - Lubricate

i01034 553 2. Tighten the battery retainers. Clean the top of the •
batteries with a clea n cloth. Keep the terminais
Ang le Blade Manual Tilt Brace clean and coated with petroleum jelly. Install the
- Lubricate terminal covers after you coat the termi nais.

SMCS Code: 6074-086 3. Close the battery access covers.

If equipped:
i02712836

Belts - Inspect/AdjustlReplace
SMCS Code: 1357-025; 1357-040; 1357-5 10

Inspect
1. Open the access door on the right side of the
machine. Open the access door on the left side of
the machine in order to inspect the air condition ing
compressor belt.

Note: Even if only one belt is worn or damaged ,

replace the belts in sets.
g00103702
IIlustratio 135
2. Inspect the cond ition of the fan drive belt, the
Lubricate the two fittings. Use Multipurpose Lithium alternator and water pump belt, and the air
Complex Grease with Molybdenum (MPGM) . condition ing compressor belt. The belts should
deflect 14 to 20 mm (.56 to .81 inch) under 110 N •
(25 Ib) of force . Use a 144 - 0235 Belt Tension
i027 12816 Gauge in order to measure the tension.

Backup Alarm - Test

SMCS Code: 7406-081

The backup alarm is on the rear of the machine.

ln order to test the alarm for proper functioning , turn

the engine start switch to the ON position .

Apply the service brake. Release the parking brake.

Move the speed range selector to the REVERSE
position .

The backup alarm should start to sound immediately.

The backup alarm will continue to sound until the
speed ra nge selector is moved to the NEUTRAL
position or to the FORWARD position .

i01376996

Battery - Inspect
SMCS Code: 1401-040

1. Open the battery access covers. The battery

access covers are located on the left side of the
mach ine outside the operator compartment.
•
 SEBU8146-06 105
Maintenance Section
Belts - InspectlAdjustlReplace

• AdjustlReplace
2

• IlIustration 136
Alternator and Water Pump Belt

1. Loosen bolts (1).

g00850323
IIlustration 137
Fan Drive Belt

1. Loosen bolts (1).

g00850322

2. Turn the adjusting nuts (2) until the correct belt

2. Tum adjusting nuts (2) until the correct belt tension tension is reached . To achieve the correct belt
is reached . To achieve the correct belt adjustment, adj ustment, move the idler pulley inward or move
move the alternator inward or move the alternator the idler pulley outward , as requ ired .
outward , as required .
3. Tighten bolts (1).
3. Tighten bolts (1 ).

•
gOl1 47368
IIlustration 138
Air cond ltioning compressor belt

1. Loosen bolts (1).

106 SEBU8146-06
Maintenance Section
Brakes, Indicators and Gauges - Test

2. Turn adjusting nuts (2) until the correct belt

tension is reached . To achieve the correct belt
adjustment, move the compressor inward or move
the compressor outward , as required.

3. Tighten bolts (1) .

@)
(])
ON - The eng ine start switch key (1) must
be turned to the ON position in order to
supply electrical power to the operator's
compartment so that the CMS will function.
•
Turn the eng ine start key to the ON position . The
4. Close the access doors. system should act in the following manner:
Note: Use the same procedure in order to replace • The indicator lights on the top portion of the
the belts. instrument panei come on briefly.
Note: If new belts are installed , check the belt • The action light comes on briefly.
adjustment again after 30 minutes of engine
operation. • The auxiliary action light comes on briefly.

i0 24314 58 • The indicator lights on the bottom portion of the

instrument panei flash briefly.
Brakes, Indicators and Gauges
• The action alarm sounds briefly.
- Test
• The pointers on the gauges point upward. Then ,
SMCS Code: 4100-081 ; 7000-081 ; 7450-081
the pointers point to the left. Then , the pointers
point to the right. Then , the pointers point to the
Inspect the dash panei for broken lenses, indicator
final position .
lights, and switches.

•
If the system functions properly, start the engine. If
CMS Functional Test any of the following events occur, do not start the
engine:
To ensure proper operation of the CMS , check the
system on a daily basis. • The indicator lights on the top portion or the bottom
portion of the instrument panei do not come on .

• The action light does not come on .

• The auxiliary action light does not come on.

• The action alarm does not sound .

Complete any necessary repairs before you start

the engine.

Panei Test Switch - With the engine

@(}) stopped , push test switch (2). Service hours
will appear in the display area until the
2 switch is pushed . Push the switch and release the
switch until the desired information appears in the
display area . The following type of information is
displayed :

• Total Service Hours

IIlustration 139
90 1043983 • Service hours in forward speed range

The battery disconnect switch must be ON in order

to supply electrical power to the machine so that the
electrical systems will function .
• Servi ce hours in reverse speed range

• Fault codes
•
 SEBU8146-06 107
Maintenance Section
Brakes, Ind icators and Gauges - Test

• Braking System (Test) 8. Reduce the engine speed to LOW IOLE. Engage
the parking brake. Lower ali attachments to the
ground . Apply a slight down pressure. Stop the
AWARNING engine.
If the machine moves during the test, reduce the 9. Make any necessary repairs before you operate
engine speed immediately, and engage the park- the machine.
ing brake.

If the machine moved while testing the brakes, NOTICE

consult your Caterpillar dealer for brake inspec- If the machine moved wh ile testing the brakes, contact
tion and repa ir. Damaged brakes must be repaired your Caterpillar dealer. Have the dealer inspect a~d ,
before returning the machine to operation. if necessary, repa ir the service brake before returnmg
the machine to operation .

Note: The machine is capable of driving through

the brakes in the first speed range.

Make sure that the area around the machine is clear

of personnel and clear of obstacles.

Test the brakes on a dry, levei surface.

Fasten the seat belt before you test the brakes .

•
IlIustration 140 901043985

1. Start the engine.

2. Raise ali attachments.

3. Oepress the service brake pedal.

4. Release the parking brake.

5. While the brake pedal is depressed , move the

directional control to the SECONO SPEEO
FORWARO position .

6. Gradually increase the engine speed to full load

speed. The machine should not move .

• 7. Move the directional control to the NEUTRAL

position.
108 SEBU8146-06
Maintenance Section
Bulldozer - Lubricate

Bulldozer - Lubricate
(Variable Pitch Angle Tilt
Blade)
i02627944

•
SMCS Code: 6050-086

901346976
IlIustration 141

Lubricate the Variable Pitch Angle Tilt Blade at every 4. Lubricate the bearings on the rod end of each of
250 hour interval. the lift cylinders (2 points).

•
1. Lubricate the bearings on the ends of each 5. Lubricate the trunnion bearing (1 point).
hydrauric cylinder (6 points) .

2. Lubricate the bearings on each end of the

stabilizer link (2 points).

3. Lubricate the bearings under the cover of the

stabilizer link (2 points) .
 SEBU8146-06 109
Maintenance Section
Cab Filter (Fresh Air) - Clean/lnspectlReplace

• Cab Filter (Fresh Air) -

Clean/lnspectlReplace
(If Equipped)
i02276929

Cab Filter (Recirculation) -

Clean/lnspectlReplace
(If Equipped)
i02277295

SMCS Code: 7342-040; 7342-070; 7342-510 SMCS Code: 7342-040; 7342-070; 7342-510

'~
L
A
2
A-A

~WDI

g01140074 g01140113
lIIustration 142 IlIustration 143
Top view
1. Remove the filter element that is positioned in the
1. Remove filter cover (1) and filter element (2). The operator's compartment below the left side of the

•
filter cover is in front of the front window of the cab o dash.

2. The filter element can be cleaned by using 2. The filter element can be cleaned by using
pressure air. Use a maximum air pressure of pressure air. Use a maximum air pressure of
205 kPa (30 psi). Direct the air from the clean side 205 kPa (30 psi). Direct the air from the clean side
to the dirty side. to the dirty side.

3. Look through the filter toward a bright light. Inspect 3. Look through the filter toward a bright light. Inspect
the element for damage. Inspect the gaskets for the element for damage. Inspect the gaskets for
damage. Replace damaged filters . damage. Replace damaged filters.

4. Install the filter element. 4. Install the filter element.

Note: Clean the filters more often in dusty conditions . Note: Clean the filters more often in dusty conditions.

•
110 SEBU8146-06
Maintenance Section
Camera - Clean/Adjust

Camera - Clean/Adjust
SMCS Code: 7348
i03638722

•
AWARNING
Failure to use an appropriate externalladder or an
appropriate platform for direct access to the rear
view camera could result in slipping and falling
which could result in personal injury or death. Se
sure to use an appropriate externa I ladder or an
appropriate platform for direct access to the rear
view camera. g01952903
IIluslralion 144

The machine's counterweight and the engine (1) 8011

hood are not approved as a maintenance plat-

forms. 1. Unfasten the 2 bolts (1).

AWARNING
Unexpected machine movement can cause injury
or death.

ln order to avoid possible machine move-

ment, move the hydraulic lockout control to the
LOCKEO position and attach a Special Instruc-
tion, SEHS7332, "Do Not Operate" or similar
warning tag to the hydraulic lockout controlo

When maintenance or servicing of the rear view

•
camera is required follow these steps.

1. Park the machine on a levei surface.

2. Place the work tool on the levei surface.

3. Move the hydraulic lockout control to the Locked g01952933

position . lIIuslralion 145

4. Turn the engine start switch to the OFF position 2. Adjust the area of the visibility of the camera so
and remove the eng ine start switch key. that a 1.5 m (5 ft 11 inch) tall obstacle which is 1 m
(3 ft) behind the counterweight can be seen .
5. Turn the battery disconnect switch to theOFF
position and remove the battery disconnect switch 3. Tighten the 2 bolts (1) to a torque ofO.5 ± 0.05 N'm
key. (4 ± 0.4 Ib in) .

Clean Camera Lens Work Area Vision System (If

Equipped)
If necessary, clean the camera lens before you
operate the machine. Use a soft cloth for cleaning . ln order to maintain sufficient vision, keep the Work

•
Area Vision System (WAVS) camera lens and the
Adjust the Area of Visibility display clean .

If the camera displays an undesired view, adjust the

area of the visibility.
 SEBU8146-06 111
Maintenance Section
Cooling System Coolant Levei - Check

• Display i02277501

Cooling System Coolant Levei

- Check
SMCS Code: 1353-535-FLV; 1395-535-FLV

AWARNING
At operating temperature, the engine coolant is
hot and under pressure.

Steam can cause personal injury.

Check the coolant levei only after the engine has

g01223034 been stopped and the fil! cap is coo I enough to
IlIustration 146
WAVS display touch with your bare hand.

Use a soft, damp cloth in order to clean the display. Remove the fil! cap slowly to relieve pressure.
The display has a soft plastic surface that can be
easily damaged by an abrasive material. The display Cooling system conditioner contains alkali. Avoid
is not sealed. Do not immerse the display with contact with the skin and eyes to prevent personal
liquid. injury.

Camera This machine's radiator has a surge tank. There

•
is no top tank in this cool ing system. The surge
tank has a filler cap and a sight glass. It is not
necessary to remove the filler cap in order to check
the coolant leveI. The sight glass is inside the engine
compartment that is on the front left side of the
mach ine. The filler cap is beneath the access door
that is on the top left side of the radiator guard o

g01223051
IlIustration 147

Use a damp cloth or water spray in order to clean

the camera lens. The camera is a sealed unit. The
camera is not affected by high pressure spray.

The camera is equipped with an internal heater to

help counteract the effects of condensation , snow, IIlustration 148 gO l1 40272
or ice.
1. Observe the sight glass in order to verify the levei
Note: For more information on WAVS, refer to of the coolant. If the coolant completely covers the
Operation and Maintenance Manual , SEBU8157 , sight glass, the coolant levei is okay. If the coolant
"Work Area Vision System". levei is visible in the sight glass, the coofant is fow.
Add coolant in order to fill the system .
~ .
112 SESU8146-06
Maintenance Section
Cooling System Coolant Sample (Levei 1) - Obtain

Note: The factory fill is Extended Life Coolant Use compressed air, high pressure water, or steam •
(ELC) . Refer to Operation and Maintenance to remove dust and debris from the rad iator core.
Manual, SEBU6250, "Caterpillar Machine Fluids However, the use of compressed air is preferred .
Recommendations" for additional information .
Maintai ning the system as ELC is preferred . See
the sections "Coolant Recommendations" and "ELC i02277521
Coolin g System Maintenance". Cooling System Coolant
Sam pie (Levei 1) - Obtain
SMCS Code: 1350-008 ; 1395-008; 7542

Obtain the sam pie of the coolant as close as possible

to the recommended sampling interval. ln order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. ln 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.

IIlustration 149
g01140173 Levei 1 Analysis

2. If it is necessary to add coolant, remove the filler NOTICE

cap slowly in order to relieve the pressure. Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test-
ing , adjusting and repair ofthe product. Se prepared to •
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication , NENG2500, "Caterpillar

Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of ali fluids according to local reg ulations and

mandates.

g00475722 Note: It is not necessary to obtain a Coolant

IlIustration 150
Sample (Levei 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
3. Look into filler tube (1) . Maintain the coolant levei systems that are filled with Cat ELC should have
between area (2) and area (3) of the filler tube. a Coolant Sam pie (Levei 2) that is obtained at
Adding coolant above this area of the filler tube the recommended interval that is stated in the
will cause the coolant to overflow the cooling Maintenance Interval Schedule.
system. If you need to add coolant daily, check the
cooling system for leaks. Note: Obtain a Coolant Sample (Levei 1) if the
cooling system is filled with any other coolant
4. Inspect the filler cap and the filler cap seal for instead of Cat ELC. This includes the following
debris , for foreign material , or for damage. Clean types of coolants.
the filler cap with a clean cloth . Replace the
radiator cap if the filler cap is damaged. • Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
5. Install the filler cap. (Caterpillar EC-1) . ~
6. Inspect the radiator core for debris. Clean the • Cat Diesel Engine Antifreeze/Coolant (DEAC)
radiator core, if necessary.
• Commercial heavy-duty coolantlantifreeze
 SEBU8146-06 113
Maintenance Section
Cooling System Coolant Sample (Levei 2) - Obtain

• Testing the coolant can be done at your Caterpillar

dealer. Caterpillar S·O·S Coolant Analysis is the best
way to monitor the condition of your coolant and your
cooling system. S·O·S Coolant Analysis is a program
that is based on periodic samples.
3. Obtain a sample. For additional information
about coolant analysis, see Special Publication ,
SEBU6250, "Caterpillar Machine Fluids
Recommendations" or consult your Caterpillar
dealer.

Perform a Coolant Analysis (Levei 1 ) at 250 hours 4. Replace the protective cap. Close the right side
for systems that do not contain extended life coolant engine compartment.
(ELC).
Submit the sample for Levei 1 analysis.
Use the following guidelines for proper sampling of
the coolant: NOTICE
Always use a designated pump for oil sampling , and
• Complete the information on the label for the use a separate designated pump for coolant sampling .
sampling bottle before you begin to take the Using the same pump for both types of samples may
samples. contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
• Keep the unused sampling bottles stored in plastic rect interpretation that could lead to concerns by both
bags. dealers and customers.
• Obtain coolant sam pies directly from the coolant
sample portoVou should not obtain the samples Note: levei 1 results may indicate a need for
from any other location . levei 2 Analysis.

• Keep the lids on empty sampling bottles until you Levei 2 is a comprehensive analysis which should be
are ready to collect the sample. performed annually. See Operation and Maintenance
Manual, "Cooling System Coolant Sample (Levei 2) -

•
• Place the sample in the shipping sleeve Obtain" for more information.
immediately after obtaining the sample in order to
avoid contamination.
i02277557

• Never collect samples from expansion bottles. Cooling system Coolant

• Never collect samples from the drain for a system. Sam pie (Levei 2) - Obtain
SMCS Code: 1350-008; 7542

levei 2 Analysis
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.

g01140364
IlIustration 151
Right view

1. Park the machine on a hard, levei surface. Set the

engine at low idle speed .

• 2. Open the right engine compartment. Remove the

protective cap from the sampling valve.
114 SESU8146-06
Maintenance Section
Cooling System Extended Life Coolant - Change

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test-
ing , adjusting and repairofthe product. Se prepared to
collect the fluid with suitable containers before open-
Submit the sample for Levei 2 analysis.

Cooling System Extended Life

i024 31318
•
ing any compartment or disassembling any compo- Coolant - Change
nent containing fluids .
SMCS Code: 1350-044; 1395-044
Refer to Special Publication , NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies NOTICE
suitable to collect and contain fluids on Caterpillar Make sure you read and understand the information
products. in the topics Safety and Cooling System Specifica-
tions for ali information pertaining to water, antifreeze
Dispose of ali fluids according to local regulations and and supplemental coolant additive requirements be-
mandates. fore you proceed with maintenance of the cooling sys-
tem.
Testing the coolant can be done at your Caterpillar
dealer. Caterpillar S·O·S Coolant Analysis is the best NOTICE
way to monitor the condition of your coolant and your Care must be taken to ensure that fluids are contained
cooling system. S·O·S Coolant Analysis is a program during performance of inspection , maintenance, test-
that is based on periodic samples. See Operation ing , adjusting and repair ofthe product. Se prepared to
and Maintenance Manual , SESU6250, "Caterpillar collect the flu id with suitable containers before open-
Machine Fluid Recommendations", "S.O.S Coolant ing any compartment or disassembling any compo-
Analysis" for more information. nent containing fluids.
Perform a Coolant Analysis (Levei 2) at initial 500 Refer to Special Publication , NENG2500, "Caterpillar •
hours for systems that contain extended life coolant Dealer Service Tool Catalog " for tools and supplies
(ELC) . Perform the analysis yearly after the initial suitable to collect and contain fluids on Caterpillar
500 hours. products.

Dispose of ali fluids according to local regu lations and

mandates.

Drain the coolant whenever the coolant is dirty or

whenever foaming is observed .

The filler cap is located inside the access door in the

top , left side of the radiator guard o

1. Slowly loosen the filler cap in order to relieve

system pressure. Remove the filler cap.

2. Remove the access cover. The cover is located in

g01140364
IlIuslralion 152 the front, bottom guard o

1. Park the machine on a hard, levei surface. Set the 3. Remove the plug from the drain valve. Install a
engine at low idle speed . 12.7 millimeter (.5 inch) pipe into the drain valve.
The pipe requires 1/2 - 14 NPTF threads.
2. Open the right side engine compartment. Remove
the protective cap from the sampling valve. 4. Clamp a hose to the pipe in order to direct the
coolant into a suitable container.
3. Obtam a sample. For additional information
about coolant analysis, see Special Publication , 5. Open the drain valve. Allow the coolant to drain •
SESU6250, "Caterpillar Machine Fluids into a suitable container.
Recommendations" or consult your Caterpillar
dealer. 6. Close the drain valve. Fill the system with a
solution wh ich consists of clean water and of
4. Replace the protective cap. Close the left side cooling system cleaner. The concentration of the
engine compartment. cooling system cleaner should be 6 to 10 percent.
 SESU8146-06 115
Maintenance Section
Cooling System Extended Life Coolant Extender - Add

• 7. Start the engine. Run the engine for 90 minutes.

Stop the engine. Orain the cleaning solution into a
suitable container.

8. While the engine is stopped, flush the system with

water. Flush the system until the draining water
Cooling System Extended Life
Coolant Extender - Add
SMCS Code: 1350; 1352-544-NL; 1395-544-NL
i02431338

is clear.

9. Close the drain valve. NOTICE

Care must be taken to ensure that fluids are contained
10. Replace the plug in the drain valve and instaI! the during performance of inspection , maintenance, test-
access cover. ing , adjusting and repairofthe product. Se prepared to
collect the fluid with suitable containers before open-
11. Add the coolant solution . See the following topics ing any compartment or disassembling any compo-
in this publication : nent containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar

• Refill Capacities
O~aler Service Tool Catalog" for tools and supplies

Note: Caterpillar antifreeze contains additive. If sUltable to collect and contain fluids on Caterpillar
you are using Caterpillar antifreeze, do not add the products.
supplemental coolant additive at this time. Also,
do not change the supplemental coolant additive Oispose of ali fluids according to local regulations and
element at this time. mandates.

12. Start the engine. Run the engine without the filler Table 17
cap until the thermostat opens and the coolant "Cat ELC Extender" and the Cooling System Capacity
levei stabilizes.

•
Recommended
13. Check the coolant leveI. Make necessary Cooling System Capacity Amount of "Cat
ELC Extender"
adjustments to the coolant leveI.
65 to 83 L (17 to 22 US gal) 1.60 L (54 oz)
14.lf the gasket is damaged, replace the filler cap.
Install the filler cap.
When a Caterpillar Extended Life Coolant (ELC)
15. Stop the engine. is used, an extender must be added to the cooling
system . See the Operation and Maintenance
Manual, "Maintenance Interval Schedule" for the
pro per service interval. The amount of extender is
determined by the cooling system capacity.

For additional information about adding an extender,

see Special Publication, SESU6250, "Caterpillar
Machine Fluids Recommendations" or consult your
Caterpillar dealer.

Extended Life Coolant (ELC)

Extender
Use a 8T - 5296 Coolant Conditioner Test Kit to
IIlustration 153
g00533931 check the concentration of the coolant.

16. Clean the radiator cores with compressed air. Vou

may need to use water in order to remove debris.

•
116 SESU8146-06
Maintenance Section
Cooling System Water Temperature Regulator - Replace

3. Add 1.60 L (54 oz) of Extender to the cooling •

AWARNING system .
Personal injury can result trom hot coolant, steam
4. Start the engine. Run the engine without the filler
and alkali.
cap until the thermostat opens and the coolant
levei stabilizes. Check for leaks.
At operating temperature, engine coolant is hot
and under pressure. The radiator and ali lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool
enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid

contact with skin and eyes.

g00475722
IlIustration 155

5. Look into filler tube (1). If necessary, add premixed

coolant in order to correct the coolant leveI.
Maintain the coolant levei between area (2) and
area (3) of the filler tube. Adding coolant above
this area of the filler tube will cause the coolant to •
overflow the cooling system .

6. Replace the radiator cap if the cap gasket is

damaged. Install the rad iator cap.
901140173
IlIustra tion 154

i02277639
1. The filler cap is located inside the access door on
the top, left side of the radiator guard oLoosen the
radiator cap slowly in order to relieve pressure.
Cooling System Water
Remove the radiator cap. Temperature Regulator -
2. It may be necessary to drain some coolant from
Replace
the radiator 50 that Extender can be added to the SMCS Code: 1355-510
cooling system .

Note: Always discard drained fluids according to NOTICE

local regulations. Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test-
ing , adjusting and repair of the product. Se prepared to
NOTICE collect the flu id with suitable containers befo re open-
Care must be taken to ensure that fluids are contained ing any compartment or disassembling any compo-
during performance of inspection, maintenance, test- nent containing fluids.
ing , adj usting and repair of the machine. Se prepared
to collect the fluid with suitable containers before Refer to Special Publication , NENG2500, "Caterpillar
opening any compartment or disassembling any com- Tools and Shop Products Guide" for tools and supplies
ponent containing fluids . suitable to collect and contain flu ids on Caterpillar
products.
Refer to Special Publication , NENG2500, "Caterpillar
Tools and Shop Products Guide", for tools and sup- Dispose of ali fluids according to local reg ulations and •
plies suitable to collect and contain flu ids in Caterpillar mandates.
machines.

Dispose of ali fluids according to local regulations and

mandates.
 SEBU8146-06 117
Maintenance Section
Cutting Edges and End Bits - InspectlReplace

• Replace the thermostat on a regular basis per the

maintenance interval schedule. This reduces the
chance of unscheduled downtime and of problems
with the cooling system.

A new thermostat should be installed after the cooling

NOTICE
If the thermostat is installed incorrectly, it will cause
the engine to overheat.

system has been cleaned . Install the thermostat 5. Install a new seal in the thermostat housing . Install
while the cooling system is completely drained or the new thermostat and the new gasket. Install the
while the cooling system coolant is drained to a levei thermostat housing on the engine cylinder head.
that is below the thermostat housing.
6. Install the elbow and the hose. Tighten the hose
clamp.
NOTICE
Failure to replace the engine's thermostat on a regu- 7. Close the right engine compartment.
larly scheduled basis could cause severe engine dam-
age. 8. Replace the coolant that was drained from the
system. Refer to Operation and Maintenance
Note: If you are only installing a new thermostat, Manual, "Capacities (Refill)".
drain the cooling system coolant to a levei that is
below the thermostat housing . i03204387

1. Open the right engine compartment. Cutting Edges and End Bits -
InspectlReplace
SMCS Code: 6801-040; 6801-510; 6804-040;
6804-510

•
gOl144256
IIlustration 156

2. Loosen the hose clamp and remove the hose from

the elbow. Disconnect the hose assembly from
the thermostat housing assembly. g01051836
IIlustration 157
3. Remove the bolts from the elbow. Remove the
elbow and the thermostat housing assembly. 1. Raise the bulldozer blade and block up the
bulldozer blade. When you remove the cutting
4. Remove the gaskets, the thermostat, and the seal edges and the end bits, maintain the bulldozer
from the thermostat housing . blade at a minimum height.

2. Remove the bolts. Then remove the cutting edge

NOTICE and the end bits.
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the 3. Thoroughly clean ali contact surfaces.
engine with the thermostats.
4. Inspect the opposite side of the cutting edge. If

•
Depending on load, failure to operate with the ther- the opposite side of the cutting edge is not worn ,
mostats could result in either an overheating or an turn the opposite side of the cutting edge outward
overcooling condition . and install the cutting edge.

5. If both sides of the cutting edge are worn , install a

new cutting edge section .
118 SEBU8146-06
Mainte ance Section
Engine Air Filter Primary Element - Clean/Replace

Note: When the cutting edge is within 10 mm

(0.4 inch) of the bottom of the support, change the
cutting edge. Do not allow wear to occur on the
support.

6. If the bottom edge or the outside edge of the end

NOTICE
Do not use the filter for longer than one year. •
bit is worn , install a new end bit.

Note: When the end bit is within 10 mm (0.4 inch) of

the bottom of the support, change the end bit. When
the end bit is within 10 mm (0.4 inch) of the outside
edge of the support, change the end bit. Do not
allow any wear to occur on the support.

7. Install ali bolts and tighten the bolts to the specified

torque.

Reference: For more information, refer to

Specifications, "Torque Specifications". 901141636
IIlustration 158
8. Ra ise the bulldozer blade and remove the
bloc ing. Lower the bulldozer blade to the ground . 1. Open the engine compartment's access door if
equipped . '
9. After you operate the machine for a few hours
check ali bolts for the proper torque. '

•
i02712859

Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1051-070; 1051 -510-PY; 1054-070-PY-
1054-510-PY ,

NOTICE
Service the primary filter element only when the alert
indic~to r for the intake air filter is flashing . Do not open 900470852
lIIustration 159
the fllter compartment unless it is time for service .
~pen ing the filter compartment can cause dirt to get
2. Remove the air cleaner cover (1).
mto the clean side of the filter housing.
3. Remove the primary fi lter element (2) from the air
NOTICE cleaner housing.
Extremely short air filter life can result if the preclean-
er system malfunctions. If air filter life is drastically re- 4. Mark the secondary filter element in order to show
that the primary filter element has been serviced .
duced from typical for the operating conditions, con-
The secondary filter element should be replaced
s~lt yo ur Caterpillar Dealer. The exhaust system dust
ejector for the strata tube precleaner must pull a min- when the primary filter element is serviced for the
imum vacuum of 508 mm (20 inch) of water. third time . Refer to Operation and Maintenance
Manual, "Eng ine Air Filter Secondary element -
Replace".
NOTICE
Service the engine air filters with the engine stopped .

•
Engine damage could result.

NOTICE
Always leave the secondary filter element in place
while you clean the primary element, or while you
clean the air cleaner housing .
 SEBU8146-06 119
Maintenance Section
Engine Air Filter Secondary Element - Replace

• Engine Air Filter Secondary

Element - Replace
SMCS Code: 1051-510-SE; 1054-510-SE
i02712918

NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning .

The secondary filter element should be replaced at the

time the primary element is serviced for the third time.
g00470857 The secondary filter element should also be replaced
IlIustration 160
if the yellow piston in the filter element indicator en-
5. Clean the inside of the air cleaner housing . Keep ters the red zone after installation of a clean primary
the secondary filter element in place while you element, or if the exhaust smoke is still black.
clean the housing .

6. If the primary filter element has not been cleaned NOTICE

six times, inspect the primary filter element. If Do not use the filter for longer than one year.
the primary filter element has been cleaned six
times, replace the primary filter element. Proceed
to Step 9. NOTICE
Always leave the secondary filter element in place
while you clean the primary element, or while you

•
7. Inspect the primary filter element. Inspect the
clean the air cleaner housing .
filter element for holes and for tears by looking
through the filter element. Look toward a bright
light. Inspect the element for damaged gaskets or
for dented metal parts. Replace damaged filters.
Always crush damaged filter elements. Properly
discard the filter elements. If you replace the
primary filter element, proceed to step 9.

8. If the primary filter element is not damaged and

the element has not been previously cleaned six
times, clean the element. The filter element can
be cleaned by using pressure air. Use a maximum
air pressure of 205 kPa (30 psi) . Direct the air
from the clean side to the dirty side. ln order to
show that the filter element has been cleaned,
mark the element. The primary filter element can
g01141636
be cleaned up to six times. lIIuslration 161

NOTICE 1. Open the engine access door, if equipped. The

Do not clean the filter elements by bumping or tapping engine access door is located on the left side of
them. Do not use filter elements with damaged pleats, the machine outside the operator's compartment.
gaskets, or seals. Do not wash the filter elements.
2. Remove the air cleaner housing cover.

9. Push the filter element firmly in order to properly 3. Remove the primary filter element.
seat the element. Write the date on the element, if
the primary element is replaced . Reference: Refer to Operation and Maintenance
Manual, "Engine Air Filter Primary Element -
• 10.lnstall the air cleaner cover. Clean/Replace".

11. Close the access door, if equipped . 4. Clean the inside of the air cleaner housing .
120 SEBU8146-06
Maintenance Section
Engine Air Precleaner - Clean

5. Inspect the gasket between the air inlet and the 3. Inspect the prec\eaner tubes for dirt and for dust. •
air cleaner housing. If the gasket is damaged ,
replace the gasket. 4. Use pressure air to clean the tubes. Put the tubes
on a flat surface. Oirect the pressurized air into
the tubes from the top oThis loosens up the dirt.
InstaI! the screens.

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

i02297692

Engine Crankcase Breather -

Clean
IlIuslralion 162 900470240 SMCS Code: 1317-070

6. Remove the secondary filter element. Pul! out in

order to remove the element.

7. InstaI! a new secondary filter element. Push

the element firmly in order to properly seat the
element.

•
8. InstaI! the primary filter element and the air c\eaner
housing cover. Tighten the bolts for the air c\eaner
housing cover finger tight. Do not use a tool to
tig ten the bolts for the air cleaner housing cover.

9. Close the engine access door, if equipped .

901150665
IIluslralion 164
i02281103 Some componenls are removed for clarily.

Engine Air Precleaner - Clean 1. Open the left engine access door.
SMCS Code: 1050-070
2. Loosen the breather outlet hose c\amps. Remove
the hose from the breather cover.

3. Loosen the breather inlet hose c\amp. Remove

the engine crankcase breather.

4. Check the condition of the cover seal. Replace the

cover seal if the cover seal is damaged.

5. Wash the breather element and the breather

element cover assembly in a c\ean nonflammable
solvent.

6. Shake the breather element until the breather

element is dry. Vou may also use pressure air to
IIluslralion 163
901141638 dry the breather element.

1. Inspect the air inlet screen for dirt and for trash . 7. Check the condition ofthe hose. Replace the hose •
if the hose is damaged.
2. Remove the screen . Clean the screen if the
screen is dirty. 8. InstaI! the breather element cover assembly.
 SESU8146-06 121
Maintenance Section
Engine Oi! Levei - Check

• 9. Install the hose and the breather outlet hose

clamps.

10. Close the engine access door.

i02713626

Engine Oil Levei - Check

SMCS Code: 1302-535-FLV; 1326-535-FLV

AWARNING
Hot oil and components can cause personal in- 901141645
jury. IlIustration 166

Do not allow hot oil or components to contact 4. Remove the oil filler cap. If necessary, add oil.
skin.
5. Clean the oil filler cap and install the oil filler cap.

NOTICE 6. Close the access cover.

Do not under till or overfill engine crankcase with oil.
Either condition can cause engine damage.
i022B1124

1. The engine oil levei gauge relies on gravity. Engine Oil Sam pie - Obtain
The machine must be on a levei surface for an

• accurate check . SMCS Code: 1000-008; 7542-008

2. Open the engine access cover that is on the left

AWARNING
side of the machine.
Hot oil and components can cause personal in-
jury.

Do not allow hot oil or components to contact

skin.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test-
ing , adjusting and repair of the product. Se prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01141640
IlIustration 165 Refer to Special Publication , NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
3. Check the engine oillevel gauge while the engine suitable to collect and contain fluids on Caterpillar
is stopped and the oil is at cold . The engine oil products.
levei may also be checked while the engine is
running at low idle and the oil is at operating Dispose of ali fluids according to local regulations and
temperature. Maintain the oil levei in the operating mandates.
area on the engine oillevel gauge. The operating

•
area is between the "ADO" mark and the "FULL"
mark.

Note: When you operate the machine on severe

slopes, the oil levei in the engine crankcase must be
at the "FULL" mark on the engine oil levei gauge.
122 SEBU8146-06
Maintenance Section
Engine Oi! and Filter - Change

Obtain the sample of the engine oil as elose as

possible to the recommended sampling interval. The
recommended sampling interval is every 250 service
hours. ln order to receive the fuI! effect of S·O·S oil
analysis, you must establish a consistent trend of
data. ln order to establish a pertinent history of data ,
Engine Oil and Filter - Change
SMCS Code: 1308; 1318-510
i02627910

•
perform consistent oi! samplings that are evenly Selection of the Oil Change Interval
spaced.

1. Open the engine access door on the right side of NOTICE

the machine. This machine is equipped with an eng ine that meets
EPA Tier 2, Euro Stage II , ar MOC Step 2 emission
regulations. A 500 hour engine oil change interval is
available, provided that operating conditions and rec-
ommended multigrade oil types are met. When these
requirements are not met, shorten the oil change
interval to 250 hours, or use an S·O·S oil sampling
and analysis program to determine an acceptable oil
change interval.

If you select an interval for oil and filter change that is

too long , you may damage the engine .

Caterpillar oil filters are recommended .

IlIuslralion 167 g01141648 Recommended multigrade oil types are listed in Table

•
18. Do not use single grade oils.
2. Remove the protective cap.

3. Use 169- 8373 Fluid Sampling Bottle in order to

obtain a sample of the engine oil.

4. Replace the protective cap.

5. Close the engine access door.

Refer to Operation and Maintenance Manual ,

"lubricant Viscosities" for the correct fluid for your
machine.

g00753767
IIluslralion 168
APl Symbol
Commercial oils Ihal are licensed by lhe American Pelroleum
Inslilule (APl) bear Ihis symbol. Commercial oils Ihal do nol bear
Ihis symbol are nol licensed and Ihese oils are not recommended .
Oils Ihal are nol lisled in Table 18 are nol recommended .

•
 SEBU8146-06 123
Maintenance Section
Engine Oil and Filter - Change

• Abnormally harsh operating cycles or harsh

environments can shorten the service life of
the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
requ ire a reduction in engine oil change intervals
from the recommendations in Table 18. Also refer
Table 18

D6T
Engine Oil Change Interval(1)
Operating Conditions
Severe
to Special Publication , SEBU5898, "Cold Weather
Recommendations For Ali Caterpillar Machines". Normal(2) High Fuel Altitude
Poor maintenance of air filters or of fuel filters Multigrade Load Sulfur above
Factor(3) from 1830 m
requires reduced oil change intervals. See your Oil Type
above 0.3% to (6000 ft)
Caterpillar dealer for more information if this product
32 L(8.5 0.5%
will experience abnormally harsh operating cycles or US gal) (4)
harsh environments. per hr
of fuel
Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
APl CH-4
11 .0
minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4)
Preferred
APl CH-4
TBN(4) 500 hr 500 hr 250 hr\5) 250 hr(6)
below 11 .0
APl CG-4 500 hr 250 hr\5) 250 hr\5) 250 hr(6)

•
(1) The traditional oil change interval for engines is 250 hours .
The standard oil change interval in th is machine is 500 hours. if
the operating conditions and recommended oil types that are
listed in this table are me!. Improvements in the engine allow
this engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuais for the other machines.
(2) Normal cond itions include these factors : Fuel sulfur below
0 .3% . altitude below 1830 m (6000 ft). and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor. harsh operating cycles , or harsh environments .
(3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If lhe average fuel
consumption of your D6T exceeds 32 L (8 .5 US gal) per hour,
follow the "High Load Factor" recommendations in Table 18. To
determine average fuel consumption , measure average fuel
consumption for a period of 50 to 100 hours. If the application
of the machine is changed , the average fuel consumption may
change.
(4) For sulfur content above 0.5% , refer to Operation and
Maintenance Manual , "Total Base Number (TBN) and Fuel
Sulfur Leveis for Direct Injection (DI) Diesel Engines" in
Manual, SEBU6250.
(5) ln order to verify an oil change interval of 500 hours, refer to
"Program A" below.
(6) Use "Program B" below to determine an appropriate interval.

Adjustment of the Oi! Change Interval

•
Note: Your Caterpillar dealer has additional
information on these programs .

Program A

Verification for an Oil Change Interval of 500 Hours

124 8EBU8146-06
Maintenance 8ection
Engine Oil and Filter - Change

This program consists of three oil change intervals of

500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If
ali of the results are satisfactory, the 500 hour oil
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test-
ing , adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
•
chang e interval is acceptable for the machine in that ing any compartment or disassembling any compo-
application . Repeat Program A if you change the nent containing fluids.
application of the machine.
Refer to 8pecial Publication , NENG2500, "Caterpillar
If a sam pie does not pass the oil analysis, take one Dealer 8ervice Tool Catalog " for tools and supplies
of these actions: suitable to collect and contain fluids on Caterpillar
products.
• 8h orten the oil change interval to 250 hours.
Dispose of ali fluids according to local regulations and
• Proceed to Program B. mandates.

• Change to a preferred oil type in Table 18.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oil

change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat program B if you change
the application of the machine.

If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multig rade oil type in the listing above.
IlIustration 169
Left view
g01141650
•
References If the machine is equipped with a high speed oil
change, use a 126 - 7539 Nozzle.
Reference: Form, PEDP7035, "Optimizing Oil
Change Intervals"

Refere nce: Form, PEDP7036, "8·0 ·8 Fluid Analysis" _. :::.:: :::. - -

Reference: Form , PEDP7076 , "Understanding the
1l ~
~- - - -­
8 ·0 ·8 Oil Analysis Tests"

Procedure for Changing the Engine

Oil and Filter
~---- -
::: " :: ::: :: ::

AWARNING
Hot o il and components can cause personal in- g01144346
IlIustration 170
jury. Top view

Do not allow hot oil or components to contact 1. Remove the bolt in order to remove the crankcase •
skin. drain access cover, wh ich is in the crankcase
guard o
 SEBU8146-06 125
Maintenance Section
Engine Oil and Filter - Change

• 7. Apply a thin coat of oil to the seal on the new filter.

Install the new engine oil filter element by hand .
When the gasket contacts the filter base, tighten
the filter element by an additional 3/4 turn (270
degrees). Rotation index marks are on the new
filter element. These rotation index marks are
spaced at 90 degree intervals. Use these rotation
2 index marks as a guide for proper tightening .

A B

g01150683
IlIustration 171
(1) drain valve
(2) shutoff valve
(3) drain valve elbow
(A) Left view
(B) Rear view

2. Install a drain hose (not shown) onto drain valve

elbow (3). g01144360
IIlustration 173
3. Open shutoff valve (2) . Allow the oil to drain into a
suitable container. 8. Open the left engine access door.

• 4. When the oil has completed draining from the 9. Remove oil filler cap (4) . Fill the crankcase with
crankcase, close shutoff valve (2). Remove the new oil. See the topic Operation and Maintenance
hose. Install the crankcase drain access cover in Manual, "Refill Capacities" in this manual. Clean
the crankcase guardo oil filler cap (4) and install oil filler cap (4).

10. To ensure that the correct amount of oil was

added , always measure the oil levei with the
engine oil dipstick (5) .

Check the "ENGINE STOPPED" side of the

dipstick while the engine is stopped . The oil should
be cold . Maintain the oillevel between the "LOW'
mark and the "FULL" mark. This method should
be used as reference only, before the engine is
started .

11. Check the "LOW IDLE" side of the dipstick

while the engine is running . The oil should be
at operating temperature. Maintain the oil levei
g011 44354 between the "ADO" mark and the "FULL" mark.
IlIustration 172
This is the only accurate way to check the oillevel.
5. Open the engine access doo r on the right side of
the machine. 12. Close the engine access doors.

6. Remove the engine oil filter element and discard

the engine oil filter element properly. Make sure
that ali of the old filter seal is removed from the

•
filter base .
126 SEBU8146-06
Maintenance Section
Engine Valve Lash - Check/Adjust

Engine Valve lash -

Check/Adjust
i01959327
Eas aJe------,>----_®_
•
SMCS Code: 1102-025

AWARNING
To prevent possible injury, do not use the starter
motor to turn the f1ywheel.
~
Hot engine components can cause burns. Allow ~
additional time for the engine to cool before mea-
901139573
suring. valve clearance. IIlustration 174
8F - 9866 Grease Gun

AWARNING
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.

NOTICE
Operation of Caterpillar engines with improper valve
adjustments will reduce engine efficiency. This re-

•
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.

NOTICE
Measure the valve clearance with the engine stopped . IlIustration 175
g01139561
To obtain an accurate measurement, allow at least 20
Remote Fitting
minutes for the valves to cool to engine cylinder head
and engine block temperature.
Lubricate the equalizer bar center pin through the
remote fitting . The remote fitting is located on the
Check the valve bridge before setting the valve lash. frame on the left side of the machine. The fitting is
Ensure that the valve bridge is seated equally on located below the dipstick.
both valve stems.
The proper lubricant for the center pin is the "Desert
Refer to your machine's Service Manual or your Gold". NLGI 2 grease
Caterpillar dealer for the complete valve adjustment
procedure. Refer to Operation and Maintenance Manual,
SEBU6250 , "Lubricating Greases" for more
information.
i02428064

Equalizer Bar Center Pin - i02834979

lubricate Equalizer Bar End Pins Oil

SMCS Code: 7206-086-PN ; 7207-086-PN levei - Check
NOTICE SMCS Code: 7206-535

•
Apply lubricant to the fittings with a hand operated
grease gun only. Use of pressure operated lubricating NOTICE
equipment damages the seals. Apply gear oil through the fittings with a hand oper-
ated lubrication pump or a suitable grease gun . Use
of pressure operated lubricating equipment damages
the seals.
 SEBU8146-06 127
Maintenance Section
Ether Starting Aid Cylinder - Replace

• NOTICE
Before and after the equalizer bar end pin is filled with
gear oil, seal (1) must be flush with the equalizer bar. If
the seals are not flush, damage to the seals can result
by overfilling.
6. Be sure that seals (1) are not pushed out. Push
back the seals if the seals are pushed out.

7. Install plug (2) .

Note: MPGM GREASE IS ALLOWED ONLY

FOR A FAILED SEAL. THE SEAL SHOULD
BE REPLACED AS SOON AS POSSIBLE. THE
COMBINATION OF GEAR OIL AND MPGM IS NOT
HARMFUL TO THE MACHINE.

When you operate the machine in arctic conditions,

lubricate the equalizer bar with EMGARD EP 75W90
gear lubricant. EMGARD EP 75W90 gear lubricant is
a synthetic lubricant. This lubricant is available from
Hudson Corporation .

i02274149

Ether Starting Aid Cylinder -

IlIustration 176
Replace
SMCS Code: 1456-510-CD

/ .. ~ \

• .-;--- .. - ..,
.
b
I
o
\

g00586858
IIlustration 177
g01138860
IIlustration 178
1. Clean the areas that are around the end pin with a
high pressure wash . Inspect the condition of the 1. Remove the upper engine compartment access
seal (1). cover on the left side of the machine.
2. Check the area for oil leakage. Be sure that the 1. The ether canister is mounted on the bracket
seal is in a neutral position . assembly which is seated toward the front of the
caboLoosen the retaining clamp. Remove the old
3. Remove plug (2). canister by turning the canister counterclockwise.
4. Check the oillevel. Oillevel (4) should be at the 2. Install the "Quick Start " canister. Turn the canister
top of the hex head on the fitting . clockwise. Hand tighten the canister in order to
seal the gasket to the canister. Tighten the clamp
5. If the oil levei is low, apply the gear oil through around the canister.
fitting (3) until the gear oil reaches oillevel (4) at
the top of the hex head on the fitting . Remove Note: The ether starting aid cylinder must be installed

•
any excess oil. This will maintain a volume of air. with the appropriate gasket. The gasket must be
The gear oil must be applied with a 7H - 1680 clean in order to make a proper seal.
Lubrication Hand Pump. Refer to Operation and
Maintenance Manual, "Lubricant Viscosities" for 3. Close the upper engine compartment access
the correct oil. The gear oil has excellent load cover.
carrying capacity.
128 SEBU8146-06
Maintenance Section
Final Drive Oil - Change

i02281 340 4. Inspect the drain plug seal. Rep lace the drain plug •
seal if the drain plug seal is damaged.
Final Drive Oil - Change
5. Clean the drain plug and install the drai n plug .
SMCS Code: 4050-535-FLV
6. Fill the final drive with oil to the bottom of the filler
AWARNING plug opening . See Operation and Maintenance
Manual , "Capacities Refill".
Hot o il and components can cause personal in-
jury. 7. Inspect the condition of the seal of the filler plug .
Replace the plug seal if the plug seal is damaged .
Do not allow hot oil or components to contact Wipe the magnet in order to clean the plug . Install
skin. the plug .

8. Repeat Step 1 to Step 7 in order to change the oil

NOTICE in the other final drive.
Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test- For additional information about final drive oil, see
ing , adjusting and repairofthe product. Be prepared to Special Publication, SEBU6250, "Caterpillar Machine
collect the fluid with suitable containers before open- Fluids Recommendations" or consult yo ur Caterpillar
ing any compartment or disassembling any compo- dealer.
nent containing fluids .

Refer to Special Publication , NENG2500, "Caterpillar i02281354

Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain flu ids on Caterpillar
Final Drive Oil Levei - Check
products.

•
SMCS Code: 4050-535-FLV
Dispose of ali fluids according to local regulations and
mandates. AWARNING
Hot oil and components can cause personal in-
jury.

Do not allow hot oil or components to contact

skin.

90114 1777
IlIustration 179

•
1. Position one final drive so that oillevel mark (1) is
horizontal. The drain plug (3) will point downward.

2. Remove oil filler plug (2) .

901141 777
IlIustration 180
3. Remove drain plug (3) . Allow the oil to drain into a
suitable container. 1. Position one final drive so that oil levei mark (1) is
horizontal and drain plug (3) is at the bottom.
 SEBU8146-06 129
Maintenance Section
Final Drive Oil Sample - Obtain

• 2. Remove oil filler plug (2).

3. The oil levei should be at the bottom of the filler

plug opening. Add oil, if necessary.

See the Table in the article "Lubricant Viscosities"

for the type of oil.

4. Install oil filler plug (2).

5. Repeat Step 1 to Step 4 in order to check the oil

levei in the other final drive.

i02281399

Final Drive Oil Sam pie - Obtain

SMCS Code: 4050-SM

AWARNING
g01 141813
IlIustration 181
Hot oi! and components can cause personal in-
jury.
1. Position one final drive so that oillevel mark (1) is
horizontal. Drain plug (3) should face downward.
Do not allow hot oi! or components to contact
skin.

•
2. Remove oil filler plug (2) and obtain the oil sample
with a 1U - 5718 Vacuum Pump .
NOTICE
Care must be taken to ensure that fluids are contained Note: Do not use the drain stream method to obtain
during pertormance of inspection , maintenance, test- a sample of the final drive oil. A stream of dirty oil
ing, adjusting and repair of the product. Be prepared to from the bottom of the compartment will contaminate
collect the fluid with suitable containers before open- the sample. Likewise, never dip an oil sample from
ing any compartment or disassembling any compo- an oil container or pour a sample from a used filter.
nent containing fluids .
3. Install oil filler plug (2).
Refer to Special Publication , NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies 4. Repeat Step 1 to Step 3 in order to sample the oil
suitable to collect and contain fluids on Caterpillar in the other final drive.
products.
Reference: Refer to, "Lubricant Viscosities" in the
Dispose of ali fluids according to local regulations and Maintenance Section of this manual for the correct
mandates. fluid for your machine.

Reference: Refer to Special Publication , SEBU6250,

Obtain the sample of the differential and final drive oil "Caterpillar Machine Fluids Recommendations"
~s close as possible to the recommended sampling "S·O·S Oil Analysis" for information that pertain~
Intervalo The recommended sampling interval is every to obtaining a sample of the final drive oil. Refer
500 service hours. ln order to receive the full effect to Special Publication , PEHP6001, "How To Take
of S·O·S oil analysis, you must establish a consistent A Good Oil Sample" for more information about
trend of data. obtaining a sample of the final drive oil .

•
130 SEBU8146-06
Maintenance Section
Front Idler Position - Check

Front Idler Position - Check

SMCS Code: 4159
i02296034

•
SystemOne Undercarriage
The following check is for Caterpillar SystemOne
Undercarriages that have the center tread idler.

g01151486
IlIustration 183
Adjustment shim (center tread idler)

5. For machines with the SystemOne Undercarriage,

remove one shim under each track idler block
when the wear on th e link and roller system is at
50% .

Consult your Caterpillar dealer for detailed

information about adjustments to the center tread
idler.

•
See Operation and Maintenance Manual, "Track
g 9 - Check/Adjust" for information on needed track
adjustments.

Reference: See Operation and Maintenance

g01149978
IlIustration 182 Manual, "Reference Material" for publications and
Elevated undercarriage system Special Instructions on removal and installation of
SystemOne Track, as needed .
1. Park the machine on a hard , flat surface. Make
sure that the bottom track is tight and that the Conventional Design
measured grouser lies directly below the track
idler shaft.

2. Measure the height (A, B) from the flat ground

surface to the grouser tip that is centered below
the track idler shaft.

3. Maintain the grouser height (rise) to the following

dimensions.

a. (A) Front Idlers

Minimum - O mm (O inch)

Maximum - 20 mm (0.8 inch)

g00669323
IIlustration 184
b. (B) Rear Idlers

•
(A) Adjusting shims
(8) Dimension between the height of the fro nt id ler tread and the
Minimum - 10 mm (0.4 inch) height of the roller tread

Maximum - 40 mm (1 .6 inch) The following check is for undercarriage systems tllat

have the conventional idler.
4. Repeat Steps 1 through 3 in order to determine
the proper height dimension under each idler.
 SEBU8146-06 131
Maintenance Section
Fuel System - Prime

• The height of the front idler tread should always

be higher than the height of the roller tread.
The dimension (B) is set approximately to 9.0 mm
(.35 inch) at the factory. Oimension (B) decreases
as the undercarriage wears. If a rebuilt idler or a
new idler is installed with track rollers that are worn ,
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing , adjusting and repair ofthe product. Be prepared to
collect the fluid with suitable containers before open-
dimension (B) decreases. ing any compartment or disassembling any compo-
nent containing fluids.
Adjustment of the front idler to the correct height can
improve the ride of the tractor and the performance of Refer to Special Publication , NENG2500, "Caterpillar
the dozer. Use the following procedures to determine Oealer Service Tool Catalog" for tools and supplies
the best operating position . suitable to collect and contain fluids on Caterpillar
products.
If the machine is operated on FIRM UNOERFOOT
conditions and excess vibration occurs, shims can be Oispose of ali fluids according to local regulations and
removed in order to raise the front idler. mandates.

If the machine is operated on SOFT UNOERFOOT

conditions and dozing performance is poor, shims can If the engine does not start, air may be trapped in the
be installed in order to lower the front idler. lowering fuellines to the engine. Use the following procedure
the front idler can improve dozing performance. If in order to purge air from the fuel lines.
ground rippling by the dozer or excess vibration occur
in 50ft material, shims can be removed in order to Electric Fuel Priming Pump
raise the front idler.
The electric fuel priming pump is located in the
Consult your Caterpillar dealer for detailed engine compartment on the left side of the machine.
information about checking the idler and about

• adjustments to the idler.

Fuel System - Prime

SMCS Code: 1258
i02712937

AWARNING
Personal injury or death can result from a fire.

Fuelleaked or spilled onto hot surfaces or electri-

cal components can cause a fire. IlIustration 185 g01141823

Clean up ali leaked or spilled fuel. Do not smoke 1. Push the button and hold the button in order to
white working on the fuel system. activate the fuel priming pump. Allow the pump to
run for several seconds.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters. 2. Release the button in order to turn ott the fuel
priming pump.

3. Start the engine . If you cannot start the engine,

the engine needs more priming . If the engine
continues to misfire or to smoke, more priming is
necessary.

• Note: The electric fuel priming pump will only operate

if the engine start switch key is in the OFF position .
Shut ott the engine before any additional priming .

4. Run the engine at the lOW IOlE position until the

engine runs smoothly.
132 SEBU8146-06
Maintenance Section
Fuel System Secondary Filter - Replace

Note: Do not activate the priming pump while vou

crank the engine.
--- .. --- .. --- ..--- .. --- .. --- .. --- .. --- .. --- .. --- .. ~
•
~
i02398364

Fuel System Secondary Filter -

Replace .. --- .. --- .. --- .. --- .. --- .. --- .. i "
SMCS Code: 1261-510-SE

AWARNING
Personal injury or death can result from a fire.
901141 950
IlIustration 186
Fuelleaked or spilled onto hot surfaces or electri-
cal components can cause a tire. 1. Tum the red handle of the fuel shutoff valve
clockwise in order to shut off the fuel supply. The
Clean up ali leaked or spilled fue!. Do not smoke fuel shutoff valve is located at the rear of the
while working on the fuel system. machine under the fuel tank.
Turn the disconnect switch OFF or disconnect the 2. Open the engine access door on the left side of
battery when changing fuel filters. the machine. The secondary fuel filter is mounted
on the left side of the engine behind the primary
fuel filter.
NOTICE

•
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing , adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids .

Refer to Special Publication , NENG2500, "Caterpillar

Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of ali fluids according to local regulations and

mandates.
901141951
IlIustration 187
NOTICE I]ront view
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel 3. Remove the secondary fuel fi lter. Drain the fuel
system parts. into a suitable container.

Note: Discard any drained fluids according to local

Before vou replace the secondary fuel filter element, regulations. Discard the fuel filter properly.
replace the primary fuel filter element.
4. Clean the filter base. Make sure that ali of the old
seal is removed .

5. Coat the seal of the new high efficiency fuel filter

with clean diesel fuel.

6. Install the new fuel filter by hand . When the •

seal contacts the base, tighten the filter fo r an
additional 3/4 tum .
 SEBU8146-06 133
Maintenance Section
Fuel System Water Separator - Drain

• Rotation index marks are positioned on the filter

at 90 degree intervals. Use these rotation index
marks as a guide when you tighten the filter.

7. Open the fuel shutoff valve. Refer to iIIustration

186.

8. Prime the fuel system . See the Topic "Fuel System

- Prime" in this manual.

9. Close the engine access door.

i02009564

Fuel System Water Separator IIlustration 188 900104007

- Orain (1) Element

(2) Bowl
(3) Orain
SMCS Code: 1263-543
Bowl (2) should be mon itored da ily for signs of water.
AWARNING If water is present, drain the water from the bowl.

Fuel leaked or spilled onto hot surfaces or elec- 1. Open drain (3). The drain is a self-ventilated drain.
trical components can cause a fire. To help pre- Catch the draining water in a suitable container.
vent possible injury, turn the start switch off when Dispose of the water properly.
changing fuel filters or water separator elements.

•
Clean up fuel spllls immediately. 2. Close drain (3).

NOTICE NOTICE
Care must be taken to ensure that flu ids are contained The water separator is under suction during normal
during performance of inspection , ma intenance, test- eng ine operation. Ensure that the drain valve is tight-
ing , adjusting and repa ir ofthe product. Be prepared to ened securely to help prevent air from entering the fuel
collect the fluid with suitable containers before open- system.
ing any compartment or disassembling any compo-
nent containing fluids .
i02281652
Refer to Special Publication , NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies Fuel System Water Separator
suitable to collect and contain flu ids on Caterpillar Element - Replace
products.
SMCS Code: 1263-510-FQ
Dispose of ali flu ids according to local regulations and
mandates.
AWARNING
NOTICE Personal injury or death may result from failure to
Do not allow dirt to enter the fuel system. Thorough ly adhere to the following procedures.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- Fuelleaked or spilled onto hot surfaces or electri-
nected fuel system component. cal components can cause a fire .

Clean up ali 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 filters.
134 SESU8146-06
Maintenance Section
Fuel System Water Separator Element - Replace

NOTICE
Do not fill fuel filter with fuel before installing the fuel
filter. Contaminated fuel causes accelerated wear to
fuel system parts.
•
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair ofthe product. Se prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
901141926
Refer to Special Publication , NENG2500, "Caterpillar IlIustration 190
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar 3. ln order to drain primary filter (1), open drain
products . valve (3) on water separator bowl (2) . The water
separator bowl is under primary filter (1). Catch
Dispose of ali fluids according to local regulations and the fuel in a suitable container.
mandates.
Note: Discard any drained fluids according to local
regulations.

4. Remove primary filter (1) and water separator

bowl (2).

5. Remove water separator bowl (2) from the primary •

filter element (1).

6. Wash water separator bowl (2) in a clean

nonflammable solvent. Use pressure air to dry
water separator bowl (2) .

7. Install the clean water separator bowl onto a new

primary filter element.
901141906
IIlustration 189
8. Wash the filter mounting base in clean ,
nonflammable solvent. Make sure that ali of the
1. The fuel shutoff valve is located at the rear of the
old seal is removed .
machine under the fuel tank. Turn the red handle
of the fuel shutoff valve in order to shut off the
9. Coat the seal of the new filter element with clean
fuel supply.
diesel fuel.
2. Remove the access cover on the left side of the
10.lnstall the new filter element by hand. When the
engine compartment.
seal contacts the base, tighten the fi lter element
for an additional 3/4 turno

Rotation index marks are positioned on the filter

elements at 90 degree intervals. Use these
rotation index marks as a guide when you tighten
the filter.

11.0pen the fuel shutoff valve.

12. Prime the fuel system, if the machine is equipped •

with a priming pump.

Refer to the Operation and Maintenance Manual,

"Fuel System - Prime" for the proper procedure.
 SESU8146-06 135
Maintenance Section
Fuel Tank Cap Filter and Strainer - Replace/Clean

• 13.lnstall the access cover. 5. Inspect the tank cap seal. If the seal is damaged ,
replace the seal.
i02281929
6. Replace the filter assembly, the valve, the gaskets,
Fuel Tank Cap Filter and and the screws. Use a 9X - 2205 Cap Filter Kit.

Strainer - Replace/Clean 7. Install the strainer.

SMCS Code: 1273-070-STR; 1273-070-Z2 8. Install the fuel cap. Rotate the fuel cap clockwise
until three tabs (5) drop into the slots in the
adapter. Rotate lever (3) clockwise until the lever
stops. Lower lever (3) over locking tab (4).

i02281990

Fuel Tank Water and Sediment

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

NOTICE
Care must be taken to ensure that fluids are contained
g01141983 during pertormance of inspection, maintenance, test-
IlIustration 191
ing, adjusting and repair ofthe product. Se prepared to
collect the fluid with suitable containers before open-
The fuel tank is located on the rear of the machine. ing any compartment or disassembling any compo-

•
The filler cap is on the left side of the machine next to nent containing fluids .
the ROPS .
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" fortools and supplies
2 suitable to collect and contain fluids on Caterpillar
products.

Dispose of ali fluids according to local regulations and

mandates.
3

g01141982
IlIustration 192

1. Lift lever (3) in order to remove the fuel tank filler

cap. Turn the lever counterclockwise until the
lever stops. Lift the cap straight up in order to
remove the cap.

2. Remove the fuel strainer from the filler neck.

IIlustration 193 g01141998

3. ln order to replace the filter assembly, remove two

screws that secure filter assembly (2) to the fuel The drain valve is under the fuel tank at the rear of

• cap. Remove filter assembly (2), valve (1), and the machine.
the gaskets.
1. Open the drain valve. Allow the water and the
4. Wash the cap and the strainer in a clean , sediment to drain into a suitable container.
nonflammable solvent.
2. Close the drain valve.
136 SEBU8146-06
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset

Fuses and Circuit 8reakers

Replace/Reset
i022 81 991

•
SMCS Code: 1417-510; 1420-529

Fuses - Fuses protect the electrical

8~ system from damage that is caused by

overloaded electrical circuits. Replace
a fuse if the element separates. If the fuse of
a particular electrical system requires frequent
replacement, check the electrical circuit. Repair the
electrical circuit, if necessary.
g01142009
IlIustration 195
NOTICE Circu it bre aker. cover. and line fuse
Always replace fuses with the same type and capacity
fuse that was removed . Otherwise, electrical damage Fuses are located beh ind cover (25).
could result.
Line Fuse (27) - 175 Amp
NOTICE
If it is necessary to replace fuses frequently, an elec- Fuses
trica l problem may exist.

Contact your Caterpillar dealer.

1. Ç
~ ~ ~ 2.

•
3. ~ ~ ~ ~ 4.

5. 0 0 ~ ~~6.

7.llIIld~ ~ Q.. 8.

v. \ii;. ~ ~ IZI 10.

11 .~~ ~~12.

13. ~ ~ ~=:ID 14.

15. ro ~ ~ Qo. 16.

17. ófJ ~ ~ 121 18.

19. 0 !;OiJ ~ ~~20.

21. 0 ~ ~ ~ IZI 22.

g00984827
IlIustration 194
23.~~ ~~2'.
Raised cover (battery box)
g01142008
IlIustration 196
Raise the battery box cover on the right side of
the machine. Open the access door to the circuit Fu ses
breakers and the fuses .
A fi lm for the fuse panei is on the inside of the battery
box cover.

Wipers (1) - 15 Amp

Accugrade 1 (2) - 15 Amp

Monitoring System (3) - 15 Amp

Accurgrade 2 (4) - 10 Amp

Implement or Drive train (5) - 15 Amp

Auxiliary Switch (6) - 15 Amp

•
 SEBU8146-06 137
Maintenance Section
Hydraulic System Oil - Change

• Fuse for the ripper pin puller, for the seat, and for
the winch (7) - 10 Amp

Floodlights on Fender (8) - 15 Amp

Flood Lights (Rear) (9) - 15 Amp

Hydraulic System Oil - Change
SMCS Code: 5050-044
i02702217

Note: The normal hydraulic oil change interval

Switching Type Converter (10) - 10 Amp is at every 2000 Servlce Hours or 1 Year. By
performing 5·0·5 oil analysis, the hydraulic
Refrigerant Condenser (1) (ROPS) (11) - 15 Amp oil change interval may be extended to 4000
Service Hours or 1 Year. 5·0·5 oil analysis must
Refrigerant Condenser (2) (ROPS) (12) - 15 Amp be performed at every 500 Service Hours or
3 Months in order to extend the hydraulic oil
Forward Horn (13) - 15 Amp change interval. The results from the 5·0·5 oil
analysis will determine if the hydraulic oil change
Ignition Key (14) - 15 Amp interval may be extended. If 5·0·5 oil analysis is
not available, the hydraulic oil change interval
Service Brake (15) - 15 Amp must remain at every 2000 Servlce Hours or 1
Year . Refer to the Operation and Maintenance
Flood Lights (Front) (16) - 15 Amp Manual, "Hydraulic System Oil Sam pie - Obtain".

Product Link (17) - 15 Amp Machines that are used in severe conditions are
not included in the 4000 hour maintenance interval.
Converter (18) - 10 Amp Machines that are used in severe conditions must
use the interval in the Maintenance Interval Schedule.
Machine ECM (19) - 15 Amp
Lubricants

•
Unswitched Fuse (20) - 15 Amp
Approved hydraulic oil must be used to obtain the
Engine ECM (21) - 15 Amp 4000 hour hydraulic oil change. Refer to the list that
follows for approved oils.
24 Volt to 12 Volt Converter (22) - 20 Amp
Caterpillar Hydraulic Oils
Spare (23) - 15 Amp
• "Cat HYDO"
Spare (24) - 15 Amp
• TDTO
Circuit Breakers
• Hydraulic environmental ester synthetic (HEES)
Circuit Breaker/Reset - Push in the

O_;l_ button in order to reset the circu it breaker.

If the electrical system is working properly,
the button will rema in depressed.
• MTO

Commercial Oils
Note: If the button does not remain depressed , check Diesel engine oils (Heavy Duty) with a minimum
the appropriate electrical circu it. Repair the electrical zinc content of 900 ppm can be used. Acceptable
circuit, if necessary. commercial oils are identified by the American
Petroleum Institute trademark ("APl "). Refer to the list
Blower (26) - Circu it Breaker that follows for acceptable types of hydraulic oils.

• CF

• CF-4

• • CG-4

• CH-4
138 SESU8146-06
Maintenance Section
Hydra lic System Oil - Change

Note: Industrial hydraulic oils are not recommended

for the hydraulic systems of Caterpillar machines.
Industrial hydraulic oils are more likely to allow
corrosion and industrial hydraulic oils are more likely
to allow excessive wear.
•
Change the Hydraulic Oil

AWARNING
At operating temperature, the hydraulic tank is hot
and under pressure.

Hot oil and components can cause personal in- 901355295

IIlustration 197
jury. Do not allow hot oil or components to contact
skin. Right side of ca b

Remove the filler cap only when the engine is 1. Remove hydraulic tank filler cap (1) slowly in arder
stopped, and the filler cap is cool enough to touch to relieve any pressure.
with your bare hand. Remove the filler cap slowly
ln order to relieve pressure. 2. Wash the filler strainer and the filler cap in a clean
nonflammable solvent.

NOTICE 3. Use a 126 - 7914 Oil Drain Coupling and attach a

Care mu st be taken to ensure that fluids are contained 1 inch hose. Make sure that enough of the swivel
during performance of inspection , maintenance, test- hose bypasses the track assembly and fills into a

•
ing , adju sting and repairofthe product. Se prepared to suitable container.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 4. Remove oil drain plug (3) wh ich is located under
nent containing fluids . the right fender of the machine.

Refer to Special Publication , NENG2500, "Caterpillar 5. Install the swivel hose into the drain plug opening .
Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar 6. Rotate the swivel hose clockwise in order to open
products. the internal drain valve. Allow the oil to drain into a
suitable container.
Dispose of ali fluids according to local regulations and
mandates 7. Remove the swivel hose. The internal drain valve
for the hydraulic tank will elose.
Operate the machine in order to warm the oil.
8. Clean the drain plug and install the drain plug.
Tighten the drain plug to a torque of 68 ± 7 N'm
Park the machine on levei ground . Lower the
(50 ± 5 Ib ft).
bulldozer blade to the ground and apply slight
downward pressure. If equipped , lower the ripper to
9. Change the hydraulic system filter.
the ground . Engage the parking brake and stop the
engine.
Reference: See Operation and Maintenance
Manual , "Hydraulic System Oil Filter - Replace".

10.lnstall the filler strainer.

11. Fill the hydraulic oil tank.

•
Reference: See Operation and Maintena nce
Manual , "Lubricant Viscosities and Capacities
(Refill)" for additional information.

12. Inspect the filler cap gasket. Replace the gasket if

damage or wea r is evident.

13.lnstall the filler cap.

 SESU8146-06 139
Maintenance Section
Hydraulic System Oil Filter - Replace

• 14. Start the engine. Operate the engine for a few

minutes. NOTICE
Care must be taken to ensure that fluids are conta ined
during performance of inspection , maintenance, test-
ing , adjusting and repair ofthe product. Se prepared to
collect the flu id with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar

Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of ali fluids according to local regulations and

mandates.
g01142156
IlIustration 198
1. Lower the bulldozer and the ripper to the ground .
15. Maintain the oil levei to the "FULL" mark in sight
gauge (2). Add oil , if necessary.

16. Stop the engine.

i02702228

Hydraulic System Oil Filter -

• Replace
SMCS Code: 5068-510

AWARNING
IlIustration 199 g01355365
At operating temperature, the hydraulic tank is hot
and under pressure. Right side of ca b

Hot oil and components can cause personal in- 2. Slowly remove hydraulic tank filler cap (2) in order
jury. Do not allow hot oil or components to contact to relieve the system pressure.
skin.
3. Remove retain ing nut (1 ).
Remove the filler cap only when the engine is
stopped, and the filler cap is coo I enough to touch Note: The charge filter is located in a compartment
with your bare hand. Remove the filler cap slowly on the left side of the mach ine.
in order to relieve pressure.
r c
I
.-J
0;:==

I~
I~ e

~Jjh'~
. '/h I. .
I
,
j~
• ==o
~

/ g01215857
IlIustration 200
140 SEBU8146-06
Maintenance Section
Hydraulic System Oil Levei - Check

4. Remove the cover and remove the oil filter from

each filter housing. Perform the following steps for
each oil filter.

5. Remove the filter element. Properly dispose of the

filter element.
Hydraulic System Oil Levei -
Check
i02702437

•
SMCS Code: 5056-535-FLV; 7479
Apply a thin coat of oil to the seal on the new filter
element. AWARNING
6. Install the filter element by hand . After the seal At operating temperature, the hydraulic tank is hot
contacts the base, tighten the filter element by an and under pressure.
additional 3/4 turn (270 degrees).
Hot oil and components can cause personal in-
7. Remove the retainer ring from the oil filler tube. jury. Do not allow hot oil or components to contact
skin.
8. Remove the strainer from the oil filler tube.
Remove the filler cap only when the engine is
9. Wash the screen in a clean nonflammable solvent. stopped, and the filler cap is coo I enough to touch
with your bare hand. Remove the filler cap slowly
10.lnspect the seal on the filler cap. Replace the seal in order to relieve pressure.
if the seal is worn or if the seal is damaged .
Lower the bulldozer and the ripper to the ground.
11.lnstall the strainer, the retainer ring , and the cap. Place the ripper shanks in the vertical position.

The hydraulic tank is on the right fender of the

•
machine.

g011 42156
IlIustration 201

12. Maintain the hydraulic oil to the "FULL" mark in

the sigh t gauge. g01 142156
IIlustration 202

1. Maintain the oil level to the "FULL" mark in the

sight gauge. Check the oil levei when the ail is
cold . Verify that the oil levei is below the "FULL"
mark before you remove the filler cap.

•
 SEBU8146-06 141
Maintenance Section
Hydraulic System Oil Sample - Obtain

• Obtain the hydraulic oil sample as close as possible

to the recommended sampling interval. The
recommended sampling interval is every 500 service
hours. ln order to receive the full effect of S·O·S oil
analysis, you must establish a consistent trend of
data. ln order to establish a pertinent history of data,
pertorm consistent oil samplings that are evenly
o spaced .

If the machine is operated under a high load

and/or under high temperature conditions,
sam pie ali f1uids at the 250 hour interval.

1. Open the access cover on the right side of the cab

g01355377 that is in front of the hydraulic tank.
IlIustratian 203
Right side af cab

2. If the hydraulic system requires additional

hydraulic oil, remove the filler cap slowly in order
to relieve any pressure. Add oil through the filler
tube.

3. Clean the filler cap and install the filler cap.

i02262329

.
•
./
Hydraulic System Oil Sam pie .'

- Obtain f' ..~

g01142263
IIlustratian 204
SMCS Code: 5050-008; 7542-008 The hydraulic ail sampling valve is shawn .

AWARNING 2. Remove the protective cap.

Hot 011 and components can cause personal in- 3. Use 8T - 9190 Fluid Sampling Bottle (1) to obtain
jury. the sample.

Do not allow hot oi! or components to contact 4. After you take a sample, remove the cap with the
skin. probe from the bottle. Discard the cap with the
probe. Install the sealing cap that is provided with
8T -9190 Fluid Sampling Bottle (1).
NOTICE
Care must be taken to ensure that fluids are contained 5. Replace the protective cap.
during pertormance of inspection , maintenance, test-
ing , adjusting and repairofthe product. Be prepared to 6. Install the access cover.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Reference: Refer to , "Lubricant Viscosities" in the
nent containing fluids . Maintenance Section of this manual for the correct
fluid for your machine.
Refer to Special Publication , NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

• Dispose of ali fluids according to local regulations and

mandates.
142 SEBU8146-06
Maintenance Section
Lift Cylinder Yoke Bearings - Lubricate

i02282411 If metais are found in the filter element, a magnet can •

be used to differentiate between ferrous metais and
Lift Cylinder Yoke Bearings - nonferrous metais.
Lubricate
Ferrous metais can indicate wear on steel parts and
SMCS Code: 5102-086-BD on cast iron parts.

Nonferrous metais can indicate wear on the

aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found .

Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger partieles in unfiltered
g01142312
IlIuslralion 205 oil. The particles could enter the lubricating system
and the particles could cause damage.
The grease fittings are on the left side of the radiator
guard and on the right side of the radiator guard o
i02282444
Lubricate the bearings by applying grease to the
fittings. Use MPGM grease. Pivot Shaft Oil Levei - Check

Oil Filter - Inspect

SMCS Code: 1318-507; 3067-507 ; 5068-507
i02106227 SMCS Code: 41 53-535-FLV

AWARNING
Hot oil and components can cause personal in-
•
jury.
Inspect a Used Filter for Oebris
Do not allow hot oil or components to contact
skin.

g001 00013
IIluslralion 206
The elemenl is shown wilh debris.
g01 142333
IlIuslralion 207
Use a filter cutter to cut the filter element open .
Spread apart the pleats and inspect the element for The oil plugs are located on both sides of the •
metal and for other debris. An excessive amount of machine on top of the track roller frame .
debris in the fil ter element can indicate a possible
failure . 1. Remove the oil plug on one side of the machi ne.
Check the oil leveI. The oil levei should be at the
bottom of the threaded hole .
 SEBU8146-06 143
Maintenance Section
Radiator Core - Clean

• 2. If necessary, add oil in order to bring the oil levei

up to the bottom of the threaded hole.

Reference: See Operation and Maintenance

Manual, "Lubricant Viscosities" in this manual for
the correct viscosity grade.
Radiator Pressure Cap -
Clean/Replace
SMCS Code: 1353-070-Z2 ; 1353-510-Z2
i02262497

3. Install the oil plug .

AWARNING
4. Repeat Steps 1 through 3 on the other side of
the machine. At operatlng temperature, the englne coolant is
hot and under pressure.

i00056126 Steam can cause personal Injury.

Radiator Core - Clean Check the coolant levei only after the engine has
been stopped and the fi" cap is cool enough to
SMCS Code: 1353-070; 1805; 1810 touch wlth your bare hand.

Remove the fi" cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid

contact with the skin and eyes to prevent personal
injury.

• IlIustration 208
g00100624

Vou can use compressed air, high pressure water,

or steam to remove dust and other debris from the
radiator core. However, the use of compressed air
is preferred .
g01142386
See Special Publication , SEBD0518, "Know Your IlIustration 209
Cooling System" for the complete procedure for Front view
clean ing the radiator core.
1. Open rad iator cap access cover (1). Slowly
remove rad iator cap (2) in order to relieve system
pressure.

2. Inspect the radiator cap for damage, for deposits,

or for foreign material. Clean the radiator cap
with a clean cloth . Replace the radiator cap if the
rad iator cap is damaged.

3. Install the rad iator cap .

•
144 SEBU8146-06
Maintenance Section
Recoil Spring Compartment Oil Levei - Check

Recoil Spring Compartment

Oil Levei - Check
i02282842

Refrigerant Dryer - Replace

(If Equipped)
i02292541

•
SMCS Code: 4158-535 SMCS Code: 7322-510; 7322-535

AWARNING AWARNING
Hot oil and components can cause personal in- Personal injury can result from contact with refrig-
jury. erant.

Do not allow hot oil or components to contact Contact with refrigerant can cause frost bite. Keep
skin. face and hands away to help prevent inj ury.

Protective goggles must always be worn when re-

frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed .

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.

Personal injury or death can result from inhaling

refrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through a •

lit cigarette or other smoking method or inhaling
IlIustrati on 210
901 142564 fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
1. Remove ali of the debris around the cover plate death.
on th e top of the track roller frame .
Do not smoke when servicing air conditioners or
2. Remove the cover plate for the oil filler. Observe wherever refrigerant gas may be present o
the levei of the oil.
Use a certified recovery and recycling cart to prop-
erly remove the refrigerant from the air condition-
ing system.

Note: The in-line dryer contains the orifice tube and

the desiccant that dries the liqu id refrigerant.

1. Stop the engine. Allow the air conditioning system

to remain inactive for five minutes in order to
equalize the pressure.

9011 1081 0
IlIustration 211

•
3. Maintain the oil levei above the top of the track
adjusting cylinder (1). Do not fill the oil above the
track adjustment valve (2) .

4. Install the cover plate.

5. Repeat the procedure for the other recoil

compartment.
 SEBU8146-06 145
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate

• Ripper Linkage and Cylinder

Bearings - Lubricate
SMCS Code: 6313-086-BD, L4
i00072976

g01147674
IlIustration 212

2. Open the lower access door that is located on the

left side of the machine.

g00 103773
IIlustration 214

Lubricate eleven grease fittings.

,..J.--l::-=---:: / ,--- --- i009256B9

•
""""'T---.-!!J~. / , . , .f~. .
Ripper Tip and Shank Protector
'L ).!.l - InspectlReplace
- .. __ ---
... ..
"'-~
--------,/ SMCS Code: 6808-040; 6808-510; 6810; 6812-040;
6812-510
g01 147675
IlIustration 213
If equipped:
3. Remove the bolt and the clip that retains the dryer.
The lines that connect to the dryer are equipped
with quick disconnects. Remove the dryer.

4. Install a new dryer.

5. Install the bolt and the clip.

6. Fasten the connections to the dryer.

7. Close the access door.

900550432
IIlustration 215

When the ripper tip is worn elose to the shank,

replace the ripper tipoWhen the shank protector is

•
worn close to the shank, replace the shank protector.
If the tip is too blunt, the tip will not penetrate properly.

1. Raise the ripper. Place blocking under the ripper.

Lower the ripper onto the blocking . The ripper
should be high enough so that the ripper tip or the
shank protector can be removed . Do not place the
ripper too high .
146 SEBU8146-06
Maintenance Section
Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) - Inspect

2. If the ripper tip is worn , drive out the pin o Remove i02429589 •
the tip and the shank pin retainer.
Seat Belt - Inspect
3. Clean the shank pin retainer and the pin o
SMCS Code: 7327-040
4. Install the new tip and the retainer.
Always check the condition of the seat belt and the
5. Install the pin from the opposite side of the cond ition of the seat belt moun ting hardware before
retainer. you operate the mach ine. Replace any parts that are
damaged or worn before yo u operate the machine.
6. If the shank protector is worn , drive out the pins.
Remove the shank protector.

7. Clea the pin retainers and the pins.

8. Install the new shank protector and the retainers .

9. Install the pins from the opposite side of the

retai ner.

10. Raise the ripper and remove the blocking .

11. Lower the ripper to the ground .

g00932801
i0228291 2 IIlustration 216
Typical example
Rollover Protective Structure
(ROPS) and Falling Object Check the seat belt mounting hardware (1 ) for wear •
or for damage. Replace any mounting hardware that
Protective Structure (FOPS) - is worn or damaged . Make sure that the mounting
Inspect bolts are tight.

SMCS Code: 7323-040; 7325-040 Check buckle (2) for wear or for damage. If the buckle
is worn or damaged , replace the seat belt.
Inspect the rollover protective structure/falling object
protective structure (ROPS/FOPS Structure) for Inspect the seat belt (3) for webbing that is worn or
bolts that are loose or damaged . Replace any frayed . Replace the seat belt if the seat belt is worn
damaged bolts and any missing bolts with original or frayed .
replacement parts only. Tighten the bolts to a torque
of 800 ± 100 N'm (600 ± 75 Ib ft) . Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Note: App ly oil to ali of the bolt threads that will be
used to install the ROPS or the FOPS before you Note: Within three years of the date of installation or
install the bolts. Improper bolt torque can result if you within five years of the date of manufacture, replace
do not apply oil to the threads. the seat belt. Replace the seat belt at the date wh ich
occurs first. A date label for determin ing the age of
Do not we ld reinforcement plates to the ROPS or the the seat belt is atlached to the seat belt, the seat belt
FOPS in order to straighten the ROPS or the FOPS . buckle, and the seat belt retractor.
Do not weld reinforcement plates to the ROPS or the
FOPS in order to repair the ROPS or the FOPS . If your machine is equipped with a seat belt
extension , also perform th is inspection procedure for
If the ROPS or the FOPS has any cracks in the the seat belt extension .
welds, in the castings, or in any metal section , consult

•
your Caterpillar dealer for repairs .
 SEBU8146-06 147
Maintenance Section
Seat Belt - Replace

• Seat Belt - Replace

SMCS Code: 7327-510
i02429594

Within three years of the date of installation or within

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. 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.

1 2
gOl143801
IlIustration 218
Front view

2. Disconnect hose (1) from the torque converter

housing.

3 4
gO l 152685
IlIustration 217

•
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (ta9) (fully extended web)
(4) Date of manufacture (underside) (buckle)

Consult your Caterpillar 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 900822757
IlIustration 219
for the seat belt extension.
3. Remove the torque converter scavenge screen
from the torque converter housing .
i02285650

Torque Converter Scavenge 4. Wash the screen in a clean , nonflammable

solvent.
Screen - Clean
5. Install the screen in the torque converter housing.
SMCS Code: 3101-070-MGS; 3105
6. Connect the hose to the torque converter housing .
When you change the transmission oil , clean the
torque converter scavenge screen . 7. Install the bottom guardo

1. Remove the bottom guard in order to gain access

to the torque converter.

Note: Drain ali fluids into a suitable container.

•
148 SEBU8146-06
Mainte nance Section
Track - ChecklAdjust

Track - Check/Adjust
SMCS Code: 4170-036
i027 12944

•
g01109482
IIlustration 221

If a machine does not have carrier rollers, the sag in

the track is measured between the sprocket and the
g011 42731
front idler. The correct adjustment of dimension (A) is
IlIustration 220 115 ± 10 mm (4.5 ± .4 inch).

Check the track adjustment. Check the track for wear

and for excessive dirt buildup.

AWARNING
Personal injury or death ean result from grease
under pressure.

Grease eoming out of the relief valve under pres-

sure ea n penetrate the body eausing injury or
death.
•
Do not wateh the relief valve to see if grease is es-
eaping. Wateh the traek or traek adjustment eylin- g011 18207
IIlustration 222
der to see if the traek is being loosened.
If the machine is equipped with a carrier roller,
Loosen t he relief valve one turn only.
calculate the average of dimension (B) and dimension
(C). The correct average val ue is 55 ± 10 mm
If traek does not loosen, elose the relief valve and
(2.2 ± 0.4 inch) .
eontaet your Caterpillar dealer.

1. Move the machine forward . Allow the machine

Loose Track Adjustment
to coast to a stop without the use of the service
brakes. Adjust the tracks while you are in the
machine's typical operating conditions. If packing
conditions prevail on the workplace, the tracks
should be adjusted without removing the packed
material.

2. To measure the sag in the track, stretch a string

over the grousers that are between the sprocket

•
and the tront idler. Take the measurement from
the string to the top of the grouser at the maximum
measurement. Dimension (A) is the maximum
distance between the string and the grouser.

g01019107
IIlustration 223
 SESU8146-06 149
Maintenance Section
Track Pins - Inspect

• NOTICE
Do not attempt to tighten track when dimension (D) is
150 mm (5.9 inch) or more.

Contact your Caterpillar dealer for track service or in-

Bolt Torque for Track Shoes
SystemOne Undercarriage
The track shoe bolts are 22.0 mm (0.87 inch).
The torque requirement for track shoe bolts is
structions. 500 ± 70 N·m (370 ± 50 Ib ft) . Tighten the bolts by an
additional tum of 120 degrees.
NOTICE
Do not attempt to tighten track when dimension (1) is Conventional Undercarriage
150 mm (5.9 inch) or more.
The track shoe bolts are 19.0 mm (0 .75 inch).
Contact your Caterpillar dealer for track service or in- The torque requirement for track shoe bolts is
structions. 400 ± 70 N·m (300 ± 50 Ib ft). Tighten the bolts by an
additional tum of 120 degrees. If you are using bolts
with a master link, tighten the bolts to a torque of
1. Remove the access cover. 400 ± 70 N·m (300 ± 50 Ib ft) . Then, tighten the bolts
by an additional tum of 180 degrees.

i01989298

Track Pins - Inspect

SMCS Code: 4175-040-PN

•
AWARNING
Fingers can be burned from hot pins and bush-
ings.

g01019116
The pins and bushings in a dry joint can become
IlIustration 224 very hot. It is possible to burn the fingers if there
is more than brief contact with these components.
2. Add multipurpose grease (MPGM) through
track adjustment valve (1). Add the MPGM until
dimension (A, S, C) is correct. Use the recommendations in order to extend the life
of the undercarriage. Use the recommendations in
3. Operate the machine back and forth in order to order to avoid excessive downtime.
equalize the pressure. Allow the machine to coast
to a complete stop. Do not use the brakes. 1. During the machine operation , listen for unusual
squeaking and for unusual squealing . This can
4. Remeasure dimension (D). indicate a dry joint.

Reference: See Operation and Maintenance 2. Check the machine for dry joints weekly. Check
Manual , "Front Idler Position - Check" for additional for dry joints immediately after machine operation .
information on System One Undercarriage. After machine operation , lightly touch the end of
each track pin or bushing . Touch the track pin
or the track bushing with the back of your hand .
Tight Track Adjustment Make a mark on any dry track pin joint that is very
hot to the touch .
1. Loosen relief valve (2) by one tum of 360 degrees.
Allow the grease to escape. Consult your Caterpillar dealer's Custom Track
Service expert if you detect dry joints or leaks. Your
2. Close the relief valve. Tighten the valve to a torque

•
Caterpillar dealer's Custom Track Service expert can
of 34 ± 7 N·m (25 ± 5 Ib ft) . perform track inspection .
3. Add MPGM through track adjustment valve (1).
Add grease until dimension (A, S, C) is correct.

4. Install the access cover.

150 SEBU8146-06
Maintenance Section
Track Roller Frame Guides - Inspect

Track Roller Frame Guides -

Inspect
i02712968

•
SMCS Code : 4177-040

Measure the rotational movement of the front roller

frame relative to the rear roller frame.

901021605
IIlustration 227
Some components are removed for clarity.

3. Raise the front of the machine with the hydraulics

of the dozer. Place the block under the inside edge
of the same track grouser. Lower the machine
onto the block.

g01021588
IlIustration 225
Some components are removed for clarity.

1. Raise the front of the machine with the hydraulics

of the dozer. Place a 100 mm (4 inch) block under
the outside edge of a track grouser. Place the
block near the track idler. Lower the machine onto
the block.
•
90 1362624
IlIustration 228

4. Put a mark on the tubular section of the front roller

frame . This mark should correspond with the mark
on the rear roller frame. Measure the distance
between the two marks on the front roller frame.

If the distance between the two marks is greater

than 4.5 mm (.18 inch) , inspect the track roller frame
guides for wear.
901021579
IlIustration 226
Repeat the entire procedure for the other side of the
machine .
2. Use a grease pencil to make a mark on the tubular
section of the front roller frame . Make a mark
on the rear of the roller frame . This mark should NOTICE
correspond with the mark that is on the tubular Never build up the track roller frame guides with hard-
section . face welding . This will cause serious wea r damage to

•
the guide slots in the front track roller frame .
 SEBU8146-06 151
Maintenance Section
Transmission Breather - Clean

• Transmission Breather -
Replace
SMCS Code: 3030-510-BRE
i02403434

1. Open the fron t access door on the right side of

the cabo

g00785460
IIlustration 229

If dimension (X) is less than 45.3 mm (1 .78 inch ),

replace the track roller frame guides. Consult your
Caterpillar dealer for information or for service.

i02400075

Transmission Breather - Clean g01198807

IlIustration 231
SMCS Code: 3030-070
2. The transmission breather is located on the bulk

•
1. Open the front access door on the right side of head bracket. The bulk head bracket holds the
the cabo ports for the power train . Unscrew and remove
transmission breather (1).

3. Install the new breather.

4. Close the front access door on the right side of

the cab o

i02894831

Transmission Oil - Change

SMCS Code: 3030; 3080-044

g01198807 AWARNING
lIIustration 230
At operating temperature, the hydraulic tank is hot
2. The transmission breather is located on the bulk and under pressure.
head bracket. The bulk head bracket holds the
ports for the power train . Unscrew and remove Hot oil and components can cause personal in-
transmission breather (1). jury. Do not allow hot oil or components to contact
skin.
3. Clean the breather in clean , nonflammable
solvent. Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to touch

•
4. Install the breather. with your bare hand. Remove the filler cap slowly
to relieve pressure .
152 SEBU8146-06
Maintenance Section
Transmission Oil - Change

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test-
ing , adjusting and repairofthe product. Be prepared to
collect the fluid with suitable containers before open-
3. Change the filter element. See the Topic
"Transmission System Oil Filter-Replace" in this
manual.

4. Remove the swivel or remove the pipe from the

drain in the bevel gear case. The drain valve will
•
ing any compartment or disassembling any compo- elose.
nent containing fluids .
5. Clean the oil drain plug and install the oil drain
Refer to Special Publication, NENG2500, "Caterpillar plug .
Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar FiII with Oil
products.
1. Open the access cover on the right side of the cab
Dispose of ali fluids according to local regulations and in front of the hydraulic ta nk.
mandates.

Orain The Oil

Operate the machine in order to warm the power
train oil. The machine must be leveI. Lower the
attachments with slight down pressure.

See the Topic "Transmission Oil Filter - Replace" in

this manual for the procedure to change the filters .

Use a 126 - 7538 Nozzle if the machine is equipped

with the high speed oil change arrangement. The
high speed oil change arrangement removes oil from
the sump in the bevel gear case. The high speed oil
change arrangement does not remove oil from the
torque converter or from the transmission case .
IIlustration 233

2. Remove cap (1) from the transmission oil filler

tube.
901198905 •
3. Fill the bevel gear case with oil. See Topic "Refill
Capacities" in this manual.

9011477 19
IlIustration 232

1. Remove the plug from the drain in the bevel gear ~~Z
3 ---1 ::::::biI._=
Õ+oc::::J!i![--=:J....hliiI:lL::
" ::!ii±:::
....

case. Install a 4C - 8563 Swivel into the valve.

Clamp a hose to the swivel. A 25.4 mm (1 inch) IlIustration 234
g01147802
pipe and hose can be used. Use a 25.4 mm
(2) Warm oil

•
(1 inch) pipe with 1-11 1/2 NPTF threads. Do not (3) Cold oil
tighten the pipe.
4. Maintain the oil levei within the marks fo r the
2. Turn the swivel or pipe clockwise in order to open operating range on the dipstick. If the eng ine is at
the internal drain valve. Allow the oil to drain into a idle and the oil is warm, maintain the oillevel with in
suitable container. range (2). If the engine is stopped and the en gine
oil is cold , maintain the oil levei with in range (3) .
 SEBU8146-06 153
Maintenance Section
Transmission Oil Filter - Replace

• 5. Clean the oil filler cap. Install the oil filler cap. 1. Remove transmission oil filter housing (1) from
the transmission oi! filter base (2).
6. Close the access door.
2. Remove the transmission oi! filter element and
properly dispose of the filter element.
i02713149

Transmission Oil Filter - 3. Clean the transmission oil filter housing with a
clean cloth .
Replace
4. Inspect the seal. If the seal is damaged , replace
SMCS Code: 3067-510 the seal.

5. Install the new filter element into the oil filter

AWARNING housing . Then , install transmission oil filter
Hot oil and components can cause personal in- housing (1) into base (2).
jury.
Note: Lubricate the threads of the transmission oil
Do not allow hot oil or components to contact filter housing .
skin.
6. Remove cap (4) from the transmission oil filler
tube.
NOTICE
Care must be taken to ensure that fluids are contained 7. Fill the transmission system with oil.
during performance of inspection, maintenance, test-
ing , adjusting and repair ofthe product. Be prepared to Reference: See Operation and Maintenance
collect the fluid with suitable containers before open- Manual, "Lubricant Viscosities" in this manual for
ing any compartment or disassembling any compo- the correct viscosity grade of oil.

•• nent containing fluids .

Refer to Special Publication , NENG2500, "Caterpillar

Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
~, -_... -: -l I"
Dispose of ali fluids according to local regulations and
mandates.
@) ~f------()
If the transmission oil filter indicator in the monitoring
panei comes on before 1000 hours, the filter should
be changed .

The transmission oil filter is located behind the front IIlustration 236 901142953
access cover on the right side of the cabo
Full marks
(5) Warm oil
(6) Cold oil

8. Maintain the oil levei within the marks for the

operating range on the dipstick. If the engine is at
idle and the oil is warm, maintain the oillevel within
range (5). If the engine is stopped and the engine
oil is cold , maintain the oillevel within range (6).

9. Clean the filler cap and install the filler cap .

• IIlustration 235 g01198916

10. Close the access cover (not shown) .
154 SESU8146-06
Maintenance Section
Transmission Oil Levei - Check

i02713160 Note: When you are operating the machine on severe •

slopes, the quantity of oil in the transmission can be
Transmission Oil Levei - Check increased up to 10 percent. When you are operating
with the increased oil quantity, prolonged operation
SMCS Code: 3030-535-FLV; 3080-535-FLV in some machines can cause high transmission oil
temperatures. After the work on the severe slopes
has been completed , drain the excessive oil quantity
AWARNING
from the bevel gear case.
Hot oi! and components can cause personal in-
jury. 3. If necessary, add oil.

Do not allow hot oi! or components to contact Reference: Refer to Operation and Maintenance
skin. Manual, "Lubricant Viscosities and Refill
Capacities" in this manual.

4. Clean the filler cap and install the filler cap.

5. Close the access cover.

i02431358

Transmission Oil Sam pie

Obtain
SMCS Code: 3030-008 ; 7542-008

IIlustration 237

1. Open the access cover on the right side of the cab

in fron t of the hydraulic tank.
901198905

jury.
AWARNING
Hot oi! and components can cause personal in-

Do not allow hot oi! or components to contact

skin.
•
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection , maintenance, test-
ing , adjusting and repair of the product. Se prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

~t:z::::;;;!;;z
3 -1 I
... , =:::h;;,.=
:S±=
jõ04CJ!![OOI-=:J'"W!iI:A=:.
Refer to Special Publication, NENG2500, "Caterpillar
Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar
IlIustration 238 901147802 products.
(2) Warm 0 11
(3) Cold Oil Dispose of ali fluids according to local regulations and
mandates.
2. Remove the transmission oil levei gauge (1) .
Maintain the oil levei within the marks for the Obtain the sample of the transmission oil as elose
operating range on the dipstick. If the engine is at as possible to the recommended sampling interval.
idle and the oil is warm, maintain the oillevel within The recommended sampling interval is every 500 •
range (2). If the engine is stopped and the engine service hours. ln order to receive the full effect of
oil is cold, maintain the oil levei within range (3). S·O·S oil analysis, you must establish a consistent
trend of data. ln order to establish a pertinent history
of data, perform consistent oi! samplings that are
evenly spaced.
 SEBU8146-06 155
Maintenance Section
Transmission Scavenge Screen - Clean

• If the machine is operated under high load and/or

under high temperature conditions, sam pie ali
fluids at the 250 hour interval. Transmission Scavenge
Screen - Clean
SMCS Code: 3030-070-MGS
i02713189

When you chang e the transmission oil , clean the

scavenge screen .

g01198946
IlIustration 239

1. Open the access cover on the right side of the cab

in front of the hydraulic tank.

g01147719
IlIustration 241

1. Remove the cover from the rear of the

• transmission . The scavenge screen is located

behind the cover.

2. wash the screen in a clean , nonflammable

solvent.

3. Inspect the seal. If the seal is damaged, replace

the seal.

g01143656 4. Install the screen and the cover.

lIIustration 240
lhe oil sampling valve for the power train is shown .
i01499083
2. Remove the protective cap.
Trunnion Bearing - Adjust
3. Use 8T -9190 Fluid Sampling Bottle (1) to obtain
a sample. SMCS Code: 6063-025

4. After you take a sample, remove the cap with the

probe from the bottle. Discard the cap with the
probe. Install the sealing cap that is provided with
8T -9190 Fluid Sampling Bottle (1) .

5. Replace the protective cap.

6. Install the access cover.

•
Reference: Refer to , "Lubricant Viscosities" in the
Maintenance Section of this manual for the correct
fluid for your machine.

IIlustration 242 g00666217

156 SE8U8146-06
Maintenance Section
Winch Fairlead Rollers - Lubricate

Adjust the trunnion bearings after the initial 100 4. Loosen the bolts that are on cap (2 ). As needed , •
hours. insert shims into spaces (A) and (8). When
possible, use an equal number of shims for
1. Lower the bulldozer blade to the ground . Walk to spaces (A) and (8).
the left side of the machine .
Note: The number of shims at space (A) must be
2. Re ove two nuts (3) from two bolts (1) on the within one of the number of shims at space (8). For
trunnion bearing . example, if space (A) has eight shims, space (8 )
must have seven , eight, or nine shims.
3. Remove two bolts (1) , bearing cap (2) , and two
shim packs (A and 8) as a unit. 5. Add one additional shim to space (A). Add one
additional shim to space (8).
4. Remove one shim from each shim pack (A and 8).
6. Tighten the bolts that are on cap (2) to a torque of
5. Install two bolts (1), bearing cap (2) , and two shim 1050 ± 150 N'm (775 ± 110 Ib ft) .
packs (A and 8).
7. The assembly should move freely on tl1 e trunn ion.
6. Install two nuts (3) on two bolts (1) . The specified minimum tolerance is 0.25 mm
(0 .010 inch) .
7. Tig hten two nuts (3) to a torque of 1050 ± 150 N'm
(775 ± 110 Ib ft) . Note: Removal of one or more sh ims after a short
period of time may be necessary. Wear can be
8. Repeat steps 2 through 7 on the right side of the caused by normal variations of the surface or
machine. variations in the thickness of the paint.

8. Perform Steps 1 through 5 on the front bearing .

Procedure for Shimming
9. Tighten the bolts that are on the fron t bearing to a •
torque of 430 ± 60 N'm (320 ± 45 Ib ft) .

10. The assembly should move freel y on the trunn ion .

The specified minimum tolerance is 0.25 mm
(0 .010 inch) .

Note: Removal of one or more shims after a short

period of time may be necessary. Wear can be
caused by normal variations of the surface or
variations in lhe thickness of the paint.

i02112664

IlIustration 243
900292740 Winch Fairlead Rollers -
Typical exam ple Lubricate
1. Remove ali of the shims from push arm assembly SMCS Code: 51 63-086
(1 ).
If equipped:
2. Install assembly (1) and cap (2) on trunnion
assembly (3) without shims.

3. Tighten the bolts that are on cap (2) to a torque of

50 N'm (37 Ib ft) .

•
Maintain equal distance on both space (A) and
space (8) of cap (2). Observe spaces (A) and
(8) in order to determine the required number of
shims.
 SEBU8146-06 157
Maintenance Section
Winch Oil Levei - Check

i02283892

Winch Oil and Breather -

Change/Clean
(If Equipped)
SMCS Code: 5163-044

AWARNING
Hot oil and components can cause personal in-
jury.

IlIustration 244
g01076211 Do not allow hot oil or components to contact
skin.
Lubricate the five fittings. Use MPGM Grease.

i03668780

Winch Oil Levei - Check

SMCS Code: 5163-535-FLV

If equipped:
4

• PA90V5

IIlustralion 246 g0 1143124

1. Remove oil filler plug (1).

2. Remove drain plug (4) on the bottom of the winch .

Allow the oil to drain into a suitable container.

3. Inspect the plug seal. If necessary, replace the

plug seal.

4. Clean the drain plug and install the drain plug .

IIlustration 245 5. Remove oillevel plug (2).
1. Remove oil levei plug (2) in order to check the oil 6. Fill the oil compartment until oil is visible at the
leveI. The oil levei should be maintained to the bottom of the opening for the oil levei plug .
bottom of the levei plug hole. See Operation and Maintenance Manual, "Refill
Capacities" .
2. If necessary, remove oil filler plug (1) and add oil.
Note: Use sight glass (3) on the other side of the
Check for oil leaks around the covers and around winch in order to check the oil leveI. The oil levei
the hoses. Repair any oil leaks. should be maintained with the sight glass.

• 7. Clean the vent plug that is in the filler plug . Use a

clean nonflammable solvent.

8. Clean the filler plug and install the filler plug .

158 SEBU8146-06
Maintenance Section
Winch Wire Rope - Install

9. Run the engine at low idle. Maintain the oil levei Table 19
so Ihat the oil levei is visible at the bottom of the
Wire Rape
opening for the oil levei plug .
Wire Rape Recammended Halding Capacity
10. Install the oil check plug . Diameter Ferrule
25 mm (1 inch) J-8 91 m (300 ft)
i02659765 29 mm J-9 84 m (276 ft)
(1 .13 inch)
Winch Wire Rope - Install
32 mm J-10 59 m (193 ft)
(If Equipped) (1 .25 inch)

SMCS Code: 5163-012

1. Put the cable in a straight line behind the tractor.

AWARNING
Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
ais. Proper care is your responsibility.

AWARNING
Personal injury or death can result from worn wire
rope cable.

Worn or frayed cable could break causing injury.

Check the wire rope cable. If cable is worn or is

frayed install a new cable.
IlIustration 247

1. Install the ferrule end into the socket .

2. Reei in the cable.

g00550538

•
i02284183

AWARNING Window Washer Reservoir -

Wear leather gloves when handling the winch ca- Fill
ble.
SMCS Code: 7306-544
NOTICE
Unroll the wire rape cable from the spool. Never lift the NOTICE
wire rape off the spool in coils. When operating in freezi ng temperatures , use
Caterpillar or any commercia lly available nonfreezing
window washer solvent.
NOTICE
Use the correct size ferrule for the winch cable in order
to attach the winch cable to the load drum. Never use
a knot in order to secure the winch cable to the load
drum.

The ca ble is attached to the drum on the winch with

•
a cable ferrule . The ferrule is placed into a socket
on the drum.

Use the following table to order the cable.

 SEBU8146-06 159
Maintenance Section
Window Wipers - InspectlReplace

• 3. Start rear wiper (3) and stop the wiper in the

leftmost position (4) . Inspect the rear window
wiper blade or replace the wiper blade from the
inside of the cab only.

4. Replace any wiper blades that are damaged or

worn . Replace any wiper blades that streak the
window.

3
i02284774

Windows - Clean
SMCS Code: 7310-070; 7340-070
g01143289
IIlustration 248
If equipped:
~!.'" Windshield Washer - Washer fluid bottle
\::!::!J (3) is on the left side of the machine in a Use commercially available window cleaning
solutions to clean the windows.
compartment between battery box (1) and
fuel tank (2). Open the access cover. Remove the
fluid bottle cap in order to fill the washer fluid bottle. To clean the outside of the rear window from the
inside of the cab, remove the sliding section of the
rear window. Use the following procedure in order to
i02284211
remove the sliding section of the rear window.

Window Wipers -

•
InspectlReplace
(If Equipped)
SMCS Code: 7305-040; 7305-510 4

1. Inspect front window wiper blade (1), the left

window wiper blade (5), and right window wiper
blade (6). 3

IIlustration 250 g01143477

2 Rear window

1. Lift latch (1) in order to si ide the small window.

Squeeze latch (2) in order to move the window
from the CLOSED position .
5 4
2. Move handle stop (3) to the UP position . To move
the handle stop to the UP position, lift the handle
and rotate the handle simultaneously. Rotate the
handle until the handle is vertical.

3. Move the small section of the window to opening

(4) in the upper window channel.

•
4. Tilt the top of the window toward the inside of the
cabo Remove the window.
g01 143314
lIIustration 249
5. Stay inside the cab in order to clean the outside
of the rear window.
2. Open up small window (2).
160 SEBU8146-06
Maintenance Section
Windows - Clean

6. After cleaning , install the sliding section of the rear

window.
•

•
 SEBU8146-06 161
Reference Information Section
Reference Materiais

• Reference Information • Special Publication , SEBD0640 , "Oil and Your

Engine"
Section
• Special Publication , SEBU6250, "Caterpillar
Machine Fluids Recommendations"

Reference Materiais • Special Publication, SEBU6981 , "Emissions

Control Warranty Information"
i02793375
• Service Manual, SENR5664, "Air Conditioning and
Reference Material Heating R-134a Ali Caterpillar Machines"

SMCS Code: 1000; 7000 • Service Manual, RENR2014 , "Caterpillar

Monitoring System"
The following literature can be obtained from any
Caterpillar dealer: Parts Manuais are available for additional serial
numbers. Consult your Caterpillar dealer for
• Special Publication , SEBD0518, "Know Your information about obtaining these Parts Manuais.
Cooling System"
Operation and Maintenance Manuais are available
• Special Publication, SEBD0970, "Coolant and Your in other languages. Consult your Caterpillar dealer
Engine" for information about obtaining these Operation and
Maintenance Manuais.
• Special Publication , SEBD0717, "Diesel Fuels and
Your Engine" Additional Reference Material

•
• Service Magazine, SEBD1587, 28 October 1985, ASTM 02896, "TBN Measurements" This can
"What ROPS/FOPS Certification Means" normally be obtained from your local technological
society, from your local li bra ry, or from your local
• Special Instruction , SEHS6929, "Inspection, college.
Maintenance and Repair of Rollover Protective
Structures (ROPS) and Attachment Installation SAE J313, "Diesel Fuels" This can be found in the
Guidelines" SAE handbook. Also, this publication can be obtained
from your local technological society, from your local
• Special Instruction, SEHS7392 , "Storage of Diesel library, or from your local college.
Engines"
SAE J754, "Nomenclature" This can normally be
• Special Instruction , SEHS7633, "Battery Test found in the SAE handbook.
Procedure"
SAE J183, "Classification" This can normally be
• Special Instruction, SEHS7768, "6V-2150 found in the SAE handbook.
Starting/Charging Analyzer Group"
Engine Manufacturers Association , " Engine Fluids
• Special Instruction, SEHS9031 , "Storage Data Book"
Procedure for Caterpillar Products"
Engine Manufacturers Association
• Speciallnstruction , REHS1110, "Installation and Two North LaSalle Street, Suite 2200
Removal of SystemOne Track" Chicago, Illinois, USA 60602
E-mail: ema@enginemanufacturers.org
• Special Instruction, REHS2403, "Installation and (312) 827-8700
Removal of SystemOne Track with the Multi-Pitch Facsimile: (312) 827-8737
SystemOne Track Press Tool"

• Special Instruction, REHS2350, "SystemOne

•
Undercarriage Overview"

• Specifications, SENR3130, "Torque Specifications"

• Special Publication, SEBU5898, "Cold Weather

Recommendations for ali Caterpillar Equipment"
162 SEBU8146-06
Reference Information Section
Reference Materiais

Decommissioning and
Disposal
i03645566

•
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 Caterpillar dealer
for additional information .

•
 SEBU8146-06 163
Index Section

• Index
A Cooling System Water Temperature Regulator -
Replace ............................................................... 116
Additional Messages ............................................. 13 Crushing Prevention and Cutting Prevention ........ 17
Adjustments ........................................ ... ................ 83 Cutting Edges and End Bits - InspectlReplace .... . 117
Alternate Exit .... ... .................. ... .... ...... ................... 44
Angle Blade Manual Tilt Brace - Lubricate .... .... .. 104
o
B Daily Inspection ..................................................... 42
Declaration of Conformity ...................................... 40
Backup Alarm ..................... ................................... 61 Decommissioning and Disposal .......................... 162
Backup Alarm - Test ............................................ 104
Battery - Inspect .................................................. 104
Battery Disconnect Switch ..................................... 60 E
Checking the Battery Disconnect System .......... 61
Before Operation ............................................. 23, 42 Electrical Storm Injury Prevention ......................... 22
Before Starting Engine .......................................... 22 Emissions Certification Film .................................. 41
Belts - InspectlAdjustlReplace .... ......................... 104 Engine Air Filter Primary Element - Cleanl
AdjustlReplace ................................................. 105 Replace ........................................... ................ .... 118
Inspect ................ ...... ........ ....... ............. ........... 104 Engine Air Filter Secondary Element - Replace ... 119
Brakes, Indicators and Gauges - Test ................. 106 Engine Air Precleaner - Clean ............................. 120
Braking System (Test) ...................................... 107 Engine and Machine Warm-Up ............................. 76
CMS Functional Test.. ...................................... 106 Idling .................................................................. 76
Bulldozer - Lubricate (Variable Pitch Angle Tilt Engine Crankcase Breather - Clean ................... . 120

• Blade) .. ...... ... ...... .. .. ........ ...... .. .... ........ ..... .......... 108
Bulldozer Blade Pitch ............................................ 83
Burn Prevention .................................. .... ............... 18
Batteries ............................................................. 18
Coolant. ................ ................ .. ........ .... .. .. ....... ... .. 18
Oils .......................... .............. ...... ....................... 18
Engine Oil and Filter - Change ............................ 122
Procedure for Changing the Engine Oil and
Filter ............................... ................................ 124
Selection of the Oil Change I nterval ................ 122
Engine Oil Level- Check ..................................... 121
Engine Oil Sample - Obtain ................................. 121
Engine Starting ............................ .. ......... ......... 22, 75
Ether Starting Aid ............................................... 75
c Subsequent Engine Starting Procedures ........... 76
Engine Starting (Alternate Methods) ..................... 94
Cab Filter (Fresh Air) - Clean/lnspectlReplace (If Engine Starting with Jump Start Cables ................ 94
Equipped) ... ........... ... ........ .... .. ... .. ......... .. .. ......... 109 Use of Jump Start Cables .................................. 94
Cab Filter (Recirculation) - Clean/lnspectlReplace (If Engine Valve Lash - ChecklAdjust ...................... 126
Equipped) .. ............ .. ............... .... ........ ... ... ......... 109 Equalizer Bar Center Pin - Lubricate ............ ....... 126
Camera .................................................................. 73 Equalizer Bar End Pins Oil Levei - Check .. .... ..... 126
Video Camera (If Equipped) .... .......................... 73 Equipment Lowering with Engine Stopped ...... 26, 85
Camera - Clean/Adjust.. ....................................... 110 Bleed Down the Accumulator .. .. ......................... 85
Adjust the Area of Visibility ............................... 110 Bleed Down the Pilot Oil System Mechanically .. 85
Clean Camera Lens .......................................... 110 Ether Starting Aid Cylinder - Replace .................. 127
Work Area Vision System (If Equipped) ............ 110
Capacities (Refill) ................................................ 100
Ecology Drains ...... ......... .. ..... ....... ..... ... ... ......... 100 F
Cooling System Coolant Levei - Check ................ 111
Cooling System Coolant Sam pie (Levei 1) - Final Drive Oil - Change ...................................... 128
Obtain ............. ...................................... .............. 112 Final Drive Oil Levei - Check ............................... 128
Levei 1 Analysis ................................................ 112 Final Drive Oil Sample - Obtain ........................... 129
Cooling System Coolant Sam pie (Levei 2) - Fire Extinguisher Location ..................................... 21

•
Obtain .................. ...... ........... ... ........................... 113 Fire Prevention and Explosion Prevention ............ 18
Levei 2 Analysis ................................................ 113 Battery and Battery Cables ................................ 19
Cooling System Extended Life Coolant - Ether .................................................................. 21
Change ............................................................... 114 Fire Extinguisher ... .. .... .......... ........ ................... .. 21
Cooling System Extended Life Coolant Extender - General .............................................................. 18
Add ..................................................................... 115 Lines, Tubes and Hoses ...... .. ............................ 20
Extended Life Coolant (ELC) Extender ............. 115 Wiring ................................................................. 20
164 SEBU8146-06
Index Section

Foreword ....... .................. ... .... .... .... ........ ................. 5 L •

California Proposition 65 Warning ........ .. .... ......... 4
Caterpillar Product Identification Number ..... .... .. . 5 Leaving the Machine ............................................. 86
Certified Engine Maintenance .... ...... ......... .... .. .... . 4 Lift Cylinder Yoke Bearings - Lubricate ............... 142
Literature Information ............ .... ... ........... ............. 4 Lifting and Tying Down the Machine .. .................... 87
Machine Capacity .................... ..... .. ..................... 5 Lubricant Viscosities ............................... ............... 96
Ma intenance ............. ... ................ .......... .. ....... .. ... 4 Lubricant Viscosities for Ambient
Operation .. ......................... .. ....... .. ....................... 4 Temperatures ......... .......................................... 97
Safety ..... ..... ....... .. .......................... .. .. ... ............... 4 Selecting the Viscosity ...................................... . 96
Front Idler Position - Check .... ......... .. .. ........ .. .. .... 130 Lubricant Viscosities and Refill Capacities ............ 96
Conventional Design ................ .... .. .. ................ 130
SystemOne Undercarriage .. ........ .. .................. 130
Fuel System - Prime .... .. ............................ ..... .. .. . 131 M
Electric Fuel Priming Pump .. ........ .. .................. 131
Fuel System Secondary Filter - Replace .... .... .. ... 132 Machine Operation .......... .. ................ .................... 44
Fuel System Water Separator - Drain ................. 133 Maintenance Interval Schedule ........................... 102
Fuel System water Separator Element - Maintenance Section ..................... .. ................... ... 96
Replace .. ............... .. .... ............................. ..... ..... 133 Maintenance Support .......................................... 101
Fuel Tank Cap Filter and Strainer - Monitoring System .......................... ................... .... 61
Replace/Clean ...................................... ... ....... ... 135 Alert Indicators ..................... .... .......................... 63
Fuel Tank Water and Sediment - Drain ............... 135 Digital Display Window (Lower) ......................... 66
Fuses and Circuit Breakers - Replace/Reset ...... 136 Digital Display Window (Upper) ............ .. .. .. ....... 66
Circuit Breakers ............................ .. ...... .. ......... 137 Electrical Connector Location ............................ 68
Fuses ..... ...... .. ......................................... ....... .. 136 Functional Test .... .. ..... ...... .... .. ............................ 62
Gauges ......... ................ .. ................................... 65
Reporting a Problem .......................................... 68
G Service Code Mode ................. .. ............... ......... 67
Service Meter Mode .................................. .. ....... 67 •
General Hazard Information ........... .. ..................... 15 Status Indicators ................................................ 62
Asbestos Information ............. ............. ... ............ 17 Travei Distance Mode ........................................ 67
Containing Fluid Spillage ........... .. ...... .. .............. 16 Warning Levei 1 ................ .. ............................... 64
Dispose of Waste Properly ...... .. ...... .. ....... .... .. ... 17 Warning Levei 2 .. ........ .. ..................................... 65
Flu id Penetration ...................... .. ...... ............... ... 16 Warning Levei 3 .... ............................................. 65
Pressurized Air and Water ................................. 16 Mounting and Dismounting .................................... 42
Trapped Pressure ... ....... ......... ........................... 16 Alternate Exit. ... ......... ......................................... 42
General Information ................. ..... .... .... ... ... ........... 30
Guards (Operator Protection) .......... ...................... 28
Other Guards (If Equipped) .................... .. .. ........ 29 o
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip Ove r Oil Filter - Inspect ................................................ 142
Protection Structure (TOPS) .. .. .... .. .... .. ............ 29 Inspect a Used Filter for Debris ................... .. .. 142
Operating Technique Information ............. .. .......... . 77
Adjustable Ripper...... .. ........ .. .. .. ..... ............... ..... 81
H Angle Blade ...... .................................................. 77
Backfilling ... .. ... ..... ........ .. ......... ........................ ... 79
Hydraulic System Oil - Change ........................... 137 Land Clearing ........... .......................................... 79
Change the Hydraulic Oil ................................. 138 Machine on a Slope .... .. ..................................... 78
Lubricants .... ........................................... .... ..... 137 Packed Soil, Hardpan , Clay, Shale or Cemented
Hydraulic System Oi! Filter - Replace .. .. ........ .. .. .. 139 Gravel. .............................................................. 80
Hydraulic System Oil Levei - Check .... .. ...... .. .. .. .. 140 Push Loading ....................................... .............. 82
Hydraulic System Oil Sample - Obtain ................ 141 Ripping ................................................. .............. 80
Rock with Fractures, Faults and Planes 01
Weakness ........................................................ 81
Selection of Speed Range .. ............................... 77
Single Shank Ripper (Solid Rock, Granite, or Hard
Identification Information ....................................... 34 Spots) ............ ............... .......... ....... ................ ... 81 •
Important Safety Information .. .. ............................... 2 Slot Dozing ...... ........ .......... .. ............................ ... 78
Straight Dozing .................. ...... ........ .. ................ 77
Stump Removal .................. ... ....... ..................... 80
V-Ditching ..... ..................... .... ............... ..... ........ 79
Operating Techn iques ....... .............. ........... ...... ...... 77
 SEBU8146-06 165
Index Section

• Operation .... ....... ....... .. .. .... ...... .... ...... ......... .... ........
Operation Information ... ...... ...................................
Changing Direction and Speed .......... .... ....... .....
Operating The Machine ................. .... ........ ....... .
Operation Section. ....... .. .. ... .. ...... .. ..... ... ... ... ...... .....
Operator Controls .................. ............ ........... ........ .
24
73
74
73
42
49
Ripper Tip and Shank Protector - Inspectl
Replace .... ..... ...... ........ ................. .......... ...... ...... 145
Rollover Protective Structure (ROPS) and Falling
Object Protective Structure (FOPS) - Inspect.. .. 146

Adjustable Armrests (1) .......... .. ......................... 51 s

Auto Kickdown Switch (10) .. .. ............................ 54
Autoshift Switch (11) .......................................... 54 S·O·S Information ................................................ 100
Bu IIdozer Control (17) ............................ ... ......... 56 Safety Messages ........ ........... ....... ............. .............. 6
Cab Dome Ught (8) ............................................ 54 Safety Section .... ... .. ................ ........... ..................... 6
Decelerator Pedal (7) .......... .. .... .. .. .................... . 54 Seat ...... ..... .................. ....................... ..... .............. 44
Difterential Steering Control and Transmission Adjusting the Seat.. ........................................... . 44
Control (3) ........................................................ 51 Seat Belt .. ........... .............. ... .... ........ ... .... ..... ... ....... 47
Engine Start Switch (12) .................................... 54 Extension of the Seat Belt ................................. 49
Gauges and Indicators (9) ................................. 54 Seat Belt Adjustment for Non-Retractable Seat
Heating and Air Conditioning Control (14) ......... 55 Belts ........................... .. ........ ....... ... ... ...... ......... 47
Horn (22) ......... ..... .. .......... ... .. .................... .... ..... 59 Seat Belt Adjustment for Retractable Seat
Hydraulic Lockout Control (20) ....... .... .... .. ......... 58 Belts .. .. ......... ... ......... ..... .......... ... .... ..... ............. 49
Ught Switch (15) ................................................ 56 Seat Belt - Inspect.. ................ ............................. 146
MVP Switch (19) ................................................ 58 Seat Belt - Replace ............ .. .. .......... .................... 147
Operator Mode Select Switch (16) .................. ... 56 Shipping the Machine ........... ................................. 87
Parking Brake Control (2) .................................. 51 Slope Operation ....... ...... ... .......... .. ..... ... ....... .... ...... 25
Ripper Control (21) ............................................ 59 Sound Information and Vibration Information ........ 26
Service Brake Control (6) ................................... 54 Sound Levei Information .................................... 26
Speed Range Selector (5) .................... ............. 53 Sound Levellnformation for Machines in European
Throttle Control Switch (18) ............................... 58 Union Countries and in Countries that Adopt the

•
Transmission Control (4) .................................... 51 "EU Directives" .. ................... ........ .................... 26
Winch Control (21) ............................................. 58 Sources ................................................ ... ........ .. . 28
Window Wiper/Washer Switches (13) ................ 55 "The European Union Physical Agents (Vibration)
Windows ..... ......... ..... .. ..... ....... ...... ... .. ....... ... ...... 60 Directive 2002/44/EC" ...................................... 26
Operator Station .. .. ... ..... ...... ....... ................. .......... 28 Specifications .......................................... .............. 30
Intended Use .. ... ................................... ..... ......... 33
Stopping the Engine .............................................. 84
p Idling the Engine for Extended Periods ............ . 84
Stopping the Engine if an Electrical Malfunction
Parking ........... ................................................. 24 , 84 Occurs ... ....... .. ........ ...... .......... ............. ............... . 85
Pivot Shaft Oil Levei - Check ............................... 142 Stopping the Machine .................... ........................ 84
Plate Locations and Film Locations ....................... 34
Certification ... ................................... ........... ... .... 35
ISO Symbols (Model Usage) .. .......... .. ............... 36 T
Product Information Section .................................. 30
Product Unk (If Equipped) ..................................... 69 Table of Contents ..................................................... 3
Data Broadcasts ...... ..................... ..................... 69 Torque Converter Scavenge Screen - Clean ...... . 147
Operation in a Blast Site .................................... 69 Towing Information ...................... .......................... 89
Regulatory Compliance ...................................... 70 Towing the Machine ............................................... 89
Brake Engagement .... .......... .............................. 93
Brake Release .............................. ..................... 93
R Connection for the Pump ............ .. ...... .. ............. 92
Connection of Brake Release Pump .... .............. 90
Radiator Core - Clean .......................................... 143 Relief Valve Setting ............................................ 91
Radiator Pressure Cap - Clean/Replace ............ . 143 Running Engine ........................... ...................... 90
Recoil Spring Compartment Oil Level- Check .... 144 Stopped Engine or Drive Une Defect... .............. 90
Reference Information Section ...... .................. .... 161 Track - ChecklAdjust ........................................... 148

•
Reference Material ..................... .. .. ....... .... ...... .... 161 Bolt Torque for Track Shoes ............................ 149
Additional Reference Material. .. ... .. ................ .. 161 Loose Track Adjustment ...................... .. .......... 148
Reference Materiais .. ........ ........ .. .......... .... .... ...... 161 Tight Track Adjustment .................................... 149
Refrigerant Dryer - Replace (If Equipped) ........... 144 Track Information .......... ... .................................... .. 22
Restricted Visibility ............ .............. ...................... 23 Track Pins - Inspect.. ........................................... 149
Ripper Unkage and Cylinder Bearings - Track Roller Frame Guides - Inspect... ................ 150
Lubricate ............................................................ 145 Tracks .......................................... ..... ... .. ................ 83
166 SEBU8146-06
Index Section

Transmission Breather - Clean ..................... ....... 151

Transmission Breather - Replace ........................ 151
Transmission Oil- Change ................ .... ... .. ......... 151
Orain The Oil .......................................... ..... ..... 152
Fill with Oil... ..................................................... 152
Transmission Oil Filter - Replace .......... .... .......... 153
•
Transmission Oil Levei - Check ........................... 154
Transmission Oil Sample - Obtain ....................... 154
Transmission Scavenge Screen - Clean .. .. ......... 155
Transportation Information .................................... 87
Trunnion Bearing - Adjust.. .................................. 155
Procedure for Shimming .................................. 156

v
Visibility Information ........... .................................... 23

w
Weld in g on Machines and Engines with Electronic
Controls ......... ..... ........................................... .... 101
Winch Fairlead Rollers - Lubricate ...................... 156
Winch Oil and Breather - Change/Clean (If
Equipped) .......................................................... 157
Winch Oil Levei - Check ...................................... 157
PA90VS ....................................................... ..... 157
Winch Wire Rope - Install (If Equipped) .............. 158
Window Washer Reservoir - Fill .... .. .................... 158
Window Wipers - InspectlReplace (If Equipped) .. 159
Windows - Clean ................................................. 159
•

•
Product and Dealer Information
Note: For product identification plate locations, see the section "Product Identification Information" in the Operation
and Maintenance Manual.

Delivery Date: _ _ _ _ _ __ __

Product Information
Model: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ _ _ _ _ _ _ _ _ _ _ _ __

Engine Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Generator Serial Number: _ _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Attachment Serial Numbers: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ __

Attachment Information : _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ __ _ _ __ _

Customer Equipment Number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _

Dealer Information
Name: Branch : _ _ _ _ _ _ _ _ _ _ _ _ __

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
 •

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Ali Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.