Caterpillar D3K, D4K, D5K Operation Manual

Operation and
Maintenance
Manual

SEBU8213-04

October 2009

D3K, D4K and D5K Track-Type
Tractors

JTD1-U
FFF1-Up (Machine)
JLF1-Up (Machine)
LLL1­MMM1-Up (Machine)
RRR1-Up (Machine)
WWW1­YYY1-Up (Machine)

p (Machine)

Up (Machine)

Up (Machine)

SAFETY.CAT.COM

i03684547

Important Safety Information

Most accidents
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 neces

Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.

Do not operat
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 heed

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safe ty Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.

A non-exh
on the product and in this publication.

that involve product operation, maintenance and repair are caused by failure to observe

sary training, skills and tools to perform these functions properly.

e or perform any lubrication, maintenance or repair on this product, until you have

ed, bodily injury or death could occur to you or to other persons.

! Become Alert! Your Safety is Involved.

austive list of operations that may cause product damage are identified by “NOTICE” labels

Caterpillar cannot anticipate e very possible circumstance that might involve a potential hazard.
The warn
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you hav e considered all safety rules and precautions applicable to the
operat
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
the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that
was av
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start

ings in this publication and on the product are, therefore, not all inclusive. You must

ion of the product in the location of use, including site-specific rules and precautions

others. You should also ensure that the product will not be damaged or become unsafe by

ailable at the time that the publication was written. The specifications, torques, pressures,

any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this
product Caterpillar recommends using Caterpil-

replacement parts or parts with equivalent

lar
specifications including, but not limited to, phys­ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema­ture failures, product damage, personal injury or

ath.

de

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

SEBU8213-04 3

Table of Contents

Table of Contents

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

Safety Section

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

Additional Messages ............................................. 12

General Hazard Information ................................. 15

Crushing Prevention and Cutting Prevention ........ 17

Burn Prevention .................................................... 18

Fire Prevention and Explosion Prevention ............ 18

Fire Extinguisher Location .................................... 22

Track Information .................................................. 22

Electrical Storm Injury Prevention ......................... 22

Before Starting Engine .......................................... 22

Adjustments .......................................................... 71

Parking .................................................................. 73

Transportation Information .................................... 77

Tow i n g I n f or

Engine Starting (Alternate Methods) ..................... 82

mation ................................................ 81

Maintenance Section

Lubricant Viscosities and Refill Capacities ........... 84

Maintenanc

Maintenance Interval Schedule ............................ 89

e Support ............................................ 88

Reference Information Section

Reference Materials ............................................ 137

Index Section

Index ................................................................... 14

0

Engine Startin g ..................................................... 22

Before Operation .................................................. 23

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

Operation .............................................................. 23

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

Slope Operation .................................................... 24

Engine Stopping ................................................... 25

Equipment Lowering with Engine Stopped ........... 25

Sound Information and Vibration Information ....... 25

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

Product Information Section

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

Identification Information ....................................... 32

Operation Section

Before Operation .................................................. 37

Machine Operation ............................................... 39

Engine Startin g ..................................................... 69

4 SEBU8213-04
Foreword

Foreword

Literature Information

This manual sh
compartment in the literature holder or seat back
literature storage area.

This manual contains safety information, operation
instructions, transportation information, lubrication
informatio

Some photographs or illustrations in this publication
show detail
from your machine. Guards and covers might have
been removed for illustrative purposes.

Continuing improvement and advancement of
product design might have caused changes to your
machine wh
Read, study and keep this manual with the machine.

Whenever
or this publication, please consult your Caterpillar
dealer for the latest available information.

Safety

ould be stored in the operator's

n and maintenance information.

s or attachments that can be different

ich are not included in this publication.

a question arises regarding your machine,

Maintenance

The maintenan
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specificservice
interval. Ite
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page
number for th
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source

Maintenance Intervals

Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, e
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service h
should always be performed at the interval that
occurs first.

Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specifie
be necessary.

d in the maintenance intervals chart might

ce section is a guide to equipment

ms without specific intervals are listed

e step-by-s tep instructions required to

" for all maintenance procedures.

tc.) can be used instead of service hour

our meter reading. Recommended service

The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warn

Read and understand the basic precautions listed
in the s
lubrication, maintenance and repair on this machine.

ing signs and labels used on the machine.

afety section before operating or performing

Operation

The op
operator and a refresher for the experienced
operator. This section includes a discussion of
gaug
controls, transportation and towing information.

Phot
through correct procedures of checking, starting,
operating and stopping the machine.

Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gai

eration section is a reference for the new

es, switches, machine controls, attachment

ographs and illustrations guide the operator

ns knowledge of the machine and its capabilities.

Perform
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under e
10 service hours or daily.

service on items at multiples of the original

very 250 service hours or monthly and every

California Proposition 65 Warning

l engine exhaust and some of its constituents

Diese
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.

Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands

r handling.

afte

ified Engine Maintenance

Cert

Proper maintenance and repair is essential to keep

engine and machine systems operating correctly.

the
As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required

ntenance listed in the Owner Manual, Operation

mai
and Maintenance Manual, and Service Manual.

SEBU8213-04 5

Foreword

It is prohibite
business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or
render inoper
element of design installed on or in an engine or
machine that is in compliance with the regulations
(40 CFR Part 8
and engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may b
altered unless approved by Caterpillar.

d for any person engaged in the

ative any emission related device or

9). Certain elements of the machine

e emission related and should not be

Machine Capacity

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

attachments or modifications may exceed

and system certifications such as brakes,

Caterpillar Product Identification
Number

ve First Quarter 2001 the Caterpillar Product

Effecti
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment

cation, Caterpillar and other construction

identifi
equipment manufacturers are moving to comply
with the latest version of the product identification
number
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The
PIN pla
character PIN. The new format will look like the
following:

ing standard. Non-road machine PINs are

tes and frame marking will display the 17

3. Check Charac

4. Machine Indicator Section (MIS) or Product
Sequence Numb
previously referred to as the Serial Number.

Machines and
Quarter 2001 will maintain their 8 character PIN
format.

Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Serial Numb

ter (character 9)

er (characters 10-17). These were

generator sets produced before First

er (S/N).

Illustration 1

Where:

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

2. Machine Descriptor (characters 4-8)

g00751314

6 SEBU8213-04
Safety Section
Safety Messages

Safety Section

i03193580

Safety Me ssage s

SMCS Code: 7000; 7405

Illustration 2

g01357030

SEBU8213-04 7

Safety Section

Safety Messages

Illustration 3

Illustration 4

1359794

g0

g01357376

There are several specific safety messages on this
machine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.

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

8 SEBU8213-04
Safety Section
Safety Messages

Replace any saf
missing. If a safety message is attached to a part of
the machine that is replaced, install a safety message
on the replace
provide new safety messages.

ety message that is damaged or

ment part. Any Caterpillar dealer can

Do Not Operate (1)

Safety Messa
side of the cab post in view of the operator.

ge (1) is positioned on the right hand

g01030982

Seat Belt (2)

Safety Message (2) is positioned on the left hand
side of the cab post in view of the operator.

g01371636

Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or heed
the warnings could result in injury or death. Con­tact any Caterpillar dealer for replacement manu­als. Proper care is your responsibility.

Aseatb
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failu
tion may result in serious injury or death.

eltshouldbewornatalltimesduringma-

re to wear a seat belt during machine opera-

SEBU8213-04 9

Safety Section

Safety Messages

DoNotWeldOntheROPS(3)

Safety Message (3) is positioned on the left rear side
of the cab post.

g01398698

Structural damage, an overturn, modification, al­teration, or improper repair, can impair this struc­ture's protective capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter­mine this structure's limitations without voiding
its certification.

Product L ink (4) (if equipped)

Safety message (4) is located in the left side of the
cab on the front support.

g01108685

This machine is equipped with a Caterpillar Pr od­uct Link communication device which must be de­activated within 12 m (40 ft) of a blast zone. Failure
to do so could result in serious injury or death.

Refer to Special Instruction, REHS1642, “Operation
of the Product Link System” for additional information.

This machine has been certified to the standards that
arelistedonthecertification plate. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification plate.

No Ether in Air Inlet (5)

Safety Message (5) is located on the left side of the
engine on the air cleaner cover. Only use the ether
starting aid group that is factory installed for safety.

g01055438

Do not use ether. This machine is equipped with

low plugs. Using ether can create explosions or

g
fires that can cause personal injury or death. Read
and follow the engine starting procedure in the
Operation and Maintenance Manual.

10 SEBU8213-04
Safety Section
Safety Messages

High Pressure Fuel Lines (6)

Safety Message (6) is located on the left side of the
engine on the high pressure fuel rail.

g01381180

Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low these inspection, maintenance and service in­structions may cause personal injury or death.

Hot Fluid Under Pressure (8)

Safety Message (8) is located under the access door
on the expansion tank filler cap.

g01370913

Pressurized system: Hot coolant can cause seri­ous burn. To open cap, stop engine, wait until ra­diator is cool. Then loosen cap slowly to relieve
the pressure.

High Pressure Cylinder (7)

Safety Message (7) is located on the track adjuster
cover that is on the outside of the track roller frame.

g01357122

High Pressure Cylinder. Do not remove any parts

rom the cylinder until all of the pressure has been

f
relieved. This will prevent possible personal injury
or death.

SEBU8213-04 11

Safety Section

Safety Messages

Improper Connections for Jump
Start Cables (9)

Safety Message (9) is located on the right access
door outside the operator station.

g01055411

Explosion Hazard! Improper jumper cable connec­tions can cause an explosion resulting in serious
injury or death. Batteries may be located in sep­arate compartments. Refer to the Operation and
Maintenance Manual for the correct jump starting
procedure.

Do Not Operate (10) (Winch)

Safety message (10) is located on the right side of
the machine on the vertical wall of the winch frame.

g01055734

Do not operate or work on this equipment unless
you have read and understand the instructions
andwarningsintheOperationandMaintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con­tact any Caterpillar dealer for replacement manu­als. Proper care is your responsibility.

Refer to Operation and Maintenance Manual, “Engine
StaringwithJumpStartCables”.

Laser

If your machine is equipped with the AccuGrade ­Laser System, this safety message is located on
each leg of the tripod for the laser.

g01282876

Movement of the transmitter could cause unex-

ected blade movement. Death or serious injury

p
could occur. Turn off the transmitter before you
move the transmitter or before you adjust the
transmitter.

12 SEBU8213-04
Safety Section
Additional Messages

Blade and Mast

When you use th

e AccuGrade - Laser System, this
safety message is located on the rear of each mast
at eye level from the ground.

g01282878

To prevent poss ible personal injury during instal­lation and removal of the laser receivers, lower the
mast to the minimum height and use an approved
access system to reach the mounting locations of
the laser receivers at the top of the mast. Do not
climb on the blade.

i02798976

Additional Messages

SMCS Code: 7000; 7405

Illustration 6

g01398723

There are several specific messages on this machine.
The location of the messages and the description of
the messages are reviewed in this section. Please
become familiarized with all messages.

Make sure that all of the messages are legible.
Clean the messages or replace the messages if
you cannot read the words. Replace the illustrations
if the illustrations are not legible. When you clean
the messages, use a cloth, water and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.

Illustration 5

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

“Gauge Display” (1)

This message is located on the inside door of the
cab glove box.

g01398718

SEBU8213-04 13

Safety Section

Additional Messages

Illustration 7

Compact Instrument Cluster Film

g01261266

No Step (2)

This message is located on the cover for the angle
cylinders (if equipped).

Air Conditione

r (4) (If equipped)

This message is located behind the air conditioner
compressor on

Illustration 10

the right side of the engine.

g01399514

This message for the air conditioner has the
appropriate information for the following services: the
air conditioner lubricant, the refrigerant charge, and
the refrigerant capacity.

Battery (5)

Illustration 8

g0090

Do not step on the angle cylinders. Follow this
instruction in order to perform work safely.

Radio (3)

s message is located on the cover for the radio.

Thi

Illustration 9

g00907584

6093

This message is located on the inside of the access
door for the battery.

Illustration 11

g01399516

NOTICE
Radio must be fastened securely to prevent falling out
during rough machine operation or overturn. Radio
mounting to DIN sleeve or bracket(s) must withstand
270 N (60 lb) minimum pulling force to resist shock
loads.

14 SEBU8213-04
Safety Section
Additional Messages

NOTICE
When starting

from another machine, make sure that
the machines do not touch. This could prevent dam­age to engine bearings and electrical circuits.

Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components o

n the stalled machine.

Severely discharged maintenance free batteries do
not fully re

charge from the alternator after jump start­ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable ar

e still rechargeable.

This machine has a 12 volt starting system. Use only
thesamevo

ltage for jump starting. Use of a higher

voltage damages the electrical system.

Lubricat

ion Chart (6)

This message is located on the right side of the
machine

behind the lower access door.

Illustration 12

Batteries in Parallel Configuration (7)

This message is located on the inside of the access
door for the battery. The machine uses two 12V
batteries in a parallel arrangement. See the Service
Manual for proper instructions.

g01398836

SEBU8213-04 15

Safety Section

General Hazard Information

i03559343

General Hazard Information

SMCS Code: 7000

Illustration 13

g01274048

NOTICE
Use only 12 volts to start the engine. Damage to the
engine may occur if more than 12 volts are used to
start the

engine.

Machine Security System (8)

If equipped, this message is located on the dash
under the indicator lamps.

Illustration 15

g00104545

Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment. These warning tags (Special
Instruction, SEHS7332) are available from your
Caterpillar dealer.

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

Be aware of high voltage power lines and power
cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.

stration 14

Illu

g00951606

This machine is equipped with a security system.

d the Operation and Maintenance Manual before

Rea
you operate the machine.

erence: See Operation and Maintenance Manual,

Ref

“Maintenance Interval Schedule” for all maintenance
recommendations.

Illustration 16

ar a hard hat, protective glasses, and other

We

g00702020

protective equipment, as required.

o not wear loose clothing or jewelry that can snag

D
on controls or on other parts of the equipment.

ake sure that all protective guards and all covers

M
are secured in place on the equipment.

16 SEBU8213-04
Safety Section
General Hazard Information

Keep the equipm
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.

Know the appropriate work site hand signals and
the personnel that are authorized to give the hand
signals. Ac

Do not smoke when you service an air conditioner.
Also, do not
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily
harm or dea
refrigerant through a lighted cigarette can cause
bodily harm or death.

Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cl
necessary repairs.

eaning solutions with care. Report all

ent free from foreign material.

cept hand signals from one person only.

smoke if refrigerant gas may be present.

th. Inhaling gas from air conditioner

Trapped Pressure

Pressure can b
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you
High pressure oil that is released can cause a hose to
whip. High pressure oil that is released can cause oil
to spray. Flu
and possible death.

e trapped in a hydraulic system.

disconnect hydraulic lines or fittings.

id penetration can cause serious injury

Fluid Penetration

Pressure ca
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rap

Do not remove any hydraulic components or parts
until pres
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or person
Manual for any procedures that are required to
relieve the hydraulic pressure.

n be trapped in the hydraulic circuit long

idly if the pressure is not relieved correctly.

sure has been relieved or personal injury

al injury may occur. Refer to the Service

Do not al
equipment.

Unless y
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance Manual
for the
servicing position.

When y
use appropriate devices such as ladders or man lift
machines. If equipped, use the machine anchorage
point
lanyards.

low unauthorized personnel on the

ou are instructed otherwise, perform

procedure for placing the equipment in the

ou perform maintenance above ground level

s and use approved fall arrest harnesses and

Pressurized Air and Water

surized air and/or water can cause debris

Pres
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

es, and eye protection. Eye protection includes

sho
goggles or a protective face shield.

e maximum air pressure for cleaning purposes

Th
must be reduced to 205 kPa (30 psi) when the
nozzle is deadheaded and the nozzle is used with

effective chip deflector and personal protective

an
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).

Illustration 17

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

g00687600

Containing Fluid Spillage

Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for the following items:

SEBU8213-04 17

Safety Section

Crushing Prevention and Cutting Prevention

Tools that are s

•

equipment that is suitable for collecting fluids

Tools that are

•

equipment that is suitable for containing fluids

Obey all loca

Asbestos Inf

Illustration 18

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.

uitable for collecting fluids and

suitable for containing fluids and

l regulations for the disposal of liquids.

ormation

g00702022

Use exhaust ven

•

jobs.

Wear an approv

•

way to control the dust.

Comply with a

•

for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requ
can be found in “29 CFR 1910.1001”.

Obey enviro

•

of asbestos.

Stay away f

•

particles in the air.

tilation on permanent machining

ed respirator if there is no other

pplicable rules and regulations

irements. These OSHA requirements

nmental regulations for the disposal

rom areas that might have asbestos

Dispose of Waste Properly

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. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
boundinaresinorsealedinsomeway.Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.

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

Never use compressed air for cleaning.

•

Avoid brushing materials that contain asbestos.

•

Avoid grinding materials that contain asbestos.

•

Useawetmethodinordertocleanupasbestos

•

materials.

A vacuum cleaner that is equipped with a high

•

efficiency particulate air filter (HEPA) can also be
used.

Illustration 19

Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.

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

g00706404

i01359664

Crushing Prevention and
Cutting Prevention

SMCS Code: 7000

pport the equipment properly before you perform

Su
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold

p the equipment. Equipment can fall if a control is

u
moved, or if a hydraulic line breaks.

o not work beneath the cab of the machine unless

D
the cab is properly supported.

18 SEBU8213-04
Safety Section
Burn Prevention

Unless you are i
adjustments while the machine is moving or while
the engine is running.

Never jump across the starter solenoid terminals
in order to start the engine. Unexpected machine
movement cou

Whenever there are equipment control linkages the
clearance i
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance w
movement.

Stay clear

If it is necessary to remove guards in order to perform
maintenan
maintenance is performed.

Keep obje
blade will throw objects or cut objects.

Do not use
Wear gloves when you handle wire cable.

nstructed otherwise, never attempt

ld result.

n the linkage area will change with the

ith machine movement or equipment

of all rotating and moving parts.

ce, always install the guards after the

cts away from moving fan blades. The fan

a kinked wire cable or a frayed wire cable.

Check the coola
been stopped.

Ensure that th
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to reli

Cooling system conditioner contains alkali. Alkali can
cause perso
the skin, the eyes, or the mouth.

nt level only after the engine has

e filler cap is cool before removing the

eve pressure.

nal injury. Do not allow alkali to contact

Oils

Hot oil and h
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.

Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be
cool enou
standard procedure in this manual in order to remove
the hydraulic tank filler cap.

ot components can cause personal

gh to touch with a bare hand. Follow the

Batteries

When you
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you
your eyes, wear protective glasses when you strike
a retainer pin.

Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injur

strike a retainer pin with force, the retainer

strikearetainerpin.Toavoidinjuryto

ed by flying debris before striking any object.

i01329099

Burn Prevention

SMCS Code: 7000

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

Coolant

Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.

. Always wear protective glasses for servicing

i03659986

Fire Prevention and Explosion
Prevention

SMCS Code: 7000

When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.

0704000

Illustration 20

g0

General

All fuels, most lubricants, and some coolant mixtures
are flammable.

SEBU8213-04 19

Safety Section

Fire Prevention and Explosion Prevention

To m in i m iz e t h e

risk of fire or explosion, Caterpillar

recommends the following actions.

Always perfor

m 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 m

achine. Refer to Operation and

Maintenance Manual, “Alternative Exit”.

Do not opera

te 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 o

r onto electrical components can cause a

fire. A fire may cause personal injury or death.

Remove flam

mable material such as leaves, twigs,
papers, trash, etc. These items may accumulate in
the engine compartment or around other hot areas
and hot pa

rts on the machine.

Keep the access doors to major machine
compartm

ents closed and access doors in working
conditioninordertopermittheuseoffire suppression
equipment, in case a fire should occur.

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

Do not operate the machine near any flame.

Keep sh

ields in place. Exhaust shields (if equipped)
protect hot exhaust components from oil spray or fuel
spray in case of a break in a line, in a hose, or in a

Exhaust shields must be installed correctly.

seal.

Do not weld or flame cut on tanks or lines that contain
flamma

ble fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding

me cutting. Ensure that the components are

or fla
properly grounded in order to avoid unwanted arcs.

Store fuels and

lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
containers. D
storing

Illustration 21

onotsmokeinareasthatareusedfor

flammable materials.

g00704059

Usecautionwhenyouarefuelingamachine.Donot
smoke while you are fueling a machine. Do not fuel
a machine near open flames or sparks. Always stop
the engine before fueling. Fill the fuel tank outdoors.
Properly clean areas of spillage.

Follow practices for safe fueling that are described
in the “Operation” section of the Operation and
Maintenance Manual section and follow local
regulations. Never store flammable fluids in the
operator compartment of the machine.

that is generated from repairing nonmetallic

Dust
hoods or fenders may be flammable and/or explosive.
Repair such components in a well ventilated area

yfromopenflames or sparks. Use suitable

awa
Personal Protection Equipment (PPE).

pect all lines and hoses for wear or deterioration.

Ins
Replace damaged lines and hoses. The lines and
the hoses should have adequate support and secure

amps. Tighten all connections to the recommended

cl
torque. Damage to the protective cover or insulation
may provide fuel for fires.

20 SEBU8213-04
Safety Section
Fire Prevention and Explosion Prevention

Battery and Battery Cables

Illustration 22

Caterpillar recommends the following in order to
minimize the risk of fire or an explosion related to
the battery.

g00704135

Discoloration

•

Cuts on the insulation of the cable

•

Fouling

•

Corroded ter

•

terminals

Replace dam
any related parts. Eliminate any fouling, which may
have caused insulation failure or related component
damage or we
reinstalled correctly.

An exposed
a short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short prod
may be a fire hazard.

An expose
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes int
may result in an unsafe condition for servicing the
machine. Repair components or replace components
before s

minals, damaged terminals, and loose

aged battery cable(s) and replace

ar. Ensure that all components are

wire on the battery cable may cause

uces heat from the battery current, which

d wire on the ground cable between the

o contact with a grounded surface. This

ervicing the machine.

Do not operate a machine if battery cables or related
parts show signs of wear or damage. Contact your
Caterpillar dealer for service.

Follow safe procedures for engine starting with jump
start cables. Improper jumper cable connections can
cause an explosion that may result in injury. Refer to
Operation and Maintenance Manual, “Engine Starting
with Jump Start Cables” for specific instructions.

Do not charge a frozen battery. This may cause an
explosion.

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.

Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in
order to check the battery charge.

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

Fire on a machine can result in personal injury
or death. Exposed battery cables that come into
contac
fires. Replace cables and related parts that show
signs of wear or damage. Contact your Caterpillar
deale

Wiri

Check electrical wires daily. If any of the following
cond
the machine.

•

•

•

•

•

t with a grounded connection can result in

r.

ng

itions exist, replace parts before you operate

ing

Fray

Signs of abrasion or wear

Cracking

scoloration

Di

Cuts on insulation

Fraying

•

Abrasion

•

Cracking

•

Other damage

•

ke sure that all clamps, guards, clips, and straps

Ma
are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive

eat during machine operation.

h

SEBU8213-04 21

Safety Section

Fire Prevention and Explosion Prevention

Attaching elec
contain flammable fluids or combustible fluids should
be avoided.

Consult your Caterpillar dealer for repair or for
replacement parts.

Keep wiring and electrical connections free of debris.

trical wiring to hoses and tubes that

Lines, Tubes and Hoses

Do not bend h
pressure lines. Do not install any lines that are bent or
damaged. Use the appropriate backup wrenches in
order to tig
torque.

igh pressure lines. Do not strike high

hten all connections to the recommended

Make sure that a
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, excess
hoses.

Do not operat
exists. Repair any lines that are corroded, loose
or damaged. Leaks may provide fuel for fires.
Consult you
replacement parts. Use genuine Caterpillar parts or
the equivalent, for capabilities of both the pressure
limit and te

ll clamps, guards, and heat shields

ive heat, and failure of lines, tubes and

eamachinewhenafire hazard

r Caterpillar dealer for repair or for

mperature limit.

Ether

Ether (if equipped) is commonly used in cold weather
applicati

Follow the correct cold engine starting procedures.
Refer to t
Manual with the label “Engine Starting”.

Do not spr
machine is equipped with a thermal starting aid for
cold weather starting.

ons. Ether is flammable and poisonous.

he section in the Operation and Maintenance

ay ether manually into an engine if the

600

Illustration 23

Check lines, tubes and hoses carefully. Wear
Personal Protection Equipment (PPE) in order to

for leaks. Always use a board or cardboard

check
when you check for a leak. Leaking fluid that is under
pressure can penetrate body tissue. Fluid penetration

ause serious injury and possible death. A pin

can c
hole leak can cause severe injury. If fluid is injected
into your skin, you must get treatment immediately.

treatment from a doctor that is familiar with this

Seek
type of injury.

lace the affected parts if any of the following

Rep
conditions are present:

fittings are damaged or leaking.

End

•

Outer coverings are chafed or cut.

•

Wires are exposed.

•

ter coverings are swelling or ballooning.

Ou

•

Flexible parts of the hoses are kinked.

•

g00687

Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while you
are usin

Do not store ether cylinders in living areas or in the
operat
ether cylinders in direct sunlight or in temperatures
above 49° C (120.2° F). Keep ether cylinders away
from o

Dispose of used ether cylinders properly. Do not
punct
away from unauthorized personnel.

ganetherspray.

or compartment of a machine. Do not store

pen flames or sparks.

ure an ether cylinder. Keep ether cylinders

Fire Extinguisher

additional safety measure, keep a fire

As an
extinguisher on the machine.

miliar with the operation of the fire extinguisher.

Be fa
Inspect the fire extinguisher and service the fire
extinguisher regularly. Follow the recommendations

he instruction plate.

on t

Consider installation of an aftermarket Fire

pression System, if the application and working

Sup
conditions warrant the installation.

Outer covers have exposed embedded armoring.

•

nd fittings are displaced.

E

•

22 SEBU8213-04
Safety Section
Fire Extinguisher Location

i01834364

Fire Extinguisher Location

SMCS Code: 7000; 7419

Make sure that
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguishe
instruction plate.

Mount the fir
per local regulations.

Do not weld
fire extinguisher. Also, do not drill holes in the ROPS
structure in order to mount the fire extinguisher on
the ROPS.

StrapthemountingplatetoalegoftheROPSin
order to m
theweightofthefire extinguisher exceeds 4.5 kg
(10 lb), mount the fire extinguisher near the bottom of
the ROPS.
upper one-third area of the ROPS.

Consult
procedure for mounting the fire extinguisher.

your Caterpillar dealer for the proper

a fire extinguisher is available. Be

r. Obey the recommendations on the

e extinguisher in the accepted location

the ROPS structure in order to install the

ount the fire extinguisher, as needed. If

Do not mount the fire extinguisher at the

i01329108

Track Info rmation

SMCS Code: 4170; 7000

Track adjusting systems use either grease or oil
under high pressure to keep the track under tension.

Grease or oil under high pressure coming out of the
relief valve can penetrate the body causing injury or
death. Do not watch the relief valve to see if grease
or oil is escaping. Watch the track or track adjustment
cylinder to see if the track is being loosened.

Mount the machi

•

Dismount the machine.

•

If you are in the operator's station during an electrical
storm, stay in the operator's station. If you are on the
ground durin
the vicinity of the machine.

ne.

g an electrical storm, stay away from

i01896223

Before Starting Engine

SMCS Code: 1000; 7000

Start the engine only from the operator's
compartment. Do not short across the battery
terminals and do not short across the batteries.
Bypassing the engine neutral start system can
damage the electrical system.

Inspect the condition of the seat belt and mounting
hardware. Replace any damaged parts or worn parts.
Regardless of appearance, replace the seat belt after
three years of use. Do not use an extension for a
seat belt on a retractable seat belt.

Adjust the seat so that full pedal travel can be
achieved. Make sure that the operator's back is
against the back of the seat.

Make sure that the machine is equipped with a
lighting system that is adequate for the job conditions.
Make sure that a ll lights are working properly. Before
you start the engine or before you move the machine,
make sure that no one is working on the machine,
working underneath the machine or working close
to the machine. Make sure that the area is free of
personnel.

i03721411

Engine Starting

The pins and bushings in a dry track pin joint
can become very hot. It is possible to burn the
fingers if there is more than brief contact with these
components.

i01122596

Electrical Storm Injury
Prevention

SMCS Code: 7000

When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:

SMCS Code: 1000; 7000

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

Move all hydraulic controls to the HOLD position
before you start the engine.

Engage the parking brake switch.

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

SEBU8213-04 23

Safety Section

Before Operation

Check for the pr
personnel. Ensure that all personnel are clear of the
machine.

Briefly sound the horn before you start the engine.

esence of bystanders or maintenance

i01963896

Before Operation

SMCS Code: 7000

Clear all personnel from the machine and from the
area.

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

Be sure that all windows are clean. Secure the doors
and the windows in either the open position or the
shut position.

Adjust the rearview mirrors (if equipped) for best
vision close to the machine. Make sure that the
machine horn, the backup alarm (if equipped) and all
other warning devices are working properly.

Reference: Refer to Operation and Maintenance
Manual, “Daily Inspection” in this manual.

Fasten the seat belt securely.

It may not be pos
large machines to all areas around the machine.
Appropriate job site organization is required in order
to minimize ha
visibility. Job site organization is a collection of rules
and procedures that coordinates machines and
people that w
of job site organization include the following:

Safety inst

•

Controlled patterns of machine movement and

•

vehicle mov

Workers that direct traffic to move when it is safe

•

Restricted areas

•

Operator t

•

Warning symbols or warning signs on machines

•

or on vehi

A system of communication

•

Communication between workers and operators

•

prior to approaching the machine

Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
evaluat

ed.

sible to provide direct visibility on

zards that are caused by restricted

ork together in the same area. Examples

ructions

ement

raining

cles

i03162317

Visibility Informat ion

SMCS

Before you start the machine, perform a walk-around
insp
hazards around the machine.

Whi
the area around the machine in order to identify
potential hazards as hazards become visible around
the

Your machine may be equipped with visual aids.
So
Television (CCTV) and mirrors. Before operating the
machine, ensure that the visual aids are in proper
wo
Adjust the visual aids using the procedures that are
located in this Operation and Maintenance Manual.
I
adjusted according to Operation and Maintenance
Manual, SEBU8157, “Work Area Vision System”.

Code: 7000

ection in order to ensure that there are no

le the machine is in operation, constantly survey

machine.

me examples of visual aids are Closed Circuit

rking condition and that the visual aids are clean.

f equipped, the Work Area Vision System shall be

i03721461

Operat

SMCS Code: 7000

ion

Machine Operating Temperature
Range

tandard machine configuration is intended

The s
for use within an ambient temperature range
of −40 °C (−40°F)to50°C(122°F).Special

gurations for different ambient temperatures

confi
may be available. Consult your Caterpillar dealer for
additional information on special configurations of

r machine.

you

ration

Ope

Only operate the machine while you are in a seat.

e seat belt must be fastened while you operate the

Th
machine. Only operate the controls while the engine
is running.

Check for proper operation of all controls and
protective devices while you operate the machine

lowly in an open area.

s

24 SEBU8213-04
Safety Section
Parking

Before you move
one will be endangered.

Do not allow ri
machine has the following equipment:

additional s

•

additional seat belt

•

Rollover Protective Structure (ROPS)

•

Never use th

Note any needed repairs during machine operation.
Report any

Carry attachments close to the ground, approximately
40 cm (15 in
go close to the edge of a cliff, an excavation, or an
overhang.

If the machine begins to sideslip, perform the
following procedure:

Discard the load.

•

Turn the

•

the machine, make sure that no

ders on the machine unless the

eat

e work tool for a work platform.

needed repairs.

ches) higher than ground level. Do not

machine downhill.

Apply the servi
The service brake is applied by fully depressing the
decel/brake pedal. Move the transmission control to
NEUTRAL posit
IDLE position. Engage the parking brake switch.

Lower all att

Stop the engine.

Turn the engine start switch key to OFF position and
remove the key.

Turn the key for the battery disconnect switch to the
OFF position. Remove the key when you exit the
machine fo

Turning the battery disconnect switch to the OFF
position w

Prevent battery discharge that is caused by a

•

battery s

Prevent battery discharge that is caused by some

•

of the com

Prevent battery discharge that is caused by

•

vandali

ce brake in order to stop the machine.

ion and the speed control to LOW

achments to the ground.

r an extended period of time.

ill provide the following benefits:

hort circuit.

ponents.

sm.

Be careful to avoid any condition which could lead

ng. Tipping can occur when you work on

to tippi
hills, banks and slopes. Also, tipping can occur
when you cross ditches, ridges or other unexpected

ctions.

obstru

Whenever it is possible, operate the machine up the

s and down the slopes. Avoid operating the

slope
machine across the slope, when possible.

he machine under control. Do not overload the

Keep t
machine beyond capacity.

re that the towing devices are adequate.

Be su

Never straddle a wire cable or allow other personnel

raddle a wire cable.

to st

Know the maximum dimensions of your machine.

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

i02801025

Parking

SMCS Code: 7000

i02780235

Slope O

SMCS Code: 7000

Machines that are operating safely in various
applications depend on these criteria: the machine

,configuration, machine maintenance,

model
operating speed of the machine, conditions of the
terrain, fluid levels, and tire inflation pressures. The

mportant criteria are the skill and judgment of

most i
the operator.

l trained operator that follows the instructions

Awel
in the Operation and Maintenance Manual has
the greatest impact on stability. Operator training

ides a person with the following abilities:

prov
observation of working and environmental conditions,
feel for the machine, identification of potential

ards, and operating the machine safely by making

haz
appropriate decisions.

n you work on side hills and when you work on

Whe
slopes, consider the following important points:

eed of travel – At higher speeds, forces of inertia

Sp

tend to make the machine less stable.

peration

Park on a level surface. If you must park on a grade,
use blocks to prevent the machine from rolling.

ughness of terrain or surface – The machine

Ro

maybelessstablewithuneventerrain.

SEBU8213-04 25

Safety Section

Engine Stopping

Direction of tr

across the slope. When possible, operate the
machine up the slopes and operate the machine
down the slope
machine uphill when you are working on an incline.

Mounted equi

may be impeded by the following components:
equipment that is mounted on the machine, machine
configurati

Nature of surface – Ground that has been newly
filled with e
machine.

Surface ma

surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
promote si

Slippage due to excessive loads – This may cause
downhill
which will increase the angle of the machine.

Width of t

narrower tires further increase the digging into the
ground which causes the machine to be less stable.

Implements attached to the drawbar – This may
decrease the weight on the uphill tracks. This may
also dec
decreased weight will cause the machine to be less
stable.

Height of the working load of the machine –

When the working loads are in higher positions, the

lity of the machine is reduced.

stabi

avel – Avoid operating the machine

s. Place the heaviest end of the

pment – Balance of the machine

on, weights, and counterweights.

arth may collapse from the weight of the

terial – Rocks and moisture of the

de slipping of the machine.

tracks or downhill tires to dig into the ground,

racks or tires – Narrower tracks or

rease the weight on the uphill tires. The

i02801029

Engine Stopping

SMCS Code: 1000; 7000

Do not stop the
machine has been operated under load. This can
cause overheating and accelerated wear of engine
components.

After the machine is parked and the parking brake is
engaged, al
LOW IDLE before shutdown. This allows hot areas of
the engine to cool gradually.

engine immediately after the

low the engine to run for five minutes at

i01329161

Equipment Lowering with
Engine St op ped

SMCS Code: 7000

Before lowering any equipment with the engine
stopped, clear the area around the equipment of
all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind
most systems use a high pressure fluid or air to
raise or lower equipment. The procedure will cause
high pressure air , hydraulic, or some other media
to be released in order to lower the equipment.
Wear appropriate personal protective equipment and
follow the established procedure in the Operation
and Maintenance Manual, “Equipment Lowering with
Engine Stopped” in the Operation Section of the
manual.

Operated equipment – Be aware of performance

res of the equipment in operation and the effects

featu
on machine stability.

ating techniques – Keep all attachments or

Oper

pulled loads low to the ground for optimum stability.

ine systems have limitations on slopes –

Mach

Slopes can affect the proper function and operation
of the various machine systems. These machine

tems are needed for machine control on slopes.

sys

Note: Safe operation on steep slopes may require

cial machine maintenance. Excellent skill of

spe
the operator and proper equipment for specific
applications are also required. Consult the Operation

d Maintenance Manual sections for the proper fluid

an
level requirements and intended machine use.

i03739322

Sound Information and
Vibration Informa tion

SMCS Code: 7000

Sound Level I nformation

The measurement for operator sound pressure
level Leq was obtained with the procedures that
are specified in “ANSI/SAE J1166 FEB2008”. The
procedure specifies the requirements of the work
cycle to use while the measurement is obtained. The
operator sound pressure level is 80 dB(A) for the cab
that is offered by Caterpillar. This reading is correct
under the following conditions: proper installation of
the cab, proper maintenance of the cab, closed cab
doors, and closed cab windows.

26 SEBU8213-04
Safety Section
Sound Information and Vibration Information

Hearing protec
machineisoperatedwithanopenoperatorstationfor
extended periods or in a noisy environment. Hearing
protection ma
operated with a cab that is not properly maintained, or
when the doors and windows are open for extended
periods or in

The exterior sound pressure level for the standard
machine is 7
with the test procedures that are specified in “SAE
J88 FEB2006”. The measurement was obtained
under the fo
(49.2 ft), machine in middle speed range, and moving.

tion may be needed when the

y be needed when the machine is

a noisy environment.

8dB(A). This measurement was obtained

llowing conditions: distance of 15 m

Sound Performance for Machines
that are Of

feredinEuropeanUnion
Countries and in Countries with the
“EU Directives”

The infor
configurations that only have the “CE mark” on the
product information plate (PIN).

Machines with Standard Cab

The dyna
dB(A) when “ISO 6396: 2008” is used to measure
the value for an enclosed cab. The cab was properly
instal
with the cab doors and the cab windows closed.

mation below applies to machine

mic operator sound pressure level is 79

led and maintained. The test was conducted

Information Co
Level

This section p
estimating the vibration level for track-type tractors.

Note: Vibrat
different parameters. Many items are listed below.

Operator tr

•

Job site organization, preparation, environment,

•

weather, an

Machine type, quality of the seat, quality of the

•

suspensio
the equipment

It is not po
this machine. The expected vibration levels can be
estimatedwiththeinformationinTable1inorder
to calcul
evaluation of the machine application can be used.

Estimate
directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an exper
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggress
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.

ate the daily vibration exposure. A simple

ienced operator and smooth terrain, subtract

ive operations and severe terrain, add the

ncerning Whole Body Vibration

rovides vibration data and a method for

ion levels are influenced by many

aining, behavior, mode, and stress

dmaterial

n system, attachments, and condition of

ssible to get precise vibration levels for

the vibration levels for the three vibration

Machin

The dynamic operator sound pressure level is 80
dB(A)
the value for an enclosed cab. The cab was properly
installed and maintained. The test was conducted
with t

“The

es with Logging Cab

when “ISO 6396: 2008” is used to measure

he cab doors and the cab windows closed.

European Union Physical
Agents (Vibration) D irective
2002/44/EC”

ration Data for Track-Type Tractors

Vib

Information Concerning Hand/Arm Vibration

el

Lev

When the machine is operated according to the

tended use, the hand/arm vibration of this machine

in
is below 2.5 meter per second squared.

Note: All vibration levels are in meter per second
squared.

SEBU8213-04 27

Safety Section

Sound Information and Vibration Information

Table 1

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

Machine

Type

Track-Type

Tractors

Typical Operating

Activity

dozing 0,74 0,58 0,70 0,31 0,25 0,31

ripping 1,25 1,19 1,02 0,40 0,41 0,28

transfer 0,87 0,80 0,97 0,43 0,40 0,34

X axis Y axis Z axis X axis Y axis Z axis

Vibration Levels Scenario Factors

Note: Refer to “ISO/TR 25398 Mechanical Vibration -

Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving
machines” for more information about vibration.
This publication uses data that is measured
by international institutes, organizations and
manufacturers. This document provides information
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and
Maintenance Manual Supplement , SEBU8257 for
more information about machine vibration levels.

The Caterpillar suspension seat meets the criteria of
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. This seat is tested
with the input “spectral class EM6”. The seat has a
transmissibility factor of “SEAT<0.7”.

The whole body vibration level of the machine varies.
There is a range of values. The low value is 0.5
meter per second squared. The machine meets the
short term level for the design of the seat in “ISO
7096”. The value is 1.61 meter per second squared
for this machine.

Guidelines for Reducing Vibration Levels on
Earthmoving Equipment

Properly adjust machines. Properly maintain
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level:

1. Use the right type and size of machine, equipment,

and attachments.

2. Maintain machines according to the manufacturer's

recommendations.

a. Tire pressures

c. Provide machines and schedule time in order

to maintain the conditions of the terrain.

4. Use a seat that meets “ISO 7096”. Keep the seat
maintained and adjusted.

a. Adjust the seat and suspension for the weight

and the size of the operator.

b. Inspect and maintain the seat suspension and

adjustment mechanisms.

5. Perform the following operations smoothly.

a. Steer

b. Brake

c. Accelerate.

d. Shift the gears.

6. Move the attachments smoothly.

7. Adjust the machine speed and the route in order

to minimize the vibration level.

a. Drive around obstacles and rough terrain.

b. Slow down when it is necessary to go over

rough terrain.

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

a. Use machines that are equipped with

suspension systems.

b. Use the ride control system on Track-Type

Tractors.

b. Brake and steering systems

c. Controls, hydraulic system and linkages

3. Keep the terrain in good condition.

a. Remove any large rocks or obstacles.

b. Fill any ditches and holes.

c. If no ride control system is available, reduce

speed in order to prevent bounce.

d. Haul the machines between workplaces.

9. Less operator comfort may be caused by other risk

factors. The following guidelines can be effective
in order to provide better operator comfort:

28 SEBU8213-04
Safety Section
Guards

a. Adjust the seat

to achieve good posture.

b. Adjust the mir

posture.

c. Provide brea

of sitting.

d. Avoid jumpi

e. Minimize repeated handling of loads and lifting

of loads.

f. Minimize any shocks and impacts during sports

and leisur

and adjust the controls in order

rors in order to minimize twisted

ks in order to reduce long periods

ng from the cab.

e activities.

Sources

The vibration information and the calculation
procedur
Vibration - Guideline for the assessment of exposure
towholebodyvibrationofrideonoperated
earthmov
measured by international institutes, organizations
and manufacturers.

This literature provides information about assessing
the whole body vibration exposure of operators of
earthmo
measured vibration emission under real working
conditions for all machines.

You should check the original directive. This
document summarizes part of the content of the
appli
substitute the original sources. Other parts of these
documents are based on information from the United
Kingd

Refer to Operation and Maintenance Manual
Supp
vibration.

e is based on “ISO/TR 25398 Mechanical

ing machines”. Harmonized data is

ving equipment. The method is based on

cable law. This document is not meant to

om Health and Safety Executive.

lement , SEBU8257 for more information about

Cab I nternal Clearance

If a machine is equipped with a cab, the position of
the operator conforms to industry standards. These
standards are “SAE J154” and “ISO 3411”. An item
should not protrude into the space of the cab. The
following items should not protrude into the cab.

Radio

•

Fire extinguisher

•

Lunch box

•

Objects in the cab should be secured. The objects
must remain in place during operations in rough
terrain. The objects must remain in place during a
rollover of the machine.

i03656846

Guards
(Operator Protection)

SMCS Code: 7000; 7150; 7150-MCH; 7325

There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.

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

The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are recommended for your
machine.

ult your local Caterpillar dealer for more

Cons
information about machine features that minimize
vibration levels. Consult your local Caterpillar dealer

ut safe machine operation.

abo

Use the following web site in order to find your local

ler:

dea

Caterpillar, Inc.

w.cat.com

ww

SEBU8213-04 29

Safety Section

Guards

Rollover Protective Structure
(ROPS), Falling Object Protective
Structure (FOPS) or Tip Over
Protection Structu re (TOPS)

The ROPS/FOPS Structure (if equipped) on your
machine is specifically designed, tested and
certified for that machine. Any alteration or any
modification to the ROPS/FOPS Structure could
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
StructurewillbeimpairediftheROPS/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.

Rock quarries

•

Forestry products

•

Additional guards may be required for specific
applications or work tools. The Operation and
Maintenance
work tool will provide specific requirements for the
guards. Consult your Caterpillar dealer for additional
informatio

Manual for your machine or your

n.

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 SEBU8213-04
Product Information Section
General Information

Product Information
Section

General Information

Specifications

SMCS Code: 1000; 6700; 7000; 7426

i03738887

Table 2

D3K HYSTAT TRACK-TYPE TRACTOR

Operating Weight (LGP)

Operating Weight (XL)

Operating W

eight (SLGP)

Length (LGP) (A)

(1)

8093 kg (17842 lb)

(1)

7795 kg (17185 lb)

(2)

8190kg(180

(3)

4255 mm (167.5 inch)

55 lb)

Length (XL) (A) 4266 mm (168 inch)

Length (SLGP) (A) 4255 mm (167.5 inch)

Width (LGP) (B) 2360 mm (92.9 inch)

Width (XL) (B) 1901 mm (74.8 inch)

Width (SLGP) (B) 2630 mm (103.5 inch)

Height to top of ROPS (C) 2763 mm (108.8 inch)

Blade width (LGP) (D) 3149 mm (124 inch)

Blade width (XL) (D) 2646 mm (104.2 inch)

Blade width (SLGP) (D) 3149 mm (124 inch)

(1)

The operating weight includes the ROPS canopy, the dozer

blade, the backup alarm, the lubricants, the coolant, a full fuel
tank, and the operator 75 kg (165 lb).

(2)

SLGP machine uses 760 mm (30 inch) track shoes.

(3)

Each length (A) includes the blade.

Illustration 24

Illustration 25

g01398729

g01256233

Table 3

D4K HYSTAT TRACK-TYPE TRACTOR

ating Weight (LGP)

Oper

Operating Weight (XL)

Length (LGP) (A)

(1)

(1)

(3)

kg (18741 lb)

8501

8147 kg (17961 lb)

4266 mm (168 inch)

Length (XL) (A) 4274 mm (168.3 inch)

Width (LGP) (B) 2360 mm (92.9 inch)

Width (XL) (B) 2010 mm (79.1 inch)

Height to top of ROPS (C) 2763 mm (108.8 inch)

Blade width (LGP) (D) 3149 mm (124 inch)

Blade width (XL) (D) 2782 mm (109.5 inch)

SEBU8213-04 31

Product Information Section

General Information

Table 4

D5K HYSTAT TRACK-TYPE TRACTOR

Operating Weight (LGP)

Operating Weight (XL)

Operating W

Length (LGP) (A)

Length (XL) (A) 4321 mm (170.1 inch)

Length (SLGP) (A) 4294 mm (169 inch)

Width (LGP) (B) 2410 mm (94.9 inch)

Width (XL) (B) 2110 mm (83.0 inch)

Width (SLGP) (B) 2410 mm (94.9 inch)

Height to top of ROPS (C) 2769 mm (109 inch)

Blade width (LGP) (D) 3220 mm (126.8 inch)

Blade width (XL) (D) 2782 m m (109.5 inch)

Blade width (SLGP) (D) 3220 mm (126.8 inch)

eight (SLGP)

(1)

9683 kg (21347 lb)

(1)

9408 kg (20741 lb)

(2)

9800 kg (216

(3)

4294 mm (169 inch)

05 lb)

Note: Add 235 kg (518 lb) to the operating weight for
machines with “EROPS”.

Special attach

ments and operating instructions are
required for Waste Handling applications and other
Custom configurations.

Intended Use

This Track-Type Tractor is an earthmoving
machine that is described by “ISO 6165:2001”. The
Track-Type Tractor is classified as a Tractor-dozer.
The tractor-dozer is a self-propelled crawler with
equipment such as a dozing attachment which cuts,
moves and grades material through forward motion
of the machine or a mounted attachment that is used
to exert a push or a pull force such as a ripper or
towing winch. Additional applications include pushing
scrapers during loading and pulling towed equipment
when the drawbar is used.

Application/Configuration Restrictions

Maximum approved Operating Weight is 13300 kg

•

(29321 lb).

Maximum drawbar pull (165 kN (37100 lb))

•

Maximum vertical drawbar load (43 kN (9650 lb))

•

The maximum fore and aft slope on this machine

•

in a static condition that maintains the proper
lubrication is a 100 percent grade or a 45 degree
slope.

The brake capacity (slope) of this machine is 45

•

degrees.

Do not use the machine in explosive environments.

•

32 SEBU8213-04
Product Information Section
Identification Information

Identification Information

i03739400

Plate Locations and Film
Locations

SMCS Code: 1000; 7000

Product Ide ntification Plates

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

Caterpillar products such as engines, transmissions
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers.

For quick reference, record the identification numbers
in the spaces that are provided below the illustration.

The plate for Ma

chine PIN (1) is located to the left
of the case on the rear of the machine. The second
plate for Machine PIN (1) is located on the left side of
the radiator g

Machine PIN (1)

Illustration 28

uard on the front of the machine.

___________________ ______________ ___________

g01400193

The Engine Serial Number Plate is located on the
left side of the cylinder block to the rear of the front
engine mounting.

Illustration 26

Illustration 27

g01621727

g01057083

stration 29

Illu

g01274351

Engine Serial Number _______ ____________________ _________

The serial number plate for the ripper is located on
the side of the ripper.

SEBU8213-04 33

Product Information Section

Identification Information

Illustration 30

Illustration 31

g01256144

g01057104

Ripper Serial Number _____________________________________

The serial number plate for the winch is located on
the side of the winch.

Illustration 33

g01323812

The winch serial number is located on the right
vertical wall of the winch frame. Do not operate or
service the winch unless your first read the Operation
and Maintenance Manual in conjunction with
understanding the instructions for the safe operation
of the winch.

Winch Serial Number

_____________________________________

Model _________________________________________________________

Certifications

ROPS/FOPS Plate

The message is positioned on the outside left canopy.

lustration 32

Il

g01256165

Illustration 34

g01398757

Structural damage, an overturn, modification, al­teration, or improper repair, can impair this struc­ture's protective capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar d ealer to deter­mine this structure's limitations without voiding
its certification.

34 SEBU8213-04
Product Information Section
Identification Information

This machine ha

s been certified to the standards that
arelistedonthecertification plate. The maximum
mass of the machine, which includes the operator
and the attach

ments without payload, should not

exceed the mass on the certification plate.

A typical exa

mple of the certification film is shown

above.

Refer to Ope

ration and Maintenance Manual,

“Guards (Operator Protection)” for more information.

Sound Certification

For quick refer

ence, record this information in the

spaces that are provided below.

Illustration 37

Engine Power of primary engine (kW)______________

•

Engine P

•

equipped)

Typical

•

market (kg)

ower for additional engine (kW) (if

_________________________________________________

operating weight of machine for European

________________________________________________

g02019094

Illustration 35

A typical example of this film is shown. Your machine may have a
different value.

g00933634

If equipped, the certification film is used to verify the
environmental sound certification of the machine.
The value that is listed on the film indicates the
guaranteed sound power level. The guaranteed
sound power level is measured at the time of
manufacture. The guaranteed sound power level
is measured according to the conditions that are
specified in “2000/14/EC”.

European Union

This plate is positioned on the bottom left side of the
Machine PIN (1) at the rear of the machine.

Year of

•

Machine Type_________________ ____________ ____________ ___

•

construction

_____________________________________

For machines that are compliant to “1998/37/EC”, the
following information is stamped onto the “CE” plate.

Illustration 38

Front of machine

g01062968

For quick reference, record this information in the
spaces that are provided below.

Illustration 36

g01883459

Engine Power of primary engine (kW)______________

•

Typical operating weight of machine for European

•

market (kg)

Year_____________________________________ ____________________

•

________________________________________________

SEBU8213-04 35

Product Information Section

Identification Information

For the name, th

e address and the country of origin
for the manufacturer, see the PIN plate.

i03722740

Declaration

of Conformity

SMCS Code: 1000; 7000

Table 5

An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific
requirements for the European Union. In 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 originally “CE” marked by the
manufacturer listed and which have not since been m odified.

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
Authori

I, the undersigned, _________, hereby certify that the construction equipment specified hereunder

Description:

ties of European Union Member States on request:

Standards & Regulations Manager,Caterpillar France S.A.S 40,
Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France

Generic Denomination:

Earth moving equipment

Function:

Model/Type:

Serial Number:

Commercial N ame: Caterpillar

Fulfils all the relevant provisions of the following Directives

ectives

Dir

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)

Done at: Signature

Date: Name/Position

Representative Equipment Type Sound Power Level - ____ dB (A)
Engine Power per _____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File

Steel track dozer

D3K, D4K, D5K

Notified Body Doc

ument No.

Note: The above information was correct as of October 2009, but may be subject to change, please refer to the individual
declaration of conformity issued with the machine for exact details.

36 SEBU8213-04
Product Information Section
Identification Information

i03638040

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Note: This inf

States, in Canada and in Europe.

Consult your
Control Warranty Statement.

This label i

ormation is pertinent in the United

Caterpillar dealer for an Emission

s located on the engine.

SEBU8213-04 37

Operation Section

Before Operation

Operation Section

Before Operation

Mounting and Dismounting

SMCS Code: 7000

ration 39

Illust

Handholds and steps

i03727105

g02009719

Do not mount a mo
moving machine. Never jump off the machine. Do
not try to mount the machine when you carry tools
or supplies. D
when you are carrying tools or supplies. Use a hand
line to pull equipment onto the platform. Do not
use any contr
operator compartment or when you exit the operator
compartment.

ving machine. Do not dismount a

o not try to dismount the machine

ols as handholds when you enter the

i02799054

Daily I nspection

SMCS Code:

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.

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

Steam can cause personal injury.

Check the coolant level only after the engine has
been stopped and the cooling system pressure
cap is cool enough to touch with your bare hand.

1000; 7000

Illustration 40

e steps and handholds whenever you mount

Us
the machine. Use steps and handholds whenever
you dismount the machine. Before you mount the

chine, clean the step and the handholds. Inspect

ma
the step and handholds. Make all necessary repairs.

ace the machine whenever you mount the machine

F
and whenever you dismount the machine. Maintain a
three-point contact with the step and with handholds.

Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.

g00037860

Remove the cooling system pressure cap slowly
to relieve pressure.

Cooling system conditioner contains a lkali. Avoid
contact with the skin and eyes to prevent personal
injury.

CE

NOTI
Accumulated grease and oil on a machine is a fire haz­ard. Remove this debris with steam cleaning or high

sure water, at least every 1000 hours or each time

pres
any significant quantity of oil is spilled on a machine.

e: For maximum service life of the machine,

Not

make a thorough daily inspection before you operate
the machine. Inspect the machine for leaks. Remove

y debris from the engine compartment and the

an
undercarriage. Ensure that all guards, covers, and
caps are secured. Inspect all hoses and belts for

mage. Inspect all lights and mirrors for damage.

da
Check the condition of the fan drive belt. Make the
needed repairs before you operate the machine.

Perform the following procedures on a daily basis.

peration and Maintenance Manual, “Backup

O

•

Alarm - Test”

38 SEBU8213-04
Operation Section
Before Operation

Operation and M

•

Indicators and Gauges - Test”

Operation and

•

System - Test”

Operation an

•

Power Angling Tilt Hinge Pins - Lubricate”

Operation a

•

(Fresh Air) - Clean/Inpsect/Replace”

Operation a

•

System Coolant Level - Check”

Operation

•

Level - Check”

Operation

•

System Oil Level - Check”

Operatio

•

Inspect”

Operatio

•

Fairlead Rollers - Lubricate”

n and Maintenance Manual, “Seat Belt -

n and Maintenance Manual, “Winch

aintenance Manual, “Brakes,

Maintenance Manual, “Braking

d Maintenance Manual, “Bulldozer

nd Maintenance Manual, “Cab Filter

nd Maintenance Manual, “Cooling

and Maintenance Manual, “Engine Oil

and Maintenance Manual, “Hydraulic

Refer to
procedures. Refer to the Maintenance Interval
Schedule for a complete list of scheduled
mainten

the Maintenance Section for the detailed

ance.

SEBU8213-04 39

Operation Section

Machine Operation

Machine Operation

i01930019

Alternate Exit

SMCS Code: 7308; 7310

Machines with cabs are equipped with alternate exits.
If a door becomes disabled, the other door can be
used as an alternate exit. Release the latch and open
the door.

i02520662

Seat

SMCS Code: 7312-025; 7324

Note: The operator's seat that is provided with this

machine is in compliance with the appropriate class
of ISO 7096.

Note: Adjust the air suspension seat at the beginning
of each shift and for each new operator.

Back Cushion Angle Adjustment (3) –

Pull the lever upward. Permit the back

cushion sprin
into the cushion. Release the lever at the desired
position.

Fore and Aft P

upward. Move the seat in the desired

direction. Release the lever at the desired
forward pos

in order to decrease lumbar support.

arm in place.

ition or the desired rearward position.

Back Extension(5) – Pull up on back

extension (5) in order to remove the back

extension

Lumbar Support (6) – Rotate the knob

counterclockwise in order to increase

lumbar sup

Adjustment knob (7) – Make a height

adjustme

Tighten the knob in order to lock the support

g forward or lean backward

osition (4) – Pull the lever

.

port. Rotate the knob clockwise

nt to the wrist rest for comfort.

Adjust the seat in order to allow full travel of the
pedals. Make the seat adjustments when the operator
is sitting against the back of the seat.

Illustration 41

Adjustment control (2) – Press on the
appropriate side of the button in order
to move joystick support (1) forward or

backward.

g01261692

Armrest

a height adjustment to the armrests for

comfort. Loosen the knobs and pull back
the arm
forward into position. Tighten the knobs in order to
lock the armrest in place.

“forw
position. Grasp the seat pan and rotate the pin
“forward-down-and-back” into the nominal position.

the

Note: The engine start switch key must be turned ON
or the engine must be running in order to adjust the
he

rest. Adjust the height and push the armrest

Seat C

the seat cushion is pinned in a groove.

Grasp the seat pan and rotate the pin

ard−up−and−back” into the steep angle

Heat

the rocker switch in order to activate the

seat heater. A red light will turn ON.

Ride

lever in order to increase the ride firmness.

Pull up on the lever in order to decrease

ride firmness.

Seat Height (12) – Push in knob (12) in

order to raise the seat height. Pull out on

e knob in order to lower the seat height.

th

ight of the seat.

Adjustment Knobs (8) – Make

ushion Tilt (9) – The front of

ed Seat (10) (If equipped) – Press

Firmness (11) – Push down on the

40 SEBU8213-04
Operation Section
Machine Operation

Ride Zone Indicator (13) – Use this
indicator in order to determine if the

suspension is
adjustment is too low. When the operator sits in the
seat, the white bar should be in the green zone of
ride zone ind

icator (13).

adjustedtoohighorthe

i03172921

Seat Belt

SMCS Code: 7327

Note: This

when the machine was shipped from Caterpillar.
At the time of installation, the seat belt and the
instructi
SAE J386 standards. See your Caterpillar dealer for
all replacement parts.

Always check the condition of the seat belt and
the condition of the mounting hardware before you
operate t

Seat Bel
Retractable Seat Belts

Fastening The Seat Belt

machine was equipped with a seat belt

ons for installation of the seat belt meet the

he machine.

tAdjustmentfor

Releasing The S

ion 43

Illustrat

Push the release button on the buckle in order to
release t
retract into the retractor.

he seat belt. The seat belt will automatically

eat Belt

g00039113

Extension of the Seat Belt

When usi
belt ex tensions, or personal injury or death can
result.

The retractor system may or may not lock up de­pending on the length of the e xtension and the
size of
up, the seat belt will not retain the person.

ng retractable seat belts, do not use seat

the person. If the retractor does not lock

Illustration 42

l seat belt (4) out of the retractor in a continuous

Pul
motion.

sten seat belt catch (3) into buckle (2). Make sure

Fa
that the seat belt is placed low across the lap of the
operator.

The retractor will adjust the belt length and the
retractor will lock in place. The comfort ride sleeve

ill allow the operator to have limited movement.

w

g00867598

lt your Caterpillar dealer for longer seat belts

Consu
and for information on extending the seat belts.

i03105875

Seat Belt

SMCS Code: 7327

Note: This machine was equipped with a seat belt

when the machine was shipped from Caterpillar.
At the time of installation, the seat belt and the
instructions for installation of the seat belt meet the
SAE J386 standards. See your Caterpillar dealer for
all replacement parts.

Always check the condition of the seat belt and
the condition of the mounting hardware before you
operate the machine.

SEBU8213-04 41

Operation Section

Machine Operation

Seat Belt Adjustment for
Retractable Seat Belts

Fastening The Seat Belt

Illustration 44

Pull seat belt (4) out of the retractor in a continuous
motion.

Fasten seat belt catch (3) into buckle (2). Make sure
that the seat belt is placed low across the lap of the
operator.

The retractor will adjust the belt length and the
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.

g00867598

Extension of the Seat Belt

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

The retractor system may or may not lock up de­pending on the length of the e xtension and the
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.

Consult your Caterpillar dealer for longer seat belts
and for information on extending the seat belts.

i03325047

Mirror

SMCS Code: 7319

Adjust all mirrors as specified in the Operation
and Mai
warning can lead to personal injury or death.

ntenance Manual. Failure to heed this

Releasing The Seat Belt

Illustration 45

Push the release button on the buckle in order to
release the seat belt. The seat belt will automatically
retract into the retractor.

g00039113

Slips and falls can result in personal injury. Use
the machines access systems when adjusting the
mirrors. If the mirrors cannot be reached using the
machine access systems follow the instructions
found within the Operation and Maintenance Man­ual, “Mirror” in order to access the mirrors.

Note: Your machine may not be equipped with all of

the mirrors that are described in this topic.

Make sure that the mirror is in proper working
condition and that the mirror is clean. Adjust the
mirror at the beginning of each work period and
adjust the mirror when you change operators.

The appropriate job site organization is also
recommended in order to minimize visibility hazards.
For more information refer to this Operation and
Maintenance Manual, “Visibility Information”.

42 SEBU8213-04
Operation Section
Machine Operation

Mirror Adjustment

Interior Mirr

ion 46

Illustrat

Rear view of interior mirror

The interior mirror can be adjusted to a position in
order to allow the operator to see preferred areas
at the re
as backing up, reversing the machine, or moving
backward.

ar of the machine during operations such

or

g01702814

Stop the engine

•

Adjust the right side rear view mirror in order to

•

view the rear w
provide as much visibility to the rear as possible.

Note: Yo u ma y
adjust certain types of mirrors.

.

ork tool, if equipped. Additionally,

need to use hand tools in order to

Operator C on trols

SMCS Code: 7300; 7301; 7451

i03160840

Right Side Rear View Mirror

Illustration 47

Left ripper tooth in mirror

Park the machine on a level surface.

•

g01703233

Lower the work tool to the ground.

•

Move the hydraulic lockout control t o the LOCKED

•

position. For further details on this procedure, refer
to Operation and Maintenance Manual, “Operator
Controls”

SEBU8213-04 43

Operation Section

Machine Operation

Illustration 48

(1) Adjustable Armrest
(2) Air conditioning and heating Controls
(3) Steering and Transmission Control
(4) Decelerator/Brake Pedal
(5) Gauges and Indicators
(6) Mirror
(7) AM/FM Radio
(8) Exterior cab door release lever
(9) Interior cab door release lever
(10) Engine Start Switch

(11) Bulldozer Control
(12) Work lights
(13) Engine throttle control
(14) Fuel efficient rpm range
(15) Parking Brake Switch
(16) Hydraulic loc kout
(17) Front window wiper
(18) Left window wiper
(19) Right window wiper
(20) Rear window wiper

g01391162

(21) W inch Controls or Ripper Controls
(22) Winch freespool switch
(23) Winch driveaway switch
(24) Auxiliary function
(25) Air suspension seat
(26) P ower Receptacle inside storage box
(27) P ocket in seat back rest (Operation and

Maintenance Manual)

44 SEBU8213-04
Operation Section
Machine Operation

Adjustable Armrests (1)

Illustration 49

See “Seat” in this manual for information on adjusting
the left armrest and right armrest (1).

Control Supports

g01269364

Air Conditioning and Heating
Control (2)

Illustration 50

Enclosed

Open ROPS enclosure arrangement has heating only.

(2A) Fan control knob
(2B) Temperature control knob
(2C) Air conditioner switch

Fan Con

ROPS

trol

OFF – Move knob (2A) to this position in

o stop the blower fan motor.

order t

g01269368

Use the following procedure in order to adjust both
of the control supports (1D) and wrist rests (1C), if
necessary.

1. Loosen knob (1B) on the outside of the wrist rest

(1C).

2. Pull wrist rest (1C) in an upward direction or push

the wrist rest downward. Move the wrist rest to
the desired height.

3. Tighten the knob.

4. When the appropriate button (1E) on armrest (1) is

pushed, the operator must slide the seat controls
to the desired location. This moves seat control
(1D) forward or backward.

Fan Spe

ed Switch (2A) – This knob

controls the four-speed blower fan motor.

LOW (1) – Move knob (2A) to this position for the
lowest fan speed.

MEDIUM LOW (2) – Move knob (2A) to this position
for a medium low fan speed.

MEDIUM HIGH (3) – Move knob (2A) to this position
for a medium high fan speed.

MAXIMUM (4) – Move knob (2A) to this position for
a maximum fan speed.

Temperature Control

perature Control Knob (2B) – Turn

Tem

knob(2B) counterclockwise to COOL. Turn
knob (2B) clockwise to WARM.

r Conditioner Switch

Ai

Air Conditioner – Press in the top of

itch (2C) in order to turn on the air

sw
conditioner. Return the switch to the middle

position (2C) in order to turn off the air conditioner.

SEBU8213-04 45

Operation Section

Machine Operation

Heating and Air

Conditioning System

Operation

The heating an
five functions:

Note: The Ope
a heating system only.

Heating – Tu
(LOW, MEDIUM LOW, MEDIUM HIGH, or
MAXIMUM). Adjust knob (2B) in order to obtain the
desired tem

Cooling – Press switch (2C) in order to turn on
the air con
speed (LOW, MEDIUM LOW, MEDIUM HIGH, or
MAXIMUM). Adjust knob (2B) in order to obtain the
desired te

Defrosting – Pressswitch(2C)inordertoturnon
the air co
speed (LOW, MEDIUM LOW, MEDIUM HIGH, or
MAXIMUM). Adjust knob (2B) in order to obtain the
desired

Pressurizing – When heating or cooling is not
desired
dust.

Turn kn
temperature. To produce the volume of air that
is necessary to keep out dust, turn knob (2A) to
MEDIUM

Defogging – Press switch (2C) in order to turn on
the ai
speed (LOW, MEDIUM LOW, MEDIUM HIGH, or
MAXIMUM). Adjust knob (2B) until the moisture level
is low
arefreeofmoisture.

temperature.

, pressure inside the cab will help keep out

ob (2B) in order to obtain the desired

r conditioner. Turn knob (2A) to the desired

ered and the front window and side windows

d air conditioning system performs

n ROPS enclosure arrangement has

rn knob (2A) to the desired speed

perature.

ditioner. Turn knob (2A) to the desired

mperature.

nditioner. Turn knob (2A) to the desired fan

LOW or to MEDIUM HIGH.

Illustration 52

Note: Make sure that parking brake switch (15) is
disengaged in order to use steering and transmission
control (3).

FORWA RD (3A) – Move lever (3) forward past the
detent position in order to move the machine forward.

NEUTRAL (3B) – Move lever (3) to the center
position in order to put the machine in the NEUTRAL
position.

REVERSE (3C) – Move lever (3) backward past
thedetentpositioninordertomovethemachine
backward.

FORWA RD LEFT (3D) – Move lever (3) t o the left
in order to turn the machine to the left. The turning
radius for the machine is proportional to the control
lever position. In order to slightly turn the machine to
the left, slightly move lever (3) to the left. If you want
to increase your turn, move lever (3) further to the
left. If you want the machine to counterrotate, move
lever (3) all the way to the left past the detent. When
the tracks counterrotate, the right side track will rotate
forward, while the left track rotates backward.

g01399951

Steering and Transmission Control
(3)

Illustration 51

g01258402

FORWARD RIGHT (3E) – Move lever (3) to the right
in order to turn the machine to the right. The turning
radius for the machine is proportional to the control
lever position. In order to slightly turn the machine to
the right, slightly move lever (3) to the right. If you
want to increase your turn, move lever (3) further to
the right. If you want the machine to counterrotate,
move lever (3) all the way to the right past the detent.
When the tracks counterrotate, the left side track will
rotate forward, while the right track rotates backward.

46 SEBU8213-04
Operation Section
Machine Operation

REVERSE LEFT (3

in order to turn the machine to the left. The turning
radius for the machine is proportional to the control
lever positio
the left, slightly move lever (3) to the left. If you want
to increase your turn, move lever (3) further to the
left. If you w
lever (3) all the way to the left past the detent. When
the tracks counterrotate, the right side track will rotate
backward, w

REVERSE RIGHT (3G) – Move lever (3) to the right
in order to t
radius for the machine is proportional to the control
lever position. In order to slightly turn the machine to
the right,
want to increase your turn, move lever (3) further to
the right. If you want the machine to counterrotate,
move lever
When the tracks counterrotate, the right side track will
rotate forward, while the left track rotates backward.

Changing the direction of the machine is performed
by first moving lever (3) to the NEUTRAL position.
Then move

For smooth directional changes, smoothly move
lever (3
the NEUTRAL position. Also, deceleration of the
engine speed makes for easier directional changes.
However

Note: In order to turn the machine, lever (3) must be
placed
the REVERSE detent position.

Track

n. In order to slightly turn the machine to

ant the machine to counterrotate, move

hile the left track rotates forward.

urn the machine to the right. The turning

slightly move lever (3) to the right. If you

(3) all the way to the right past the detent.

lever (3) in the opposite direction.

) to the NEUTRAL position and away from

, this is not required.

in either the FORWARD detent position or in

Speed (3H)

F) – Move lever (3) to the left

HIGH – Roll the wheel (3H) to the right

when a higher speed is desired.

The machine is set with the following factory settings.

Maximum forward speed of 9.0 km/h (5.6 mph)

•

Maximum reverse speed of 10.0 km/h (6.2 mph)

•

REVERSE and FORWARD Speeds – The
REVERSE speed is totally independent of the speed
of the machine in the FORW ARD position.

Note: There is a maximum limit of 10.0 km/h
(6.2 mph) on the forward speed and on the reverse
speed. Consult your Caterpillar dealer in order to
change the speed settings.

Speed Recall Button (3J)

Preset the Speed Values

The power train ECM programs the preset values for
a forward speed and a reverse speed with input from
speed recall button (3J).

In order to program the preset values, the operator
should hold down the button for at least 3 seconds
under the following conditions.

“FNR”

F–The steering and transmission control allows

machinetravelintheFORWARDdirection.

N–The steering and transmission control is in the
NEUTRAL position.

lustration 53

Il

LOW – Roll the wheel (3H) to the left when

ower speed is desired.

al

Note: Wheel (3H) allows variable speeds via the
incremental rotation of the wheel.

g01399958

R–The steering and transmission control allows
machine travel in the REVERSE direction.

Forward – The “FNR” status is FORWARD when the
programmed criteria are met. Then, only the forward
joystick input (speed value) is captured.

Reverse – The “FNR” status is REVERSE wh en the
programmed criteria are met. Then, only the reverse
joystick input (speed value) is captured.

Neutral – The “FNR” status is NEUTRAL when
the programmed criteria are met. Both the current
forward and reverse joystick inputs (speed values)
are captured.

1. Ensure that parking brake switch (14) is
disengaged.

2. Move the steering and transmission control to the
FORWARD position.

SEBU8213-04 47

Operation Section

Machine Operation

3. Roll thumb whee
speed, while the steering and transmission control
is in forward.

4. Move the steering and transmission control to the
REVERSE position.

5. Roll thumb wheel (3H) to the desired REVERSE
speed, while the steering and transmission control
is in revers

6. Move the steering and transmission control to
NEUTRAL. Ho
seconds.

7. Press Spee
machine is moving forward in order to return to
the preset speed.

8. Press Speed Recall Button (3J) brieflywhile
moving reverse and the machine will return to the
preset sp

No Preset to the Speed Values

Note: The operator must program the preset values

after each shutdown of the keyswitch circuit. Refer to
Steps 1 t

If the values have not been programmed since the
last shu
speed recall button will not result in any change in
the speed value for the corresponding direction.

Forward – If only the FORWARD preset value is
programmed since the last shutdown of the keyswitch

it, the depressing of the button brieflypermits

circu
only the FORWARD speed value to be changed to
the preset value.

Reverse – If only the REVERSE preset value is
programmed since the last shutdown of the keyswitch

uit, the depressing of the button brieflypermits

circ
only the REVERSE speed value to be changed to
the preset value.

eed.

hrough 6 in order to preset the speed values.

tdown of the keyswitch circuit, pressing the

l (3H) to the desired FORWARD

e.

ldtheSpeedRecallButtonfor3

d Recall Button (3J) brieflywhilethe

The decelerato
ET or the gauge display. The decelerator/brake pedal
has the two following configurations: Transmission
Brake Only and
Deceleration.

Note: ET is th
use with Caterpillar machines.

Transmissi

Configure the decelerator/brake pedal as a
hydrostati
withthehydrostatictransmissiononly.Theengine
speed does not change when you press the
decelerat

When pedal (4) is completely depressed beyond
the detent
The gauge display (“Compact Instrument Cluster”)
can change the decelerator/brake pedal. so that the
engine ma
depressed.

Transmi

r/brake pedal is configured through

Transmission Brake and Engine

e Electronic Technician service tool for

on Brake Only

c braking in order to slow the machine

or/brake pedal.

spring, the parking brake will engage.

intains a constant speed when the pedal is

ssion Brake and Engine

Deceleration

Configur
hydrostatic braking and the engine deceleration are
done at the same time.

When the decelerator/brake pedal is pressed, the
engine speed will be reduced proportionally.

Note: Change the configuration of the
decelerator/brake pedal with the gauge display or
with C

Gauge

The following text is operator information for use with
the C

e the decelerator/brake pedal so that the

aterpillar electronic technician (ET).

s and Indicators (5)

ompact Instrument Cluster.

Compact Instrument Cluster

Horn (3K)

n–Push down button (3K) in order to

Hor

activate the horn.

Decelerator/Brake Pedal (4)

Push decelerator/brake pedal (4) all the way
downward in order to apply the brakes or use the

akes to stop the machine. Use the brakes on a

br
downgrade in order to maintain a safe operating
mode. Release pedal (4) in order to allow the

chine to move. Release pedal (4) in order to

ma
increase ground speed.

Refer to Monitoring System, KENR6339, “Systems
Operation” for more information on the Compact

trument Cluster.

Ins

48 SEBU8213-04
Operation Section
Machine Operation

Illustration 54

CIC LCD Screen

(5A) Mode Button
(5B) Scroll Button
(5C) Compact Instrument Cluster LCD Display

g01400135

The Compact Instrument Cluster LCD Display (45)
shows the four Operator modes.

The Mode button (5A) and the Scroll button (5B) are
used in order to navigate the CIC Menu structure.

CIC Operator Mo

des Menu

The following is displayed on the CIC Operator
Modes menu:

Mode 0 – Default

Mode 1 – Steering Modulation Settings

Mode 2 – Impl

ement Modulation Settings

Mode 3 – Brake/Decel Pedal Settings

See Table 6 for details of the CIC Operator menu.

Following is the operation of the Mode button (5A)
and the Scroll button (5B).

Move to different modes – Press and release the
Mode button (5A).

Scroll through the submodes or the screens
within each mode – Press and release the Scroll

button (5B).

Illustration 55

Diagram of CIC Navigation

g01359688

SEBU8213-04 49

Operation Section

Machine Operation

Table 6

CIC Menu

Operator Modes

Maximum Forwards Speed

erse Speed

Fine

Medium

Coarse

Fine

Standard

Fast

Brake Only

Mode 0

Default

Mode 1

Steering Modulation Settings

Mode 2

Implement Modulation Settings

Mode 3

Brake/Decel Pedal Settings

Maximum Rev

Engine Oil Pressure

Engine Speed

System Voltage

Service Hour Meter

Brake And Engine Decel

Following is the content of the CIC Operator Modes
menu.

Mode 0 - Default

ustration 56

Ill

Mode 0 - Default LCD Screen

The Mode 0 - Default screen has the following
submenus:

Maximum Forward Speed

he Maximum Forward Speed screen indicates the

T
maximum forward speed of the machine.

aximum Reverse Speed

M

The Maximum Reverse Speed screen indicates the
maximum reverse speed of the machine.

g01328919

Engine Oil Pressure

Illustration 57

Mode 0 Engine Oil Pressure LCD Screen

g01328962

The Engine Oil Pressure screen indicates the current
engine oil pressure.

Engine Speed

Illustration 58

Mode 0 Engine Speed LCD Screen

g01328963

The Engine Speed screen indicates the current
engine speed of the machine.

50 SEBU8213-04
Operation Section
Machine Operation

System Voltage

Illustration 59

Mode 0 System Voltage LCD Screen

g01329052

The System Voltage screen indicates the current
system voltage.

Service Hour Meter

Illustration 60

Mode 0 Service Hour Meter LCD Screen

g01329053

The Service Hour Meter screen indicates the total
operating hours of the machine.

Mode 1 - Steering Modulation Settings

Coarse

Illustration 63

Mode 1 - Steering Modulation Settings - Coarse LCD Screen

g01328936

Mode 2 - Implement Modulation Settings

The Mode 2 - Implement Modulation Settings screen
has the following submenus:

Fine

Illustration 64

Mode 2 - Implement Modulation - Fine LCD Screen

Standard

g01328942

The Mode 1 - Steering Modulation Settings screen
has the following submenus:

Fine

Illustration 61

Mode 1 - Steering Modulation Settings - Fine LCD Screen

g01328924

Medium

01328926

Illustration 62

Mode 1 - Steering Modulation Settings - Medium LCD Screen

g

Illustration 65

Mode 2 - Implement Modulation - S tandard LCD Screen

Fast

Illustration 66

de 2 - Implement Modulation - Fast LCD Screen

Mo

g01328946

g01328944

SEBU8213-04 51

Operation Section

Machine Operation

Mode 3 - Brake/D

Brake Pedal Only

Illustration 67

Mode 3 - Brake P edal Only LCD Screen

Brake Pedal and Decelerate Pedal

Illustration 68

Mode 3 - Brake Pedal and Decelerate Pedal LCD Screen

Refer to Operations and Maintenance Manual,
“Monitoring System” or the Service Manual for more
information.

ecel Pedal Settings

g01328958

g01328959

Enter the cab an
latches. Close both doors in order to operate the
machine properly.

d close the door until the door

Cab Door Release Lever (9)

Machines with cabs are equipped with alternate exits.
If a door becomes disabled, the other door can be
used as an alt
the door.

Release lat

Fully open the door until the door latches.

Releasing the Fully Opened Door and
Latched Door

Use the correct method in order to release the door
when the door is latched open against the side of
the machi

Open the side window and release the platform

•

door latc

Also, you may stand on the ground in order to

•

release

Engine S

ernate exit. Release the latch and open

ch (9) in order to unlock the cab door.

ne.

h.

the platform door latch.

tart Switch (10)

Mirror (6)

For best operator vision, adjust the rear view mirror.
Adjust the mirror before you operate the machine and
after operators change.

AM/FM Radio (7) (If equipped)

If a radio other than one available from your Cater­pillar dealer is installed, an in-line fuse must be
provided. Failure to do so can damage the electri­cal system if an electrical short occurs in the radio
circuit.

Note: Multiple radio installation groups are available.

If a radio is not installed, a cover is available for the
opening. Consult your Caterpillar dealer for additional
information.

Cab Doo r Release Lever (8)

Machines with cabs are equipped with two entrances.
Release latch (8) and open the door.

OFF – Insert the engine start switch key

om the OFF position and remove the

only fr
engine start switch key only from the OFF

position. In the OFF position, there is no power to

lectrical circuits in the cab.

most e

Turn the engine start switch key to the OFF position
in order to stop the engine.

ON – Turn the engine start switch key
clockwise to the ON position in order to

vate all of the cab circuits.

acti

START – Turn the engine start switch key
clockwisetotheSTARTpositioninorderto

k the engine. Release the engine start

cran
switch key after the engine starts and the engine start
switch key returns to the ON position.

e: If the engine fails to start, the engine start

Not

switch key must be returned to the OFF position in
order to attempt to start the engine again.

52 SEBU8213-04
Operation Section
Machine Operation

Bulldozer Control (11)

TILT RIGHT (11F) – Push lever (11) to

the right in order to lower the right side of

the blade. Lev
position when the lever is released.

BladeAngle(11G)

er (11) returns to the HOLD

Illustration 69

g01257156

FLOAT (11A) – Push lever (11) forward
past the detent force. This activates the
blade floa

t function (implement valve).
Release the lever. The lever returns to the NEUTRAL
position (HOLD). In the FLOAT position, the blade
moves up

and down with the ground contour.

The implement valve will remain in the FLOAT
position until you manually move lever (11) to the

r lower direction. The valve spool position then

raise o
returns to the HOLD position.

The floa

t position of the spool is also cancelled, if you
turn the engine start key to the OFF position, or the
hydraulic lockout (15) is activated.

Note: Lever travel corresponds to the speed of blade
movement for the dozer functions that are listed.

LOWER (11B) – Push lever (11) forward
in order to lower the blade. Do not pass the

nt position. Release lever (11). Lever

dete

(11) will return to the HOLD position.

HOLD (11C) – Lever (11) will retu rn to the

D position, when you release lever (11)

HOL
anytime. The movement of the blade will

stop.

Illustration 70

g0125849

ANGLE LEFT – Roll the thumb wheel
(11G) to the right in order to angle the blade
to the le

ft.

ANGLE RIGHT – Roll the thumb wheel
(11G) to the left in order to angle the blade
to the r

ight.

Bulldozer Blade Shake

control mode (11H)

Blade

Pushbutton(11H)inordertosendacommandtothe

ylinder that begins a high vibration application.

tilt c
The blade will shake until button (11H) is released
or a timeout of 3 seconds is completed. This allows

val of debris from the bulldozer blade.

remo

Righ

tOperatorConsole

9

SE (11D) – Pull back on lever (11) in

RAI

order to raise the blade. Release lever (11).
Lever (11) will return to the HOLD position

less the lever is set in Float.

un

TILT LEFT (11E) – Pulllever(11)totheleft
in order to lower the left side of the blade.

ver (11) returns to the HOLD position

Le

when the lever is released.

Illustration 71

g01391309

SEBU8213-04 53

Operation Section

Machine Operation

Low Idle – Rotate knob (13)
counterclockwise in order to lower
the idle speed

.

High Idle – Rotate knob (13) clockwise in
order to increase the idle speed.

Table 7

Throttle Position Engine RPM

1 950

Illustration 72

(12) Work lights
(12a) Front floodlights (If equipped)
(12b) Front lights for long range (If equipped)
(12c) Rear cab lights (If equipped)
(13) Engine throttle control (k nob)
(14) Fuel efficient reverse
(14a) Indicator light for seat belt (If equipped)
(15) Parking brake switch
(16) Hydraulic lockout

g01693534

Depress the work light switch (12) in order to turn on
all of the machine lights.

2 1100

3 1175

4 1250

5

6 1550

7

8 1850

9 2000

10 2150

1400

1700

Work Lights (12)

Work lights – This switch turns on all the

lights.

Front Floodlights (12a) (If equipped)

Front Floodlights – Usethisswitchto

operate the front floodlights, if equipped.

Front Cab Lights for Long Range (12b)
(If equipped)

Front Cab Lights for Long Range – Use

this switch to operate the front cab lights for

ong range, if equipped.

the l

Rear Cab Lights (12c) (If equipped)

r Cab Lights – Use this switch to

Rea

operate the rear cab lights, if equipped.

Note: T

he engine speed does not increase above
2000 RPM until the hydraulic oil temperature exceeds
15 °C (59.0 °F). Then, the engine speed will slowly

se up to 2150 RPM.

increa

Fuel E

fficient Reverse (14)

Fuel Efficient Reverse (14) automatically reduces

ne speed when the machine is traveling in

engi
reverse. Fuel Efficient Reverse is designed to reduce
fuel consumption and noise.

The engine rpm will recover automatically to the
setting of the engine speed dial when the machine is

manded to travel forward or when the machine is

com
in neutral. The engine rpm will also increase as you
increase the desired REVERSE speed.

Fuel Efficient Reverse – Fuel efficient
reverse is activated when the engine start

itch is turned to the ON position. The

sw
indicator light on the switch will light. When you
press fuel efficientreverseswitch(14),thefunction

anges from ON to OFF, and vice versa.

ch

Engine Throttle Contr ol (13)

Engine throttle control (13) controls the engine speed.

Indicator Light for Seat Belt (14a) (If
equipped)

Seat belt – This light indicates when the

seat belt is not used.

54 SEBU8213-04
Operation Section
Machine Operation

Parking Brake Switch (15)

Illustration 73

Parking Brake – This switch engages
the parking brake. This switch also locks

the trans
machine should not move when the parking brake
switch is engaged. After the parking brake switch
is disen
until a direction is chosen. When the parking brake
switch is engaged, the parking brake indicator on the
dashboa
for stopping the machine.

Engaged – Push switch (15) away from the operator
in orde

Disengaged – Push switch (15) toward the operator
in ord

Hydra

Hydraulic lockout (16) shuts down the implement
hydr

gaged, the parking brake will not turn off

rd will light. Do not use the parking brake

r to engage the parking brake.

er to disengage the parking brake.

ulic lockout (16)

aulics to the machine.

Locked – Push the switch away from the

oper

hydraulic system.

Unlocked – Pushtheswitchtowardthe

ope

hydraulic system.

mission in NEUTRAL. The

ator in order to lock out the implement

rator in order to unlock the implement

g01695273

Window Wiper and Window Washer
(17) (18) (18)

Illustration 74

Front Window Wiper Switch (17) – Press
the top of switch (17) in order to activate the

window wiper for the front window. Press
the bottom of switch (17) one time in order to turn off
the window wiper for the front window. Press the top
of switch (17) and hold switch (17) in order to activate
the window washer for the front window.

Left Side Window Wiper S witch (18) –

Press the top of switch (18) in order to

activate the window wiper for the left
window. Press the bottom of switch (18) one time in
order to turn off the window wiper for the left window.
Press the top of switch (18) and hold switch (18) in
order to activate the window washer and the window
wiper for the left window.

Right Side Window Wiper Switch (19) –

Press the top of switch (19) in order to

activate the window wiper for the right
window. Press the bottom of switch (19) one time
in order to turn off the window wiper for the right
window. Press the top of switch (19) and hold switch
(19) in order to activate the window washer and the
window wiper for the right window.

Rear Window Wiper Switch (20) – Press

the top of switch (20) in order to activate the

window wiper for the rear window. Press
the bottom of switch (20) one time in order to turn off
the window wiper for the rear window. Press the top
of switch (20) and hold switch (20) in order to activate
the window washer for the rear window.

(19) (If Equipped)

g01391319

Note: Make sure that the window is wet before
operating window wipers.

SEBU8213-04 55

Operation Section

Machine Operation

Winch Con trols or Ripper Controls
(21)

Winch Controls 21, 22, 23 (If Equipped)

Illustration 75

Reel In (21A) – Move the lever to the left in
order to reel in the winch cable. The winch

cable should move toward the winch under
power. Speed for the winch cable is proportional to
the lever position. Release the lever. The Lever will
return to the HOLD position.

Hold (21B) – Release the lever. The lever will return
to HOLD position. This maintains the current position
ofthewinchcable.Thewinchbrakeisappliedinthe
HOLD position.

g01391320

Note: Do not act
machine is moving.

DriveAway(23

awayswitchonetimeinordertoactivate

this mode. This mode allows the operator to
drive the tra
out the cable under power and the cable is attached
to the load. Drive away (23) releases the winch brake
(BRAKE OFF)

ivate the winch freespool when the

)–Press the winch drive

ctor away from a load as the winch reels

.

Ripper Controls 21 (If Equipped)

Illustration 76

RAISE (

order to raise the ripper. Release the lever.

The lever will return to the HOLD position.

21A) – Pull the lever to the left in

g01391351

Reel Out (21C) – Move the lever to the
right in order to reel out the winch cable.

The winch cable reels out under power.
Speed for the winch cable is proportional to the lever
position. Release the lever. The Lever will return to
the HOLD position.

Both Free Spool and Drive Away modes have three
conditions that must be met in order to activate the
function.

The operator must be present.

•

The implement levers must be released.

•

Thehydrauliclockoutswitchmustbeinthe

•

UNLOCKED position.

Free Spool (22) – Press the freespool

switchonetimeinordertoreleasethe

winch cable. The winch cable unreels by
manually pulling the winch cable. No machine or
hydraulic assistance is needed. The winch will remain
in the FREE SPOOL position until you press the
switch again or the lever is moved from the HOLD
position.

21B) – Release the lever. The

(21C) – Push the lever to the right

posi

HOLD (

lever will return to HOLD position. Ripper
movement stops in the current position.

LOWER

in order to lower the ripper. Release the
lever. The lever will return to the HOLD

tion.

Auxiliary Control 24 (If e quipped)

Illustration 77

g01391360

56 SEBU8213-04
Operation Section
Machine Operation

Use auxiliary s
hydraulics when the machine has a winch or a rear
attachment.

witch (24) in order to activate the rear

Fire Plow Controls (If Equipped)

Illustration 78

g01623055

Seat Switch (Tr

The Operator is Not Present – The

seat switch in

movement of the machine or implements
that is not commanded if the operator is out of
the seat. The
software when the machine operator is sitting in the
seat or when the operator leaves the operator seat.

The parking
implements will not unlock unless the operator is
seated.

Note: The hystat control system and the implement
operation will not shut down when the machine is
moving and

the operator raises from the seat.

Power Rece

actor Operator)

the operator seat prevents

switch communicates with the ECM

brake will not disengage and the

ptacle (26)

5918

Illustration 79

For machines that are equipped with the fire plow,
use auxiliary switch (24A) in order to engage the

th float valve. Use lever (24D) for the fourth

four
valve function. Use auxiliary switch (24B) in order to
engage the fifth float valve. Use lever (24E) for the

valve function.

fifth

1. Push the auxiliary lever away from the operator in
er to extend the cylinder.

ord

2. Pull the auxiliary lever toward the operator in order

etract the cylinder.

to r

r Suspensi on Seat (25)

Ai

The air suspension seat offers a safe, comfortable,

able ride that is less fatiguing for the operator.

st

See “Seat” in this manual for more information.

g0162

Illustration 80

Power Receptacle – A twelve volt power receptacle
is located inside the storage box on left hand side of
seat. Power receptacle (26) can be used for powering
automotive electrical equipment or accessories.
Remove the cap before use.

Note: Do not use the power supply as a lighter for
a cigarette.

g01391373

Pocket in seat backrest (27)

Place the Operation and Maintenance Manual into
the pocket in seat backrest (27). Hold other pertinent
material in this pocket that maintains information that
is useful to operate the machine effectively.

SEBU8213-04 57

Operation Section

Machine Operation

Fuel Shutoff Control in Cab (If
equipped)

electrical system. The switch must be ON before you
start the engine.

ON – Insert the battery disconnect switch
key, and turn the battery disconnect switch
key clockwise

in order to activate the

Illustration 81

Fire plow

Control

Panel for the AccuGrade -

g01625983

Laser System (If equipped)

If equipped, the GPS display and the AccuGrade

- Laser System is located below the compact

ment cluster (CIC).

instru

For more information regarding the operation of the

l panel for the AccuGrade - Laser System, refer

contro
to Operation and Maintenance Manual, SEBU8161,
“AccuGrade - Laser System”. For more information

ding the operation of the control panel for

regar
the AccuGrade - GPS , refer to Operation and
Maintenance Manual, SEBU8280, “AccuGrade ­GPS (C

D700)”.

i02539833

OFF – Turn the
key counterclockwise in order to shut off
the entire electrical system.

The battery
switch serve different functions. When the battery
disconnect switch is turned off, the entire electrical
system is d
is turned off, the battery remains connected to the
electrical system.

Turn the battery disconnect switch key to the OFF
position and remove the battery disconnect switch
key when y
service any other components of the machine.

Turn the b
position and remove the battery disconnect switch
key when the machine is left for an extended period
of one mo
short circuit from draining the battery. This procedure
will also prevent the components from draining the
battery
from being drained by vandalism.

Close t

Never turn the battery disconnect switch key to OFF
with the engine running. Electrical system damage
could

disconnect switch and the engine start

isabled. When only the engine start switch

ou service the electrical system or you

attery disconnect switch key to the OFF

nth or longer. This procedure will prevent a

.Thisprocedurewillalsopreventthebattery

he access door.

result.

battery disconnect switch

NOTIC

E

Battery Disconnect Switch

SMCS Code: 1411 - B11; 1411

The battery disconnect switch is located at the rear of
the machine. Open the access door.

Illustration 82

g01271477

58 SEBU8213-04
Operation Section
Machine Operation

i02513591

Backup Alarm

SMCS Code: 7406

The backup ala
machine.

Illustration 83

Backup alarm – The alarm will sound when the
steering and transmission control (lever) is in the
REVERSE position. The alarm is used to alert people
behind the machine that the machine is backing up.

rm is mounted on the rear of the

g01257741

The self testin
the monitoring system are properly operating. The
self testing feature verifies that the display module is
properly oper

The operator must observe the outputs in order to
determine if
self testing feature is three seconds long.

The monitor
operating mode.

g feature verifies that the modules of

ating.

the modules are operating properly. This

ing panel will then return to the normal

Alert Indicators

Illustration 84

g01211250

i03182441

Monit

SMCS Code: 7490

oring System

Functional Test

The monitoring system informs the operator of the
status of the machine systems. The monitoring

em informs the operator of problems or of an

syst
impending problem.

If the action al arm does not sound during this test

machine monitoring displays are not function-

or
ing, do not operate the machine until the cause
has been corrected. Machine operation with faulty

tion alarms or displays could result in injury or

ac
death as any Warning Category 3 notifications will
not be relayed to the operator.

When the engine starts the monitoring system runs
a test. The operator must observe the monitoring

ystem during the test to determine proper operation.

s

Action Lamp (1) – Theactionlampison
the Gauge cluster. If the action lamp is ON,
then attention to service is required.

Reference: See “Warning Categories” for information
on indicated service.

Electrical System (2) – This indicator
indicates a malfunction in the electrical

system. If this alert indicator flashes, the
system voltage is too high or too low for machine
operation.

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 electrical system stops
within one minute, the electrical system is operating
normally. During the periods of low engine speeds,
the alternator is overloaded.

Modify the operating cycle. This will prevent the
electrical system from overloading. This will also
prevent the electrical system from discharging the
batteries. You can also reduce the loads on the
electrical system. Use the medium fan speed in the
cab instead of the high fan speed.

SEBU8213-04 59

Operation Section

Machine Operation

Run the engine s
electrical system at a light load. If the light remains on,
drive the machine to a convenient stop. Investigate
the cause of th
alternator belt, a broken alternator belt, a faulty
battery, a faulty alternator, etc.

peed at normal rpm. Run the

e problem. The cause may be a loose

Warning Categories

Warning Category 1

In category
category alerts the operator that the machine system
needs attention.

Warning Category 2

In this cat
warning category requires you to change the machine
operation. The machine operation must be altered in
order to r
of the systems or in more than one of the systems.
If the engine speed is too high, change the machine
operatio
speed.

1, the action light is solid amber. This

egory, the action light flashes red. The

educe the excessive temperature in one

n in order to reduce the excessive engine

Hydraulic Oil Filter (3) – This indicator

is illuminated when the filter is clogged

or when the filt
this indicator may illuminate until the hydraulic oil
temperature warms up.

Glow Plug (4)

illuminated when the glow plugs are on.

Operator Seat (5) – This indicator will

illuminate if the operator leaves the seat

unoccupied.

Hydraulic Lockout (6) – This indicator

is illuminated when the hydraulic lockout

is activated. The implement hydraulics are
OFF.

Fuel/Water Separator(7) – The indicator

will illuminate when either of two items

occurs. The fuel/water separator must
be drained or the fuel/water separator should be
changed.

er is dirty. In extreme cold,

– This indicator is

If the al
the machine.

Warnin

In this category, the action lamp flashes red. Also,
the act
immediate shutdown of the operation in order to
prevent severe damage to the system and/or to the
machi

Do not operate the machine until the cause has been
corre

Note: If the action lamp flashes amber there is a
comm

Indi

ert indicator continues to flash, do not operate

gCategory3

ion alarm will sound. This category requires

ne.

cted.

unication failure.

cators

Note: When the fuel filters are plugged, action lamp

(1) may illuminate in a solid amber color or a flashing
red color. This depends on the amount of plugging of
the fuel/water separator.

Engine A ir Filter(8) – This indicator is

illuminated when the filter is clogged or

when the filter is dirty.

MachineSecuritySystem(9) –The

indicator will illuminate when the machine

security system is activated and an attempt
to start the machine is made.

Float (10) – This indicator is illuminated

when the float mode is selected.

Parking Brake (11) – This indicator is

illuminated when the parking brake is

engaged. If the operator leaves the seat
with the parking brake switch OFF, the parking brake
is applied automatically and the indicator flashes .
Toggle the parking brake switch in order to disengage
the parking brake.

Illustration 85

Engine Oil Pressure (12) – This indicator

is illuminated when engine oil pressure is

low.

g01625704

60 SEBU8213-04
Operation Section
Machine Operation

Gauges

Illustration 86

Hydraulic Oil Temperature (13) – The
gauge indicates the temperature of the
hydraul

ic oil in the hydraulic oil sump for the
steering and implement circuits. If the gauge needle
enters the red zone the hydraulic oil temperature
is exces

sive. The Compact Instrument Cluster will
display a warning. If necessary, reduce the load that
is on the machine until the hydraulic oil temperature

ses.

decrea

g0121137

Digital D isplay Window (17)

0

Illustration 87

Gauge display (Compact Instrument Cluster)

g0162571

3

Engine Coolant Temperature (14) –

The water temperature regulator regulates
the coo

lant temperatures. If the gauge
needle enters the red zone the coolant temperature
is excessive. Increased temperatures will sound

rning alarm. Continued operation of the

the wa
machine during the sounding of the warning alarm
or the gauge needle in the red zone may damage

ngine. Stop the machine in a safe place and

the e
investigate the cause.

Fuel Level (15) – The fuel level gauge

cates the amount of fuel that remains

indi
in the fuel tank. A gauge needle in the red

zone indicates a low fuel level.

NOTICE
Running out of fuel can cause engine damage. Do not
continue to operate the machine when critically low on
fuel.

Illustration 88

”Film

“CIC

g01270291

Digital display window (17) provides readouts that

the following items:

show

Operational hours (service hours)

•

Engine speed (tachometer)

•

gnostic codes

Dia

•

Selected speed and direction

•

Hydraulic Oil Temp

•

plement Control Modes

Im

•

Steering Control Modes

•

System Voltage

•

il Pressure

O

•

Press up arrow button (18) until the desired function

s displayed. Press the right arrow button (18) in order

i
to access the parameters of the displayed function.

SEBU8213-04 61

Operation Section

Machine Operation

Machine Speed (

Speed setting – The indicator displays the speed

setting durin

g machine operation.

Indicator)

Engine Oil Pressure

Engine oil pressure – The indicator displays the

status of the engine oil pressure during machine
operation.

Tachometer

Digital tachometer – The tachometer displays the

engine rpm during machine operation.

System Voltage

System vol

status of the electrical system during machine
operation.

tage – System voltage displays the

Service Hour Meter

Hour Meter – This display

determi

Service

indicates the total operating hours of
the engine. Use the display in order to

ne the service hour maintenance intervals.

i03555467

Product Link
(If Equipped)

SMCS Code: 7606

The Product Link PL121SR is a satellite
communication device that transmits information
regarding t
dealers, and Caterpillar customers. The unit contains
a Global Positioning System receiver (GPS receiver)
and a satell

The Product Link PL121SR is capable of two-way
communica
user. The remote user can be a dealer or a customer.
At any time, a user can request updated information
from a mach
of the machine. Also, the system parameters for
Product Link PL121SR can be changed. Data is
transmit
data is transmitted to a ground station. The receiving
stationtransmitsthedatatoCaterpillarInc.Thedata
can then
customer.

Data Broadcasts

he machine to Caterpillar, Caterpillar

ite transceiver.

tion between the machine and a remote

ine such as hours of use or the location

ted from the machine to a satellite. Next, the

be sent to a Caterpillar dealer and to the

Service Code

Refere

window will display the appropriate service codes
when the service codes are activated.

The electronic monitoring system has screens for the
service mode that may indicate that a problem exists.
These units of measurement display the diagnostic
codes.

Contact your Caterpillar dealer for more information
on the service modes.

nce: The Gauge Display in the digital display

Electronic Monitoring System

Machine
operation is being transmitted by Product Link to
Caterpillar and/or Caterpillar dealers in order to
better
products and services. The information that is
transmitted may include the following data: machine
seria
emissions data, fuel usage, service meter hours,
version numbers for software and hardware, and
insta

Caterpillar and/or Caterpillar dealers may use this
info
to the customer and/or the machine, checking or
maintaining Product Link equipment, monitoring the
mach
the machine, improving the machine's efficiency,
evaluating or improving Caterpillar products and
ser
valid court orders, performing market research, and
offering the customer new products and services.

Caterpillar may share some or all of the collected
information with Caterpillar affiliated companies,
de
will not sell or rent collected information to any other
third party and will exercise reasonable efforts to

ep the information secure. Caterpillar recognizes

ke
and respects customer privacy. For more information,
please contact your local Caterpillar dealer.

data about the machine's condition and

serve the customer and to improve Caterpillar

l number, location of the machine, fault codes,

lled attachments.

rmation for various purposes: providing services

ine's health or performance, helping to maintain

vices, complying with legal requirements and

alers, and authorized representatives. Caterpillar

62 SEBU8213-04
Operation Section
Machine Operation

Operation in a Blast Site

If the machine is required to work within 12 m (40 ft)
of a blast site, then Product Link PL121SR must
be disabled. In order to disable theProduct Link
PL121SR install a Product Link Disconnect Switch
in the machine cab that will allow the Product Link
PL121SR module to be shut off. Refer to Special
Instruction, REHS2365, “An Installation Guide for the
Product Link PL121SR and for the PL300” for more
details and installation instructions. Y ou may also
disconnect the Product Link PL121SR module from
the main power source by disconnecting the wiring
harness at the Product Link module.

This blast site warning does not supersede the
published requirements or regulations found in “Title
30 of the Code of Federal Regulations (CFR)”. This
warning does not allow deviation from the published
requirements or regulations found in “Title 30 of
the Code of Federal Regulations (CFR)”. A hazard
assessment should be conducted by each customer.
Every customer should meet all of the requirements
of “Title 30 of the Code of Federal Regulations (CFR)”
in order to ensure the safe storage, transportation,
loading, and blasting of any explosive.

Regulatory Compliance

Illustration 89

NOTICE
Transmission of information using Product Link is sub­ject to legal requirements that may vary from location
to location, including, but not limited to, radio frequen­cy use authorization. The use of Product Link must be
limited to those locations where all legal requirements
for the use of the Product Link communication network
have been satisfied.

g0113198

2

The following Product Link PL121SR specifications
are provided in order to aid in conducting any related
hazard assessment and to ensure compliance with
all local regulations:

The transmit power rating for the Product Link

•

PL121SR transmitter is five to ten watts

The operating frequency range for the Product Link

•

PL121SR module is 148 MHz to 150 MHz.

Consult your Caterpillar dealer if there are any
questions.

Information for the initial installation of the Product
Link PL121SR is available in Special Instruction,
REHS2365, “Installation Guide for the Product Link
PL121SR”.

Operation, configuration, and troubleshooting
information for the Product Link PL121SR can be
found in System Operation Troubleshooting Testing
and Adjusting, RENR7911.

In the event that a machine outfitted with Product Link
is located in or relocated to a location where (i) le­gal requirements are not satisfied or (ii) transmitting
or processing of such information across m ultiple lo­cations would not be legal, Caterpillar disclaims any
and all liability related to such failure to comply and
Caterpillar may discontinue the transmission of infor­mation from that machine.

Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a
specific country.

SEBU8213-04 63

Operation Section

Machine Operation

Illustration 90

Note: A translated extract of the above document
is provided below.

g01435306

64 SEBU8213-04
Operation Section
Machine Operation

Table 8

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 which this declaration relates, is in conformity with the following standards and / or other normative documents.

EN 301 721 V1.2.1 (June 2001)

EN 300 489-20V1.2.1 (November 2002)

EN 60950-1/A11:2004, 1st Edition

We hereby declare that all essential radio test suites have been carried out and that the above named product is in conformity
to all the essential requirements of Directive “1999/5/EC”.

The conformity assessment procedure referred to in Article 10 and detailed in Annex [IV] of Directive “1999/5/EC” has been
followed with the involvement of the following Notified Body:

BABT, Claremont House, 34 Molesey Foad, Walton-on-Thames, KT12 4RQ, UK

Identification mark: 0168 The equipment will also carry the

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

n Diego, CA 92124, USA

Sa

Polina Braunstein

President

Class 2 Equipment identifier.

(signature of authorized person) (date)

Class 2 equipment identifier

SEBU8213-04 65

Operation Section

Machine Operation

i03739620

Operation Information

SMCS Code: 7000

To prevent inj
workingonthemachineornearthemachine.To
prevent injury, keep the machine under control at all
times.

Reduce machine speed when you maneuver in tight
quarters or

Select the necessary travel speed before you start
downhill.

When you go downhill, use the same speed that
wouldbeus

Use the decelerator/brake pedal on a downgrade in
order to m
following controls in order to slow down the travel
speed of the machine: decelerator/brake pedal and
buttons f

When the load will be pushing the machine, push
the spee
downhill.

1. Adjust t

2. Fasten the seat belt.

3. Raise all lowered attachments in order to negotiate

any obstacles.

ury, make sure that no people are

when you are going over a hill.

ed to go uphill.

aintain a safe operating mode. Use the

or speed control.

d selector to LOW speed before you start

he operator's seat.

5. Move switch (3)

toward the operator to the

DISENGAGED position.

6. Turn knob (4) i

n order to set the desired engine

speed.

Note: The dec

elerator/brake pedal can be depressed

in order to temporarily reduce travel speed.

7. Move lever (

2) for the desired direction.

8. Release pedal (1).

9. Roll the thumb wheel for the ground speed control

in order to set the desired ground speed. The
wheel for t

he ground speed control is located on

lever (2).

10. Drive the m

achine forward for best visibility and

for best control.

Hydrostatic Drive Operating
Principl

This machine has a hydrostatic drive system which
transfe
hydrostatic drive system eliminates the conventional
type of transmission. The hydrostatic drive system
does not
hydrostatic drive system also eliminates the steering
clutch and brake arrangement.

In the simplest form, a hydrostatic drive system is a
system which contains the following components: a
hydra
motor, and high pressure lines that carry oil between
the components. The pump converts mechanical
power
oil pressure.

e

rs power from the engine to the tracks. The

use a bevel gear and a driveline. The

ulic pump with a control system, a hydraulic

to hydraulic power in the form of oil flow and

Illustration 91

(1) Decelerator/brake pedal
(2) Steering and transmission control (lever)
(3) Parking brake switch
(4) Engine throttle control (k nob)
(5) Winch control lever or ripper control lever (if equipped)

g01258916

4. Push down on pedal (1) in order to prevent the
machine from moving.

To m e e

t requirements, the machine must be able to
move forward and rearward. The machine must also
be able to turn. The pumps are designed to deliver

ing flows of oil to either the forward side or the

vary
reverse side of the hydraulic motors.

rack can be driven at varying speeds in either a

The t
forward direction or in a reverse direction.

ce there are two tracks, there are two hydraulic

Sin
pumps, two sets of hydraulic lines, and two hydraulic
motors.

66 SEBU8213-04
Operation Section
Machine Operation

For the forward

modes or the reverse modes, the
pumps and the motors work in conjunction with each
other. The pumps can produce flow to either the
forwardsideo

f the motors or to the reverse side of
the motors. The pumps can vary the amount of flow in
either direction in order to produce infinitely variable
speed capabi

lities. To turn the machine, each pump
is capable of reducing flow independently. This allows
one track to be driven at a slower speed in order to
cause the ma

chinetoturn.

Slowing the machine or stopping the machine is done
by reducing

the flow of oil to the drive motors or by
stopping the flow of oil to the drive motors. Braking
of the machine is caused by hydrostatic braking of
the tracks

.

The parking brakes are engaged while the brake
pedal (1) i

s fully depressed. The parking brakes are
engaged in the following conditions: parking brake
switch ON , the transmission control NEUTRAL, and
the engin

eOFF.

The parking brakes are attached to the final drives.
The parki

ng brake is spring-applied and oil pressure
released. The engine must be running in order to
release the parking brakes.

The parking brakes disengage when switch (3) is
moved from ENGAGED position. The parking brakes
also dis

engage when brake pedal (1) is released.

General Operational Safety Tips

The seat belt must be fastened at all times.

For a p
pedal (1) or quickly move lever (2) to the NEUTRAL
position. Either movement causes an immediate stop.

For all turns that are on level ground or on side
hill operations, move lever (2) toward the RIGHT
posi
LEFT position for left turns.

Brak

•

•

•

•

rompt stop, quickly depress decelerator/brake

tion for right turns. Move lever (2) toward the

es are applied under the following conditions.

Pedal (1) is fully depressed.

Steering and transmission control (2) is in
NEUTRAL.

Parking brake switch (3) is in the ENGAGED
position.

The engine is OFF.

Operating Principle for the Winch

Illustration 92

(5) Winch control lever
(6) Winch freespool switch
(7) Winch drive away switch

The winc

h for this Caterpillar machine is a
hydraulically driven winch that utilizes a dedicated
piston pump for power input. The winch includes
both pla

netary gears and standard spur gears. The
winch brake is applied by spring pressure. This will
secure the load while control lever (5) is in t he HOLD

on. The winch brake is released hydraulically.

positi
The winch case is designed to bolt directly to the rear
of the machine.

When the winch is operated in either the REEL IN or
theREELOUTdirection,ahydraulicmotordrives

ar train. The control lever supplies oil to the

the ge
winch motor by the hydrostatic control system. The
control lever for the winch is a proportionate control.

mount of hydraulic oil that will be sent to the

The a
winch motor will increase as lever (5) is moved. The
speed of the winch cable increases as the amount of

aulic oil to the winch motor increases. The winch

hydr
brake will be released by pilot pressure when lever
(5) is moved into either the REEL IN or the REEL

irections.

OUT d

The mechanism for the free spool for the winch is a

ined gear. The mechanism for the free spool is

spl
spring-engaged and hydraulically released. Press
the freespool switch once in order to activate the

espool function. Then, hydraulic oil is ported

fre
through the logic valve for the winch. The hydraulic oil
flows from the logic valve for the winch into a cylinder

r the freespool mechanism. This will force the

fo
piston for the freespool mechanism against the coil
spring. This will disengage the splined connection.

isallowsthewinchcabletobepulledoffthewinch

Th
drum by hand.

g0126139

1

SEBU8213-04 67

Operation Section

Machine Operation

The DRIVE AWAY f
drive the tractor away from a load while the winch
cable is attached to the load. When the winch drive
away switch is
drive away valve in order to open an oil flow passage
in the motor drive from one port to another port.
Then, the thr
the rate of oil through the valve. This prevents the
drive motor from spinning too fast. This provides a
controlled
provide a maximum ground speed for the tractor of
approximately 3.2 km/h (2 mph).

An optional assembly of three fairlead rollers
or four fairlead rollers is available. The optional
fairlead a
directional pulls are routinely encountered. The
use of the optional fairlead assemblies will help to
maximize t
winch cable by eliminating wear.

release of the winch cable. This will also

ssemblieswouldbeusedwhenslightside

he life of the winch case and the life of the

unction allows the operator to

turned on, a spool shifts in the winch

ottle spool inside the valve controls

Warm-Up Procedure f or the Winch

Note: War

1. Warm up the hydraulic system for the machine.

For more
Maintenance Manual, “Engine and Machine
Warm-Up”.

mupthewinchateachstart-up.

information, refer to Operation and

Using the Winch

Attaching the

Personal injury or death can result from unexpect­ed movement of objects. Be sure all persons are
clear of cable and objects before a machine is
winched or moved. A safe distance of at least one
and a half times the working length of the cable
should be maintained. The tail end of a moving ob­ject can throw debris at bystanders.

A minimum of five complete wraps of cable must
be maintained on the winch drum. Do not handle
a load with a winch drum that has less than five
wraps.

Do not operate the winch under loads that exceed
the maximum rated bare drum line pull. If exces­sive loa
and sheave blocks. Any attempt to exceed the ca­pacity of one winch is extremely hazardous. Never
try to co

ds are encountered, use a multi-part line

uple two or more tractors together.

Winch Cable

2. Use the reel-in and reel-out function to operate the

winch. This will allow the hydraulic oil to circulate

hout the winch.

throug

Note: The winch should be operated under a no-load

tion during warm-up.

condi

The warm-up procedure is recommended at each
start-up and is mandatory when temperatures are

w4°C(40°F).

belo

NOTICE
If at all possible, always line up the rear end of the
machine with the load, so that the load can be winched
in a straight path. This avoids unnecessary strain and
wear on the side rollers. It also helps to wind the cable
onto the winch drum in level layers.

NOTICE
The winches described in this manual are neither de-

ed nor intended for use or application used in the

sign
lifting or moving of persons.

ou are working on a hill, maneuver the machine

1. If y

above the load and align the rear of the machine
with the object.

2. If you are working on a level surface, align the rear

of the machine with the object.

ear leather gloves when handling the winch ca-

W
ble.

68 SEBU8213-04
Operation Section
Machine Operation

i02161716

NOTICE
When winding t
tempt to maintain tension by allowing the winch ca­ble to slip through the hands. Always use hand-over­hand techniqu
clothing away from the winch drum and rollers.

3. Press switc

position. Pull out the cable and attach the cable
to the load.

he winch cable on the drum, never at-

e, being very carefull to keep hands and

h (6) one time into the FREESPOOL

Prestart Checks

SMCS Code: 7000

Before the sta
10 hours of operation, perform the checks and tests.
The checks and tests are in the Maintenance Interval
Schedule.

Test the backup alarm.

•

rt of each operational shift, or every

Note: Never operate the winch when there is less
than five wraps of the winch cable around the load
drum. Use r
complete wraps of the winch cable for a visual
warning.

Note: Make sure that there is enough clearance
between the object and the machine so that the
machine c

Note: Make sure that the ground is stable before
winchin

4. To tighten the main cable, make sure that the

drum is n
in order to turn off the FREESPOOL mode. This
allows REEL IN position (5A) to operate.

Note: Avoid sudden shock of a load or jerking of a
load. This type of operation may cause heavy loads
in exce
failure of the cable or the winch.

Unhoo

ed paint in order to paint the last five

an turn.

g in a load.

ot rotating. Press switch (6) one time

ss of the rated capacity, which may result in

king the Winch Cable

Test the brakes.

•

Check the i

•

Inspect the cab filter (fresh air).

•

Clean the cab filter (fresh air) or re place the cab

•

filter (fresh air).

Check the cooling system level.

•

Check the

•

Drain the water separator at the fuel filter.

•

Drain the water and sediment from the fuel tank.

•

Check th

•

Inspect the seat belt.

•

Check the transmission oil level.

•

Perfo

•

ndicators and gauges.

engine oil level.

e hydraulic system oil level.

rm the walk around inspection.

Personal injury or death can result from persons
too close to the machine.

When reeling in the cable, make sure that all
persons are clear from rolling objects or cable
whiplash.

1. Move the lever to REEL OUT position (5C). Reel

out the winch cable in order to release tension.

2. Press switch (6) one time away from the operator

into the FREESPOOL position. With switch (6) in
the FREESPOOL position, pull out enough cable
in order to unfasten the cables or the chokers.

3. Move the lever to REEL IN position (5A). Slowly

reel in the cable until the cable is completely
wound.

SEBU8213-04 69

Operation Section

Engine Starting

Engine Starting

Engine Starting

SMCS Code: 1000; 7000

1. Move the bat

position.

2. Move the im

position.

tery disconnect switch to the ON

plement controls to the HOLD

i03322101

Thesteeringan

•

in NEUTRAL.

The implement

•

HOLD position.

5. Before the en
presence of bystanders or maintenance
personnel. Ensure that all personnel are clear of
the machine
you start the engine.

6. Turn knob (3
you start the engine.

Note: If th
indicator light turns off. Then, turn on the engine start
switch.

7. Turn engine start switch (4) to the START position.

Do not cra
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is no
that the oil pressure is sufficient.

e machine is cold, wait until the glow plug

nk the engine for more than 30 seconds. Al-

t kept low until the oil gauge display verifies

d transmission control must be

control lever must be in the

gine is started, check for the

.Briefly sound forward horn (5) before

) to one-third of the full travel before

NOTICE

Illustration 93

(1) Steering and transmission control (lever)
(2) Parking brake switch
(3) Engine throttle control (k nob)
(4) Engine start switch
(5) Forward horn
(6) Hydraulic lockout

3. Move lever (1) into the NEUTRAL position.

4. Move switch (2) to the ENGAGED position.

Note: The engine will not start unless switch (2) is in

the ENGAGED position.

Four conditions must be satisfied in order to start
the engine.

Theoperatormustbeseatedintheseat.

•

The parking brake must be engaged.

•

g01700454

8. Release the engine start switch key after the
engine starts.

9. Allow the engine to warm up at LOW IDLE. Refer
to Operation and Maintenance Manual, “Engine
and Machine Warm-up”.

Ether Starting Aid (If Equipped)

If the temperature of the coolant is below 0 °C (32 °F)
a premeasured amount of ether is automatically
injected into the engine air intake when you crank
the engine.

1. Perform Step 1 through Step 6 of the Engine
Starting procedure.

2. Turn start switch key (4) to the START position.
Crank the engine.

NOTICE
Do not crank the engine for more than 30 seconds. Al­low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies
that the oil pressure is sufficient.

The implements must be in the LOCK OUT

•

position. Use hydraulic lockout (6) in order to
lock out the implements.

3. Release start switch key (4) when the engine

starts.

70 SEBU8213-04
Operation Section
Engine Starting

For starting be
following cold weather starting aids is recommended:

Coolant heate

•

Fuel heater

•

Jacket water heater

•

Extra batte

•

Reference: At temperatures below −23°C (−10°F),
consult you
information or refer to Special Publication,
SEBU5898, “Cold Weather Recommendations for
all Caterp

low −18°C (0°F), the use of one of the

r

ry capacity

r Caterpillar dealer for additional

illar Machines”.

i02801522

Engine and Machine Warm-Up

SMCS Code: 1000; 7000

NOTICE
Keep the engine speed slow until the indicator light for
the engine oil pressure goes out.

If the light does not go out within ten seconds, stop
the engine and investigate the cause before starting
the engine again. Failure to correct the problem can
cause engine damage.

1. Allow the engine to warm up at low idle.

2. Look at the indicators and the gauges frequently

during operation.

Note: During extreme cold conditions, the alert
indicator for the hydraulic oil filter bypass may come
on. As the hydraulic oil warms up, the alert indicator
should go out.

Also, in order to help the hydraulic oil to warm up,
hold the bulldozer blade control lever in the LIFT
position for periods of ten seconds or less. This
will allow the hydraulic oil to reach relief pressure,
which causes the hydraulic oil to warm up more
rapidly.

Cycle all controls in order to allow warm hydraulic
oil to circulate through all hydraulic cylinders and
through all hydraulic lines.

When you idle the machine for warm-up, observe
the following recommendations:

If the temperature is greater than 0°C (32°F),

•

warm up the engine for approximately 5
minutes.

If the temperature is less than 0°C (32°F), warm

•

up the engine for approximately 15 minutes.

If the temperature is less than − 18°C (0°F) or if

•

hydraulic functions are sluggish, additional time
may be required.

SEBU8213-04 71

Operation Section

Adjustments

Adjustments

i02799322

Bulldozer Blade Tip

SMCS Code: 6060; 7000

The standard position for the cutting edge angle is 56
degrees. This provides optimum performance under
normal conditions.

Tip the blade forward in order to obtain a cutting edge
angle up to 60 degrees. Tipping the blade forward
provides improved penetration in hard materials.

Tip the blade rearward in order to obtain a cutting
edge angle up to 52 degrees. Tipping the blade
rearward provides a better carrying capability of soft
material.

Adjustment of Bulldozer Blade
Pitch

1. Lower the bulld

control for the lift cylinder in the FLOAT position.

2. Actuate the ti

from the tilt brace. Boss (5) must be loose and
able to move freely. Stop the engine.

3. Remove pin (2) and cover (1), if necessary.

Keep fingers
pin holes in the tilt brace and/or push arm bracket at
any time during the adjustment procedure.

4. Install the slotted end of cover (1) onto boss (5).

5. Turn the to

set.

6. Install t

Note: If the cover plate does not cover both mounting

bolt (3)
incorrectly adjusted.

he cover (1) and replace locking pin (2).

and retainer bolt (8), then the top link is

ozer blade to the ground. Place the

lt cylinder in order to remove all force

NOTICE

clear. Do not place your fingers into the

p link until the desired cutting angle is

Illustration 94

g012

58184

i02515382

Ripper Tip and Shank Protector

SMCS Code: 6808; 6810; 6812

Illustration 96

Replace the ripper tip and the shank protector
(if equipped) before wear occurs on the shank.
Follow the replacement procedures in the Operation
and Maintenance Manual, “Ripper Tip and Shank
Protector - Inspect/Replace”.

g01258327

llustration 95

I

The bulldozer blade can be placed in several pitch

ositions such as the following pitches: the extended

p
position (A), the middle position (B), and the retracted
position (C).

g01258266

72 SEBU8213-04
Operation Section
Adjustments

i02799338

Cutting Edg es and End Bits

SMCS Code: 6801; 6804

Illustration 97

g01097854

Replace the cutting edges or reverse the cutting
edges. Replace the end bits. These processes must
be performed before wear occurs on the blade base.
For the replacement procedures, see the Operation
and Maintenance Manual, “Cutting Edges and End
Bits - Inspect/Replace”.

SEBU8213-04 73

Operation Section

Parking

Parking

i02808917

Stopping the Mach ine

SMCS Code: 7000

NOTICE
Park on a level surface. If it is necessary to park on a
grade, chock the tracks securely.

i02799345

Stopping the Engine

SMCS Code: 1000; 7000

NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac­celerated wear of the engine components.

Refer to the following procedure, to allow the engine
to cool, and to prevent excessive temperatures in the
turbocharger housing (if equipped), which could cause
oil coking problems.

1. Operate the engine for five minutes at low idle

with no load.

This allows hot areas in the engine to cool
gradually. This will extend the engine life.

2. Move all control levers into the HOLD position.

Illustration 98

1. Move steering and transmission control lever (2)
to the NEUTRAL position in order to stop the
machine.

2. Apply decel/brake pedal (1) in order to hold the
machineinposition.

3. Turn the engine throttle control (knob) (4) to the
LOW IDLE position.

4. Push parking brake switch (3) away from the
operator to the ENGAGED position.

5. Release pedal (1).

6. Use lever (5) in order to lower all attachments to

the ground and apply slight downward pressure.

7. Move all attachment controls to the NEUTRAL
position.

g01258916

Illustration 99

3. Turn the engine start switch key to the OFF
position in order to stop the engine.

opping the Engine if an

St

g01270374

i02789742

Electrical Malfunction Occurs

CS Code: 1000; 7000

SM

ngine Start Switch Key ON or OFF

E

Emergency Engine Shutdown

Engine Start Switch Key ON or OFF

1. Apply the parking brake.

2. Lower the dozer blade or the ripper, if necessary.

74 SEBU8213-04
Operation Section
Parking

3. Dismount the ma

Illustration 100

4. Open the access door for the fuse panel.

chine.

g01259901

i03316659

Equipment Lowering with
Engine Stoppe

d
(Electrohydraulic Implement
Va lve)

SMCS Code: 7000

Dead Engine Lower

Actuator Sp

Relieve the pressure in the hydraulic tank.

ools

Illustration 101

5. Use the fuse puller that is located on the panel
door (not shown). Pull the 15 Amp fuse for the
Engine Stop from the fuse panel.

Note: Do not operate the machine again until the
malfunction has been corrected.

g01393642

Illustration 102

There is an access door for the dozer/ripper valves on
the right side of the machine. Open the access door.

This procedure requires two people. One person
must operate the control valves and the other person
remains at the dozer blade. Care must be taken
when you perform this procedure. The person at the
dozer blade must make sure that the area is clear.

g01399056

SEBU8213-04 75

Operation Section

Parking

Illustration 103

Top vi e w

(1) Adjustment screw to lift control valve
(2) Adjustment screw to angle control valve
(3) Adjustment screw to tilt control valve
(4) Adjustment screw to ripper control valve
(5) Adjustment screw to lift control valve
(6) Adjustment screw to angle control valve
(7) Adjustment screw to tilt control valve
(8) Adjustment screw to ripper control valve

g01400073

1. Loosen locknut (1A) and turn adjustment screw
(1) inward.

Note: After completing the dead engine lower for
each function, back out the adjustment screw fully.
Then, tighten the locknut.

Note: Before you screw in all dead engine lower
screws, clean all the dirt and paint from the
adjustment screw.

7. Loosen locknut

(7A) and turn adjustment screw (7)
inward. This relieves the rod pressure from the tilt
cylinder to the tank. This tilts the dozer blade left.

Illustration 104

Anti-drift valve

g01700573

8. Before releasing pressure on the fourth valve (8,
8A), completely back off adjustment screw on
anti-drift valve (9). This will make sure that the
pressure is fully released.

a. Mark the location of the adjuster valve. Then,

back off the adjustment screw completely.

9. Loosen locknut (8A) and turn adjustment screw (8)
inward. This relieves the head pressure from the
ripper cylinder to the tank. This lowers the ripper.

Close the access door. Close the hydraulic oil tank
cap.

Note: Perform steps 2 through 4 in order to change
the angle or lower the equipment.

2. Loosen locknut (2A) and turn adjustment screw
(2) inward. This relieves head pressure to the right
angle cylinder and rod pressure to the left angle
cylinder. This angles the dozer blade to the right.

3. Loosen locknut (3A) and turn adjustment screw
(3) inward. This relieves head pressure to the tilt
angle cylinder. This tilts the dozer blade to the
right.

4. Loosen locknut (4A) and turn adjustment screw
(4) inward. This relieves rod pressure from the
ripper cylinder to the tank. This raises the ripper.

5. Loosen locknut (5A) and turn adjustment screw
(5) inward. This relieves rod pressure from the lift
cylinder to the tank. This lowers the dozer blade.

6. Loosen locknut (6A) and turn adjustment screw
(6) inward. This relieves rod pressure to the right
angle cylinder and head pressure from the left
angle cylinder to the tank. This angles the dozer
blade left.

Note: After completing the work for the dead engine
lower, cycle each section of the implement valve
10 times in order to remove any air from the valve
sections.

76 SEBU8213-04
Operation Section
Parking

i02801552

Leaving the Machine

SMCS Code: 7000

Illustration 105

g01259039

1. Use the steps and the handholds when you get
off the machine. Face the machine and use both
hands. Make sure that the steps are clear of
debris before you dismount.

Note: Do not use the angle cylinders as a step.

2. Inspect the engine compartment for debris. Clean

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

3. Turn the key for the battery disconnect switch
to the OFF position. This will help to prevent a
battery short circuit and the current draw that is
made by certain components. When the machine
is not operated for an extended period, remove the
key from the battery disconnect switch. Removing
the key will help to protect the machine from
vandalism.

4. Install all vandalism protection locks and
vandalism covers. Lock the doors.

SEBU8213-04 77

Operation Section

Transportation Information

Transportation Information

i03739521

Shipping t he Machine

SMCS Code: 7000; 7500

Investigate the travel route for overpass clearances.
Make sure that there is adequate clearance for the
machine that is being transported. This is especially
true for machines that are equipped with a cab, or a
canopy.

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
prevent the machine from slipping as you load the
machine. Removing ice, snow, or other slippery
material will prevent the machine from slipping in
transit.

NOTICE
Obey all state and local laws governing the weight,
width and length of a load.

5. Turn the start s
the parking brake switch. Remove the key.

6. Turn the batte
position. Remove the key.

7. Lock the door
any vandalism protection.

8. Install the
the tracks in the front and in the rear.

Consult you
instructions for your machine.

witch key to the OFF position. Lock

ry disconnect switch to the OFF

and lock the access covers. Attach

tie-downs at several locations and block

r Caterpillar dealer for shipping

Calculating the Mass of the
Machine

Usethefollowingtabletocalculatethemassof
your Cate
machinethatisinthefirst row. Add the additional
weight of the various attachments and work tools that
are consi

rpillar machine. Start with the mass of the

stent with your machine.

Remove the starting aid (ether) cylinder, if equipped.

Make sure the cooling system has proper antifreeze if
moving machine to a colder climate.

Observe all regulations governing wide loads.

Illustration 106

1. Place blocks under the trailer wheels or under the
rail car wheels before loading, as shown.

2. Lower all attachments to the floor of the transport
machine. Move the transmission control lever to
the NEUTRAL position.

g00040011

3. Engage the parking brake switch.

4. Stop the engine.

78 SEBU8213-04
Operation Section
Transportation Information

Table 9

D3K, D4K, and D5

The machine is operated with the dozer blade, the

ROPS canopy, the backup alarm, the operator (75 kg

(165 lb)), co

olant, lubricants and the full fuel tank.

(1)

Radiator grill (HD)
43 kg (95 lb)

Rear guard
116kg(256lb)

ROPS cab
235kg(518lb)

ROPS cab (logging machine)
324kg(715lb)

Auxiliary drive

Installation AR (winch)

Ripper
612 kg (1350 lb)

Winch mounting
111kg(245lb)

Front counterweight
286kg(630lb)

Accugrade Installation (Attachment ready option)
16 kg (35 lb)

Hydraulic system (4 valve)
19 kg (42 lb)

Front sweep assembly
132kg(291lb)

Rear sweep assembly
56 kg (124 lb)

Screens (canopy) at the front and the door
67 kg (148 lb)

Side screen
55 kg (121 lb)

Rear screen (cab)
43 kg (95 lb)

Rear screen (canopy)
39 kg (86 lb)

Full track roller guard

Guide guard (center track)

Sound suppression (EEC)
5kg(11lb)

Other Approved Attachments or Work tools

The Total Mass of the Machine without the operator

(1)

The weights that are given herein describe the machine as the machine is manufactured by Caterpillar Inc.

K Track-Type Loaders

D3K XL
7795 kg

(17185 lb)

D3K LGP

8093 kg

(17842 lb)

D4K XL
8147 kg

(17961

lb)

D4K
LGP

8501

kg

(18742

lb)

D5K

XL

9408

kg

(20741

lb)

D5K
LGP

9683

kg

(21347

lb)

++++++

++++++

++++++

+++++

+31 kg
(68 lb)

+91 kg
(201 lb)

+31 kg
(68 lb)

+91 kg
(201 lb)

+32 kg
(71 lb)

+93 kg
(205 lb)

+32 kg
(71 lb)

+93 kg
(205 lb)

-12 kg
(26 lb)

+47 kg
(104 lb)

-12 kg
(26 lb)

+47 kg
(104 lb)

++++++

++++++

++++++

++++++

++++++

++++++

++++++

++++++

++++++

++++++

++++++

+74 kg
(163 lb)

+24 kg
(53 lb)

+74 kg
(163 lb)

+24 kg
(53 lb)

+85 kg
(187 lb)

+26 kg
(57 lb)

+85 kg
(187 lb)

+26 kg
(57 lb)

+105
kg
(232 lb)

+31 kg
(68 lb)

+105
kg
(232 lb)

+31 kg
(68 lb)

++++++

++++++

======

SEBU8213-04 79

Operation Section

Transportation Information

i03727347

Lifting and Tying Down the
Machine

SMCS Code: 7000; 7500

Improper lifting and improper tie-downs can a llow
the load to shift or fail and cause injury or damage.
Use only properly rated cables and slings with lift
and tie down points provided.

Follow the instructions in Operation and M ain­tenance Manual, “Lifting and Tying Down the
Machine” for the proper technique for securing
the machine. Refer to Operation and Maintenance
Manual, “Specifications” for specific weight in­formation.

NOTICE
Improper lifting and improper tie-downs can allow the
load to shift and cause injury or damage.

The weight and the instructions that are given
herein describe the machine as the machine is
manufa

ctured by Caterpillar.

Refer to the Operation and Maintenance Manual,

fications” for specific weight information.

“Speci

1. Engage the parking brake.

Illustration 108

Rear view

2. Use proper rated cables and slings for lifting. The
crane should be positioned so that the machine
is lifted parallel to the ground. Position the slings
beneath the front of the track and beneath the
rear of the track.

3. On sharp corners, use corner protectors.

4. To prevent contact with the machine, lifting cables

should have sufficient length.

5. The width of the spreader bar and the strength of
the spreader bar should be sufficient to prevent
contact with the machine.

When the wire cables are lifted the wire cables
should slide to front track rollers and to the rear
track rollers.

g01355314

Illustration 107

g01355253

Tie-Down Points For Fire Plow
Machines (If Equipped)

When a machine with attachments for the fire plow
is tied down, the four external tie-down points must
be used.

llustration 109

I

Right track roller frame

Some components are removed for clarity.

g01627047

80 SEBU8213-04
Operation Section
Transportation Information

1. Use properly ra
machine that is a fire plow.

2. Use the additi
track roller frame in order to stabilize the machine.

Note: Do not a
tie-down points.

ted cables in order to tie down the

onal two tie-down points on each

ttempt to lift the machine from the

SEBU8213-04 81

Operation Section

Towing Information

Towing Inform ation

i02801575

Towing the Machine

SMCS Code: 7000

Personal injury or death could result when towing
a disabled machine incorrectly.

Block the machine to prevent movement before fi-
nal drives are disengaged. The machine can roll
free if it
gaged, the machine cannot be stopped or steered.

Follow th
perform the towing procedure.

Relieve
fore any disassembly.

Even af
hydraulic oil can still be hot enough to burn. Allow
the hydraulic oil to cool before draining.

To tow the machine, both final drives must be disen­gaged. Otherwise, damage could result.

This machine is equipped with spring-applied
brakes. These brakes are also oil pressure released
brakes. If the engine or the system for pressure oil is
inoperable, the brakes are applied and the machine
cannot be moved.

Note: Do not tow the machine with the sun gears
in place. Remove the sun gear from each final
drive.

Reference: See the publication Power Train

Disassembly and Assembly in the machine's Service
Manual for the procedure. Consult your Caterpillar
Dealer for the proper procedure in order to remove
the sun gear, if necessary.

These towing instructions are for moving a disabled
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 convenient location for repair. Always haul the
machine if long distance moving is required.

Shields must be provided on both machines. This
will protect the operator if the tow line or the tow bar
breaks.

is not blocked. With final drives disen-

e recommendations below, to properly

the hydraulic tank and line pressure be-

ter the machine has been turned off, the

NOTICE

Do not allow any
except the operator. Only allow the operator on the
disabled machine if the operator can control the
steering and/

Before you tow the machine, make sure that the tow
line or the to
the tow line or the tow bar has enough strength for
the towing procedure that is involved. The strength of
the tow line
percent of the gross weight of the towing machine.
This requirement is for a disabled machine that is
stuck in the

Attach the cable to the towing eye on the front of
the machin
Attach the cable to the drawbar pin on the rear of the
machineifyouaretowingthemachinebackward.

Do not use a chain for pulling a disabled machine.
A chain link can break. This may cause personal
injury. U
rings. Put an observer in a safe position in order to
watch the pulling procedure. The observer can stop
the proce
pulling whenever the towing machine moves without
moving the towed machine.

Keep the tow line angle to a minimum. Do not exceed
a 30 degree angle from the straight ahead position.

Quick machine movement could overload the tow
line or the tow bar. This could cause the tow line
or the t
movement will be more effective.

Norma
as the disabled machine. Make sure that the towing
machine has enough brake capacity, enough weight,
and en
able to control both machines for the grade that is
involved and for the distance that is involved.

You must provide sufficient control and sufficient
braking when you are moving a disabled machine
down
additional machines that are connected to the rear of
the disabled machine. This will prevent the machine
fro

All situation requirements cannot be listed. Minimal
tow
surfaces. On inclined surfaces or surfaces that are in
poor condition, maximum towing machine capacity
is

Do not tow a loaded machine.

Consult your Caterpillar dealer for the equipment that
is necessary for towing a disabled machine.

seawirecablewithendsthathaveloopsor

dure if the wire cable starts to break. Stop

ow bar to break. Gradual, steady machine

lly, the towing machine should be as large

ough power. The towing machine must be

hill. This may require a larger towing machine or

m rolling away out of control.

ing machine capacity is required on smooth, level

required.

person on the disabled machine

or braking.

w bar is in good condition. Make sure that

or of the tow bar should be at least 150

mud and for towing on a grade.

e if you are towing the machine forward.

82 SEBU8213-04
Operation Section
Engine Starting (Alternate Methods)

Engine Starting (Alternate
Methods)

i02799419

Engine Star
Start Cables

SMCS Code: 1

Failure to properly service the batteries may cause
personal injury.

Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
machine.

Do not smoke when checking ba ttery electrolyte
levels.

Electrolyte is an acid and can cause personal in­jury if it contacts the skin or eyes.

Always wear eye protection when starting a ma­chine with jump start cables.

Improper jump start procedures can cause an ex­plosion resulting in personal injury.

When using jumper cables, always connect the
positive (+) jumper cable to the positive (+) bat­tery terminal first. Next, connect the negative (-)
jumper cable to the frame away from the batteries.
Follow the procedure in the Operation and Main­tenance Manual.

Jump start only with an energy source of the same
voltage as the stalled machine.

T urn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the
energy source is connected.

Do not attempt to charge a battery that has ice in

y of the cells.

an

Charging a battery in this condition can cause an

xplosion that may result in personal injury or

e
death.

lways let the ice melt before attempting to

A
charge.

ting with Jum p

000; 7000

NOTICE
When starting
the machines do not touch. This could prevent dam­age to engine bearings and electrical circuits.

Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components o

Severely discharged maintenance free batteries do
not fully re
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable ar

Thismachinehasa12voltstartingsystem.Useonly
thesamevo
voltage damages the electrical system.

from another machine, make sure that

n the stalled machine.

charge from the alternator after jump start-

e still rechargeable.

ltage for jump starting. Use of a higher

Use of Jump Start Cables

1. Place th

machine in the NEUTRAL position. Engage the
parking brake. Lower all attachments to the
ground.

Note: See “Equipment Lowering with Engine
Stoppe

2. On the stalled machine, turn the engine start switch

to the O

3. On the stalled machine, turn the battery disconnect

switc

4. Move the machine or the auxiliary power source

close
reach. DO NOT ALLOW THE MACHI NE OR THE

AUXILIARY POWER SOURCE TO CONTACT
THE S

5. Stop the engine on the machine that is the

elec
power source, turn off the charging system.)

6. Che

and for correct tightness. Make these checks on
both machines. Make sure that the batteries in
the
batteries for low electrolyte.

7. Co

positive cable terminal of the discharged battery.

Do
metal except for battery terminals.

e transmission control on the stalled

Move all controls to the HOLD position.

d” for more information.

FF position. Turn off the accessories.

h to the ON position.

to the stalled machine so that the cables can

TALLED MACHINE.

trical source. (If you are using an auxiliary

ck the battery caps for correct placement

stalled machine are not frozen. Check the

nnect the positive jump start cable to the

not allow positive cable clamps to contact any

SEBU8213-04 83

Operation Section

Engine Starting (Alternate Methods)

Note: This mach
Only the battery terminals inside the right access door
should be used in order to jump start the machine.

8. Connect the positive jump start cable to the
positive terminal of the electrical source.

9. Connect one end of the negative jump start cable
to the negative terminal of the electrical source.

10. Make the final connection. Connect the negative
cable to the frame of the stalled machine. Make
this connec
the fuel, away from the hydraulic lines, and away
from all moving parts.

11. Start the engine of the machine that is the
electrical source. (If you are using an auxiliary
power sour
the auxiliary power source.)

12. Allow the
for two minutes.

13. Attempt t

Reference: For more information, refer to

Operati
Starting”.

ine is equipped with two batteries.

tion away from the battery, away from

ce, energize the charging system on

electrical source to charge the batteries

ostartthestalledengine.

on and Maintenance Manual, “Engine

14. Immedia
disconnect the jump start cables in reverse order.

tely after the stalled engine starts,

84 SEBU8213-04
Maintenance Section
Lubricant Viscosities and Refill Capacities

Maintenance Section

Lubricant Viscosities and
Refill Capacities

i03727400

Lubricant Viscosities

SMCS Code: 7000; 7581

Selecting the Viscosity

The proper oil viscosity grade is determined by
the minimum outside temperature. This is the
temperature when the machine is started and while
the machine is operated. In order to determine the
proper oil viscosity grade, refer to the “Min” column
in the table. This information 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
the highest temperature that is anticipated. Use the
highest oil viscosity that is allowed for the ambient
temperature when you start the machine.

Machines that are operated continuously should
use oils that have the higher oil viscosity in the final
drives and in the differentials. The oils that have the
higher oil viscosity will maintain the highest possible
oil film thickness. Consult your dealer if additional
information is needed.

Lubricant Viscosities for Ambient
Temperatures

Note: When you operate the machine at temperatures

below 20°C (4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations For
All Caterpillar Equipment”. This is available from your
Caterpillar dealer.

Table 10

LUBRICANT VISCOSITIES FOR AMBIENT TEMPERATURES

(1)

°C °FCompartment or System Oil Type and Classification Oil Viscosities

MinMaxMinMa

x

(continued)

SEBU8213-04 85

Maintenance Section

Lubricant Viscosities and Refill Capacities

(Table 10, contd)

(7)

(11)

(12)

(1 2)

(11)

(1 2)

(1 2)

(6)

(1 0)

(13) (10)

(1 0)

(1)

°C °FCompartment or System Oil Type and Classification Oil Viscosities

Min Max Min Max

−40 30 −40 86

-40 40 -40 104

−30 30 −22 86

−30 50 −22 122

-18 40 0 104

-20 40 -4 104

−20 40 −4104

−15 50 5 122

−25 40 −4104

-15 50 5 122

−40 10 −40 50

−40 20 −40 68

−30 20 −22 68

0353295

10 50 50 122

-20 43 -4 110

−40 0 −40 32

−40 10 −40 50

−30 10 −22 50

5

-30 25 -22

(continued)

77

122

77

Engine Crankcase

(2)(3)

Hydrostatic Transmission

Hydraulic Systems

Gear Case for the Winch

Final Drives

LUBRICANT VISCOSITIES FOR AMBIENT TEMPERATURES

SAE 0W20 −40 10 −40 50

SAE 0W30

Cat DEO Multigrade

Cat DEO SYN

Cat Arctic DEO SYN

(4)

CAT ECF-1, CAT ECF-2,

CAT ECF-3

(5)

SAE 0W40

SAE 5W30

SAE 5W40

SAE 10W30

SAE 10W40 -18 50 0 122

SAE 15W40 −9.5 50 15 122

Cat HYDO Advanced 10

Cat HYDO

(7)

(8)

Cat DEO
Cat MTO

Cat TDTO-TMS

Cat TDTO

Cat DEO SYN

Cat Arctic DEO SYN

Cat Arctic TDTO SYN

Cat TO-4

commercial TO-4

Cat BIO HYDO Advanced

(HEES)

commercial BF-2

(9)

Cat ECF-1a Cat ECF-2, Cat

ECF-3, Cat TO-4M

SAE 0W20 −40 40 −40 104

SAE 0W30 −40 40 −40 104

SAE 5W30 −30 40 −22 104

SAE 5W40 −30 40 −22 104

SAE 10W

0W −20 40 −4104

SAE 1

SAE 10W30

SAE 15W40

Cat MTO

Cat TDTO-TMS

SAE 0W-20

SAE 0W-30

Cat TDTO

Cat TDTO-TMS

Cat Arctic TDTO SYN

commercial TO-4

SAE 5W30

SAE 10W −20 10 −450

(13)

E30

SA

SAE 50

(13) (1 4)

Cat TDTO-TMS

SAE 0W20

SAE 0W30

Cat TDTO

Cat TDTO-TMS

Cat Arctic TDTO SYN

commercial TO-4

SAE 5W30

SAE 10W −30 0 −22 32

SAE 30 −25 25 −13

SAE 50 −15 50

Cat TDTO-TMS

86 SEBU8213-04
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 10, contd)

LUBRICANT VISCOSITIES FOR AMBIENT TEMPERATURES

SAE 75W90 -30 40 -22 104

SAE 75W-140

SAE 80W90

SAE 85W140

Track Pins

Cat GO (Gear Oil)
Cat Synthetic GO

(1 5)

(16)

commercial API GL-5 gear oil

SAE 90

Cat DEO

SAE 30

Cat DEO SYN

Track Idlers and Track Rollers

Cat ECF-1

a, Cat ECF-2,

SAE 40 -10 4 0 14 104

Cat ECF-3

API CF

(1)

When you operate the machine at temperatures below 20°C (4°F), refer to Special Publication, SEBU5898, “Cold Weather

Recommendations for All Caterpillar Machines”. This is available from your Caterpillar dealer.

(2)

Supplem
for col
soaked
cooler

(3)

API CF oils are not recommended for C aterpillar 3500 Series and smaller Direct Injection (DI) diesel engines. API CF-4 oils are not
recommended for Caterpillar machines with diesel engines.

(4)

Cat Arctic DEO SYN is an SAE 0W-30 oil viscosity grade.

(5)

API CJ­speci
ECF-1
Recom

(6)

SAE 10W-30 is the preferred viscosity grade for the 3116, 3 126, C7, C-9 and the C9 diesel engines when the ambient temperature is
between -18° C (0° F) and 40° C (104° F).

(7)

Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when
ambient temperature is between −20 °C (−4 °F) and 40 °C (104 °F). Cat HYDO Advanced 10 has an SAE viscosity grade of 10W. Cat
HYDO Advanced 10 has a 50% increase in the standard oil drain interval for machine hydraulic systems (3000 hours versus 2000
hours) over second and third choice oils - when following the maintenance interval schedule for oil filter changes and for oil sampling that is
stated in the Operation and Maintenance M anual for your particular machine. 6000 hour oil drain intervals are possible when using S·O ·S
Services oil analysis. Contact your Cat dealer for details. In order to gain the most benefit from the improved performance designed into Cat
HYDO Advanced 10, when switching to Cat HYDO A dvanced 10, cross contamination with the previous oil should be kept to less than 10%.

(8)

Seco

Cat
spe
the
usi
Cat

(9)

Commercial biodegradable hydraulic oil (HEE S) must meet the Caterpillar BF-2 specification.

(10)

Cat T DTO-TMS (“Transmission Multi-Season”) (synthetic blend that exceeds the specifications of TO-4M multigrade oil)

(11)

vi
vi
lu

(12)

TO-4 specification for the SAE 30 viscosity grade. Typical viscosity grades are SAE 0W-20, SAE 0W-30, and SA E 5W-30. The Second
Choice is oils with a TO-4 additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W -30 .

(13)

50°C (122°F).

(14)

h

(15)

(16)

ental heat is recommended for cold soaked starts below the minimum ambient temperature. Supplemental heat may be required

d soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. Cold

starts occur when the engine has not been operated for a period of time. This allows the oil to become more viscous due to

ambient temperatures.

4, A PI CI-4, API C I-4 PLUS, and API CH-4 oils are acceptable if the requirements of Caterpillar's ECF-1-a (Engine Crankcase Fluid

fication - 1 -a) are met. API CJ-4, API C I-4, API CI-4 PLUS, and API C H-4 oils that have not m et the requirements of Caterpillar's

-a or ECF-2specification may cause reduced engine life. Refer to Special Publication, SEBU 6250, “Caterpillar Machine Fluid
mendations” for more information to the C AT ECF specifications and other commercial oils.

nd choice oils are C at HYDO, Cat MTO, Cat DEO, Cat DEO-ULS, Cat TDTO, Cat Arctic TDTO, Cat TDTO-TMS, Cat DEO SYN,

Arctic DEO SYN. Third choice oils are commercial oils that meet Cat ECF-1-a, Cat ECF-2, Cat ECF-3, Cat TO-4, or the Cat TO-4M
cifications, and that have a minimum zinc additive level of 0.09 percent (900 ppm). Commercial biodegradable hydraulic oil must meet
Cat BF-2 specification. Refer to the m achine Operation and Maintenance Manual an d/or contact your local Caterpillar dealer before

ng commercial oils that meet Cat BF-2 in Cat Hydraulic Excavators. The minimum viscosity for commercial alternative oils used in most

machine hydraulic and hydrostatic transmission systems is 6.6 cSt at 100 °C (212 °F) (“ASTM D445”).

First Choice is Cat Arctic T DTO SYN with SAE 0W-20 viscosity grade. The Second Choice is oils of full synthetic base stock without

The
scosity index improvers that meet the performance requirements of the TO-4 specification for the SAE 30 viscosity grade. Typical lubricant
scosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. The Third Choice is oils that contain a TO-4 additive package and a

bricant viscosity grade of SA E 0W -20, SAE 0W-30 , or SAE 5W-30.

The First Choice is oils of full synthetic base stock without viscosity index impro vers that meet the performance requirements of the Cat

Except for the winch hydraulic system, use SAE 30 viscosity grade for 0°C (32°F) to 43°C (110°F) or Cat TDTO-TMS for −20°C (−4°F) to

o not use SAE 50 oil viscosity grade in transmissions with “ICM” control. Do not use SAE 50 oil v iscosity grade for the winch cases with

D

ydraulic drive.

Cat GO (Gear Oil) is available in SAE 80W-90 and SAE 85W-140 viscosity grades.
Cat Synthetic GO is an SAE 75W-140 oil viscosity grade.

SAE 5W40 -35 40 -31 104

(1)

°C °FCompartment or System Oil Type and Classification Oil Viscosities

Min Max Min Max

-30 45 -22 113

−20 40 −4104

-10 50 14 122

04032104

-20 25 -4 77

SEBU8213-04 87

Maintenance Section

Lubricant Viscosities and Refill Capacities

i02516980

Capacities (Refill)

SMCS Code: 7000; 7560

Table 11

APPROXIMATE REFILL CAPACITIES

Compartment or System

Engine Crankcase

Each Final Drive D3K 8.2 2.2 1.8

Each Final Drive D4K 9.5 2.5 2.1

Each Final Drive D5K 9.5 2.5 2.1

Hydraulic Ta nk 60 15.8 13.2

Hydraulic System 84 22.2 18.4

Fuel Tank 195 51.5 42.9

Radiator for the Cooling System

Cooling System

Gear Case for the Winch

Liters

11 2. 9 2. 4

7.5 2.0 1.6

22.4 5.9 4.9

4.7 1.2 1.0

US Gal Imp Gal

i01822901

S·O·S Information

SMCS Code: 7542

S·O·S Services is a highly recommended process
for Caterpillar customers to use in order to minimize
owning and operating cost. Customers provide
oil samples, coolant samples, and other machine
information. The dealer uses the data in order to
provide the customer with recommendations for
management of the equipment. In addition, S·O·S
Services can help determine the cause of an existing
product problem.

Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.

Refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for a specific
sampling location and a service hour maintenance
interval.

Consult your Caterpillar dealer for complete
information and assistance in establishing an S·O·S
program for your equipment.

88 SEBU8213-04
Maintenance Section
Maintenance Support

Maintenance Support

i02801604

Welding on Machines and
Engines with Electronic
Controls

SMCS Code: 1000; 6700; 7000

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. Turn the battery disconnect switch to the OFF
position.

NOTICE

Do NOT use electrical components (ECM or ECM sen-

or electronic component grounding points for

sors)
grounding the welder.

3. Clam

p the ground cable from the welder to the
component that will be welded. Place the clamp
ascloseaspossibletotheweld.Makesurethat

lectrical path from the ground cable to the

the e
component does not go through any bearing. Use
this procedure in order to reduce the possibility of

age to the following components:

dam

Bearings of the drive train

•

Hydraulic components

•

ectrical components

El

•

Other components of the machine

•

4. Protect any wiring harnesses from the debris
which is created from welding. Protect any wiring

arnesses from the splatter which is created from

h
welding.

se standard welding procedures in order to weld

5.U

the materials together.

SEBU8213-04 89

Maintenance Section

Maintenance Interval Schedule

i03653330

Maintenance Interval Schedule

SMCS Code: 7000

Ensure that al
instructions are read and understood before any
operation or any maintenance procedures are
performed.

The user is responsible for the performance of
maintenanc
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere t
procedures may result in diminished performance of
the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST,
in order t
Products that operate in severe operating conditions
may require more frequent maintenance.

Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
perform

Note: If Cat HYDO Advanced 10 hydraulic oil is
used, th
The normal interval of 2000 hours is extended to
3000 hours. S·O·S services may extend the oil
change
for details.

l safety information, warnings and

e, including all adjustments, the use of

o proper maintenance intervals and

o determine the maintenance intervals.

ed.

e hydraulic oil change interval will change.

even longer. Consult your Caterpillar dealer

Every 10 Servic

Backup Alarm - Test .............................................. 91

Brakes, Indic
Bulldozer Power Angling Tilt Hinge Pins -

Lubricate ............................................................. 95

Cab Filter (Fr

Cooling System Coolant Level - Check .............. 100

Engine Oil Level - Check .................................... 107

Hydraulic Sy

Seat Belt - Inspect .............................................. 129

Winch Cable - Inspect ......................................... 132

Winch Fairl

ead Rollers - Lubricate ...................... 135

eHoursorDaily

ators and Gauges - Test ................... 94

esh Air) - Clean/Inspect/Replace ..... 96

stem Oil Level - Check ................... 124

Every 50 Service Hours or Weekly

Cab Filter

Replace ............................................................... 96

Front Idler Position - Check/Adjust ...................... 111

Ripper Lin

Lubricate ........................................................... 127

Track - Check/Adjust ........................................... 130

Track Pin

(Recirculation) - Clean/Inspect/

kage and Cylinder Bearings -

s - Inspect ............................................ 131

Every 250 Service Hours or Monthly

Belt - In

Engine Oil Sample - Obtain ................................ 108

Final Drive Oil Level - Check ............................... 110

Fuel Tan

Track Roller Frame - Inspect .............................. 132

Winch Oil Level - Check ..................................... 134

Initia
System

spect/Replace ........................................... 93

k Water and Sediment - Drain ................ 118

l 500 Hours (for New Systems, Refilled

s, and Converted Systems)

When Required

Battery - Recycle .................................................. 91

Battery or Battery Cable - Inspect/Replace .......... 92

it Breakers - Reset ........................................ 96

Circu

Condenser (Refrigerant) - Clean .......................... 97

Cutting Edges and End Bits - Inspect/Replace ... 103

ne Air Filter Primary Element - Clean/

Engi

Replace ............................................................. 103

Engine Air Filter Secondary Element - Replace .. 105

ne Air Precleaner - Clean ............................ 106

Engi

Ether Starting Aid Cylinder - Replace ................. 109

Free Spool Drag - Adjust ..................................... 111

l System - Prime ............................................ 113

Fue

Fuel System Water Separator - Drain .................. 115

Fuel Tank Cap - Clean ......................................... 118

es - Replace ................................................... 119

Fus

Oil Filter - Inspect ................................................ 126

Radiator Core - Clean ......................................... 126

diator Pressure Cap - Clean/Replace ............ 127

Ra

Ripper - Inspect/Replace .................................... 128

Winch Cable - Replace ....................................... 133

ndow Washer Reservoir - Fill .......................... 135

Wi

Window Wipers - Inspect/Replace ...................... 136

Windows - Clean ................................................. 136

Cooling System Coolant Sample (Level 2) -

n ............................................................... 101

Obtai

Every500ServiceHours

ng System Coolant Sample (Level 1) -

Cooli

Obtain ............................................................... 100

Engine Air Precleaner - Clean ............................ 106

l Drive Oil Sample - Obtain ........................... 111

Fina

Hydraulic System Oil Sample - Obtain ............... 125

Winch Oil Sample - Obtain ................................. 134

y 500 Service Hours or 3 Months

Ever

Engine Oil and Filter - Change ........................... 108

l System Secondary Filter - Replace ............. 114

Fue

Fuel System Water Separator - Replace ............. 116

Every 500 Service Hours or 1 Year

Trunnion - Adjust ................................................. 132

Winch Drum Bearing - Lubricate ......................... 135

ery 1000 Service Hours or 6 Months

Ev

Battery - Inspect .................................................... 91

ngine Valve Lash - Check ................................. 109

E

90 SEBU8213-04
Maintenance Section
Maintenance Interval Schedule

Hydraulic Syst
Rollover Protective Structure (ROPS) - Inspect .. 129

Winch Oil Filter - Replace ................................... 133

Every 2000 Ser

Cooling System Coolant Sample (Level 2) -

Obtain ............................................................... 101

Final Drive Oil - Change ...................................... 110

Hydraulic System Oil - Change ........................... 120

Winch Oil - C

Winch Vent Plug - Clean ..................................... 134

em Oil Filter - Replace ................. 123

vice Hours or 1 Year

hange ............................................. 133

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -

Clean/Replace .................................................. 102

Engine Air

Replace ............................................................. 103

Engine Air Filter Secondary Element - Replace .. 105

Every3Ye
Every5Ye

Seat Belt - Replace ............................................. 129

Every 60

Filter Primary Element - Clean/

ars After Date of Installation or

ars After Date of Manufacture

00 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 99

Every 12

Cooling System Coolant (ELC) - Change ............. 97

000 Service Hours or 6 Years

SEBU8213-04 91

Maintenance Section

Backup Alarm - Test

i02808927

Backup Alarm - Test

SMCS Code: 7406

Illustration 110

Turn the engine start switch to the ON position in
order to perform the test.

Apply the decel/brake pedal. Disengage the parking
brake switch. Move the transmission control lever to
the REVERSE position.

The backup alarm should sound immediately. The
alarm alerts the people behind the machine that the
machine is backing up. The backup alarm should
continue to sound until the transmission control
lever is moved to the NEUTRAL position or to the
FORWARD position.

g01217394

i01989120

Battery - Inspect

SMCS Code: 1401-040

Tighten the ba
1000 hour interval.

1. Open the batt

2. Cleanthetopofthebatterieswithaclean

cloth. Keep
petroleum jelly. Install the terminal covers after
youcoattheterminals.

3. Close the battery access cover.

ttery retainers on all batteries at every

ery access cover.

the terminals clean and coated with

i00993589

Battery - Recycle

SMCS Code: 1401-005; 1401-510; 1401-535;

1401-561; 1401

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following
locations:

A battery supplier

•

An authorized battery collection facility

•

Recycling facility

•

Illustration 111

The backup alarm is on the rear of the machine.

The nonadjustable backup alarm is set at the
appropriate sound level when the machine is shipped
from the factory.

g01257741

92 SEBU8213-04
Maintenance Section
Battery or Battery Cable - Inspect/Replace

i02801605

Battery or Battery Ca ble ­Inspect/Repl

SMCS Code: 1401-040; 1401-510; 1401; 1402-040;

1402-510

ace

Personal in

jury may occur from failure to properly

service the batteries.

Batteries

give off flammable fumes that can ex­plode. Electrolyte is an acid and can cause per­sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jumper ca­ble ends t

o contact each other or the engine. Im­proper jumper cable c onnections can cause an ex­plosion.

Always wear protective glasses when working
with batteries.

1. TurntheenginestartswitchkeyOFF.Turnallof

the switches OF F.

Illustration 113

g01399056

Illustration 112

g01259128

2. Turn the battery disconnect switch OFF. Remove

the key.

3. Disconnect the negative battery cable from the

disconnect switch.

Note: Do not allow the disconnected battery cable to
contact the disconnect switch.

00107

Illustration 114

There are two ba tteries on this machine.

rimary battery

(1) P

Secondary battery

(2)

g014

4. Disconnect the negative battery cable at battery
. The primary battery is located behind the right

(1)
side access door.

sconnect the positive battery cable at the

5. Di

battery.

movethematandthefloorplate in the cab in

6. Re

order to access the secondary battery. Perform
steps 4 and 5 in order to disconnect the secondary

ttery.

ba

SEBU8213-04 93

Maintenance Section

Belt - Inspect/Replace

7. Inspect the bat
the battery cables for wear or damage.

8. Make any neces
the battery cables or the batteries.

Note: Replac
when the battery is replaced. Do not exceed a
change interval of 48 months when the secondary
battery car

9. Connect the positive battery cable to the battery
positive te

10. Connect the negative battery cable to the battery
negative t

11. Connect the battery cable at the battery
disconnec

12. Install the key and turn the battery disconnect
switch ON

rier (strap) is replaced.

Belt-In

SMCS Code: 1357-040; 1357-510

tery terminals for corrosion. Inspect

sary repairs. If necessary, replace

e the secondary battery carrier (strap)

rminals.

erminals.

tswitch.

.

i03722700

spect/Replace

Inspect

Illustration 116

A/C compressor

3. Inspect the condition of the serpentine belt (1) for
any of the following conditions:

excessive cracking

•

excessive wear

•

excessive damage

•

The belt deflection should not be more than
14 to 20 mm (.56 to .81 inch) under 110 N (25 lb)
of force. Use a 144-0235 Belt Tension Gauge in
order to measure the tension.

g01259370

1. Park the machine on level ground. Lower the
dozer blade to the ground. Move the transmission

l to the NEUTRAL position and engage the

contro
parking brake. Shut off the engine.

2. Open t

Illustration 115

he engine enclosure.

g01275091

Note: The deflection of the serpentine belt has the
same limit with an alternator only.

Note: Thismachineisequippedwithonebelt
tensioner (2). The belt tensioner automatically adjusts
the belt to the correct position.

4. Close the engine enclosure.

Replace

Contact your Caterpillar dealer in order to replace
the belt, if necessary.

94 SEBU8213-04
Maintenance Section
Brakes, Indicators and Gauges - Test

i02801609

Brakes, Indicators and Gauges

-Test

SMCS Code: 4100-081; 7000-081; 7450-081

tion 117

Illustra

Check the operation of the Caterpillar Monitoring
System.
engine.

Observe the self test when you start the

g01213312

“X10” readout

•

Symbol for the hour meter

•

“8.8.8.X.8.8” readout

•

The pointers
pointers point to the left. Then, the pointers point
to the right. Then, the pointers point to the final
positions.

The action light stays illuminated.

•

The action alarm sounds once for one second.

•

The monito
mode.

If the abov
system will not function in the normal operating
mode. Consult your Caterpillar dealer for an electrical
system ch
start the engine.

Turn on al
operation. Sound the forward horn.

in the gauges point upward. Then, the

ring panel is then in the normal operating

e tests are not correctly completed, the

eck. Any repairs must be made before you

l of the machine lights. Check for proper

The syst
you turn the engine start switch to the ON position.

The sel
the display modules are operating properly.

The int
are automatically checked.

Illustration 118

The operator must observe whether gauges (1),
indicators (2), and displays (3) are operating properly.
The self test lasts for approximately three seconds.

em performs an automatic self test when

f test verifies that the monitoring panel and

ernal circuits, the indicators, and the gauges

g01213323

Move the
brakes.

machineforwardandtesttheservice

Braking System (Test)

If the ma chine moves during the test, reduce the

e speed immediately, and engage the park-

engin
ing brake.

e machine moved while testing the brakes,

If th
consult your Caterpillar dealer for brake inspec­tion and repair. Damaged brakes must be repaired

re returning the machine to operation.

befo

Make sure that the area around the machine is clear

ersonnel and clear of obstacles.

of p

Test the brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

During the self test, all alert indicators flash.

The digital display shows the following readouts:

All indicators of units (Deg C, kPa, rpm, and liters)

•

SEBU8213-04 95

Maintenance Section

Bulldozer Power Angling Tilt Hinge Pins - Lubricate

i02801610

Bulldozer Power Angling Tilt
HingePins-Lu

SMCS Code: 6050

bricate

Illustration 119

1. Start the engine (1).

2. Raise all attachments (2).

3. Fully depress decel/brake pedal (5).

4. Release parking brake switch (3).

5. While decel/brake pedal (5) is fully depressed,

move the steering and transmission control (6) to
the FORWARD position.

6. Gradually increase the engine speed (4) to full
load speed. The machine should not move.

7. Move the steering and transmission control (6) to
the NEUTRAL position.

8. Reduce the engine speed (4) to LOW IDLE.
Engage the parking brake (3). Lower all
attachments (2) to the ground. Apply a slight down
pressure. Stop the engine (1).

9. Make any necessary repairs before you operate
the machine.

g01270816

Illustration 120

Apply lubricant to the grease fitting for the head end
of the tilt cylinder (1).

Apply lubricant to the grease fitting for the rod end of
the tilt cylinder (2).

Apply lubricant to the grease fitting for the rod end of
the angle cylinder (3). Repeat for the left and right
side angle cylinders.

Apply lubricant to the grease fitting for the head end
of the angle cylinder (4). Repeat for the left and right
side angle cylinders.

Apply lubricant to the grease fitting for the pivot pin
on the main C-frame (5). Repeat for the left and right
side angle cylinders.

Apply lubricant to the grease fitting for the rod end of
the lift cylinder (6). Repeat for the left and right side
lift cylinders.

Apply lubricant to the grease fitting for the head end
of the lift cylinder (7). Repeat for the left and right
side lift cylinders.

g01400115

NOTICE
If the machine moved while testing the brakes, contact
your Caterpillar dealer. Have the dealer inspect and,
if necessary, repair the service brake before returning
the machine to operation.

Apply lubricant to the grease fittings for the pitch link
(8, 9).

96 SEBU8213-04
Maintenance Section
Cab Filter (Fresh Air) - Clean/Inspect/Replace

i02801611

Cab Filter (Fresh Air) ­Clean/Inspec

t/Replace
(If Equipped)

SMCS Code: 73

Note: Clean the filter element more often in dusty

conditions
flow from the air vents, check the filter element.

Note: Enclo

1. Open the access cover for the filter on the left side

of the mach

Illustration 121

2. Remove filter element (1). Clean the filter element

with compressed air.

Note: Do not clean the filter elements while the filter
elements are installed on the machine.

42-040; 7342-070; 7342-510

. If there is a noticeable reduction in the air

sed ROPS only

ine.

g01259839

Illustration 122

1. Remove filter element (1). The filter element is
located next to the seat on the left side. Clean the
filter element with compressed air.

Note: Do not clean the filter element while the filter
element is installed on the machine.

Note: Do not use water in order to clean the filter
element.

Note: The fi lter must be thoroughly dried before you

install the filter.

2. Replace any filter element that is worn or
damaged.

3. Install the filter element and replace the filter
cover.

Note: Install the filter element with the filter media
toward the inside of the cavity.

g01213198

Note: Do not wash the filter element with water.

Note: Keep the filter element dry.

3. Install the filter element. Install the access cover.

i02801612

Cab Filter (Recirculation) ­Clean/Inspect/Replace

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

Note: Clean the filter element more often in dusty

conditions. If there is a noticeable reduction in the air
flow from the air vents, check the filter element.

i02801613

Circ

SMCS Code: 1417; 1420

The main circuit breaker is located in the front of the
right console behind the cover plate.

uit Breakers - Reset

SEBU8213-04 97

Maintenance Section

Condenser (Refrigerant) - Clean

Illustration 123

Front view

Illustration 124

Main Circuit Breaker – The105Ampmaincircuit
breaker is the only circuit breaker. Push the button in
order to reset the main circuit breaker. The button
will stay depressed if the circuit is working properly.
Check the appropriate electrical circuit if the button
does not stay depressed.

g01259901

g01400116

Illustration 125

1. Remove the cover for the condenser.

2. Inspect the condenser for debris. Clean the

condenser, if necessary.

3. Use clean water to wash all of the dust and dirt
from the condenser.

4. Install the cover for the condenser.

g01259914

i02808933

Cooling System Coolant (ELC)

-Change

SMCS Code: 1352-044; 1395-044

NOTICE

Do not change the coolant until you read and under-

the cooling system information in Special Pub-

stand
lication, SEBU6250, “Caterpillar Machine Fluids Rec­ommendations”.

i02518214

Con

denser (Refrigerant) -

Clean

S Code: 1805-070

SMC

TICE

NO
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a

iff brush.

st

Repair the fins if found defective.

Failure to do so could result in damage to the cooling
system components.

NOTICE
Mixing ELC with other products will reduce the effec­tiveness of the coolant.

This could result in damage to cooling system compo­nents.

If Caterpillar products are not available and com­mercial products must be used, make sure they
havepassedtheCaterpillarEC-1specification for
pre-mixed or concentrate coolants and Caterpillar
Extender.

98 SEBU8213-04
Maintenance Section
Cooling System Coolant (ELC) - Change

NOTICE

Care must be ta

ken to ensure that fluids are contained
during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to
collect the flu

id with suitable containers before open­ing any compartment or disassembling any compo­nent 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 a

ll fluids according to local regulations and

mandates.

Note: This machine was filled at the factory with
Caterpill

ar Extended Life Coolant.

If the coolant in the machine is changed to Extended
Life Cool

ant from another type of coolant, see Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.

1. Open the left engine access door first in order to

access the latch for the top access panel.

2. Open the access panel on top of the engine

compartment in order to remove the cooling
system

pressure cap.

Illustration 127

g01259915

3. Loosen cooling system pressure cap (1) slowly
when you are inside the engine compartment in
order to release the pressure from the cooling
system.

4. Remove the pressure cap.

Illustration 128

g01260273

Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.

Illustration 126

g01259916

5. Remove access cover (3) that is in the engine
guard.

6. Open drain valve (2) and allow the coolant to
drain into a suitable container. The drain valve is
located on the bottom of the radiator.

7. Flush the cooling system. Follow Step 7.a through
Step 7.h in order to properly flush the cooling
system.

a. Close drain valve (2).

b. Fill the cooling system with clean water.

c. Install pressure cap (1).

SEBU8213-04 99

Maintenance Section

Cooling System Coolant Extender (ELC) - Add

d. Start the engin

engine reaches operating temperature.

e. Stop the engin

f. Loosen pressure cap (1) slowly in order to

relieve any p

g. Open drain valve (2) and allow the coolant to

drain into a

h. Flush the radiator with clean water until the

draining wa

8. Close the drain valve and install the access cover
underneat

9. Add the Extended Life Coolant. Refer to the
following

Special Publication, SEBU6250, “Caterpillar

•

Machine F

Operation and Maintenance Manual, “Capacities

•

(Refill)”

10. Start the engine. Operate the engine without
the cool
temperature regulator opens and the coolant level
stabilizes.

11. Maintain the coolant level between the maximum
mark and the minimum mark on the top shunt tank.

Note: Refer to Operation and Maintenance Manual,
“Cooling System Coolant Level - Check” for additional

mation.

infor

12. Inspect the O-ring of the cooling system pressure
cap. I
pressure cap.

13. Inst

14. Stop the engine.

15. Close the access panel on top of the engine

compartment.

16. Close the left engine access door.

h the engine.

topics:

ing system pressure cap until the water

f the O-ring is damaged, replace the

all the cooling system pressure cap.

e and run the engine until the

e and allow the engine to cool.

ressure in the cooling system.

suitable container.

ter is transparent.

luids Recommendations”

i02336986

Cooling Syste m Coolant
Extender (ELC

SMCS Code: 1352-544-NL; 1395-544-NL

Personal injury can result from hot coolant, steam
and alkali.

At operating temperature, engine coolant is hot
and under pressure. The radiator and all 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.

Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.

Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.

When Caterpillar Extended Life Coolant (ELC)
is used, an extender must be added to the
cooling system. See Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
determined by the cooling system capacity.

Table 12

Amount of Caterpillar Extender (ELC)

Cooling System Capacity

22to30L(6to8USgal) 0.57L (20oz)

31to38L(8to10USgal) 0.71 L(24oz)

39 to 49 L (10 to 13 US gal) 0.95 L (32 oz)

50 to 64 L (13 to 17 US gal) 1.18 L (40 oz)

65 to 83 L (17 to 22 US gal) 1.60 L (54 oz)

84to114L(22to30USgal) 2.15 L(72 oz)

115 to 163 L (30 to 43 US gal) 3.00 L (100 oz)

164 to 242 L (43 to 64 US gal) 4.40 L (148 oz)

)-Add

Recommended Amount

of Caterpillar Extender

Note: For cooling systems with larger capacities,
use the formula in Table 13 in order to determine the
correctamountofextender.

100 SEBU8213-04
Maintenance Section
Cooling System Coolant Level - Check

Table 13

Calculation of ELC Extender

(1)

V

×0.02=X

(1)

V is the total volume of the cooling system.

(2)

X is the amount of ELC Extender that is required.

(2)

For additional information about adding an extender,
see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “Extended Life
Coolant (ELC)” or consult your Caterpillar dealer.

i02801616

Cooling System Coolant Level

- Check

SMCS Code: 1353; 1354; 1395; 7520

1. Open the left engine access door.

Note: Obtain a C

oolant Sample (Level 1) if the

cooling sy stem is filled with any other coolant
instead of Cat ELC. This includes the following

types of coola

Commercial long life coolants that meet the

•

Caterpillar

nts.

Engine Coolant Specification -1

(Caterpillar “EC−1”)

Cat Diesel E

•

Commercial heavy-duty antifreeze/coolant

•

ngine Antifreeze/Coolant (DEAC)

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the s

ame pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor­rect inte

rpretation that could lead to concerns by both

dealers and customers.

Note: Level 1 results may indicate a need for
Level 2 A

nalysis.

Illustration 129

g01260015

2. Maintain the coolant level between minimum mark
(B) and maximum mark (A) on expansion tank (2).
If you need to add coolant daily, check the cooling
system for leaks.

3. Close the left engine access door.

i02806920

Cooling System Coolant
Sample (Level 1) - Obtain

SMCS Code: 1395-554

Note: It is not necessary to obtain a Coolant
Sample (Level 1) if the cooling system is filled
with C at ELC (Extended Life Coolant). Cooling

systems that are filled with Cat ELC should have
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Maintenance Interval Schedule.

Illustration 130

g01260015

1. Open the left engine access door.

2. Open the access panel on top of the engine

compartment.

3. The cooling system pressure cap (1) is located on
the top of expansion tank (2). Remove the cooling
system pressure cap slowly in order to relieve
system pressure.

4. Obtain the coolant sample from the top tank and
collect the sample into the proper sampling bottle.

Note: Always discard drained fluids according to
local regulations.