Cat D5K

SEBU8498-04 (en-us)
April 2019
Operation and
Maintenance
Manual
D3K2, D4K2, D5K2 Track-Type Tractors
KFF 1-UP (D3K2)
KLL 1-UP (D3K2)
GAE 1-UP (D3K2)
KMM 1-UP (D4K2)
KRR 1-UP (D4K2)
KWW 1-UP (D5K2)
KYY 1-UP (D5K2)
TRF 1-UP (D5K2)
Scan to find and purchase genuine Cat® parts and related

service information.
i06558969
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

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

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8498-04 3
Table of Contents
Table of Contents General Information ........................................ 34
Identification Information ................................. 36

Foreword ........................................................... 4
Safety Section Operation Section
Before Operation ............................................. 42

Safety Messages............................................... 6
Machine Operation .......................................... 44
Additional Messages ....................................... 14
Engine Starting................................................ 83
General Hazard Information............................ 17
Adjustments..................................................... 85
Crushing Prevention and Cutting Prevention.. 20
Parking ............................................................ 88
Burn Prevention............................................... 20
Transportation Information .............................. 92
Fire Prevention and Explosion Prevention...... 21
Towing Information .......................................... 97
Fire Safety ....................................................... 24
Engine Starting (Alternate Methods)............... 98
Fire Extinguisher Location............................... 25
Track Information ............................................ 25 Maintenance Section
Electrical Storm Injury Prevention ................... 25 Lubricant Viscosities and Refill Capacities ... 100
Before Starting Engine .................................... 26 Maintenance Support .................................... 107
Engine Starting................................................ 26 Maintenance Interval Schedule..................... 108
Before Operation ............................................. 26 Warranty Section
Visibility Information ........................................ 26 Warranty Information..................................... 162
Operation......................................................... 27 Reference Information Section
Parking ............................................................ 27 Reference Materials ...................................... 163
Slope Operation .............................................. 28 Index Section
Engine Stopping .............................................. 28 Index.............................................................. 166
Equipment Lowering with Engine Stopped ..... 29
Sound Information and Vibration Information . 29
Operator Station .............................................. 32
Guards (Operator Protection) ......................... 32
Product Information Section

4 SEBU8498-04
Foreword
Foreword Whenever a question arises regarding your machine,

or this publication, please consult your Cat dealer for
the latest available information.
California Proposition 65 Warning
Safety
Diesel engine exhaust and some of its
constituents are known to the State of The safety section lists basic safety precautions. In
California to cause cancer, birth defects, addition, this section identifies the text and locations
of warning signs and labels used on the machine.
and other reproductive harm.
Read and understand the basic precautions listed in
WARNING – This product can the safety section before operating or performing
expose you to chemicals lubrication, maintenance, and repair on this machine.
including ethylene glycol, which
is known to the State of California to Operation
cause birth defects or other reproductive
harm. For more information go to: The operation section is a reference for the new
operator and a refresher for the experienced
www.P65Warnings.ca.gov operator. This section includes a discussion of
gauges, switches, machine controls, attachment
Do not ingest this chemical. Wash hands controls, transportation, and towing information.
after handling to avoid incidental Photographs and illustrations guide the operator
ingestion. through correct procedures of checking, starting,
operating, and stopping the machine.
WARNING – This product can
expose you to chemicals Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
including lead and lead gains knowledge of the machine and its capabilities.
compounds, which are known to the
State of California to cause cancer, birth Maintenance
defects, or other reproductive harm. For
more information go to: The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
www.P65Warnings.ca.gov the items to be maintained at a specific service
interval. Items without specific intervals are listed
Wash hands after handling components under the "When Required" service interval. The
that may contain lead. Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Literature Information Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
This manual should be stored in the operator's
compartment in the literature holder or seat back Maintenance Intervals
literature storage area.
Use the service hour meter to determine servicing
This manual contains safety information, operation
intervals. Calendar intervals shown (daily, weekly,
instructions, transportation information, lubrication
information, and maintenance information. monthly, etc.) can be used instead of service hour
meter intervals if the calendar intervals provide more
Some photographs or illustrations in this publication convenient servicing schedules and approximate the
show details or attachments that can be different indicated service hour meter reading. Perform the
from your machine. Guards and covers might have recommended service at the interval that occurs first.
been removed for illustrative purposes.
Under severe, dusty, or wet operating conditions,
Continuing improvement and advancement of more frequent lubrication than is specified in the
product design might have caused changes to your maintenance intervals chart might be necessary.
machine which are not included in this publication.
Read, study, and keep this manual with the machine.
SEBU8498-04 5
Foreword
Perform service on items at multiples of the original 2. Machine Descriptor (characters 4-8)
requirement. For example, at every 500 service
hours or 3 months, also service those items listed 3. Check Character (character 9)
under every 250 service hours or monthly and every
10 service hours or daily. 4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Certified Engine Maintenance
Machines and generator sets produced before First
Proper maintenance and repair are essential to keep Quarter 2001 will maintain their 8 character PIN
the engine and machine systems operating correctly. format.
As the heavy-duty off-road diesel engine owner, you
are responsible for the performance of the required Components such as engines, transmissions, axles,
maintenance listed in the Owner Manual, Operation and work tools will continue to use an 8 character
and Maintenance Manual, and Service Manual. Serial Number (S/N).
It is prohibited for any person engaged in the

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or to
render inoperative, any emission-related device or
element of design installed on or in an engine or
machine that is in compliance with all applicable
regulations of the intended country to which it has
been shipped. Certain elements of the machine and
engine such as the exhaust system, fuel system,
electrical system, intake air system, and cooling
system may be emission-related and should not be
altered unless approved by Caterpillar.
Machine Capacity
Additional attachments or modifications may exceed
machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Cat dealer for further information.
Product Identification Number

Effective First Quarter 2001 the Product Identification
Number (PIN) has changed from 8 to 17 characters.
To provide uniform equipment identification,
construction equipment manufacturers are moving to
comply with the latest version of the product
identification numbering standard. Non-road machine
PINs are defined by ISO 10261. The new PIN format
will apply to all machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:
Illustration 1 g03891925
Where:
1. World Manufacturing Code (characters 1-3)
6 SEBU8498-04
Safety Section
Safety Messages
Safety Section
i04001015
Safety Messages
SMCS Code: 7000; 7405
SEBU8498-04 7
Safety Section
Safety Messages
8 SEBU8498-04
Safety Section
Safety Messages
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. 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.
SEBU8498-04 9
Safety Section
Safety Messages
Replace any safety message that is damaged or

missing. If a safety message is attached to a part of
the machine that is replaced, install a safety
message on the replacement part. Any Caterpillar
dealer can provide new safety messages.
Do Not Operate (1)

Safety Message (1) is positioned on the right-hand
cab post in view of the operator.
A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
Do not operate or work on this machine unless tion may result in serious injury or death.
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. Do Not Weld On the ROPS/FOPS
Contact any Caterpillar dealer for replacement (3)
manuals. Proper care is your responsibility.
Safety Message (3) is positioned on the left-hand
rear cab post.
Seat Belt (2)
Safety Message (2) is positioned on the left-hand cab
post in view of the operator.
10 SEBU8498-04
Safety Section
Safety Messages
Illustration 7 g02391415 Illustration 8 g01108685
Structural damage, an overturn, modification, al- This machine is equipped with a Caterpillar Prod-
teration, or improper repair, can impair this struc- uct Link communication device. When electric/
ture's protective capability thereby voiding this electronic detonators are used, this communica-
certification. Do not weld on or drill holes in the tion device should be deactivated within 12 m
structure. Consult a Caterpillar dealer to deter- (40 ft) of a blast site, or within the distance man-
mine this structure's limitations without voiding dated under applicable legal requirements. Fail-
its certification. ure to do so could cause interference with
blasting operations and result in serious injury or
death.
This machine has been certified to the standards that
are listed on the certification plate. The maximum
mass of the machine, which includes the operator Refer to Special Instruction, REHS1642, “Operation
and the attachments without a payload, should not of the Product Link System” for additional
exceed the mass on the certification plate. information.
Product Link (4) (if equipped) No Ether in Air Inlet (5)

Safety message (4) is located on the left-hand cab Safety Message (5) is located on the left side of the
post in view of the operator. engine on the air cleaner cover. Only use the ether
starting aid group that is factory installed for safety.
SEBU8498-04 11
Safety Section
Safety Messages
Do not use ether. This machine is equipped with High Pressure Cylinder. Do not remove any parts
glow plugs. Using ether can create explosions or from the cylinder until all of the pressure has
fires that can cause personal injury or death. been relieved. This will prevent possible personal
Read and follow the engine starting procedure in injury or death.
the Operation and Maintenance Manual.
Hot Fluid Under Pressure (8)

High Pressure Fuel Lines (6)
Safety Message (8) is located under the access door
Safety Message (6) is located on the left side of the on the expansion tank filler cap.
engine on the high-pressure fuel rail.
Pressurized system: Hot coolant can cause seri-

Contact with high pressure fuel may cause fluid ous burn. To open cap, stop engine, wait until ra-
penetration and burn hazards. High pressure fuel diator is cool. Then loosen cap slowly to relieve
spray may cause a fire hazard. Failure to follow the pressure.
these inspection, maintenance and service in-
structions may cause personal injury or death.
Improper Connections for Jump
High Pressure Cylinder (7) Start Cables (9)
Safety Message (7) is located on the track adjuster Safety Message (9) is located on the right access
door outside the operator station.
cover that is on the outside of the track roller frame.
12 SEBU8498-04
Safety Section
Safety Messages
Explosion Hazard! Improper jumper cable con- Do not operate or work on this equipment unless
nections can cause an explosion resulting in seri- you have read and understand the instructions
ous injury or death. Batteries may be located in and warnings in the Operation and Maintenance
separate compartments. Refer to the Operation Manual. Failure to follow the instructions or heed
and Maintenance Manual for the correct jump the warnings could result in injury or death. Con-
starting procedure. tact any Caterpillar dealer for replacement man-
uals. Proper care is your responsibility.
Refer to Operation and Maintenance Manual,

“Engine Staring with Jump Start Cables”.
Laser
Do Not Operate (10) (Winch) If your machine is equipped with the AccuGrade -
Laser System, this safety message is located on
Safety message (10) is located on the right side of each leg of the tripod for the laser.
the machine on the vertical wall of the winch frame.
SEBU8498-04 13
Safety Section
Safety Messages
Movement of the transmitter could cause unex- To prevent possible personal injury during instal-
pected blade movement. Death or serious injury lation and removal of the laser receivers, lower
could occur. Turn off the transmitter before you the mast to the minimum height and use an ap-
move the transmitter or before you adjust the proved access system to reach the mounting lo-
transmitter. cations of the laser receivers at the top of the
mast. Do not climb on the blade.
Blade and Mast

When you use the AccuGrade - Laser System, this
safety message is located on the rear of each mast at
eye level from the ground.
14 SEBU8498-04
Safety Section
Additional Messages
i04014493 Make sure that all of the messages are legible. Clean
the messages or replace the messages if you cannot
Additional Messages read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
SMCS Code: 7000; 7405 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.
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.
Lubrication Chart (1)
This message is located on the left side of the
machine behind the lower access door.
There are several specific messages on this

machine. The location of the messages and the
description of the messages are reviewed in this
section. Become familiarized with all messages.
SEBU8498-04 15
Safety Section
Additional Messages
Required Engine Oil (2)

This message is located on the engine oil filler tube.
Do not step on the angle cylinders. Follow this

Illustration 20 g02782016 instruction in order to perform work safely.
Refer to Operation and Maintenance Manual, Radio (4)

“Lubricant Viscosities”.
This message is located on the cover for the radio.
No Step (3)
If equipped, this message is located on the cover for
the angle cylinders.
16 SEBU8498-04
Safety Section
Additional Messages
NOTICE
Radio must be fastened securely to prevent falling
out during rough machine operation or overturn. Ra-
dio mounting to DIN sleeve or bracket (s) must with-
stand 270 N (60 lb) minimum pulling force to resist Illustration 24 g01399516
shock loads.
NOTICE
Air Conditioner (5) (If equipped) When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
This message is located behind the air conditioner age to engine bearings and electrical circuits.
compressor on the right side of the engine.
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
This machine has a 12 volt starting system. Use only
the same voltage for jump starting. Use of a higher
voltage damages the electrical system.
Batteries in Parallel Configuration (7)

This message is located on the inside of the access
This message for the air conditioner has the door for the battery. The machine uses two 12V
appropriate information for the following services: the batteries in a parallel arrangement. See the Service
air conditioner lubricant, the refrigerant charge and Manual for proper instructions.
the refrigerant capacity.
Battery (6)
This message is located on the inside of the access
door for the battery.
SEBU8498-04 17
Safety Section
General Hazard Information
i07746355

SMCS Code: 7000
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. Illustration 27 g00104545
Typical example
Machine Security System (8)
Attach a “Do Not Operate” warning tag or a similar
If equipped, this message is located on the dash warning tag to the start switch or to the controls.
under the indicator lamps. Attach the warning tag before you service the
equipment or before you repair the equipment.
Warning tag SEHS7332 is available from your Cat
dealer.
Operating the machine while distracted can result

in the loss of machine control. Use extreme cau-
tion when using any device while operating the
machine. Operating the machine while distracted
can result in personal injury or death.
Know the width of your equipment to maintain proper

clearance when you operate the equipment near
fences or near boundary obstacles.
Be aware of high-voltage power lines and power
This machine is equipped with a security system. cables that are buried. If the machine comes in
Read the Operation and Maintenance Manual before contact with these hazards, serious injury or death
you operate the machine. may occur from electrocution.
Reference: See Operation and Maintenance
Manual, “Maintenance Interval Schedule” for all
maintenance recommendations.
18 SEBU8498-04
Safety Section
When you perform maintenance above ground level,

use appropriate devices such as ladders or man lift
machines. If equipped, use the machine anchorage
points and use approved fall arrest harnesses and
lanyards.
Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out. The debris and/or hot
water could result in personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
Wear a hard hat, protective glasses, and other must be reduced to 205 kPa (30 psi) when the
protective equipment, as required. nozzle is deadheaded and the nozzle is used with an
effective chip deflector and personal protective
Do not wear loose clothing or jewelry that can snag equipment. The maximum water pressure for
on controls or on other parts of the equipment. cleaning purposes must be below 275 kPa (40 psi).
Make sure that all protective guards and all covers Avoid direct spraying of water on electrical
are secured in place on the equipment. connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
Keep the equipment free from foreign material. reduce the possibility of fine debris igniting when re-
Remove debris, oil, tools, and other items from the deposited on hot surfaces.
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools, Trapped Pressure
and other items that are not a part of the equipment.
Pressure can be trapped in a hydraulic system.
Know the appropriate work site hand signals and the Releasing trapped pressure can cause sudden
personnel that are authorized to give the hand machine movement or attachment movement. Use
signals. Accept hand signals from one person only. caution if you disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose
Do not smoke when you service an air conditioner. to whip. High-pressure oil that is released can cause
Also, do not smoke if refrigerant gas may be present. oil to spray. Fluid penetration can cause serious
Inhaling the fumes that are released from a flame that injury and possible death.
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause Fluid Penetration
bodily harm or death.
Pressure can be trapped in the hydraulic circuit long
Never put maintenance fluids into glass containers. after the machine has been stopped. The pressure
Drain all liquids into a suitable container. can cause hydraulic fluid or items such as pipe plugs
to escape rapidly if the pressure is not relieved
Obey all local regulations for the disposal of liquids. correctly.
Use all cleaning solutions with care. Report all Do not remove any hydraulic components or parts
necessary repairs. until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
Do not allow unauthorized personnel on the components or parts until pressure has been relieved
equipment. or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
Unless you are instructed otherwise, perform relieve the hydraulic pressure.
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance
Manual for the procedure for placing the equipment
in the servicing position.
SEBU8498-04 19
Safety Section
Obey all local regulations for the disposal of liquids.
Inhalation
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 Illustration 30 g02159053
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment Exhaust
from a doctor that is familiar with this type of injury.
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
Containing Fluid Spillage enclosed area, adequate ventilation is necessary.
Care must be taken in order to ensure that fluids are
contained during performance of inspection, Asbestos Information
maintenance, testing, adjusting, and repair of the
equipment. Prepare to collect the fluid with suitable Cat equipment and replacement parts that are
containers before opening any compartment or shipped from Caterpillar are asbestos free.
disassembling any component that contains fluids. Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Refer to Special Publication, NENG2500, “Cat dealer you handle any replacement parts that contain
Service Tool Catalog” for the following items: asbestos or when you handle asbestos debris.
• Tools that are suitable for collecting fluids and Use caution. Avoid inhaling dust that might be
equipment that is suitable for collecting fluids generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
• Tools that are suitable for containing fluids and to your health. The components that may contain
equipment that is suitable for containing fluids asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
20 SEBU8498-04
Safety Section
Crushing Prevention and Cutting Prevention
• Use exhaust ventilation on permanent machining Do not work beneath the cab of the machine unless
jobs. the cab is properly supported.
• Wear an approved respirator if there is no other Unless you are instructed otherwise, never attempt
way to control the dust. adjustments while the machine is moving or while the
engine is running.
• Comply with applicable rules and regulations for
the work place. In the United States, use Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine
Occupational Safety and Health Administration movement could result.
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan, Whenever there are equipment control linkages the
use the requirements found in the “Ordinance on clearance in the linkage area will change with the
Prevention of Health Impairment due to Asbestos” movement of the equipment or the machine. Stay
in addition to the requirements of the Industrial clear of areas that may have a sudden change in
Safety and Health Act. clearance with machine movement or equipment
movement.
• Obey environmental regulations for the disposal of Stay clear of all rotating and moving parts.
asbestos.
If it is necessary to remove guards in order to perform
• Stay away from areas that might have asbestos maintenance, always install the guards after the
particles in the air. maintenance is performed.
Dispose of Waste Properly Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to your
eyes, wear protective glasses when you strike a
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i07399130
Burn Prevention
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be SMCS Code: 7000
disposed of according to local regulations. Do not touch any part of an operating engine. Allow
machine systems to cool before any maintenance is
Always use leakproof containers when you drain
performed. Relieve all pressure in the air system, in
fluids. Do not pour waste onto the ground, down a
the oil system, in the lubrication system, in the fuel
drain, or into any source of water.
system, or in the cooling system before any lines,
fittings, or related items are disconnected.
i01359664
Crushing Prevention and

Cutting Prevention
SMCS Code: 7000
Support the equipment properly before you perform
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold up
the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
SEBU8498-04 21
Safety Section
Fire Prevention and Explosion Prevention
Induction System Do not smoke while checking the battery electrolyte

levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
Sulfuric Acid Burn Hazard may cause serious batteries. Wash hands after touching batteries. The
personal injury or death. use of gloves is recommended.
The exhaust gas cooler may contain a small i07746336
amount of sulfuric acid. The use of fuel with sul-
fur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid Fire Prevention and Explosion
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin Prevention
and clothing on contact. Always wear the appro- SMCS Code: 7000
priate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for
first aid that are noted on a material safety data
sheet (MSDS) for sulfuric acid.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level only after the engine has
been stopped.
General
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch All fuels, most lubricants, and some coolant mixtures
with a bare hand. Remove the filler cap slowly to are flammable.
relieve pressure. To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact Always perform a Walk-Around Inspection, which
the skin, the eyes, or the mouth. may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your Cat
Oils dealer for service.
Hot oil and hot components can cause personal Understand the use of the primary exit and
injury. Do not allow hot oil to contact the skin. Also, alternative exit on the machine. Refer to Operation
do not allow hot components to contact the skin. and Maintenance Manual, “Alternative Exit”.
Remove the hydraulic tank filler cap only after the Do not operate a machine with a fluid leak. Repair
engine has been stopped. The filler cap must be cool leaks and clean up fluids before resuming machine
enough to touch with a bare hand. Follow the operation. Fluids that are leaking or spilled onto hot
standard procedure in this manual to remove the surfaces or onto electrical components can cause a
hydraulic tank filler cap. fire. A fire may cause personal injury or death.
Remove flammable material such as leaves, twigs,
Batteries papers, trash, and so on. These items may
accumulate in the engine compartment or around
The liquid in a battery is an electrolyte. Electrolyte is other hot areas and hot parts on the machine.
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes. Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire
suppression equipment, in case a fire should occur.
22 SEBU8498-04
Safety Section
Clean all accumulations of flammable materials such

as fuel, oil, and debris from the machine.
Do not operate the machine near any flame.
Keep shields in place. Exhaust shields (if equipped)
protect hot exhaust components from oil spray or fuel
spray in case of a break in a line, in a hose, or in a
seal. Exhaust shields must be installed correctly.
Do not weld or flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding or
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive. Repair such components in a well
ventilated area away from open flames or sparks.
Use suitable Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Replace damaged lines and hoses. The lines and the Illustration 33 g03839130
hoses should have adequate support and secure
clamps. Tighten all connections to the recommended Use caution when you are fueling a machine. Do not
torque. Damage to the protective cover or insulation smoke while you are fueling a machine. Do not fuel a
may provide fuel for fires. machine near open flames or sparks. Do not use cell
phones or other electronic devices while you are
Store fuels and lubricants in properly marked refueling. Always stop the engine before fueling. Fill
containers away from unauthorized personnel. Store the fuel tank outdoors. Properly clean areas of
oily rags and flammable materials in protective spillage.
containers. Do not smoke in areas that are used for
storing flammable materials. Avoid static electricity risk when fueling. Ultra low
sulfur diesel (ULSD) poses a greater static ignition
hazard than earlier diesel formulations with a higher
sulfur content. Avoid death or serious injury from fire
or explosion. Consult with your fuel or fuel system
supplier to ensure that the delivery system is in
compliance with fueling standards for proper
grounding and bonding practices.
SEBU8498-04 23
Safety Section
Never store flammable fluids in the operator • Abrasion

compartment of the machine.
• Cracking
Battery and Battery Cables • Discoloration
• Cuts on the insulation of the cable
• Fouling
• Corroded terminals, damaged terminals, and
loose terminals
Replace damaged battery cable(s) and replace any
related parts. Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short produces heat from the battery current, which
may be a fire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surface. This
Illustration 34 g03839133 may result in an unsafe condition for servicing the
machine. Repair components or replace components
Caterpillar recommends the following in order to before servicing the machine.
minimize the risk of fire or an explosion related to the
battery.
Do not operate a machine if battery cables or related
parts show signs of wear or damage. Contact your Fire on a machine can result in personal injury or
Cat dealer for service. death. Exposed battery cables that come into
contact with a grounded connection can result in
Follow safe procedures for engine starting with jump- fires. Replace cables and related parts that show
start cables. Improper jumper cable connections can signs of wear or damage. Contact your Cat
cause an explosion that may result in injury. Refer to dealer.
Operation and Maintenance Manual, “Engine Starting
with Jump Start Cables” for specific instructions.
Do not charge a frozen battery. This may cause an
Wiring
explosion.
Check electrical wires daily. If any of the following
Gases from a battery can explode. Keep any open conditions exist, replace parts before you operate the
flames or sparks away from the top of a battery. Do machine.
not smoke in battery charging areas. Do not use cell
phones or other electronic devices in battery • Fraying
charging areas.
• Signs of abrasion or wear
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in • Cracking
order to check the battery charge.
• Discoloration
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other • Cuts on insulation
restraints for damage. Replace any damaged parts.
Check for signs of the following, which can occur • Other damage
over time due to use and environmental factors: Make sure that all clamps, guards, clips, and straps
• Fraying are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
24 SEBU8498-04
Safety Section
Fire Safety
Attaching electrical wiring to hoses and tubes that Make sure that all clamps, guards, and heat shields
contain flammable fluids or combustible fluids should are installed correctly. During machine operation, this
be avoided. will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes, and
Consult your Cat dealer for repair or for replacement hoses.
parts.
Do not operate a machine when a fire hazard exists.
Keep wiring and electrical connections free of debris. Repair any lines that are corroded, loose, or
damaged. Leaks may provide fuel for fires. Consult
Lines, Tubes, and Hoses your Cat dealer for repair or for replacement parts.
Use genuine Cat parts or the equivalent, for
Do not bend high-pressure lines. Do not strike high- capabilities of both the pressure limit and
pressure lines. Do not install any lines that are bent temperature limit.
or damaged. Use the appropriate backup wrenches
in order to tighten all connections to the Ether
recommended torque.
Ether (if equipped) is commonly used in cold-weather
applications. Ether is flammable and poisonous.
Only use approved Ether canisters for the Ether
dispensing system fitted to your machine, do not
spray Ether manually into an engine, follow the
correct cold engine starting procedures. Refer to the
section in the Operation and Maintenance Manual
with the label “Engine Starting” .
Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49° C (120.2° F). Keep ether cylinders away
from open flames or sparks.
Check lines, tubes, and hoses carefully. Wear
Personal Protection Equipment (PPE) in order to Dispose of used ether cylinders properly. Do not
check for leaks. Always use a board or cardboard puncture an ether cylinder. Keep ether cylinders
when you check for a leak. Leaking fluid that is under away from unauthorized personnel.
pressure can penetrate body tissue. Fluid penetration
can cause serious injury and possible death. A pin Fire Extinguisher
hole leak can cause severe injury. If fluid is injected
into your skin, you must get treatment immediately. As an additional safety measure, keep a fire
Seek treatment from a doctor that is familiar with this extinguisher on the machine.
type of injury.
Be familiar with the operation of the fire extinguisher.
Replace the affected parts if any of the following Inspect the fire extinguisher and service the fire
conditions are present: extinguisher regularly. Follow the recommendations
on the instruction plate.
• End fittings are damaged or leaking.
Consider installation of an aftermarket Fire
• Outer coverings are chafed or cut. Suppression System, if the application and working
conditions warrant the installation.
• Wires are exposed.
i07041871
• Outer coverings are swelling or ballooning.
• Flexible parts of the hoses are kinked. Fire Safety

SMCS Code: 7000
• Outer covers have exposed embedded armoring.
• End fittings are displaced. Note: Locate secondary exits and how to use the
secondary exits before you operate the machine.
Note: Locate fire extinguishers and how to use a fire

extinguisher before you operate the machine.
SEBU8498-04 25
Safety Section
Fire Extinguisher Location
If you find that you are involved in a machine fire, i01834364

your safety and that of others on site are the top
priority. The following actions should only be Fire Extinguisher Location
performed if the actions do not present a danger or
risk to you and any nearby people. Assess the risk of SMCS Code: 7000; 7419
personal injury and move away to a safe distance as
soon as you feel unsafe. Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Move the machine away from nearby combustible Inspect the fire extinguisher and service the fire
material such as fuel/oil stations, structures, trash, extinguisher. Obey the recommendations on the
mulch, and timber. instruction plate.
Lower any implements and turn off the engine as Mount the fire extinguisher in the accepted location
soon as possible. If you leave the engine running, the per local regulations.
engine will continue to feed a fire. The fire will be fed
from any damaged hoses that are attached to the Do not weld the ROPS structure in order to install the
engine or pumps. fire extinguisher. Also, do not drill holes in the ROPS
structure in order to mount the fire extinguisher on
If possible, turn the battery disconnect switch to the the ROPS.
OFF position. Disconnecting the battery will remove
the ignition source in the event of an electrical short. Strap the mounting plate to a leg of the ROPS in
Disconnecting the battery will eliminate a second order to mount the fire extinguisher, as needed. If the
ignition source if electrical wiring is damaged by the weight of the fire extinguisher exceeds 4.5 kg (10 lb),
fire, resulting in a short circuit. mount the fire extinguisher near the bottom of the
ROPS. Do not mount the fire extinguisher at the
Notify emergency personnel of the fire and your upper one-third area of the ROPS.
location.
Consult your Caterpillar dealer for the proper
If your machine is equipped with a fire suppression procedure for mounting the fire extinguisher.
system, follow the manufacturers procedure for
activating the system. i01329108
Note: Fire suppression systems need to be regularly

inspected by qualified personnel. You must be
Track Information
trained to operate the fire suppression system. SMCS Code: 4170; 7000
If you are unable to do anything else, shut off the Track adjusting systems use either grease or oil
machine before exiting. By shutting off the machine, under high pressure to keep the track under tension.
fuels will not continue to be pumped into the fire.
Grease or oil under high pressure coming out of the
If the fire grows out of control, be aware of the relief valve can penetrate the body causing injury or
following risks: death. Do not watch the relief valve to see if grease
or oil is escaping. Watch the track or track adjustment
• Tires on wheeled machines pose a risk of cylinder to see if the track is being loosened.
explosion as tires burn. Hot shrapnel and debris
can be thrown great distances in an explosion. The pins and bushings in a dry track pin joint can
become very hot. It is possible to burn the fingers if
• Tanks, accumulators, hoses, and fittings can there is more than brief contact with these
rupture in a fire, spraying fuels and shrapnel over components.
a large area.
i01122596
• Remember that nearly all the fluids on the
machine are flammable, including coolant and oils. Electrical Storm Injury
Additionally, plastics, rubbers, fabrics, and resins
in fiberglass panels are also flammable. Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
• Mount the machine.

• Dismount the machine.
26 SEBU8498-04
Safety Section
Before Starting Engine
If you are in the operator's station during an electrical i01963896

storm, stay in the operator's station. If you are on the
ground during an electrical storm, stay away from the Before Operation
vicinity of the machine.
SMCS Code: 7000
i01896223
Clear all personnel from the machine and from the
area.
Before Starting Engine Remove all obstacles from the path of the machine.
SMCS Code: 1000; 7000 Beware of hazards such as wires, ditches, etc.
Start the engine only from the operator's Be sure that all windows are clean. Secure the doors
compartment. Do not short across the battery and the windows in either the open position or the
terminals and do not short across the batteries. shut position.
Bypassing the engine neutral start system can
damage the electrical system. Adjust the rearview mirrors (if equipped) for best
vision close to the machine. Make sure that the
Inspect the condition of the seat belt and mounting machine horn, the backup alarm (if equipped) and all
hardware. Replace any damaged parts or worn parts. other warning devices are working properly.
Regardless of appearance, replace the seat belt after
three years of use. Do not use an extension for a seat Reference: Refer to Operation and Maintenance
belt on a retractable seat belt. Manual, “Daily Inspection” in this manual.
Adjust the seat so that full pedal travel can be Fasten the seat belt securely.
achieved. Make sure that the operator's back is
against the back of the seat. i07746368
Make sure that the machine is equipped with a

lighting system that is adequate for the job Visibility Information
conditions. Make sure that all lights are working SMCS Code: 7000
properly. Before you start the engine or before you
move the machine, make sure that no one is working Before you start the machine, perform a walk-around
on the machine, working underneath the machine or inspection in order to ensure that there are no
working close to the machine. Make sure that the hazards around the machine.
area is free of personnel.
While the machine is in operation, constantly survey
i04638809
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine.
Engine Starting
Your machine may be equipped with visual aids.
SMCS Code: 1000; 7000 Some examples of visual aids are Closed Circuit
If a warning tag is attached to the start switch or to Television (CCTV) and mirrors. Before operating the
the controls, do not start the engine. Also, do not machine, ensure that the visual aids are in proper
move any controls. working condition and that the visual aids are clean.
Adjust the visual aids using the procedures that are
Move all hydraulic controls to the HOLD position located in this Operation and Maintenance Manual. If
before you start the engine. equipped, the Work Area Vision System shall be
adjusted according to Operation and Maintenance
Make sure that the parking brake is engaged. (The Manual, SEBU8157, “Work Area Vision System”. If
system defaults to this locked position at engine equipped, the Cat Detect Object Detection shall be
shutdown.) adjusted according to the Operation and
Maintenance Manual, “Cat Detect Object Detection”
Diesel engine exhaust contains products of for your machine.
combustion which can be harmful to your health.
Always start the engine in a well ventilated area. It may not be possible to provide direct visibility on
Always operate the engine in a ventilated area. If you large machines to all areas around the machine.
are in an enclosed area, vent the exhaust to the Appropriate job site organization is required in order
outside. to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules
Check for the presence of bystanders or and procedures that coordinates machines and
maintenance personnel. Ensure that all personnel people that work together in the same area.
are clear of the machine. Examples of job site organization include the
following:
Briefly sound the horn before you start the engine.
• Safety instructions
SEBU8498-04 27
Safety Section
Operation
• Controlled patterns of machine movement and Note any needed repairs during machine operation.
vehicle movement Report any needed repairs.
• Workers that direct safe movement of traffic Carry attachments close to the ground,
approximately 40 cm (15 inches) higher than ground
• Restricted areas level. Do not go close to the edge of a cliff, an
excavation, or an overhang.
• Operator training
If the machine begins to sideslip, perform the
• Warning symbols or warning signs on machines or following procedure:
on vehicles
• Discard the load.
• A system of communication
• Turn the machine downhill.
• Communication between workers and operators
prior to approaching the machine Be careful to avoid any condition which could lead to
tipping. Tipping can occur when you work on hills,
Modifications of the machine configuration by the banks and slopes. Also, tipping can occur when you
user that result in a restriction of visibility shall be cross ditches, ridges or other unexpected
evaluated. obstructions.
Whenever it is possible, operate the machine up the
i03721461 slopes and down the slopes. Avoid operating the
machine across the slope, when possible.
Operation
Keep the machine under control. Do not overload the
SMCS Code: 7000 machine beyond capacity.
Be sure that the towing devices are adequate.
Machine Operating Temperature
Range Never straddle a wire cable or allow other personnel
to straddle a wire cable.
The standard machine configuration is intended for Know the maximum dimensions of your machine.
use within an ambient temperature range of −40 °C
(−40 °F) to 50 °C (122 °F). Special configurations for Always keep the Rollover Protective Structure
different ambient temperatures may be available. (ROPS) installed during machine operation.
Consult your Caterpillar dealer for additional
information on special configurations of your
i02801025
machine.
Operation Parking
SMCS Code: 7000
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the Park on a level surface. If you must park on a grade,
machine. Only operate the controls while the engine use blocks to prevent the machine from rolling.
is running.
Apply the service brake in order to stop the machine.
Check for proper operation of all controls and The service brake is applied by fully depressing the
protective devices while you operate the machine decel/brake pedal. Move the transmission control to
slowly in an open area. NEUTRAL position and the speed control to LOW
IDLE position. Engage the parking brake switch.
Before you move the machine, make sure that no
one will be endangered. Lower all attachments to the ground.
Do not allow riders on the machine unless the Stop the engine.
machine has the following equipment:
Turn the engine start switch key to OFF position and
• additional seat remove the key.
• additional seat belt Turn the key for the battery disconnect switch to the
OFF position. Remove the key when you exit the
• Rollover Protective Structure (ROPS) machine for an extended period of time.
Never use the work tool for a work platform. Turning the battery disconnect switch to the OFF
position will provide the following benefits:
28 SEBU8498-04
Safety Section
Slope Operation
• Prevent battery discharge that is caused by a Width of tracks or tires – Narrower tracks or
battery short circuit. narrower tires further increase the digging into the
ground which causes the machine to be less stable.
• Prevent battery discharge that is caused by some
of the components. Implements attached to the drawbar – This may
decrease the weight on the uphill tracks. This may
• Prevent battery discharge that is caused by also decrease the weight on the uphill tires. The
vandalism. decreased weight will cause the machine to be less
stable.
i07746366 Height of the working load of the machine – When
the working loads are in higher positions, the stability
Slope Operation of the machine is reduced.
SMCS Code: 7000 Operated equipment – Be aware of performance
features of the equipment in operation and the effects
Machines that are operating safely in various on machine stability.
applications depend on these criteria: the machine
model, configuration, machine maintenance, Operating techniques – Keep all attachments or
operating speed of the machine, conditions of the pulled loads low to the ground for optimum stability.
terrain, fluid levels, and tire inflation pressures. The
most important criteria are the skill and judgment of Machine systems have limitations on slopes –
the operator. Slopes can affect the proper function and operation
of the various machine systems. These machine
A well trained operator that follows the instructions in systems are needed for machine control.
the Operation and Maintenance Manual has the
greatest impact on stability. Operator training
Note: Operators with lots of experience and proper
provides a person with the following abilities:
observation of working and environmental conditions, equipment for specific applications are also required.
feel for the machine, identification of potential Safe operation on steep slopes may also require
hazards and operating the machine safely by making special machine maintenance. Refer to Lubricant
appropriate decisions. Viscosities and Refill Capacities in this manual for the
proper fluid level requirements and intended machine
When you work on side hills and when you work on use. Fluids must be at the correct levels to ensure
slopes, consider the following important points: that systems will operate properly on a slope.
Speed of travel – At higher speeds, forces of inertia
i07483613
tend to make the machine less stable.
Roughness of terrain or surface – The machine Engine Stopping
may be less stable with uneven terrain.
SMCS Code: 1000; 7000
Direction of travel – Avoid operating the machine
across the slope. When possible, operate the Do not stop the engine immediately after the machine
machine up the slopes and operate the machine has been operated under load. This operation can
down the slopes. Place the heaviest end of the cause overheating and accelerated wear of engine
machine uphill when you are working on an incline. components.
Mounted equipment – Balance of the machine may After the machine is parked and the parking brake is
be impeded by the following components: equipment engaged, allow the engine to run for 5 minutes at
that is mounted on the machine, machine LOW IDLE before shutdown. This procedure allows
configuration, weights, and counterweights. hot areas of the engine to cool gradually.
Nature of surface – Ground that has been newly For more information, refer to the following topics in
filled with earth may collapse from the weight of the the Operation Section of the Operation and
machine. Maintenance Manual:
Surface material – Rocks and moisture of the • "Stopping the Engine"
surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may • "Stopping the Engine if an Electrical Malfunction
promote side slipping of the machine.
Occurs"
Slippage due to excessive loads – This may cause
downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
SEBU8498-04 29
Safety Section
Equipment Lowering with Engine Stopped
i01329161 The exterior sound pressure level for the standard

machine is 78dB(A). This measurement was
Equipment Lowering with obtained with the test procedures that are specified in
“SAE J88 FEB2006”. The measurement was
Engine Stopped obtained under the following conditions: distance of
15 m (49.2 ft), machine in middle speed range and
SMCS Code: 7000 moving.
Before lowering any equipment with the engine
stopped, clear the area around the equipment of all Sound Performance for Machines
personnel. The procedure to use will vary with the
type of equipment to be lowered. Keep in mind most
that are Offered in European Union
systems use a high pressure fluid or air to raise or Countries and in Countries with the
lower equipment. The procedure will cause high
pressure air, hydraulic, or some other media to be “EU Directives”
released in order to lower the equipment. Wear
appropriate personal protective equipment and follow The information below applies to machine
the established procedure in the Operation and configurations that only have the “CE mark” on the
Maintenance Manual, “Equipment Lowering with product information plate (PIN).
Engine Stopped” in the Operation Section of the
manual. Machines with Standard Cab
The dynamic operator sound pressure level is 77 dB
i04644418
(A) when “ISO 6396: 2008” is used to measure the
value for an enclosed cab. The cab was properly
Sound Information and installed and maintained. The test was conducted
with the cab doors and the cab windows closed.
Vibration Information
SMCS Code: 7000 Machines with Logging Cab
Sound Level Information The dynamic operator sound pressure level is 79 dB

(A) when “ISO 6396: 2008” is used to measure the
The measurement for operator sound pressure level value for an enclosed cab. The cab was properly
Leq was obtained with the procedures that are installed and maintained. The test was conducted
specified in “ANSI/SAE J1166 FEB2008”. The with the cab doors and the cab windows closed.
procedure specifies the requirements of the work
cycle to use while the measurement is obtained. The “The European Union Physical
operator sound pressure level is 80 dB(A) for the cab
that is offered by Caterpillar. This reading is correct Agents (Vibration) Directive 2002/
under the following conditions: proper installation of 44/EC”
the cab, proper maintenance of the cab, closed cab
doors and closed cab windows.
Vibration Data for Track-Type Tractors
Hearing protection may be needed when the
machine is operated with an open operator station for Information Concerning Hand/Arm Vibration
extended periods or in a noisy environment. Hearing Level
protection may be needed when the machine is
operated with a cab that is not properly maintained, When the machine is operated according to the
or when the doors and windows are open for intended use, the hand/arm vibration of this machine
extended periods or in a noisy environment. is below 2.5 meter per second squared.
Information Concerning Whole Body Vibration
Level
This section provides vibration data and a method for
estimating the vibration level for track-type tractors.
Note: Vibration levels are influenced by many

different parameters. Many items are listed below.
• Operator training, behavior, mode and stress

• Job site organization, preparation, environment,
weather and material
30 SEBU8498-04
Safety Section
Sound Information and Vibration Information
• Machine type, quality of the seat, quality of the

suspension system, attachments and condition of
the equipment
It is not possible to get precise vibration levels for this
machine. The expected vibration levels can be
estimated with the information in Table 1 in order to
calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
Note: All vibration levels are in meter per second
squared.
Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Typical Operating Vibration Levels Scenario Factors

Machine Type
Activity X axis Y axis Z axis X axis Y axis Z axis
Track-Type dozing 0,74 0,58 0,70 0,31 0,25 0,31
Tractors
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
Note: Refer to “ISO/TR 25398 Mechanical Vibration - Guidelines for Reducing Vibration Levels on
Guideline for the assessment of exposure to whole Earthmoving Equipment
body vibration of ride on operated earthmoving
machines” for more information about vibration. This Properly adjust machines. Properly maintain
publication uses data that is measured by machines. Operate machines smoothly. Maintain the
international institutes, organizations and conditions of the terrain. The following guidelines can
manufacturers. This document provides information help reduce the whole body vibration level:
about the whole body exposure of operators of 1. Use the right type and size of machine, equipment,
earthmoving equipment. Refer to Operation and
and attachments.
Maintenance Manual Supplement , SEBU8257 for
more information about machine vibration levels. 2. Maintain machines according to the
The Caterpillar suspension seat meets the criteria of manufacturer's recommendations.
“ISO 7096”. This represents vertical vibration level a. Tire pressures
under severe operating conditions. This seat is tested
with the input “spectral class EM6”. The seat has a b. Brake and steering systems
transmissibility factor of “SEAT<0.7”.
c. Controls, hydraulic system and linkages
The whole body vibration level of the machine varies.
There is a range of values. The low value is 0.5 meter 3. Keep the terrain in good condition.
per second squared. The machine meets the short a. Remove any large rocks or obstacles.
term level for the design of the seat in “ISO 7096”.
The value is 1.61 meter per second squared for this b. Fill any ditches and holes.
machine.
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.
SEBU8498-04 31
Safety Section
Sound Information and Vibration Information
a. Adjust the seat and suspension for the weight f. Minimize any shocks and impacts during sports
and the size of the operator. and leisure activities.
b. Inspect and maintain the seat suspension and
adjustment mechanisms.
Sources
5. Perform the following operations smoothly. The vibration information and the calculation
procedure is based on “ISO/TR 25398 Mechanical
a. Steer Vibration - Guideline for the assessment of exposure
to whole body vibration of ride on operated
b. Brake earthmoving machines”. Harmonized data is
measured by international institutes, organizations
c. Accelerate. and manufacturers.
d. Shift the gears. This literature provides information about assessing
6. Move the attachments smoothly. the whole body vibration exposure of operators of
earthmoving equipment. The method is based on
7. Adjust the machine speed and the route in order to measured vibration emission under real working
minimize the vibration level. conditions for all machines.
a. Drive around obstacles and rough terrain. You should check the original directive. This
document summarizes part of the content of the
b. Slow down when it is necessary to go over applicable law. This document is not meant to
rough terrain. substitute the original sources. Other parts of these
documents are based on information from the United
8. Minimize vibrations for a long work cycle or a long Kingdom Health and Safety Executive.
travel distance.
Refer to Operation and Maintenance Manual
a. Use machines that are equipped with Supplement , SEBU8257 for more information about
suspension systems. vibration.
b. Use the ride control system on Track-Type Consult your local Caterpillar dealer for more
Tractors. information about machine features that minimize
vibration levels. Consult your local Caterpillar dealer
c. If no ride control system is available, reduce about safe machine operation.
speed in order to prevent bounce. Use the following web site in order to find your local
d. Haul the machines between workplaces. dealer:
9. Less operator comfort may be caused by other risk Caterpillar, Inc.

factors. The following guidelines can be effective www.cat.com
in order to provide better operator comfort:
Cab Internal Clearance
a. Adjust the seat and adjust the controls in order
to achieve good posture. If a machine is equipped with a cab, the position of
the operator conforms to industry standards. These
b. Adjust the mirrors in order to minimize twisted standards are “SAE J154” and “ISO 3411”. An item
posture. should not protrude into the space of the cab. The
following items should not protrude into the cab.
c. Provide breaks in order to reduce long periods
of sitting. • Radio
d. Avoid jumping from the cab. • Fire extinguisher
e. Minimize repeated handling of loads and lifting • Lunch box
of loads.
32 SEBU8498-04
Safety Section
Operator Station
Objects in the cab should be secured. The objects Rollover Protective Structure
must remain in place during operations in rough
terrain. The objects must remain in place during a (ROPS), Falling Object Protective
rollover of the machine. Structure (FOPS) or Tip Over
i07746362
Protection Structure (TOPS)
The ROPS/FOPS Structure (if equipped) on your
Operator Station machine is specifically designed, tested and certified
SMCS Code: 7300 for that machine. Any alteration or any modification to
the ROPS/FOPS Structure could weaken the
Any modifications to the inside of the operator station structure. This places the operator into an
should not project into the operator space or into the unprotected environment. Modifications or
space for the companion seat (if equipped). The attachments that cause the machine to exceed the
addition of a radio, fire extinguisher, and other weight that is stamped on the certification plate also
equipment must be installed so that the defined place the operator into an unprotected environment.
operator space and the space for the companion seat Excessive weight may inhibit the brake performance,
(if equipped) is maintained. Any item that is brought the steering performance and the ROPS. The
into the cab should not project into the defined protection that is offered by the ROPS/FOPS
operator space or the space for the companion seat Structure will be impaired if the ROPS/FOPS
(if equipped). A lunch box or other loose items must Structure has structural damage. Damage to the
be secured. Objects must not pose an impact hazard structure can be caused by an overturn, a falling
in rough terrain or in the event of a rollover. object, a collision, etc.
Do not mount items (fire extinguishers, first aid kits,
i07746359 work lights, etc) by welding brackets to the ROPS/
FOPS Structure or by drilling holes in the ROPS/
Guards FOPS Structure. Welding brackets or drilling holes in
the ROPS/FOPS Structures can weaken the
(Operator Protection) structures. Consult your Cat dealer for mounting
guidelines.
SMCS Code: 7000; 7150-MCH; 7150; 7325
The Tip Over Protection Structure (TOPS) is another
There are different types of guards that are used to type of guard that is used on mini hydraulic
protect the operator. The machine and the machine excavators. This structure protects the operator in the
application determine the type of guard that should event of a tipover. The same guidelines for the
be used. inspection, the maintenance and the modification of
A daily inspection of the guards is required in order to the ROPS/FOPS Structure are required for the Tip
check for structures that are bent, cracked, or loose. Over Protection Structure.
Never operate a machine with a damaged structure.
The operator becomes exposed to a hazardous
Other Guards (If Equipped)
situation if the machine is used improperly or if poor
operating techniques are used. This situation can Protection from flying objects and/or falling objects is
occur even though a machine is equipped with an required for special applications. Logging
appropriate protective guard. Follow the established applications and demolition applications are two
operating procedures that are recommended for your examples that require special protection.
machine. 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
• Rock quarries
SEBU8498-04 33
Safety Section
Operator Protection
• Forestry products
Additional guards may be required for specific
applications or work tools. The Operation and
Maintenance Manual for your machine or your work
tool will provide specific requirements for the guards.
Refer to Operation Maintenance manual,
"Demolition" for additional information. Consult your
Cat dealer for additional information.
34 SEBU8498-04
General Information
Product Information (Table 2, contd)

D3K2 HYSTAT TRACK-TYPE TRACTOR
Section Length (SLGP) (A) 4255 mm (167.5 inch)
Width (LGP) (B) 2360 mm (92.9 inch)

General Information Width (XL) (B) 1901 mm (74.8 inch)
i06043309 Width (SLGP) (B) 2630 mm (103.5 inch)
Height to top of ROPS (C)(4) 2754 mm (108.4 inch)

Specifications
Height to top of ROPS (C)(5) 2748 mm (108.2 inch)
SMCS Code: 1000; 6700; 7000; 7426
Blade width (LGP) (D) 3149 mm (124.0 inch)
Blade width (XL) (D) 2646 mm (104.2 inch)
Blade width (SLGP) (D) 3149mm (124.0 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.
(4) Overall height with SystemOne track
(5) Overall height with SALT track
Table 3
Operating Weight (LGP) 8476 kg (18686 lb)
Illustration 36 g02389762 Operating Weight (XL) 8108 kg (17875 lb)
Length (LGP) (A) 4255 mm (167.5 inch)
Length (XL) (A) 4274 mm (168.3 inch)
Width (XL) (B) 2010 mm (79.1 inch)
Height to top of ROPS (C) 2754 mm (108.4 inch)
Blade width (LGP) (D) 3149 mm (124 inch)
Table 4
Operating Weight (LGP) 9522 kg (20992 lb)
Table 2
Operating Weight (XL) 9214 kg (20313 lb)
Operating Weight (SLGP) 9723 kg (21435 lb)
Operating Weight (LGP)(1) 8365 kg (18442 lb)
Length (LGP) (A) 4309 mm (169.6 inch)
Operating Weight (XL)(1) 7922 kg (17465 4 lb)
Operating Weight (SLGP)(2) 8609 kg (18980 lb)
Length (SLGP) (A) 4439 mm (174.7 inch)
Length (LGP) (A)(3) 4255 mm (167.5 inch)
(continued)
(continued)
SEBU8498-04 35
Specifications
(Table 4, contd)
Width (XL) (B) 2110 mm (83.0 inch)
Width (SLGP) (B) 2410 mm (94.9 inch)
Blade width (LGP) (D) 3220 mm (126.8 inch)
Blade width (SLGP) (D) 3220 mm (126.8 inch)
Note: Add 250 kg (551 lb) to the operating weight for

machines with “EROPS” .
Intended Use
This Track-Type Tractor is an earthmoving machine
that is described by “ISO 6165:2012”. The Track-
Type Tractor is classified as a Dozer. The 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 for the
D3K2 is 11257 kg (24817 lb)
• Maximum approved Operating Weight for the
D4K2 and D5K2 is 13300 kg (29321 lb).
• Maximum drawbar pull (170 kN (38218 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.
Special attachments and operating instructions are
required for Waste Handling applications and other
Custom configurations.
36 SEBU8498-04
Identification Information
Identification Information
i04280971
Plate Locations and Film

Locations
SMCS Code: 1000; 7000
Product Identification 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. Illustration 38 g02448218
The plate for Machine 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 guard on the front of the machine.
Machine PIN (1)
CE Plate (2)
Year of Manufacture (If required) (3)
Country of Origin (4)
The Engine Serial Number Plate is located on the left
side of the engine block directly behind the dip stick
tube.
SEBU8498-04 37
Plate Locations and Film Locations
Ripper Serial Number

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

The serial number plate for the ripper is located on
the side of the ripper.
38 SEBU8498-04
Structural damage, an overturn, modification, al-

teration, or improper repair, can impair this struc-
ture's protective capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.
This machine has been certified to the standards that

are listed on the certification plate. The maximum
mass of the machine, which includes the operator
and the attachments without payload, should not
exceed the mass on the certification plate.
A typical example of the certification film is shown
The winch serial number is located on the right above.
vertical wall of the winch frame. Do not operate or
service the winch unless your first read the Operation Refer to Operation and Maintenance Manual,
and Maintenance Manual with understanding the “Guards (Operator Protection)” for more information.
instructions for the safe operation of the winch.
Winch Serial Number
Sound Certification
Model
Certifications
ROPS/FOPS Plate
The message is positioned on the outside left
canopy.
A typical example of this film is shown. Your machine
may have a different value.
SEBU8498-04 39
If equipped, the certification film is used to verify the For the name, the address and the country of origin
environmental sound certification of the machine. for the manufacturer, see the PIN plate.
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
The machines are compliant to “2006/42/EC”. The
CE plate is positioned on the bottom left side of the
Machine PIN (1) at the rear of the machine.
For quick reference, record this information in the

spaces that are provided below.
• Engine Power of primary engine (kW)

• Engine Power for additional engine (kW) (if
equipped)
• Typical operating weight of machine for European
market (kg)
• Year of construction
• Machine Type
40 SEBU8498-04
Declaration of Conformity
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 modified.
EC DECLARATION OF CONFORMITY OF MACHINERY
Manufacturer: Caterpillar Inc., 100 N.E. Adams Street, Peoria, IL 61629 USA
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean 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
I, the undersigned, _________, hereby certify that the construction equipment specified hereunder
Description: Generic Denomination: Earth moving equipment
Function: Steel track dozer

Model/Type: D3K2, D4K2, D5K2
Serial Number:
Commercial Name: Caterpillar
Fulfils all the relevant provisions of the following Directives
Directives Notified Body Document No.
2006/42/EC
2000/14/EC amended by 2005/88/EC, Note (1)
2004/108/EC
Note (1) Annex – ___ Guaranteed Sound Power Level - ____ dB (A)
Representative Equipment Type Sound Power Level - ____ dB (A)
Engine Power per _____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File
Done at: Signature
Date: Name/Position
Note: The above information was correct as of November 2011, but may be subject to change, please refer to the individual declaration of con-
formity issued with the machine for exact details.
SEBU8498-04 41
Emissions Certification Film
i07709181
Emissions Certification Film

SMCS Code: 1000; 7000; 7405
Note: This information is pertinent in the United

States, in Canada and in Europe.
Consult your Cat dealer for an Emission Control
Warranty Statement.
This label is located on the engine.
42 SEBU8498-04
Operation Section
Before Operation
Operation Section Do not mount a moving machine. Do not dismount a

moving machine. Never jump off the machine. Do not
try to mount the machine when you carry tools or
supplies. Do not try to dismount the machine when
Before Operation you are carrying tools or supplies. Use a hand line to
pull equipment onto the platform. Do not use any
controls as handholds when you enter the operator
i04203489
compartment or when you exit the operator
compartment.
Mounting and Dismounting
SMCS Code: 7000 i07487178
Daily Inspection
SMCS Code: 1000; 7000
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
Illustration 50 g02392096 been stopped and the cooling system pressure
Handholds and steps cap is cool enough to touch with your bare hand.
Remove the cooling system pressure cap slowly
to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.
NOTICE
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning or
high pressure water, at least every 1000 hours or
each time any significant quantity of oil is spilled on a
machine.
Note: For maximum service life of the machine,

make a thorough daily inspection before you operate
Use steps and handholds whenever you mount the the machine. Inspect the machine for leaks. Remove
machine. Use steps and handholds whenever you any debris from the engine compartment and the
dismount the machine. Before you mount the undercarriage. Ensure that all guards, covers, and
machine, clean the step and the handholds. Inspect caps are secured. Inspect all hoses and belts for
the step and handholds. Make all necessary repairs. damage. Inspect all lights and mirrors for damage.
Check the condition of the fan drive belt. Make the
Face the machine whenever you mount the machine needed repairs before you operate the machine.
and whenever you dismount the machine. Maintain a
three-point contact with the step and with handholds. Note: Watch closely for leaks. If you observe a leak,
find the source of the leak and correct the leak. If you
Note: Three-point contact can be 2 feet and one suspect a leak or you observe a leak, check the fluid
hand. Three-point contact can also be 1 foot and two levels more frequently.
hands.
Perform the following procedures on a daily basis.
SEBU8498-04 43
Operation Section
Daily Inspection
• Operation and Maintenance Manual, “Backup

Alarm - Test”
• Operation and Maintenance Manual, “Brakes,

Indicators, and Gauges - Test”
• Operation and Maintenance Manual, “Bulldozer
Power Angling Tilt Hinge Pins - Lubricate”
• Operation and Maintenance Manual, “Cab Filter
(Fresh Air) - Clean/Inpsect/Replace”
• Operation and Maintenance Manual, “Cooling

System Coolant Level - Check”
• Operation and Maintenance Manual, “Engine Oil

Level - Check”
• Operation and Maintenance Manual, “Fuel System
Water Separator - Drain”
• Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check”
• Operation and Maintenance Manual, “Seat Belt -

Inspect”
• Operation and Maintenance Manual, “Winch

Cable - Inspect”
• Operation and Maintenance Manual, “Winch
Fairlead Rollers - Lubricate”
• Operation and Maintenance Manual, “Ripper
Linkage and Cylinder Bearing - Lubricate”
• Operation and Maintenance Manual, “Camera -

Clean/Adjust”
Refer to the Maintenance Section for the detailed
procedures. Refer to the Maintenance Interval
Schedule for a complete list of scheduled
maintenance.
44 SEBU8498-04
Operation Section
Machine Operation
Machine Operation Rear Window with Ring Seal (If

Equipped)
i05063109
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.
Fire Suppression Arrangement (If

Equipped)
Hinged Side Screens (If Equipped)
(1) Ring
(2) O-ring seal
Alternate Exit – The rear window serves

as an alternate exit.
To remove the rear window, pull ring (1) and push out
the glass.
Completely remove O-ring seal (2) from the seal that
supports the glazing support seal. This will provide
enough clearance so that the seal can hinge and the
glazing can pass outward. Climb through the opening
of the rear window in order to exit the cab.
Fire plow option
Rear Window with Lever (If
Equipped)
Use the internal release that is inside of the window
for an emergency exit, if necessary.
i07059455
Alternate Exit
SMCS Code: 7308; 7310
S/N: GAE1–Up
(3) Lock pin
(4) Lever
(A) Unlocked position
(B) Locked position
The rear window serves as an alternate exit. The rear

window can be removed from the inside of the cab or
from the outside of the cab.
SEBU8498-04 45
Operation Section
Seat
Note: When lock pin (3) is in the locked position (B), 2. Grip lever (4). Fully turn the lever in the direction of
the rear window cannot be removed. When you the arrow and pull backward in order to remove
operate the machine, place lock pin (3) in unlocked the window.
position (A).
Removing Rear Window from the Inside

Hammer (If Equipped)
1. Place lock pin (3) in unlocked position (A).

2. Grip the lever (4). Fully turn the lever in the
direction of the arrow and push the rear window
outward.
Removing Rear Window from the

Outside
Alternate Exit – The rear window serves

as an alternate exit.
Break Glass – Strike the rear window

with the hammer in order to break the
glass.
A hammer is mounted on the left side of the cab.
Illustration 55 g01137162 Strike the rear window with the hammer in order to
break the glass. Climb through the opening of the
rear window in order to exit the cab.
1. Make sure that lock pin (3) is in the unlocked
position (A).
i04311630
Seat
SMCS Code: 7312-025; 7324
Note: The operator 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.
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.
46 SEBU8498-04
Operation Section
Seat Belt
Heated Seat (9) (If equipped) – Press the

top of the rocker switch for heat. Press
the bottom of the rocker switch to turn
OFF.
Heated and Ventilated Seat (9) (If
equipped) – Press the top of the rocker
switch for high heat. Press the bottom of
the rocker switch for low heat. The center switch
position is OFF.
Seat Height (10) – Push in knob (10) in

order to raise the seat height. Pull out
on the knob in order to lower the seat
height.
i04575638
Seat Belt
SMCS Code: 7327
Illustration 57 g02473018 Note: This machine was equipped with a seat belt
when the machine was shipped from Caterpillar. At
Back Cushion Angle Adjustment (1) – the time of installation, the seat belt and the
Pull the lever upward. Permit the back instructions for installation of the seat belt meet the
cushion spring forward or lean SAE J386 and ISO 6683 standards. Consult your Cat
backward into the cushion. Release the lever at dealer for all replacement parts.
the desired position.
Always check the condition of the seat belt and the
Fore and Aft Position (2) – Pull the lever condition of the mounting hardware before you
upward. Move the seat in the desired operate the machine.
direction. Release the lever at the
desired forward position or the desired rearward Seat Belt Adjustment for
position.
Retractable Seat Belts
Back Extension(3) – Pull up on back
extension (3) in order to remove the Fastening The Seat Belt
back extension.
Lumbar Support (4) – Turn the knob or
press the switch (if equipped) to
increase or decrease lumbar support.
Adjustment Control (5) – Lift handle (5)
and slide the armrest and joystick
support (6) forward or backward.
Release handle (5) at the desired position.
Seat Cushion Tilt (7) – The front of the
seat cushion is pinned in a groove.
Grasp the seat pan and rotate the pin
“ forward−up−and−back”” into the steep angle
position. Grasp the seat pan and rotate the pin
“ forward-down-and-back”” into the nominal Illustration 58 g00867598
position.
Pull seat belt (4) out of the retractor in a continuous
Heated and Ventilated Seat (8) (If motion.
equipped) – Press the left side of the
two position rocker switch for the Fasten seat belt catch (3) into buckle (2). Make sure
heating mode. Press the right side of the rocker that the seat belt is placed low across the lap of the
switch for the ventilation operation. operator.
SEBU8498-04 47
Operation Section
Mirror
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. Slips and falls can result in personal injury. Use
the machine's access systems when adjusting
Releasing The Seat Belt the mirrors. If the mirrors cannot be reached us-
ing the machine access systems follow the in-
structions 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
Illustration 59 g00039113 Maintenance Manual, “Visibility Information”.
Push the release button on the buckle in order to Mirror Adjustment

release the seat belt. The seat belt will automatically
retract into the retractor.
Interior Mirror
Extension of the Seat Belt
When using retractable seat belts, do not use

seat belt extensions, or personal injury or death
can result.
The retractor system may or may not lock up de-
pending on the length of the extension and the
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.
Longer, non-retractable seat belts and extensions for
the non-retractable seat belts are available.
Caterpillar requires only non-retractable seat belts to Illustration 60 g01702814
be used with a seat belt extension.
Rear view of interior mirror
Consult your Cat dealer for longer seat belts and for
information on extending the seat belts. The interior mirror can be adjusted to a position that
allows the operator to see preferred areas at the rear
of the machine. This action assists visibility during
i06046411
operations such as backing up, reversing the
machine, or moving backward.
Mirror
SMCS Code: 7319
Adjust all mirrors as specified in the Operation

and Maintenance Manual. Failure to heed this
warning can lead to personal injury or death.
48 SEBU8498-04
Operation Section
Mirror
Right Side Rear View Mirror
Left ripper tooth in mirror
• Park the machine on a level surface.
• Lower the work tool to the ground.

• Move the bulldozer control or ripper control (if
equipped) to the HOLD position. For further details
on this procedure, refer to Operation and
Maintenance Manual, “Operator Controls”
• Stop the engine.

• Adjust the right side rear view mirror in order to
view the rear work tool, if equipped. Additionally,
provide as much visibility to the rear as possible.
SEBU8498-04 49
Operation Section
Operator Controls
Note: Use a hand tool to adjust this mirror.
i05033406
Operator Controls
SMCS Code: 7300; 7301; 7451
(1) Armrest (10A) Vandalism guard (if equipped) (20) Heated joystick switch (if equipped)
(2) Air conditioning and heating Controls (11) Bulldozer Control (21) Winch Controls or Ripper Controls (if
(3) Steering and Transmission Control (12) Work lights equipped)
(4) Decelerator/Brake Pedal (13) Engine throttle control (22) Winch freespool switch (if equipped)
(5) Gauges and Indicators (14) Parking brake switch (23) Winch driveaway switch (if equipped)
(6) Mirror (15) Hydraulic lockout (24) Auxiliary function (if equipped)
(7) AM/FM Radio (if equipped) (16) Stable blade control (25) Air suspension seat
(8) Exterior cab door release lever (17) Front window wiper (if equipped) (26) Pocket in seat backrest (Operation and
(9) Interior cab door release lever (18) Front wiper delay (if equipped) Maintenance Manual)
(10) Engine Start Switch (19) Rear window wiper (if equipped) (27) Power Receptacle inside storage box
50 SEBU8498-04
Operation Section
Operator Controls
Armrest Adjustments (1) 3. Release lever (1A).
Air Conditioning and Heating

Control (2)
Enclosed ROPS
Open ROPS arrangement only has heating.
(2A) Fan control knob
(2B) Temperature control knob
Control Supports (2C) Air conditioner switch
Use the following procedure in order to adjust both of Fan Control

the control supports (1), if necessary.
1. Pull lever (1A) upward that is on the outside of OFF – Move knob (2A) to this position in
armrest (1). order to stop the blower fan motor.
2. Pull control support (1) in a forward direction or Fan Speed Switch (2A) – This knob
rearward direction to a comfortable position. 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
Temperature Control Knob (2B) – Turn
knob(2B) counterclockwise to COOL.
Turn knob (2B) clockwise to WARM.
Air Conditioner Switch (If Equipped)

Air Conditioner – Press in the top of
switch (2C) in order to turn on the air
conditioner. Press the bottom of switch
(2C) in order to turn off the air conditioner.
SEBU8498-04 51
Operation Section
Operator Controls
Heating and Air Conditioning System

Operation
Steering and Transmission Control
The heating and air conditioning system performs
five functions:
(3)
Note: The Open ROPS arrangement has a heating
system only.
Heating – Turn knob (2A) to the desired speed
(LOW, MEDIUM LOW, MEDIUM HIGH, or
MAXIMUM). Adjust knob (2B) in order to obtain the
desired temperature.
Cooling – Press switch (2C) in order to turn on the
air conditioner. Turn knob (2A) to the desired speed
Defrosting – Press switch (2C) in order to turn on
the air conditioner. Turn knob (2A) to the desired fan
speed (LOW, MEDIUM LOW, MEDIUM HIGH, or Illustration 65 g01258402
Pressurizing – When heating or cooling is not
desired, pressure inside the cab will help keep out
dust.
Turn knob (2B) in order to obtain the desired

temperature. To produce the volume of air that is
necessary to keep out dust, turn knob (2A) to
MEDIUM LOW or to MEDIUM HIGH.
Defogging – Press switch (2C) in order to turn on the
air conditioner. Turn knob (2A) to the desired speed
MAXIMUM). Adjust knob (2B) until the moisture level
is lowered and the front window and side windows
are free of moisture. Illustration 66 g02675557
Note: Make sure that parking brake switch (14) is

disengaged in order to use steering and transmission
control (3).
52 SEBU8498-04
Operation Section
Operator Controls
the tracks counterrotate, the right side track will

rotate backward, while the left track rotates forward.
REVERSE RIGHT (3G) – 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 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 lever (3) in the opposite direction.
Deceleration of the engine speed makes for easier
directional changes. However, this action is not
required.
Note: In order to turn the machine, lever (3) must be

placed in either the FORWARD detent position or in
the REVERSE detent position.
FORWARD (3A) – Move lever (3) forward past the
detent position in order to move the machine forward. Track Speed (3H)
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 the
detent position in order to move the machine
backward.
FORWARD LEFT (3D) – Move lever (3) to the left in
order to turn the machine to the left. The turning
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. Illustration 68 g02725525
FORWARD RIGHT (3E) – Move lever (3) to the right LOW – Roll the wheel (3H) to the left
in order to turn the machine to the right. The turning when a lower speed is desired.
the right, slightly move lever (3) to the right. If you Note: Wheel (3H) allows variable speeds via the
want to increase your turn, move lever (3) further to incremental rotation of the wheel.
the right. If you want the machine to counterrotate,
move lever (3) all the way to the right past the detent. HIGH – Roll the wheel (3H) to the right
When the tracks counterrotate, the left side track will when a higher speed is desired.
rotate forward, while the right track rotates backward.
REVERSE LEFT (3F) – Move lever (3) to the left in The machine is set with the following factory settings.
order to turn the machine to the left. The turning
radius for the machine is proportional to the control • Maximum forward speed of 9.0 km/h (5.6 mph)
the left, slightly move lever (3) to the left. If you want • Maximum reverse speed of 10.0 km/h (6.2 mph)
to increase your turn, move lever (3) further to the REVERSE and FORWARD Speeds – The forward
left. If you want the machine to counterrotate, move and reverse speed is independent of each other.
lever (3) all the way to the left past the detent. When Changing one speed does not change the other.
SEBU8498-04 53
Operation Section
Operator Controls
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.
Horn (3J)
Horn – Push down button (3J) in order to
activate the horn.
Traction Control Button (3K)

Traction control button (3K) reduces unwanted track Illustration 70 g02790334
slip in cases of heavy blade load and a poor
underfoot condition.
“ FNR””
F – The steering and transmission control allows
machine travel in the FORWARD direction.
N – The steering and transmission control is in the
NEUTRAL position.
R – The steering and transmission control allows
machine travel in the REVERSE direction.
Manual Engagement - Traction Control
1. Place the “FNR” in FORWARD.

3. After blade load has been reduced or underfoot

conditions have improved, press the traction
control button (3K) briefly to disable the Traction
Control System. The traction control indicator (TC)
is removed from the gauge display.
4. Placing the “FNR” into the NEUTRAL or
REVERSE position disables the Traction Control
System.
5. Repeat Steps 1 and 2 to enable the Traction
Control System again.
Automatic Engagement - Traction Control
2. Under heavy blade load and poor underfoot 1. Place the “FNR” in NEUTRAL.
conditions, press traction control button (3K) 2. Hold traction control button (3K) for 3 seconds or
briefly to enable the Traction Control System. The use the CIC Operator Modes Menu to enable (or
traction control indicator (TC) is shown on the disable) the automatic Traction Control System.
gauge display.
54 SEBU8498-04
Operation Section
Operator Controls
Bidirectional Shift Control

Bidirectional shift control allows the operator to
program FORWARD and REVERSE preset speed
values. The speed values are automatically recalled
each time the 'FNR' is shifted into FORWARD or
REVERSE.
“ FNR””
F – The steering and transmission control allows
machine travel in the FORWARD direction.
N – The steering and transmission control is in the
NEUTRAL position.
R – The steering and transmission control allows
Illustration 72 g02666725 machine travel in the REVERSE direction.
a. To use the CIC Operator Modes Menu,

In order to program the preset speed values, the
navigate to the Auto Traction Control System operator must first enable “Bidirectional Shift Control”
menu using the up arrow. Then, use the right .
arrow to toggle between OFF and ON.
Enabling and Disabling
Use the CIC Operator Modes Menu to enable (or

disable) bidirectional shift control. Navigate to the
Bidirectional Shift Control menu using the up arrow
and then use the right arrow to toggle between OFF
and ON.
3. In the auto traction control engagement mode

each time the “FNR” is placed in FORWARD,
traction control is enabled. The traction control
(TC) indicator is now shown on the gauge display.
Note: The operator can disable traction control
during the FORWARD cycle using the 3K switch, as
needed.
4. When the “FNR” is in FORWARD, Steps 2 and 3 of

“Manual Engagement - Traction Control” can be
used at any time, as required by blade load and
underfoot conditions.
5. Placing the “FNR” into the NEUTRAL or
REVERSE position disables the Traction Control
System.
SEBU8498-04 55
Operation Section
Operator Controls
4. Repeat Steps 1 through Step 3 in the REVERSE

direction to program the REVERSE speeds.
Programming Using the Momentary parking
brake Switch (14)
1. Place the “FNR” into NEUTRAL.

2. Set the parking brake with the momentary parking
brake switch (14).
3. Place the “FNR” into FORWARD.
4. Roll the track speed wheel (3H) to increase or
decrease the desired preset speed.
Illustration 74 g02667176 Note: One of the arrows next to the bidirectional
indicator (tractor) will be flashing along with the
corresponding desired preset speed value
5. Repeat Steps 3 and 4 for REVERSE.

6. Place the “FNR” into NEUTRAL.
7. Remove the parking brake with the momentary
parking brake switch (14).
Recalling Preset Speed Values
When the “FNR” is shifted into FORWARD, the

preset REVERSE speed setting is recalled. This
action makes sure that the preset REVERSE speed
is ready for the next time the 'FNR' is shifted into
REVERSE.
When the “FNR” is shifted into REVERSE , the preset
The “Tractor with Arrows” indicator appears in the FORWARD speed setting is recalled. This action
gauge display window when the “Bidirectional Mode” makes sure that the preset FORWARD speed is
is enabled. The indicator is removed when the ready for the next time the “FNR” is shifted into
“Bidirectional Mode” is disabled. FORWARD.
Note: The operator must enable Bidirectional Shift Note: Shifting to NEUTRAL or from NEUTRAL will
Control after each shutdown of the keyswitch circuit. not recall the preset speed values.
If the Bidirectional Shift Control has not been enabled
since the last shutdown of the keyswitch circuit, Preset Speed Values Retention
shifting the “FNR” into FORWARD or REVERSE will
not result in any change in the speed values. Programmed preset speed setting values are saved
before each shutdown of the keyswitch circuit. Then,
Programming with the Decelerator/Brake Pedal the active speed values are already preset at the
(4) activation of the keyswitch circuit. The preset speed
setting values become available once bidirectional
1. Push decelerator/brake pedal (4) all the way shift control is enabled.
downward to stop the machine with the “FNR” Note: If the preset speed setting values have never
already in FORWARD. been programmed, then the default FORWARD and
2. Roll the track speed wheel (3H) to increase or REVERSE speed setting values are used.
decrease the desired preset speed.
Operator Not Present System
Note: One of the arrows next to the bidirectional
indicator (tractor) will be flashing along with the This machine is equipped with an Operator “Not
corresponding desired preset speed value. Present” System. This system prevents the machine
from being accidentally put in gear if an operator is
3. Release decelerator/brake pedal (4) to store the not present. The system considers the operator to be
preset speed value for the desired direction. “Present” if any of the following conditions are met.
56 SEBU8498-04
Operation Section
Operator Controls
• The seat cushion sensor is activated.

• The operator is pressing down the decel/brake
pedal to any position other than the fully released
position.
• The steering and transmission control is in the
Forward or Reverse position with track speed
detected.
If none of these conditions are met, the operator is
considered “Not Present”. Then, the system will lock
the transmission in neutral, apply the parking brake,
and cause the parking brake light on the dash to
flash.
Note: When the parking brake light is flashing, the Illustration 76 g02727111
parking brake switch must be cycled in order to
release the parking brake. Release, apply, then When the “Operator Not Present” system is active,
release the parking brake. the parking brake light on the dash will flash. When
the parking brake light flashes, this condition requires
If the system activates with the steering and cycling parking brake switch (14).
transmission control not in neutral, the steering and
transmission control will need to be cycled through • Release - Apply - Release switch (14)
neutral in order to put the machine into gear.
To release the parking brake, the steering and
Decelerator/Brake Pedal (4)
transmission control must be in Neutral and the
operator must be present. If both of these conditions Push decelerator/brake pedal (4) all the way
are met, the parking brake will release when the downward in order to apply the brakes or use the
parking brake switch is pressed. If both of these brakes to stop the machine. Use the decelerator/
conditions are NOT met, the parking brake light will brake pedal (4) on a downgrade in order to maintain
flash. a safe operating mode. Release decelerator/brake
pedal (4) in order to allow the machine to move.
Operator Not Present – The operator is Release pedal (4) in order to increase ground speed.
considered “Not Present” when NONE
of the following conditions are met. Decelerator/brake pedal (4) can operate in two ways.
• The seat cushion sensor is activated. • Decrease both engine and track speed
• The operator is pressing down the decel/brake • Decrease only track speed
pedal to any position other than the fully released This feature is changed at the gauge display or by
position. using Cat ET (electronic technician).
Transmission Brake Only
detected.
Note: Change the configuration of the decelerator/
If any of these conditions are met, the operator is brake pedal with the gauge display or with Caterpillar
considered “Present”. electronic technician (ET).
Note: Make sure to understand that the seat belt has Configure the decelerator/brake pedal as a
no connection with the operator “Present” status. hydrostatic braking in order to slow the machine with
the hydrostatic transmission only. The engine speed
does not change when you press the decelerator/
brake pedal.
When decelerator/brake pedal (4) is completely
depressed, the parking brake will engage. The gauge
display (Compact Instrument Cluster) can change the
decelerator/brake pedal. so that the engine maintains
a constant speed when the pedal is depressed.
SEBU8498-04 57
Operation Section
Operator Controls
Transmission Brake and Engine Scroll through the submodes or the screens
Deceleration within each mode – Press and release the Scroll
button (5B).
Configure the decelerator/brake pedal so that the
hydrostatic braking and the engine deceleration are
done at the same time. CIC Operator Modes Menu
When the decelerator/brake pedal is pressed, the The following is displayed on the CIC Operator
engine speed will be reduced proportionally. When Modes menu:
decerator/brake pedal (4) is completely depressed,
the parking brake will engage. Mode 0 – Default
Note: Change the configuration of the decelerator/ Mode 1 – Bidirectional Speed Setting
brake pedal with the gauge display or with Caterpillar Mode 2 – Auto Traction Control Setting
electronic technician (ET).
Mode 3 – Decel/Brake Pedal Settings
Gauges and Indicators (5)
The following text is operator information for use with Mode 4 – Steering Modulation Settings
the Gauge Display.
Mode 5 – Implement Modulation Settings
Compact Instrument Cluster
Refer to Monitoring System, KENR5959, “Systems See Table 6 for details of the CIC Operator menu.
Operation” and the Operation and Maintenance
Manual, “Monitoring System” for more information on
the Compact Instrument Cluster (gauge display).
Gauge Display
(5A) Mode Button
(5B) Scroll Button
(5C) Gauge Display (CIC)
The Gauge Display (Compact Instrument Cluster or

CIC) (5) shows the five Operator modes.
The Mode button (5A) and the Scroll button (5B) are
used in order to navigate the CIC Menu structure.
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).
58 SEBU8498-04
Operation Section
Operator Controls
Table 6
CIC Menu
Operator Modes
Maximum Forward Speed and Maximum Reverse Speed
Engine Oil Pressure
Engine Speed
Mode 0
System Voltage
Default
Odometer
Service Hour Meter
ECO mode Fuel Savings %
Mode 1
On/Off
Bidirectional Speed Setting
Mode 2
On/Off
Auto Traction Control Setting
Mode 3 Brake And Engine Decel

Decel/Brake Pedal Settings Brake Onlyl
Medium
Mode 4
Coarse
Steering Modulation Settings
Fine
Standard
Mode 5
Fast
Implement Modulation Settings
Fine
Following is the content of the CIC Operator Modes Maximum Reverse Speed
menu.
The Maximum Reverse Speed is shown on the upper
Mode 0 - Default right-hand side of the screen. This number indicates
the maximum reverse speed of the machine.
Engine Oil Pressure
Mode 0 - Default Home LCD Screen
The Mode 0 - Default screen has the following Illustration 79 g01328962

submenus: Mode 0 Engine Oil Pressure LCD Screen
Maximum Forward Speed The Engine Oil Pressure screen indicates the current
engine oil pressure.
The Maximum Forward Speed is shown on the
center of the screen. This number indicates the
maximum forward speed of the machine.
SEBU8498-04 59
Operation Section
Operator Controls
Engine Speed The Service Hour Meter screen indicates the total
operating hours of the machine.
ECO mode Fuel Savings
Mode 0 Engine Speed LCD Screen
The Engine Speed screen indicates the current
engine speed of the machine. The ECO screen displays the instantaneous
percentage of fuel saved when operating in ECO
System Voltage
mode or when using decelerator pedal (4).
Mode 1 - Bidirectional Speed Setting
Mode 0 System Voltage LCD Screen
The System Voltage screen indicates the current
system voltage. The control setting mode for bidirectional speed is set
to the ON or OFF position.
Total Distance Traveled
Mode 2 - Traction Control Setting
The Total Distance Traveled screen displays the total Illustration 86 g02669101
number of kilometers or miles that the machine has
traveled. The Auto Traction Control setting is set to the ON or
OFF position.
Service Hour Meter
Mode 0 Service Hour Meter LCD Screen
60 SEBU8498-04
Operation Section
Operator Controls
Mode 3- Decel/Brake Pedal Settings This feature can be changed and the modifications
stored through the key cycle. Press and hold the right
Decelerator and Brake Pedal display button to store the setting. (Hold the right
display button until the computer disk on the display
flashes.)
Coarse
Mode 3- Decelerator Pedal and Brake Pedal LCD
Screen
This feature can be changed and the modifications Illustration 90 g01328936

stored through the key cycle. Press and hold the right Mode 4 - Steering Modulation Settings - Coarse LCD
display button to store the setting. (Hold the right Screen
display button until the computer disk on the display
flashes.) Fine
Brake Pedal Only
Mode 4 - Steering Modulation Settings - Fine LCD
Screen
Mode 3- Brake Pedal Only LCD Screen
Refer to Operations and Maintenance Manual, Mode 5 - Implement Modulation Settings

“Monitoring System” or the Service Manual for more
information. The Mode 5 - Implement Modulation Settings screen
has the following submenus:
Mode 4 - Steering Modulation Settings Standard
The Mode 4 - Steering Modulation Settings screen
has the following submenus:
Medium
Mode 5 - Implement Modulation - Standard LCD
Screen
This feature can be changed and the modifications
stored through the key cycle. Press and hold the right
Mode 4 - Steering Modulation Settings - Medium display button to store the setting. (Hold the right
LCD Screen display button until the computer disk on the display
flashes.)
SEBU8498-04 61
Operation Section
Operator Controls
Fast Enter the cab and close the door until the door
latches. Close both doors in order to operate the
machine properly.
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 alternate exit. Release the latch and open
the door.
Illustration 93 g01328944 Release latch (9) in order to unlock the cab door.
Mode 5 - Implement Modulation - Fast LCD Screen
Fully open the door until the door latches.
Fine
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
machine.
• Open the side window and release the platform
door latch.
Illustration 94 g01328942 • Also, you may stand on the ground in order to

release the platform door latch.
Mode 5 - Implement Modulation - Fine LCD Screen
Engine Start Switch (10)
Mirror (6)
OFF – Insert the engine start switch key
For best operator vision, adjust the rear view mirror. only from the OFF position and remove
Adjust the mirror before you operate the machine and the engine start switch key only from the
after operators change. OFF position. In the OFF position, there is no
power to most electrical circuits in the cab.
AM/FM/CD Radio (7) (If equipped)
Turn the engine start switch key to the OFF position
in order to stop the engine.
ON – Turn the engine start switch key

If a radio other than one available from your Cat- clockwise to the ON position in order to
erpillar dealer is installed, an in-line fuse must be activate all of the cab circuits.
provided. Failure to do so can damage the electri-
cal system if an electrical short occurs in the ra- START – Turn the engine start switch
dio circuit. key clockwise to the START position in
order to crank the engine. Release the
engine start switch key after the engine starts
Note: Multiple radio installation groups are available. and the engine start switch key returns to the ON
If a radio is not installed, a cover is available for the position.
opening. Consult your Caterpillar dealer for additional
information.
Cab Door Release Lever (8)

Machines with cabs are equipped with two entrances.
Release latch (9) and open the door.
62 SEBU8498-04
Operation Section
Operator Controls
Note: If the engine fails to start, the engine start RAISE (11D) – Pull back on lever (11) in
switch key must be returned to the OFF position. order to raise the blade. Release lever
Then, attempt to start the engine again. (11). Lever (11) will return to the HOLD
position.
Vandalism Guard (10A) (If TILT LEFT (11E) – Push lever (11) to the
Equipped) left in order to lower the left side of the
blade. Lever (11) returns to the HOLD
Vandalism guard (10A) offers vandalism protection (if position when the lever is released.
equipped).
TILT RIGHT (11F) – Pull lever (11) to the
Bulldozer Control (11) right in order to lower the right side of
the blade. Lever (11) returns to the
HOLD position when the lever is released.
Blade Angle (11G)
FLOAT (11A) – Push lever (11) forward

past the detent force. This action
activates the blade float function
(implement valve). Release the lever. The lever
returns to the NEUTRAL position (HOLD). In the ANGLE LEFT – Roll the thumb wheel
FLOAT position, the blade moves up and down (11G) to the right in order to angle the
with the ground contour. blade to the left.
The implement valve will remain in the FLOAT ANGLE RIGHT – Roll the thumb wheel
position until you manually move lever (11) to the (11G) to the left in order to angle the
raise or lower direction. The valve spool position then blade to the right.
returns to the HOLD position.
Bulldozer Blade Shake (11H)
The float position of the spool is also canceled, if you
turn the engine start key to the OFF position. The Press button (11H) in order to send a command to
same action occurs when the hydraulic lockout (16) the tilt cylinder that begins a high vibration
is activated. application. The blade will shake until button (11H) is
released or a timeout of 3 seconds is completed. This
Note: Lever travel corresponds to the speed of blade procedure allows removal of debris from the
movement for the dozer functions that are listed. bulldozer blade.
LOWER (11B) – Push lever (11) forward
in order to lower the blade. Do not pass
the detent position. Release lever (11).
Lever (11) will return to the HOLD position.
HOLD (11C) – Lever (11) will return to the
HOLD position, when you release lever
(11) anytime. The movement of the blade
will stop unless the lever is set in FLOAT.
SEBU8498-04 63
Operation Section
Operator Controls
Bulldozer Blade Pitch (11J) Press button (11JJ) in order to pitch the
blade at a rearward angle.
Right Operator Console
Power pitch control mode, if equipped

Press button (11J) in order to pitch the Illustration 98 g02675636
blade at a forward angle.
(12) Work lights
(13) Engine throttle control (knob)
(14) Parking brake switch
(15) Hydraulic lockout
(16) Stable blade control switch
Depress the work light switch (12) in order to turn on

all of the machine lights.
Work Lights (12)

Work lights – This switch turns on all the
lights.
Engine Throttle Control (13)

Engine throttle control (13) controls the engine
speed.
Low Idle – Rotate knob (13)
counterclockwise in order to lower the
idle speed.
64 SEBU8498-04
Operation Section
Operator Controls
High Idle – Rotate knob (13) clockwise in Note: This feature does not affect track speed.
order to increase the idle speed. The machine will still maintain the desired ground
speed.
Table 7
Throttle Position Engine RPM Parking Brake Switch (14)
1 950
2 1150
3 1350
4 1550
5 1700
6 1850
7 2000
8(1) 2100
9(2) 2100
10 2100
(1) FERF - Fuel efficient reverse and forward. See “ECO Mode” for
engine derating. Illustration 100 g02675557
(2) FER - Fuel Efficient Reverse (only). See “ECO Mode” for en-
gine derating.
Parking Brake – This switch is a
momentary switch. When the parking
Automatic Engine Control brake is ON, the indicator light in the
instrument cluster is illuminated. This switch
NEUTRAL Position – At throttle position 8 or 9, also locks the transmission in NEUTRAL. The
when the machine is stopped in the NEUTRAL for 3 machine will not move when the parking brake
seconds without any lever or direction activated, the switch is engaged. After the parking brake switch
engine will decrease to LOW IDLE. is disengaged, the parking brake will not turn off
until a direction is chosen. When the parking
brake switch is engaged, the parking brake
ECO Mode indicator on the dashboard will light. Do not use
the parking brake for stopping the machine.
Fuel Economy (ECO) Mode – The ECO
mode is controlled by the position of Engaged – Press switch (14) one time to engage the
engine throttle control (13). This ECO parking brake.
mode is designed to reduce fuel consumption
and noise. The ECO symbol is illuminated in the Disengaged – Press switch (14) one time to
display window on the Compact Instrument disengage the parking brake.
Cluster when the fuel economy mode is active.
FERF – FERF will automatically decrease engine
speed in REVERSE and FORWARD.
FER – FER will automatically decrease engine speed
in REVERSE only.
Note: Engine speed will automatically control

between 1600 rpm and 2100 rpm.
SEBU8498-04 65
Operation Section
Operator Controls
Note: To release the parking brake, the steering and Front Window Wiper Intermittent Switch
transmission control must be in Neutral and the (18) – This intermittent switch is a three
operator must be present. If both of these conditions position switch. The bottom position is
are met, the parking brake will release when the no delay, middle position is a 3 second delay, and
parking brake switch is pressed. If both of these the top position is a 5 second delay. This
conditions are NOT met, the parking brake light will intermittent switch turns on the intermittent
flash. operation of the front and door window wipers.
Rear Window Wiper Switch (19) – Press
Hydraulic Lockout (15) the top of switch (19) to activate the
window wiper for the rear window. Press
This switch is a momentary switch. When the
hydraulic lockout is ON (active), the indicator light in the bottom of switch (19) to turn off the window
the instrument cluster is illuminated. The switch for wiper for the rear window. Press the top of switch
hydraulic lockout (15) shuts down the implement (19) and hold switch (19) to activate the window
hydraulics to the machine. washer for the rear window.
Stable Blade Control (16)

Stable blade switch (16) provides lift and lower
compensation that increases stability of the dozer
blade when the machine is operating.
Note: Stable Blade Control makes fine grading
easier.
Window Wiper and Window

Washer (17) (18) (19) (If Equipped)
Front Window Wiper Switch (17) – Press

the top of switch (17) to activate the
window wipers for the front window and
doors. Press the bottom of switch (17) to turn off
the window wipers for the front window and
doors. Press the top of switch (17) and hold
switch (17) in order to activate the window
washers for the front window and doors.
66 SEBU8498-04
Operation Section
Operator Controls
Note: Do not operate the window wipers on dry Hold (21B) – Release the lever. The lever will return
windows. The rear window wiper does not have an to HOLD position. This action maintains the current
intermittent wiper mode. position of the winch cable. The winch brake is
applied in the HOLD position.
Heated Joystick Switch (20) (If
Equipped) 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.
• The hydraulic lockout switch must be in the

UNLOCKED position.
FREE SPOOL (22) – Press the freespool
switch one time in order to release the
Use this switch to activate heating elements in the winch cable. The winch cable unreels by
right-hand and left-hand joysticks, if equipped. Three manually pulling the winch cable. No machine or
settings are available for the heated joystick: OFF, hydraulic assistance is needed. The winch will
low temperature and high temperature. remain in the FREE SPOOL position until you
press the switch again or the lever is moved from
the HOLD position.
Winch Controls or Ripper Controls
(21) Note: Do not activate the winch freespool when the
machine is moving.
Winch Controls 21, 22, 23 (If Equipped) DRIVE AWAY (23) – Press the winch
drive away switch one time in order to
activate this mode. This mode allows
the operator to drive the tractor away from a load
as the winch reels out the cable under power and
the cable is attached to the load. DRIVE AWAY
(23) releases the winch brake (BRAKE OFF).
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.
SEBU8498-04 67
Operation Section
Operator Controls
Ripper Controls 21 (If Equipped) Fire Plow Controls (If Equipped)
RAISE (21A) – Pull the lever to the left in

order to raise the ripper. Release the
lever. The lever will return to the HOLD
position.
HOLD (21B) – Release the lever. The

lever will return to HOLD position.
Ripper movement stops in the current
position.
LOWER (21C) – Push the lever to the

right in order to lower the ripper.
Release the lever. The lever will return to
the HOLD position.
Auxiliary Control 24 (If equipped) Illustration 107 g01625918
For machines that are equipped with the fire plow,

use auxiliary switch (24A) in order to engage the
fourth float valve. Use lever (24D) for the fourth valve
function. Use auxiliary switch (24B) in order to
engage the fifth float valve. Use lever (24E) for the
fifth valve function.
1. Push the auxiliary lever away from the operator in
order to extend the cylinder.
2. Pull the auxiliary lever toward the operator in order
to retract the cylinder.
Air Suspension Seat (25)

The air suspension seat offers a safe, comfortable,
stable ride that is less fatiguing for the operator.
Use auxiliary switch (24) in order to activate the rear See “Seat” in this manual for more information.
hydraulics when the machine has a winch or a rear
attachment.
Seat Sensor (Tractor Operator)
Operator Not Present – The operator is
considered “ Not Present”” when NONE of
the following conditions are met.
68 SEBU8498-04
Operation Section
Operator Controls
• The seat cushion sensor is activated. For more information regarding the operation of the
control panel for the AccuGrade Machine Control
• The operator is pressing down the deceerator/ system, contact your Cat dealer.
brakel pedal to any position other than the fully
released position. Additional Features of Fire
• The steering and transmission control is in the Suppression Arrangement (If
Forward or Reverse position with track speed Equipped)
detected.
If any of these conditions are met, the operator is Fuel Shutoff Control in Cab (If equipped)
considered “Present” .
Power Receptacle (26)

Location of fire plow fuel shutoff control
Power Receptacle – A 12 V, 10 Amp 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.
Pocket in Seat Back (27)

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

Machine Control (Laser and GPS)
(If equipped)
If equipped, the GPS and Laser control system
display is located below the gauge display.
SEBU8498-04 69
Operation Section
Operator Controls
Quick Release Cab Floorplate (If Seat Belt Warning Light (If Equipped)
Equipped)

Illustration 110 g03207758 (A) Seat belt warning light
(B) Console warning light for seat belt
Quick Release Right Engine Panel (If

Equipped) Independent Work Light Switches (If
Equipped)

Release the right-side engine panel by removing the (A) Long range lights
four fast pins, as shown. (B) Front flood lights
(C) Rear lights
70 SEBU8498-04
Operation Section
Operator Controls
Hinged Door and Side Screens (If Hinged Radiator Grill Guard (If Equipped)
Equipped)
Use external release (A) to open the screen to clean

the door.
Release the two top latches to swing the heavy duty

grill forward.
Auxiliary Hydraulic Functions with Float

and Winch (If Equipped)
Use the internal release that is inside of the window

for an emergency exit, if necessary.

(1) Winch control lever
(2) Winch freespool switch
(3) Winch brake off
(4) Fourth valve float switch
(5) Fourth valve function (extend/retract)
(6) Fifth function lever
(7) Fifth valve float switch
SEBU8498-04 71
Operation Section
Diesel Particulate Filter Regeneration
REEL OUT (1A) – Move the lever to this 1. Push fifth function lever (6) away from the operator
position in order to reel out the winch in order to extend the cylinder.
cable. The winch cable reels out under
power. Speed for the winch cable is proportional 2. Pull fifth function lever (6) toward the operator in
to the lever position. Release the lever. The Lever order to retract the cylinder.
will return to the HOLD position.
i04574643
HOLD (1B) – Move the lever into this
position in order to maintain the current
position of the winch cable. The winch
Diesel Particulate Filter
brake is applied at this time. Regeneration
REEL IN (1C) – Move the lever to the left SMCS Code: 108F
in order to reel in the winch cable. The
winch cable should move toward the Regeneration
winch under power. Speed for the winch cable is
proportional to the lever position. Release the Regeneration is the removal of soot from the Diesel
lever. The Lever will return to the HOLD position. Particulate Filter (DPF). The DPF traps both soot and
ash. Passive regeneration of the DPF is removing the
FREESPOOL (2) – Press freespool soot. A back pressure valve is used if needed to heat
switch (2) one time to release the winch the exhaust gas.
cable. The winch cable unreels by
manually pulling the winch cable. No machine or Note: During normal operation a hissing noise may
hydraulic assistance is needed. The winch will be heard during low load, low engine speed
remain in the FREESPOOL position until you conditions. No action is needed.
press the switch again or until you activate any
other function for the winch. Soot Level Monitoring
Note: Do not activate the winch freespool when the During the normal working cycle of the engine the
machine is moving. ECM will control when the regeneration will occur.
Regeneration will take place by low speed automatic
DRIVE AWAY (3) – Press winch DRIVE regeneration or by enhanced automatic regeneration.
AWAY switch (3) to release the winch
brake (BRAKE OFF). This function will DPF Light On
also activate the DRIVE AWAY solenoid. The
winch brake will be released. The winch clutch DPF light – This indicator illuminates
will be engaged and hydraulic flow will bypass when soot level is high in the diesel
the winch pump. To unwind the winch cable, tie particulate filter (DPF).
the cable to a permanent object. Then, drive the
machine away from the permanent object at a Note: If the DPF light turns on, do NOT contact the
speed that is less than 3 km/h (1.8 mph). The CAT dealer. Simply change the machine operation to
winch will remain in the DRIVE AWAY position increase exhaust temperature.
until you press the switch again or until you
activate any other function for the winch. If the soot level is elevated, the DPF light will come
on. The light will remain on until the soot level
Fourth Valve Function reduces. The engine is safe to operate with the DPF
light on as long as no other warning lights are active.
Remote Cylinder - Float – Press float Do one of the following actions to help reduce the
switch (4) to engage the fourth valve soot level.
function.
• Allow the machine to idle with no operator input for
Remote Cylinder - Extend – Press top of 30 to 60 minutes. This action activates the
switch (5) to extend the cylinder. backpressure valve that continuously raises the
exhaust temperature for an improved regeneration
rate.
Remote Cylinder - Retract – Press
bottom of switch (5) to retract the • Achieving higher engine exhaust temperatures
cylinder.
The following methods are ways to achieve a higher
Fifth Valve Function Control exhaust temperature.
Press float switch (7) to engage the fifth valve • Turn off the ECO mode
function.
72 SEBU8498-04
Operation Section
Battery Disconnect Switch
• Operate the engine at higher speeds

NOTICE
Never move the battery disconnect switch to the OFF
• Change the decel/brake pedal functionality so that
position while the engine is operating. Serious dam-
engine speed does not decrease when the pedal age to the electrical system could result.
that is activated
• Increase the machine load by continuously
pushing a heavy load for 30 to 60 minutes Checking the Battery Disconnect
If the DPF light and a Warning Category 2 or Warning System
Category 3 light turns ON, the operator must contact
the Cat dealer for service of the engine diesel NOTICE
particulate filter (DPF). To ensure no damage to the engine occurs, verify
that the engine is fully operational before cranking
i04020225 the engine. Do not crank an engine that is not fully
operational.
Battery Disconnect Switch Perform the following procedure in order to check the
SMCS Code: 1411; 1411-B11 battery disconnect system.
1. With the battery disconnect switch in the ON
position, verify that electrical components in the
operator compartment are functioning. Verify that
the hour meter is displaying information. Verify that
the engine will crank.
2. Turn the battery disconnect switch to the OFF
position.
3. Verify that the following items are not functioning:
electrical components in the operator
compartment, hour meter and engine cranking, If
any of the items continue to function with the
battery disconnect switch in the OFF position,
contact your Cat dealer.
i04292917
Open access door (1) on the right side of the
machine. Backup Alarm
Disconnect Switch ON – To activate the SMCS Code: 7406
electrical system, insert the key for the
battery disconnect switch and turn the The backup alarm is mounted on the rear of the
key clockwise. The battery disconnect switch machine.
must be turned to the ON position before you
start the engine.
Disconnect Switch OFF – To deactivate
the electrical system, turn the key for
the battery disconnect switch
counterclockwise to the OFF position.
The battery disconnect switch and the engine start
switch perform different functions. To disable the
entire electrical system, turn off the battery
disconnect switch. When you only turn off the engine
start switch, the battery remains connected to the
electrical system.
Turn the battery disconnect switch to the OFF
position and remove the key when you service the Illustration 119 g02459536
electrical system or any other machine components.
Backup alarm – The alarm will sound when the
steering and transmission control is in the REVERSE
SEBU8498-04 73
Operation Section
Monitoring System
position. The alarm is used to alert people behind the The monitoring panel will then return to the normal
machine that the machine is backing up. operating mode.
i04292989
Alert Indicators
Monitoring System
SMCS Code: 7490
Functional Test
The monitoring system informs the operator of the
status of the machine systems. The monitoring
system informs the operator of problems or of an
impending problem.
If the action alarm does not sound during this test

or machine monitoring displays are not function- Illustration 120 g02459656
ing, do not operate the machine until the cause
has been corrected. Machine operation with
faulty action alarms or displays could result in in- Action Lamp (1) – The action lamp is on
jury or death as any Warning Category 3 notifica- the Compact Instrument Cluster (CIC). If
tions will not be relayed to the operator. the action lamp is ON, then attention to
service is required.
When the engine starts, the monitoring system runs a Reference: See “Warning Categories” for
test. The operator must observe the monitoring information on indicated service.
system during the test to determine proper operation.
The self testing feature verifies that the modules of Warning Categories
the monitoring system are properly operating. The
self testing feature verifies that the display module is Warning Category 1
properly operating.
In category 1, the action light is solid amber. This
The operator must observe the outputs in order to category alerts the operator that the machine system
determine if the modules are operating properly. This needs attention.
self testing feature is 3 seconds long.
Warning Category 2
In this category, the action light flashes red. The
warning category requires you to change the
machine operation. Examples include the following
conditions.
• The machine operation must be altered in order to
reduce the excessive temperature in one or more
of the systems.
• If the engine speed is too high, change the
machine operation in order to reduce the
excessive engine speed.
If the alert indicator continues to flash, do not operate
the machine.
74 SEBU8498-04
Operation Section
Monitoring System
Warning Category 3 Hydraulic Oil and Winch Oil Filter (7) –

This indicator is illuminated when the
In this category, the action lamp flashes red. Also, the filter is clogged or when the filter is
action alarm will sound. This category requires dirty. In extreme cold, this indicator may
immediate shutdown of the operation in order to illuminate until the hydraulic oil temperature
prevent severe damage to the system and/or to the warms up.
machine.
Inactive Function (8)
Do not operate the machine until the cause has been
corrected.
Note: If the action lamp flashes amber there is a Engine Air Filter(9) – This indicator is
communication failure. illuminated when the filter is clogged or
when the filter is dirty.
Indicators
Operator Not Present (10) – This
indicator will illuminate if the operator is
NOT present. The operator is
considered “ Not Present”” when NONE of the
following conditions are met.
• The seat cushion sensor is activated.

• The operator is pressing down the decel/brake
pedal to any position other than the fully released
position.
detected
If any of these conditions are met, the operator is
Illustration 121 g02459660 considered “Present” .
Glow Plugs (2) – This indicator is Hydraulic Lockout (11) – This indicator
illuminated when the glow plugs are on. is illuminated when the hydraulic
Start the engine when this indicator lockout is activated. The implement
turns OFF. hydraulics are OFF.
Soot Load (3) – This indicator Fuel/Water Separator(12) – The indicator

illuminates when soot level is high in the will illuminate when either of two items
diesel particulate filter (DPF). See occurs. The fuel/water separator must
“Diesel Particulate Filter Regeneration” in this be drained or change the three fuel filters (fuel
manual for more information when the DPF light screen, primary element, and secondary
is on for lowering the soot level. element).
Engine Idle Shutdown (4) – If this feature

is enabled in ET (electronic technician),
this indicator will illuminate and the
alarm will sound 20 seconds before the engine
shuts down.
Parking Brake (5) – This indicator is

illuminated when the parking brake is
engaged. If the parking brake indicator
flashes, see additional information in this
“Operation and Maintenance Manual”.
Machine security system (6) – This
indicator will illuminate when the
machine security system is activated.
SEBU8498-04 75
Operation Section
Monitoring System
Note: When the fuel filters are plugged, action lamp

NOTICE
(1) may illuminate in a solid amber color or a flashing Running out of fuel can cause engine damage. Do
red color. This occurrence depends on the amount of not continue to operate the machine when critically
plugging of the fuel/water separator. low on fuel.
Gauges
Compact Instrument Cluster

Hydraulic Oil Temperature (13) – The Compact Instrument Cluster (CIC)
gauge indicates the temperature of the
(16) Display display window
hydraulic oil in the hydraulic oil sump (17) Menu button
for the steering and implement circuits. If the (18) Scroll button
gauge needle enters the red zone, the hydraulic
oil temperature is excessive. The Compact Digital display window (16) provides readouts that
Instrument Cluster will display a warning. If show the following items:
necessary, reduce the load that is on the machine
until the hydraulic oil temperature decreases. • Maximum speed forward and reverse (default
readout)
Engine Coolant Temperature (14) – The
water temperature regulator regulates • Engine Oil Pressure
the coolant temperatures. If the gauge
needle enters the red zone, the coolant • Engine Speed
temperature is excessive. Increased
• Volt - system voltage
temperatures will sound the warning alarm.
Continued operation of the machine during the • Total distance traveled
sounding of the warning alarm or the gauge
needle in the red zone may damage the engine. • Service hour meter
Stop the machine in a safe place and investigate
the cause. • Instantaneous Fuel Savings
Fuel Level (15) – The fuel level gauge Press up arrow button (17) until the desired function
indicates the amount of fuel that is displayed. Navigate from the default readout to
remains in the fuel tank. A gauge needle additional readouts by pressing scroll button (18).
in the red zone indicates a low fuel level.
Machine Speed
Speed setting – The indicator displays the speed
setting during machine operation.
Engine Oil Pressure

Engine oil pressure – The indicator displays the
status of the engine oil pressure during machine
operation.
76 SEBU8498-04
Operation Section
Monitoring System
Engine Speed Operator Menu

Digital tachometer – The tachometer displays the The “Operator” menu is the default menu that is
engine rpm during machine operation. displayed at machine startup.
The operator adjusts the machine operation within
System Voltage the following parameters: operating conditions,
preferences of the operator and requirements for
System voltage – System voltage displays the efficient operation. The operator uses the Operator
status of the electrical system during machine Menu to view and set the variable parameters of the
operation. machine. The monitoring system display reviews the
version of the software in order to determine the set
of parameters that are displayed and variable.
Total Distance Traveled
This display indicated the total distance traveled by
the machine.
Service Hour Meter

Service Hour Meter – This display
indicates the total operating hours of the
engine. Use the display in order to
determine the service hour maintenance
intervals.
Percentage of Fuel Saved

This display indicates the amount of real-time
savings in fuel consumption.
Menu Screens
Toggle between the Operator Menu and the Service

Menu by depressing both mode button (17) and scroll
button (18) for 3 seconds.
Menu button (17) – Press the up arrow
button (17) until the desired menu is
displayed.
Scroll button (18) – Press the right arrow
button (18) in order to access the
parameters of the displayed menu/
mode.
SEBU8498-04 77
Operation Section
Product Link

Operator menu
The Operator Menu allows the user to adjust • “Maximum forward speed”
parameters for the following modes:
• “Maximum reverse speed”
• Default mode (mode 0)
• “Engine oil pressure”
• Bidirectional speed (mode 1)
• “Engine speed”
• Auto traction control (mode 2)
• “System voltage”
• Brake/decel pedal (mode 3)
• “Total distance traveled”
• Steering modulation (mode 4)
• “Service hour meter”
• Implement modulation (mode 5)
• “Percentage of fuel saved”
To move between the different modes, press and
release mode button (17). To scroll through the i07742538
associated parameters press and release scroll
button (18), until the desired category is highlighted.
Product Link
Default (Mode 0) SMCS Code: 7606
The Default mode allows the operator to access Note: Your machine may be equipped with the Cat ®
pertinent information about the machine systems. Product Link™ system.
78 SEBU8498-04
Operation Section
Product Link
The Cat Product Link communication device utilizes Caterpillar may share some or all the collected
cellular and/or satellite technology to communicate information with Caterpillar affiliated companies,
equipment information. This information is dealers, and authorized representatives. Caterpillar
communicated to Caterpillar, Cat dealers, and will not sell or rent collected information to any other
Caterpillar customers. The Cat Product Link third party and will exercise reasonable efforts to
communication device uses Global Positioning keep the information secure. Caterpillar recognizes
System (GPS) satellite receivers. and respects customer privacy. For more information,
please contact your local Cat dealer.
The capability of two-way communication between
the equipment and a remote user is available with the
Cat Product Link communication device. The remote Operation in a Blast Site for
user can be a dealer or a customer. Product Link Radios
Data Broadcasts
Data concerning this machine, the condition of the
machine, and the operation of the machine is being This equipment is equipped with a Cat® Product
transmitted by Cat Product Link to Caterpillar and/or Link communication device. When electric deto-
nators are being used for blasting operations, ra-
Cat dealers. The data is used to serve the customer dio frequency devices can cause interference
better and to improve upon Cat products and
services. The information transmitted may include: with electric detonators for blasting operations
machine serial number, machine location, and which can result in serious injury or death. The
operational data, including but not limited to: fault Product Link communication device should be
codes, emissions data, fuel usage, service meter deactivated within the distance mandated under
all applicable national or local regulatory require-
hours, software, and hardware version numbers and ments. In the absence of any regulatory require-
installed attachments.
ments Caterpillar recommends the end user
Caterpillar and/or Cat dealers may use this perform their own risk assessment to determine
information for various purposes. Refer to the safe operating distance.
following list for possible uses:
Refer to your products Operation and Maintenance
• Providing services to the customer and/or the Manual Supplement, “Regulatory Compliance
machine Information” for more information.
• Checking or maintaining Cat Product Link For information regarding the methods to disable the
equipment Cat Product Link communication device, please refer
to your specific Cat Product Link manual listed below:
• Monitoring the health of the machine or
• Operation and Maintenance Manual, SEBU8142, “
performance
Product Link - PL121, PL321, PL522, and PL523”
• Helping maintain the machine and/or improve the
• Operation and Maintenance Manual, SEBU8832, “
efficiency of the machine
Product Link PLE702, PLE602, PLE601, PL641,
• Evaluating or improving Cat products and PL631, PL542, PL240, PL241, PL141, PL131,
services PL161, and PL042 Systems”
• Complying with legal requirements and valid court Note: If no radio disable switch is installed and the
orders equipment will be operating near a blast zone, a
Product Link radio disable switch may be installed on
• Performing market research the equipment. The switch will allow the Cat Product
Link communication device to be shut off by the
• Offering the customer new products and services operator from the equipment control panel. For more
details and installation procedures, refer to the
following:
• Special Instruction, REHS7339, “Installation
Procedure for Product Link PLE640 Systems”
• Special Instruction, REHS8850, “Installation
Procedure for the Elite Product Link PLE601,
PLE641, and PLE631 Systems”
• Special Instruction, SEHS0377, “Installation
Procedure for the Product Link PL131, PL141,
and PL161 Systems”
SEBU8498-04 79
Operation Section
Operation Information
• Special Instruction, REHS9111, “Installation 4. Push down on pedal (1) in order to prevent the
Procedure for the Pro Product Link PL641 and machine from moving.
PL631 Systems”
5. Disengage parking brake switch (4) and hydraulic
i04305089
lockout switch (5).
6. Rotate engine throttle control (6) in order to set the
Operation Information desired engine speed.
SMCS Code: 7000
Note: Decelerator/brake pedal (1) can be depressed
To prevent injury, make sure that no people are in order to reduce travel speed temporarily. Also,
working on the machine or near the machine. To thumb wheel (2) may be used to reduce travel speed.
prevent injury, keep the machine under control at all
times. 7. Move steering and transmission control lever (3)
for the desired direction.
Reduce machine speed when you maneuver in tight
quarters or when you are going over a hill. 8. Release pedal (1).
Select the necessary travel speed before you start 9. Roll thumb wheel (2) for the ground speed control
downhill. in order to set the desired ground speed. The
When you go downhill, use the same speed that thumb wheel for the ground speed control is
would be used to go uphill. located on lever (3).
Use the decelerator/brake pedal on a downgrade in 10. Drive the machine forward for best visibility and
order to maintain a safe operating mode. Use the for best control.
following controls in order to slow down the travel
speed of the machine: decelerator/brake pedal and Hydrostatic Drive Operating
thumb wheel.
Principle
When the load will be pushing the machine, turn the
speed selector to LOW speed before you start This machine has a hydrostatic drive system which
downhill. transfers power from the engine to the tracks. The
hydrostatic drive system eliminates the conventional
1. Adjust the operator seat. type of transmission. The hydrostatic drive system
2. Fasten the seat belt. does not use a bevel gear and a driveline. The
hydrostatic drive system also eliminates the steering
3. Raise all lowered attachments in order to negotiate clutch and brake arrangement.
any obstacles.
In the simplest form, a hydrostatic drive system is a
system which contains the following components: a
hydraulic pump with a control system, a hydraulic
motor and high-pressure lines that carry oil between
the components. The pump converts mechanical
power to hydraulic power in the form of oil flow and oil
pressure.
To meet 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
varying flows of oil to either the forward side or the
reverse side of the hydraulic motors.
The track can be driven at varying speeds in either a
forward direction or in a reverse direction.
Since there are two tracks, there are two hydraulic
Illustration 126 g02468719 pumps, two sets of hydraulic lines, and two hydraulic
(1) Decelerator/brake pedal
motors.
(2) Thumb wheel
(3) Steering and transmission control (lever)
(4) Parking brake switch
(5) Hydraulic lockout switch
(6) Engine throttle control
(7) Winch control lever or ripper control lever (if equipped)
80 SEBU8498-04
Operation Section
For the forward modes or the reverse modes, the • The engine is OFF.
pumps and the motors work with each other. The
pumps can produce flow to either the forward side of
the motors or to the reverse side of the motors. The Operating Principle for the Winch
pumps can vary the amount of flow in either direction
in order to produce infinitely variable speed
capabilities. To turn the machine, each pump reduces
flow independently. This action allows one track to be
driven at a slower speed in order to cause the
machine to turn.
Slowing or stopping the machine is done by reducing
the flow of oil to the drive motors or stopping 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) is fully depressed. The parking brakes are
engaged in the following conditions: parking brake
switch ON , the transmission control NEUTRAL and
the engine OFF.
The parking brakes are attached to the final drives.
The parking brake is spring-applied and oil pressure (7) Winch control lever
(7A) Reel-In
released. The engine must be running in order to (7B) Winch brake ON
release the parking brakes. (7C) Reel-Out
(8) Winch freespool switch
The parking brakes disengage when switch (4) is (9) WINCH DRIVE AWAY SWITCH
moved from ENGAGED position. The parking brakes
also disengage when brake pedal (1) is released. The winch for this Caterpillar machine is a
hydraulically driven winch that utilizes a dedicated
General Operational Safety Tips piston pump for power input. The winch includes both
planetary gears and standard spur gears. The winch
The seat belt must be fastened at all times. brake is applied by spring pressure. This action will
secure the load while control lever (7) is in the HOLD
For a prompt stop, quickly depress decelerator/brake position. The winch brake is released hydraulically.
pedal (1) or quickly move lever (3) to the NEUTRAL The winch case is designed to bolt directly to the rear
position. Either movement causes an immediate of the machine.
stop.
When the winch is operated in either the REEL IN or
For all forward turns that are on level ground or on the REEL OUT direction, a hydraulic motor drives the
side hill operations, move lever (3) forward. Then, gear train. The control lever supplies oil to the winch
move lever (3) toward the RIGHT position for right motor by the hydrostatic control system. The control
turns. Move lever (3) toward the LEFT position for left lever for the winch is a proportionate control. The
turns. amount of hydraulic oil that will be sent to the winch
motor will increase as lever (7) is moved. The speed
Changing the direction of the machine is performed of the winch cable increases as the amount of
by first moving lever (3) to the NEUTRAL position. hydraulic oil to the winch motor increases. The winch
brake will be released by pilot pressure when lever
For all reverse turns that are on level ground or on (7) is moved into either the REEL IN or the REEL
side hill operations, move lever (3) in the reverse OUT directions.
direction. Then, move lever (3) toward the RIGHT
position for right turns. Move lever (3) toward the The mechanism for the free spool for the winch is a
LEFT position for left turns. splined gear. The mechanism for the free spool is
spring-engaged and hydraulically released. Press the
The brakes are applied in any of the following FREESPOOL switch once in order to activate the
conditions. freespool function. Then, hydraulic oil is ported
through the logic valve for the winch. The hydraulic
• Pedal (1) is fully depressed. oil flows from the logic valve for the winch into a
cylinder for the freespool mechanism. This action will
• Steering and transmission control (3) is in force the piston for the freespool mechanism against
NEUTRAL. the coil spring and will disengage the splined
connection. This action allows the winch cable to be
• Parking brake switch (4) is in the ENGAGED pulled off the winch drum by hand.
position.
SEBU8498-04 81
Operation Section
The DRIVE AWAY function allows the operator to

drive the tractor away from a load while the winch
cable is attached to the load. When winch driveaway The warm-up procedure is recommended at each
switch (9) is turned on, a spool shifts in the winch start-up and is mandatory when temperatures are
drive away valve in order to open an oil flow passage below 4 °C (40 °F).
in the motor drive from one port to another port.
Then, the throttle spool inside the valve controls the
rate of oil through the valve. This action prevents the
drive motor from spinning too fast and provides a Using the Winch
controlled release of the winch cable. This operation
will also provide a maximum ground speed for the Attaching the Winch Cable
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
assemblies would be used when slight side Personal injury or death can result from unex-
directional pulls are routinely encountered. The use pected movement of objects. Be sure all persons
of the optional fairlead assemblies will help maximize are clear of cable and objects before a machine is
the life of the winch case and the winch cable by winched or moved. A safe distance of at least one
eliminating wear. and a half times the working length of the cable
should be maintained. The tail end of a moving
Warm-Up Procedure for the Winch object can throw debris at bystanders.
Note: Warm up the winch at each start-up. 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
1. Warm up the hydraulic system for the machine. wraps.
For more information, refer to Operation and
Maintenance Manual, “Engine and Machine
Warm-Up”.
2. Use the reel-in and reel-out function to operate the
Do not operate the winch under loads that exceed
winch. This operation will allow the hydraulic oil to the maximum rated bare drum line pull. If exces-
circulate throughout the winch. sive loads are encountered, use a multi-part line
and sheave blocks. Any attempt to exceed the ca-
Note: The winch should be operated under a no-load pacity of one winch is extremely hazardous.
condition during warm-up. Never try to couple two or more tractors together.
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-
signed nor intended for use or application used in the
lifting or moving of persons.
1. If you are working on a hill, maneuver the machine

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.
82 SEBU8498-04
Operation Section
Prestart Checks
3. Move the lever to REEL IN position (7A). Slowly

reel in the cable until the cable is wound 100
Wear leather gloves when handling the winch percent.
cable.
i04308464
NOTICE
When winding the winch cable on the drum, never at-
Prestart Checks
tempt to maintain tension by allowing the winch cable SMCS Code: 7000
to slip through the hands. Always use hand-over-
hand technique, being very carefull to keep hands Before the start of each operational shift, or every 10
and clothing away from the winch drum and rollers. hours of operation, perform the checks and tests.
The checks and tests are in the Maintenance Interval
Schedule.
3. Press switch (8) one time into the FREESPOOL
position. Pull out the cable and attach the cable to • Test the backup alarm.
the load. • Test the brakes.
Note: Never operate the winch when there is less • Check the indicators and gauges.
than five wraps of the winch cable around the load
drum. Use red paint in order to paint the last five • Inspect the cab filter (fresh air).
complete wraps of the winch cable for a visual
warning. • Check the cooling system level.
Note: Make sure that there is enough clearance • Check the engine oil level.
between the object and the machine so that the
machine can turn. • Drain the water separator at the fuel filter.
Note: Make sure that the ground is stable before • Drain the water and sediment from the fuel tank.
winching in a load.
• Check the hydraulic system oil level.
4. To tighten the main cable, make sure that the drum
• Inspect the seat belt.
is not rotating. Press switch (8) one time in order to
turn off the FREESPOOL mode. This action allows • Perform the "Daily Inspection".
REEL IN position (7A) to operate.
Note: Avoid sudden shock of a load or jerking of a

load. This type of operation may cause heavy loads
in excess of the rated capacity, which may result in
failure of the cable or the winch.
Unhooking the Winch Cable
Personal injury or death can result from persons

too close to the machine.
When reeling in the cable, make sure that all per-
sons are clear from rolling objects or cable
whiplash.
1. Move the lever to REEL OUT position (7C). Reel

out the winch cable in order to release tension.
2. Press switch (8) one time away from the operator
into the FREESPOOL position. With switch (8) in
the FREESPOOL position, pull out enough cable
in order to unfasten the cables or the chokers.
SEBU8498-04 83
Operation Section
Engine Starting
Engine Starting • Hydraulic lockout (6) of the implements must

be engaged. This engagement has occurred
when the key switch is turned OFF
i04307304
• Steering and transmission control (1) must be

Engine Starting in NEUTRAL.
SMCS Code: 1000; 7000
• Implement control lever (7) must be in the
1. Turn the battery disconnect switch to the ON HOLD position.
position.
4. Before the engine is started, check for the
2. Move the implement controls to the HOLD presence of bystanders or maintenance
position. personnel. Ensure that all personnel are clear of
the machine. Briefly sound forward horn (2) before
you start the engine.
5. Put engine throttle control (4) at the low idle
position to start the engine.
Note: If the machine is cold, wait until the glow plug

indicator light turns off. Then, turn on the engine start
switch.
6. Turn engine start switch (3) to the START position.
NOTICE
Do not crank the engine for more than 30 seconds.
Allow the starter to cool for 2 minutes before cranking
again. Turbocharger damage may result if the engine
rpm is not kept low until the oil pressure is sufficient.
7. Release the engine start switch key after the

engine starts.
8. Allow the engine to warm up at LOW IDLE. Refer
to Operation and Maintenance Manual, “Engine
and Machine Warm-up”.
Starting Aid (If Equipped)

Ether starting aid system is completely automatic.
The system injects a premeasured amount of ether
Illustration 128 g02470159 into the engine air intake when the engine is
(1) Steering and transmission control (lever) cranking.
(2) Forward horn
(3) Engine start switch If the temperature is below −18° C (−0° F), the
(4) Engine throttle control (knob) following procedures are recommended to aid
(5) Parking brake switch starting.
(6) Hydraulic lockout
(7) Implement control lever
• Change the engine oil as stated in Operation and
Maintenance Manual
3. Move steering and transmission control lever (1)
into the NEUTRAL position. • Change the hydraulic oil as stated in Operation
and Maintenance Manual
Five conditions must be satisfied in order to start
the engine. • Install an ether stating aid
• The operator must be seated in the seat. • Install an engine breather canister heater
• Parking brake (5) must be engaged. This If temperature is below −25° C (−13° F), the
engagement has occurred when the key switch following procedure is recommended to aid starting.
is turned OFF.
84 SEBU8498-04
Operation Section
Engine and Machine Warm-Up
• Install an engine jacket water heater. • If the temperature is greater than 0°C (32°F),
warm up the engine for approximately 5
1. Perform Step 1 through Step 5 of the Engine minutes.
Starting procedure.
• If the temperature is less than 0°C (32°F),
2. Turn start switch key (3) to the START position.
warm up the engine for approximately 15
Crank the engine.
minutes.
NOTICE • If the temperature is less than − 18°C (0°F) or
Do not crank the engine for more than 30 seconds.
Allow the starter to cool for 2 minutes before cranking if hydraulic functions are sluggish, additional
again. Turbocharger damage may result if the engine time may be required.
rpm is not kept low until the oil pressure is sufficient.
3. Release start switch key (3) when the engine

starts.
Reference: At temperatures below −25° C

(−13.0° F), consult your Cat dealer for additional
information or refer to Special Publication,
SEBU5898, “Cold Weather Recommendations for all
Caterpillar 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:
SEBU8498-04 85
Operation Section
Adjustments
Adjustments Manual Adjustment of Bulldozer

Blade Pitch
i04659631
Bulldozer Blade Pitch

SMCS Code: 6060; 7000
The standard position for the cutting edge angle is 56
degrees. This position provides optimum
performance under normal conditions.
Tip the blade forward in order to obtain a cutting edge
angle up to 60 degrees. Pitching 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. Pitching the blade
rearward provides a better carrying capability of soft
material. Illustration 129 g01258184
The bulldozer blade can be placed in several pitch

positions such as the following pitches: the extended
position (A), the middle position (B) and the retracted
position (C).
1. Lower the bulldozer blade to the ground. Place the
control for the lift cylinder in the FLOAT position.
2. Actuate the tilt cylinder in order to remove all force
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.
NOTICE
Keep fingers clear. Do not place your fingers into the
pin holes in the tilt brace and/or push arm bracket at
any time during the adjustment procedure.
4. Install the slotted end of cover (1) onto boss (5).

5. Turn the top link until the desired cutting angle is
set.
6. Install the cover (1) and replace locking pin (2).
86 SEBU8498-04
Operation Section
Ripper Tip and Shank Protector
Note: If the cover plate does not cover both mounting 2. Press button (E) to pitch the blade rearward to the
bolt (3) and retainer bolt (8), then the top link is retracted position.
incorrectly adjusted.
i06173975
Power Adjustment of Bulldozer
Blade Pitch Ripper Tip and Shank
The bulldozer blade can be moved into the following
Protector
pitch positions with implement control lever (9), if SMCS Code: 6808; 6810; 6812
equipped: the extended position (D) and the
retracted position (E).

Replace the ripper tip before wear occurs on the
1. Press button (D) to pitch the blade forward to the shank. Follow the replacement procedures in the
Operation and Maintenance Manual, “Ripper -
extended position. Inspect/Replace”.
SEBU8498-04 87
Operation Section
Cutting Edges and End Bits
i04309453
Cutting Edges and End Bits

SMCS Code: 6801; 6804
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”.
Note: Make sure to replace or flip the cutting edges
to prevent damage to the blade base plate.
Preventing damage to the base blade is of utmost
importance.
88 SEBU8498-04
Operation Section
Parking
Parking i04309748
i04309547
Stopping the Engine
SMCS Code: 1000; 7000
Stopping the Machine
SMCS Code: 7000 NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
NOTICE celerated wear of the engine components.
Park on a level surface. If it is necessary to park on a
grade, chock the tracks securely. 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 5 minutes at low idle with

no load.
This operation allows hot areas in the engine to
cool gradually and will extend the engine life.
2. Move all control levers into the HOLD position.
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
machine in position.
3. Turn the engine throttle control (knob) (4) to the
LOW IDLE position. Illustration 135 g02471438
4. Press parking brake switch (3) to engage the

3. Turn the engine start switch key to the OFF
parking brake.
position in order to stop the engine.
5. Release pedal (1).
Note: Turn the battery disconnect switch to the OFF
6. Use lever (5) and implement control lever (7) to position and remove the key when the machine is left
lower all attachments to the ground or HOLD for an extended period.
position and apply slight downward pressure.
i04310095
7. Move all attachment controls to the NEUTRAL
position. Engage hydraulic lockout (6). Stopping the Engine if an
Electrical Malfunction Occurs
SMCS Code: 1000; 7000
Engine Start Switch Key ON or OFF

Emergency Engine Shutdown
Engine Start Switch Key ON or OFF
SEBU8498-04 89
Operation Section
1. Apply the parking brake. Note: Do not operate the machine again until the
malfunction has been corrected.
2. Lower the dozer blade or the ripper, if necessary.
3. Dismount the machine. i04360096
Equipment Lowering with

Engine Stopped
(Electrohydraulic Implement
Valve)
SMCS Code: 7000
Dead Engine Lower

Actuator Spools
Relieve the pressure in the hydraulic tank.
4. Open the panel door for the fuse panel.
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.
5. Use the fuse puller that is located behind the panel

door (not shown). Pull the 15 Amp fuse for the
Engine Stop from the fuse panel.
6. Turn off the battery disconnect switch inside the
rear access door on the right side of the machine,
90 SEBU8498-04
Operation Section
Electrohydraulic Implement Valve
6. Loosen locknut (6A) and turn adjustment screw (6)

inward. This action 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.
inward. This action relieves the rod pressure from
the tilt cylinder to the tank. This procedure tilts the
dozer blade left.

Top view
(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

inward. Illustration 140 g01700573
Anti-drift valve
Note: After completing the dead engine lower for
each function, back out the adjustment screw fully. 8. Before releasing pressure on the fourth valve (8,
Then, tighten the locknut.
8A), completely back off adjustment screw on anti-
Note: Before you screw in all dead engine lower drift valve (9). This action will make sure that the
screws, clean all the dirt and paint from the pressure is fully released.
adjustment screw.
a. Mark the location of the adjuster valve. Then,
Note: Perform steps 2 through 4 in order to change back off the adjustment screw completely.
the angle or lower the equipment. 9. Loosen locknut (8A) and turn adjustment screw (8)
inward. This action relieves the head pressure
from the ripper cylinder to the tank. This procedure
inward. This action relieves head pressure to the
lowers the ripper.
right angle cylinder and rod pressure to the left
angle cylinder. This angles the dozer blade to the Close the access door. Close the hydraulic oil tank
right. cap.
inward. This action relieves head pressure to the
tilt angle cylinder. This procedure tilts the dozer
blade to the right.
inward. This action relieves rod pressure from the
ripper cylinder to the tank. This procedure raises
the ripper.
inward. This action relieves rod pressure from the
lift cylinder to the tank. This procedure lowers the
dozer blade.
SEBU8498-04 91
Operation Section
Leaving the Machine
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.
i04360009
Leaving the Machine

SMCS Code: 7000
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 action 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.
92 SEBU8498-04
Operation Section
Transportation Information
Transportation Information 6. Turn the battery disconnect switch to the OFF

position. Remove the key.
i04315150 7. Lock the door and lock the access covers. Attach
any vandalism protection.
Shipping the Machine 8. Install the tie-downs at several locations and block
SMCS Code: 7000; 7500 the tracks in the front and in the rear.
Investigate the travel route for overpass clearances. Consult your Caterpillar dealer for shipping
Make sure that there is adequate clearance for the instructions for your machine.
machine that is being transported. This clearance is
especially true for machines that are equipped with a Calculating the Mass of the
cab, or a canopy.
Machine
Remove ice, snow, or other slippery material from the
loading dock and from the truck bed before loading. Use the following table to calculate the mass of your
Removing ice, snow, or other slippery material will Caterpillar machine. Start with the mass of the
prevent the machine from slipping as you load the machine that is in the first row. Add the additional
machine. Removing ice, snow, or other slippery weight of the various attachments and work tools that
material will prevent the machine from slipping in are consistent with your machine.
transit.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
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.
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.
3. Engage the parking brake switch.
4. Stop the engine.
5. Turn the start switch key to the OFF position. Lock
the parking brake switch. Remove the key.
SEBU8498-04 93
Operation Section
Shipping the Machine
Table 8
D3K, D4K, and D5K Track-Type Loaders
D4K LGP
The machine is operated with the dozer blade, the ROPS canopy, D3K XL D3K LGP D4K XL D5K XL D5K LGP
8510 kg
the backup alarm, the operator (75 kg (165 lb)), coolant, lubri- 7958 kg 8403 kg 8201 kg 9314 kg 9646 kg
(18761
cants, and the full fuel tank. (1) (17544 lb) (18525 lb) (18080 lb) (20534 lb) (21266 lb)
lb)
+ +
Pump Aux Drive
+ + + + 5 kg 5 kg
14 kg (31 lb)
(11 lb) (11 lb)
+ +
Winch
+ + + + 80 kg 80 kg
88 kg (194 lb)
(176 lb) (176 lb)
4 Valve
+ + + + + +
18 kg (40 lb)
4 Valve for Winch

+ + + + + +
11 kg (25 lb)
Drawbar
+ + + + + +
8 kg (18 lb)
Ripper Ar
+ + + + + +
111 kg (245 lb)
Winch Mounting Plate

+ + + + +
612 kg (1349 lb)
EROPS
+ + + + + +
217 kg(479 lb)
EROPS with Poly Glass

+ + + + + +
217 kg(479 lb)
6 Lights
+ + + + + +
1 kg (2 lb)
Sound Suppressed NACD

+ + + + + +
8 kg (18 lb)
Sound Suppressed EU
+ + + + + +
8 kg (18 lb)
+6 kg +6 kg +42 kg +42 kg
Undercarriage Ar (SystemOne) -5 kg (11 lb) -5 kg (11 lb)
(13 lb) (13 lb) (92 lb) (92 lb)
+64 kg +27 kg -6 kg -42 kg -54 kg

Track Ar SystemOne -6 kg (13 lb)
(141 lb) (60 lb) (13 lb) (92 lb) (119 lb)
Radiator Guard (HD)

+ + + + + +
46 kg (101 lb)
Rear guard
+ + + + + +
115 kg (254 lb)
Front Counterweight
+ + + + + +
286 kg (631 lb)
Power Pitch
+ + + + + +
24 kg (53 lb)
Accugrade Grade Control

+ + + + + +
13 kg (29 lb)
(continued)
94 SEBU8498-04
Operation Section
Shipping the Machine
(Table 8, contd)
Power Pitch and Grade Control
+ + + + + +
38 kg (83 lb)
Front Sweeps
+ + + + + +
56 kg (123 lb)
Rear Sweeps
+ + + + + +
134 kg (296 lb)
OPROPS Front Screens

+ + + + + +
78 kg (172 lb)
OROPS/EROPS Side Screens

+ + + + + +
55 kg (121 lb)
EROPS Rear Screen

+ + + + + +
39 kg (86 lb)
OROPS Rear Screen

+ + + + + +
43 kg (95 lb)
+82 kg +82 kg +83 kg +83 kg +95 kg +95 kg

Full Length Guards SystemOne
(181 lb) (181 lb) (183 lb) (183 lb) (209 lb) (209 lb)
+82 kg +82 kg +86 kg +86 kg +113kg +113kg

Full Length Guards SALT
(181 lb) (181 lb) (190 lb) (190 lb) (249 lb) (249 lb)
+28 kg +28 kg +26 kg +26 kg +31 kg +31 kg

Center Guides SystemOne
(62 lb) (62 lb) (57 lb) (57lb) (68 lb) (68 lb)
+27 kg +27 kg +26 kg +26 kg +32 kg +32 kg

Center Guides SALT (60 lb) (60 lb) (57 lb) (57lb) (70 lb) (70 lb)
Jacket Water Heater

+ + + + + +
1 kg (2 lb)
Starting Aid - Ether

+ + + + + +
2 kg (5 lb)
Machine Security System

+ + + + + +
0.2 kg (0.5 lb)
Product Link PL321SR (World View)

+ + + + + +
13 kg (29 lb)
Product Link PL121SR (World View)

+ + + + + +
7 kg (15 lb)
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.
SEBU8498-04 95
Operation Section
Lifting and Tying Down the Machine
i05056331
Lifting and Tying Down the

Machine
SMCS Code: 7000; 7500
Improper lifting and improper tie-downs can al-

low 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 Mainte-
nance Manual, “Lifting and Tying Down the Ma- Illustration 143 g02786285
chine” 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
manufactured by Caterpillar.
Refer to the Operation and Maintenance Manual,
“Specifications” for specific weight information.
1. Engage the parking brake.
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.
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.
96 SEBU8498-04
Operation Section
Lifting and Tying Down the Machine

Right track roller frame
Some components are removed for clarity.
1. Use properly rated cables in order to tie down the

machine that is a fire plow.
2. Use the additional two tie-down points on each
track roller frame in order to stabilize the machine.
Note: Do not attempt to lift the machine from the tie-
down points.
SEBU8498-04 97
Operation Section
Towing Information
Towing Information Before you tow the machine, make sure that the tow
line or the tow bar is in good condition. Make sure
that the tow line or the tow bar has enough strength
i06057815 for the towing procedure that is involved. The
strength of the tow line or of the tow bar should be at
Towing the Machine least 150 percent of the gross weight of the towing
machine. This requirement is for a disabled machine
SMCS Code: 7000 that is stuck in the mud and for towing on a grade.
Attach the cable to the towing eye on the front of the
machine if you are towing the machine forward.
Attach the cable to the drawbar pin on the rear of the
Personal injury or death could result when towing
machine if you are towing the machine backward.
a disabled machine incorrectly.
Do not use a chain for pulling a disabled machine. A
Block the machine to prevent movement before
chain link can break. This action may cause personal
final drives are disengaged. The machine can roll
injury. Use a wire cable with ends that have loops or
free if it is not blocked. With final drives disen-
gaged, the machine cannot be stopped or rings. Put an observer in a safe position in order to
steered. watch the pulling procedure. The observer can stop
the procedure if the wire cable starts to break. Stop
Follow the recommendations below, to properly pulling whenever the towing machine moves without
perform the towing procedure. moving the towed machine.
Relieve the hydraulic tank and line pressure be- Keep the tow line angle to a minimum. Do not exceed
fore any disassembly. a 15 degree angle from the straight ahead position.
Even after the machine has been turned off, the Quick machine movement could overload the tow line
hydraulic oil can still be hot enough to burn. Al- or the tow bar. This action could cause the tow line or
low the hydraulic oil to cool before draining. the tow bar to break. Gradual, steady machine
movement will be more effective.
Normally, the towing machine should be as large as
NOTICE the disabled machine. Make sure that the towing
To tow the machine, both final drives must be disen- machine has enough brake capacity, enough weight,
gaged. Otherwise, damage could result. and enough power. The towing machine must be
able to control both machines for the grade that is
This machine is equipped with spring-applied brakes.
involved and for the distance that is involved.
These brakes are also oil pressure released brakes.
If the engine or the system for pressure oil is You must provide sufficient control and sufficient
inoperable, the brakes are applied and the machine braking when you are moving a disabled machine
cannot be moved. downhill. This activity may require a larger towing
machine or additional machines that are connected
Note: Do not tow the machine with the sun gears to the rear of the disabled machine. This action will
in place. Remove the sun gear from each final prevent the machine from rolling away out of control.
drive.
All situation requirements cannot be listed. Minimal
Reference: See the publication Power Train towing machine capacity is required on smooth, level
Disassembly and Assembly in the machine Service surfaces. On inclined surfaces or surfaces that are in
Manual for the procedure. Consult your Cat Dealer poor condition, maximum towing machine capacity is
required.
for the proper procedure in order to remove the sun
gear, if necessary. Do not tow a loaded machine.
These towing instructions are for moving a disabled Consult your Cat dealer for the equipment that is
machine for a short distance at low speed. Move the necessary for towing a disabled machine.
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
action will protect the operator if the tow line or the
tow bar breaks.
Do not allow any person on the disabled machine
except the operator. Only allow the operator on the
disabled machine if the operator can control the
steering and/or braking.
98 SEBU8498-04
Operation Section
Engine Starting (Alternate Methods)
Engine Starting (Alternate NOTICE

When starting from another machine, make sure that
Methods) the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
i02799419
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
Engine Starting with Jump components on the stalled machine.
Start Cables Severely discharged maintenance free batteries do
SMCS Code: 1000; 7000 not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
Failure to properly service the batteries may This machine has a 12 volt starting system. Use only
cause personal injury. the same voltage for jump starting. Use of a higher
voltage damages the electrical system.
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. Use of Jump Start Cables
Do not smoke when checking battery electrolyte 1. Place the transmission control on the stalled
levels. machine in the NEUTRAL position. Engage the
Electrolyte is an acid and can cause personal in- parking brake. Lower all attachments to the
jury if it contacts the skin or eyes. ground. Move all controls to the HOLD position.
Always wear eye protection when starting a ma- Note: See “Equipment Lowering with Engine
chine with jump start cables. Stopped” for more information.
Improper jump start procedures can cause an ex- 2. On the stalled machine, turn the engine start
plosion resulting in personal injury. switch to the OFF position. Turn off the
When using jumper cables, always connect the accessories.
positive (+) jumper cable to the positive (+) bat- 3. On the stalled machine, turn the battery disconnect
tery terminal first. Next, connect the negative (-)
jumper cable to the frame away from the bat- switch to the ON position.
teries. Follow the procedure in the Operation and 4. Move the machine or the auxiliary power source
Maintenance Manual.
close to the stalled machine so that the cables can
Jump start only with an energy source of the reach. DO NOT ALLOW THE MACHINE OR THE
same voltage as the stalled machine. AUXILIARY POWER SOURCE TO CONTACT
THE STALLED MACHINE.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the 5. Stop the engine on the machine that is the
energy source is connected. electrical source. (If you are using an auxiliary
power source, turn off the charging system.)
6. Check the battery caps for correct placement and
for correct tightness. Make these checks on both
Do not attempt to charge a battery that has ice in machines. Make sure that the batteries in the
any of the cells. stalled machine are not frozen. Check the
batteries for low electrolyte.
Charging a battery in this condition can cause an
explosion that may result in personal injury or 7. Connect the positive jump start cable to the
death. positive cable terminal of the discharged battery.
Always let the ice melt before attempting to Do not allow positive cable clamps to contact any
charge.
metal except for battery terminals.
Note: This machine is equipped with two batteries.

Only the battery terminals inside the right access
door should be used in order to jump start the
machine.
SEBU8498-04 99
Operation Section
Engine Starting with Jump Start Cables
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 connection away from the battery, away from
the fuel, away from the hydraulic lines, and away
from all moving parts.
11. Start the engine of the machine that is the
electrical source. (If you are using an auxiliary
power source, energize the charging system on
the auxiliary power source.)
12. Allow the electrical source to charge the batteries
for two minutes.
13. Attempt to start the stalled engine.
Reference: For more information, refer to Operation

and Maintenance Manual, “Engine Starting”.
14. Immediately after the stalled engine starts,
disconnect the jump start cables in reverse order.
100 SEBU8498-04
Maintenance Section
Lubricant Viscosities and Refill Capacities
Maintenance Section 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
Lubricant Viscosities and thickness. Refer to “General Information for
Lubricants” article, “Lubricant Viscosities” tables, and
Refill Capacities any associated footnotes. Consult your Cat dealer if
additional information is needed.
i04321533
NOTICE
Not following the recommendations found in this
Lubricant Viscosities manual can lead to reduced performance and com-
partment failure.
(Fluids Recommendations)
SMCS Code: 7000; 7581
Engine Oil
General Information for Lubricants
Cat oils have been developed and tested in order to
When you are operating the machine in temperatures provide the full performance and life that has been
below −18°C (−0°F), refer to Special Publication, designed and built into Cat engines.
Caterpillar Machines”. This publication is available Cat DEO-ULS or oils that meet the Cat ECF-3
from your Cat dealer. specification and the API CJ-4 are required for use in
the applications listed below. Cat DEO-ULS and oils
For cold-weather applications where transmission oil meeting Cat ECF-3 specification and the API CJ-4
SAE 0W-20 is recommended, Cat Cold Weather and ACEA E9 oil categories have been developed
TDTO is recommended. with limited sulfated ash, phosphorus, and sulfur.
These chemical limits are designed to maintain the
Refer to the “Lubricant Information” section in the expected aftertreatment devices life, performance,
latest revision of the Special Publication, SEBU6250, and service interval. If oils meeting the Cat ECF-3
“Caterpillar Machine Fluids Recommendations” for a specification and the API CJ-4 specifications are not
list of Cat engine oils and for detailed information. available, oils meeting ACEA E9 may be used. ACEA
This manual may be found on the Web at Safety.Cat. E9 oils meet the chemical limits designed to maintain
com.
aftertreatment device life. ACEA E9 oils are validated
The footnotes are a key part of the tables. Read ALL using some but not all ECF-3 and API CJ-4 standard
footnotes that pertain to the machine compartment in engine performance tests. Consult your oil supplier
question. when considering use of an oil that is not Cat ECF-3
or API CJ-4 qualified.
Selecting the Viscosity Failure to meet the listed requirements will damage
aftertreatment-equipped engines and can negatively
In order to select the proper oil for each machine impact the performance of the aftertreatment
compartment, refer to the “Lubricant Viscosity for devices. The Diesel Particulate Filter (DPF) will plug
Ambient Temperature” table. Use the oil type AND oil sooner and require more frequent DPF ash service
viscosity for the specific compartment at the proper intervals.
ambient temperature.
Typical aftertreatment systems include the following:
The proper oil viscosity grade is determined by the
minimum ambient temperature (the air in the • Diesel Particulate Filters (DPF)
immediate vicinity of the machine). Measure the
temperature when the machine is started and while • Diesel Oxidation Catalysts (DOC)
the machine is operated. In order to determine the
proper oil viscosity grade, refer to the “Min” column in • Selective Catalytic Reduction (SCR)
the table. This information reflects the coldest
ambient temperature condition for starting a cold • Lean NOx Traps (LNT)
machine and for operating a cold machine. Refer to
the “Max” column in the table for operating the Other systems may apply.
machine at the highest temperature that is
anticipated. Unless specified otherwise in the
“Lubricant Viscosities for Ambient Temperatures”
tables, use the highest oil viscosity that is allowed for
the ambient temperature.
SEBU8498-04 101
Maintenance Section
Fluids Recommendations
Table 9
Lubricant Viscosities for Ambient Temperatures
Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104
Engine Crankcase Cat DEO-ULS SAE 10W-30 −18 40 0 104
Cat DEO-ULS SAE 15W-40 −9.5 50 15 122
Hydraulic Systems
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
The following are the preferred oils for use in most
Cat machine hydraulic systems:
• Cat HYDO Advanced 10 SAE 10W
• Cat HYDO Advanced 30 SAE 30W

• Cat BIO HYDO Advanced
Cat HYDO Advanced fluids have 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 you follow the
maintenance interval schedule for oil filter changes
and for oil sampling that is stated in the Operation
and Maintenance Manual for your particular machine.
6000 hour oil drain intervals are possible when using
S·O·S Services oil analysis. Consult your Cat dealer
for details. When switching to Cat HYDO Advanced
fluids, cross contamination with the previous oil
should be kept to less than 10%.
Second choice oils are listed below.
• Cat MTO
• Cat DEO
• Cat DEO-ULS
• Cat TDTO
• Cat TDTO Cold Weather
• Cat TDTO-TMS
• Cat DEO-ULS Cold Weather
102 SEBU8498-04
Maintenance Section
Table 10
Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat HYDO Advanced 10
SAE 10W −20 40 −4 104
Cat TDTO
Cat HYDO Advanced 30
SAE 30 0 50 32 122
Cat TDTO
Cat BIO HYDO Advanced “ISO 46” Multi-Grade −30 45 −22 113
Cat MTO
Hydraulic System Cat DEO-ULS SAE10W-30 −20 40 −4 104
Cat DEO
Cat DEO-ULS
SAE15W-40 −15 50 5 122
Cat DEO
Cat TDTO-TMS Multi-Grade −15 50 5 122
Cat DEO-ULS Cold Weather SAE0W-40 −40 40 −40 104
Cat TDTO Cold Weather SAE 0W-20 −40 40 −40 104
Transmission, Axles, Final Drive

Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
When you are operating the machine in temperatures
below −20°C (−4°F), refer to Special Publication,
Caterpillar Machines”. This publication is available
from your Cat dealer.
Where recommended for use, Cat FDAO SYN Cat
FDAO or commercial oil that meets Cat FD-1 are the
preferred oil types to maximize gear and bearing life.
Do not use Cat FDAO, Cat FDAO SYN, or Cat FD-1
in compartments containing clutches and/or brakes.
Cat TDTO, Cat TDTO-TMS, or commercial oil that
meets Cat TO-4 oil types must be used in any
compartment containing friction material unless
specified otherwise by Caterpillar.
For the Final Drives in severe usage or in continuous
operations, WARMUP is required. Exercise the final
drives for several minutes with the engine at a partial
throttle in order to warm up the oil prior to production
operation
SEBU8498-04 103
Maintenance Section
Table 11
Compartment or Oil Type and °C °F

Application Oil Viscosities
System Classification Min Max Min Max
Cat FDAO SAE 60 −7 50 19 122
commercial FD-1
SAE 50 −15 32 5 90
Cat TDTO COLD
Moderate Usage or In-
WEATHER SAE 30 −25 15 −13 59
termittent Operation
Cat TDTO
Cat TDTO-TMS Cat TDTO-TMS −35 15 −31 59
commercial TO-4
Final Drive
Cat FDAO SAE 60 −25 50 −13 122
commercial FD-1
Severe Usage or Con- SAE 50 −33 14 −27 58
Cat TDTO COLD
tinuous Operation (Mul- WEATHER SAE 30 −40 0 −40 32
tiple Shifts/Day) Cat TDTO
Cat TDTO-TMS Cat TDTO-TMS −40 0 −40 32
commercial TO-4
Special Applications
Cat Synthetic GO is an SAE 75W-140 viscosity grade
oil.
Table 12
Compartment or Oil Type and °C °F

Application Oil Viscosities
System Classification Min Max Min Max
SAE 75W-90 −30 40 −22 104
Cat GO SAE 75W-140 -30 45 -22 113

Cat Synthetic GO
Pins, and Track Pins Normal SAE 80W-90 −20 40 −4 104
commercial API GL-5
gear oil SAE 85W-140 −10 50 14 122
SAE 90 0 40 32 104
SAE 0W20 −40 10 −40 50
SAE 0W30 −40 20 −40 68
Cat TDTO SAE 5W30 −30 20 −22 68
Winches (winch gear
Normal Cat TDTO-TMS
oil) SAE 10W −20 10 −4 50
commercial TO-4
SAE 30 0 43 32 110
Cat TDTO-TMS −10 35 14 95
Cat DEO SAE 30 −20 25 −4 77

Track Idlers and Track
Cat DEO SYN SAE 40 −10 40 14 104
Rollers
Normal Cat ECF-1
API CG-4
SAE 5W-40 −35 40 −31 104
API CF
Special Lubricants Each pin joint should be flushed with the new grease.
Ensure that all old grease is removed. Failure to meet
Grease this requirement may lead to failure of a pin joint.
In order to use a non-Cat grease, the supplier must

certify that the lubricant is compatible with Cat
grease.
104 SEBU8498-04
Maintenance Section
Table 13
Recommended Grease
°C °F
Compartment or System GreaseType NLGI Grade
Min Max Min Max
Cat Advanced 3Moly NLGI Grade 2 −20 40 −4 104
NLGI Grade 2 −30 50 −22 122

External Lubrication Points (End Cat Ultra 5Moly NLGI Grade 1 −35 40 −31 104
bearings, blade pivots, C-frame
pivot, winch rollers, drum) NLGI Grade 0 −40 35 −40 95
Cat Arctic Platinum NLGI Grade 0 −50 20 −58 68
Cat Desert Gold NLGI Grade 2 −20 60 −4 140
Reference: Refer to Special Publication, SEBU6250, Diesel fuel must meet “Cat Specification for Distillate
“Caterpillar Machine Fluids Recommendations” for Fuel” and the latest versions of “ASTM D975” or “EN
additional information about grease. This manual 590” in order to ensure optimum engine performance.
may be found on the Web at Safety.Cat.com. Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for the latest fuel
information and for Cat fuel specification. This
Diesel Fuel Recommendations manual may be found on the Web at Safety.Cat.com.
NOTICE
Ultra Low Sulfur Diesel (ULSD) fuel 0.0015 percent
(≤15 ppm (mg/kg)) sulfur is required by regulation for
use in engines certified to nonroad Tier 4 standards
(U.S. EPA Tier 4 certified) and that are equipped with
exhaust aftertreatment systems.
European ULSD 0.0010 percent (≤10ppm (mg/kg))
sulfur fuel is required by regulation for use in engines
certified to European nonroad Stage IIIB and newer
standards and are equipped with exhaust aftertreat-
ment systems.
Misfueling with fuels of higher sulfur level will

invalidate the warranty and have the following
Illustration 146 g02157153 negative effects:
NACD Film • Shorten the time interval between
aftertreatment device service intervals (cause
the need for more frequent service intervals)
• Adversely impact the performance and life of

aftertreatment devices (cause loss of
performance)
• Reduce regeneration intervals of

aftertreatment devices
• Reduce engine efficiency and durability.
• Increase the wear.

• Increase the corrosion.
• Increase the deposits.

EAME Film • Lower fuel economy
• Shorten the time period between oil drain intervals

(more frequent oil drain intervals).
SEBU8498-04 105
Maintenance Section
• Increase overall operating costs. When biodiesel fuel is used, certain guidelines must
be followed. Biodiesel fuel can influence the engine
Failures that result from the use of improper fuels oil, aftertreatment devices, non-metallic, fuel system
are not Cat factory defects. Therefore the cost of components, and others. Biodiesel fuel has limited
repairs would not be covered by a Cat warranty. storage life and has limited oxidation stability. Follow
the guidelines and requirements for engines that are
Caterpillar does not require the use of ULSD in off seasonally operated and for standby power
road and machine applications that are not Tier 4/ generation engines.
Stage IIIB certified engines. ULSD is not required in
engines that are not equipped with after treatment In order to reduce the risks associated with the use of
devices. For Tier 4/Stage IIIB/Stage IV certified biodiesel, the final biodiesel blend and the biodiesel
engines always follow operating instructions. Fuel fuel used must meet specific blending requirements.
tank inlet labels are installed in order to ensure that
the correct fuels are used. All the guidelines and requirements are provided in
the latest revision of Special Publication, SEBU6250,
Refer to Special Publication, SEBU6250, “Caterpillar “Caterpillar Machine Fluids Recommendations”. This
Machine Fluids Recommendations” for more details manual may be found on the Web at Safety.Cat.com.
about fuels, lubricants, and Tier 4 requirements. This
manual may be found on the Web at Safety.Cat.com.
Coolant Information
Fuel Additives The information provided in this “Coolant
Recommendation” section should be used with the
Cat Diesel Fuel Conditioner and Cat Fuel System “Lubricants Information” provided in the latest
Cleaner are available for use when needed. These revision of Special Publication, SEBU6250,
products are applicable to diesel and biodiesel fuels. “Caterpillar Machine Fluids Recommendations”. This
Consult your Cat dealer for availability. manual may be found on the Web at Safety.Cat.com.
Biodiesel The following two types of coolants may be used in

Cat diesel engines:
Biodiesel is a fuel that can be made from various
renewable resources that include vegetable oils, Preferred – Cat ELC (Extended Life Coolant)
animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In Acceptable – Cat DEAC (Diesel Engine Antifreeze/
Coolant)
order to use any of these oils or fats as fuel, the oils
or fats are chemically processed (esterified). The
water and contaminants are removed.
Coolant Additives
U.S. distillate diesel fuel specification “ASTM D975-
09a” includes up to B5 (5 percent) biodiesel.
Currently, any diesel fuel in the U.S. may contain up NOTICE
Never use water alone without Supplemental Coolant
to B5 biodiesel fuel. Additives (SCA) or without inhibited coolant. Water
European distillate diesel fuel specification “EN 590” alone is corrosive at engine operating temperatures.
includes up to B5 (5 percent) and in some regions up In addition, water alone does not provide adequate
to B7 (7 percent) biodiesel. Any diesel fuel in Europe protection against boiling or freezing.
may contain up to B5 or in some regions up to B7
biodiesel fuel. If the coolant exhibits any of the following issues,
refer to PELJ1330 for the proper coolant conditioner
Note: The diesel portion used in the biodiesel blend additives.
must be Ultra Low Sulfur Diesel (15 ppm sulfur or
• Ammonia odor coming from the coolant
less, per “ASTM D975”). In Europe the diesel fuel
portion used in the biodiesel blend must be sulfur free • Elevated pH, such as pH>10
diesel (10 ppm sulfur or less, per “EN 590”). The final
blend must have 15 ppm sulfur or less. • Aluminum corrosion elevated when measured by
coolant analysis by S·O·S Services
Note: B20 biodiesel blend level is acceptable for use
in D3K2, D4K2, D5K2 machine engines. • Change in coolant color, such as a change from
strawberry red to light pink with ELC (Extended
Life Coolant)
106 SEBU8498-04
Maintenance Section
Capacities (Refill)
At no point during the life of this machine should Refer to the Operation and Maintenance Manual,
Cooling System Coolant Extender (ELC) be “Maintenance Interval Schedule” for a specific
added. sampling location and a service hour maintenance
interval.
i04311390
Consult your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
Capacities (Refill) equipment.
SMCS Code: 7000; 7560
Table 14
APPROXIMATE REFILL CAPACITIES
Imp
Compartment or System Liters US Gal
Gal
Engine Crankcase 11 2.9 2.4
Each Final Drive D3K 10.0 2.6 2.2

Hydraulic Tank 60 15.8 13.2
Hydraulic System 84 22.2 18.4
Fuel Tank 195 51.5 42.9

Radiator for the Cooling System 7.9 2.1 1.7
Cooling System 23.0 6.1 5.1
Gear Case for the Winch 4.7 1.2 1.0
Note: When you are operating on severe slopes, the

quantity of oil in the power train can be increased up
to 10 percent. When you are operating with the
increased oil quantity, prolonged operation in some
machines can cause high-power train oil
temperatures. After the work on the severe slopes
has been completed, drain the excessive oil quantity
from the bevel gear case.
i07445339
S·O·S Information
SMCS Code: 7542
S·O·S Services is a highly recommended process for
Cat customers to use in order to minimize owning
and operating cost. Customers provide oil samples,
coolant samples, and other machine information. The
dealer uses the data in order to provide the customer
with recommendations for management of the
equipment. In addition, 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.
The effectiveness of S·O·S Services is dependent on
timely submission of the sample to the laboratory at
recommended intervals.
SEBU8498-04 107
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 sensors)
or electronic component grounding points for ground-
ing the welder.
3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp as
close as possible to the weld. Make sure that the
electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure in order to reduce the possibility of
damage to the following components:
• Bearings of the drive train
• Hydraulic components
• Electrical components
• Other components of the machine
4. Protect any wiring harnesses from the debris

which is created from welding. Protect any wiring
harnesses from the splatter which is created from
welding.
5. Use standard welding procedures in order to weld
the materials together.
108 SEBU8498-04
Maintenance Section
Maintenance Interval Schedule
i07754735 “ Radiator Pressure Cap - Clean/Replace”. . . . . . 150
Maintenance Interval Schedule “ Ripper - Inspect/Replace” . . . . . . . . . . . . . . . . . . 151
SMCS Code: 7000 “ Winch Cable - Replace”. . . . . . . . . . . . . . . . . . . . 157
Ensure that all safety information, warnings, and “ Window Washer Reservoir - Fill” . . . . . . . . . . . . 160
instructions are read and understood before any
operation or any maintenance procedures are “ Window Wipers - Inspect/Replace” . . . . . . . . . . 160
performed.
“ Windows - Clean”. . . . . . . . . . . . . . . . . . . . . . . . . 160
The user is responsible for the performance of
maintenance. All adjustments, the use of proper Every 12 000 Service Hours or 6
lubricants, fluids, filters, and the replacement of
components due to normal wear and aging are Years
included. Failure to adhere to proper maintenance
intervals and procedures may result in diminished “ Cooling System Coolant (ELC) - Change” . . . . . 116
performance of the product and/or accelerated wear
of components. Every 10 Service Hours or Daily
Use mileage, fuel consumption, service hours, or “ Backup Alarm - Test” . . . . . . . . . . . . . . . . . . . . . . 110
calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals. “ Brakes, Indicators and Gauges - Test” . . . . . . . . 113
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to the “ Bulldozer Power Angling Tilt Hinge Pins -
maintenance procedure for any other exceptions that Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
may change the maintenance intervals.
“ Cab Filter (Fresh Air) - Clean/Inspect/
Note: The aftertreatment system can be expected to Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
function properly for the useful life of the engine
(emissions durability period), as defined by “ Cooling System Coolant Level - Check”. . . . . . . 118
regulation. All prescribed maintenance requirements
must be followed. “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 127
“ Hydraulic System Oil Level - Check ” . . . . . . . . . 147
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be “ Seat Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 152
performed.
“ Winch Cable - Inspect” . . . . . . . . . . . . . . . . . . . . 156
Note: If Cat HYDO Advanced hydraulic oils are used,
the hydraulic oil change interval is extended to 3000 “ Winch Fairlead Rollers - Lubricate” . . . . . . . . . . 158
hours. S·O·S services may extend the oil change
even longer. Consult your Cat dealer for details. Every 50 Service Hours or Weekly
When Required “ Cab Filter (Recirculation) - Clean/Inspect/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . 110
“ Ripper Linkage and Cylinder Bearings -
“ Battery or Battery Cable - Inspect/Replace”. . . . .111 Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
“ Cutting Edges and End Bits - Inspect/ “ Track - Check/Adjust” . . . . . . . . . . . . . . . . . . . . . 154

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
“ Ether Starting Aid Cylinder - Replace” . . . . . . . . 130
“ Free Spool Drag - Adjust” . . . . . . . . . . . . . . . . . . 131
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 132
“ Fuel Tank Cap - Clean” . . . . . . . . . . . . . . . . . . . . 139
“ Fuses - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 141
“ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 149
“ Radiator Core - Clean” . . . . . . . . . . . . . . . . . . . . 149
SEBU8498-04 109
Maintenance Section
Maintenance Interval Schedule
“ Track Pins - Inspect” . . . . . . . . . . . . . . . . . . . . . . 155 “ Winch Oil Sample - Obtain”. . . . . . . . . . . . . . . . . 159
Every 100 Service Hours or 2 Every 500 Service Hours or 6

Weeks Months
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 140 “ Front Idler Position - Check/Adjust” . . . . . . . . . . 132
Initial 250 Service Hours Every 500 Service Hours or 1 Year

“ Fuel System Filter (In-Line) - Replace”. . . . . . . . 133 “ Battery - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . 110
Every 250 Service Hours or “ Rollover Protective Structure (ROPS) -

Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Monthly
“ Belts - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Every 1500 Service Hours
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 128 “ Condenser (Refrigerant) - Clean” . . . . . . . . . . . . 115
“ Final Drive Oil Level - Check” . . . . . . . . . . . . . . . 131 “Engine Crankcase Breather Element -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
“ Fuel System Water Separator - Drain” . . . . . . . . 136
“ Hydraulic System Oil Filter - Replace” . . . . . . . . 146
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 139
“ Winch Oil Filter - Replace” . . . . . . . . . . . . . . . . . 158
“ Winch Oil Level - Check” . . . . . . . . . . . . . . . . . . . 159
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted “Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Systems)
“ Final Drive Oil - Change” . . . . . . . . . . . . . . . . . . . 130
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 “ Winch Oil - Change” . . . . . . . . . . . . . . . . . . . . . . 158
“ Winch Vent Plug - Clean” . . . . . . . . . . . . . . . . . . 159
“Cooling System Coolant Sample (Level 1) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 “ Alternator and Fan Belts - Replace” . . . . . . . . . . 110
“ Engine Air Filter Primary Element - Clean/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 “ Belt Tensioner - Inspect” . . . . . . . . . . . . . . . . . . . 112
“ Engine Air Filter Secondary Element - “ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
“ Engine Air Precleaner - Clean” . . . . . . . . . . . . . . 125 “ Hydraulic System Oil - Change” . . . . . . . . . . . . . 144
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 129 “ Hydraulic Tank Breather - Replace” . . . . . . . . . . 148
“ Final Drive Oil Sample - Obtain” . . . . . . . . . . . . . 131 Every 3 Years

“ Fuel System Filter (In-Line) - Replace”. . . . . . . . 133 “ Seat Belt - Replace”. . . . . . . . . . . . . . . . . . . . . . . 153
“ Fuel System Secondary Filter - Replace”. . . . . . 134
“ Fuel System Water Separator - Replace” . . . . . 137
“ Hydraulic System Oil Sample - Obtain” . . . . . . . 148
“ Trunnion - Adjust” . . . . . . . . . . . . . . . . . . . . . . . . 156
“ Winch Drum Bearing - Lubricate” . . . . . . . . . . . . 157
110 SEBU8498-04
Maintenance Section
Alternator and Fan Belts - Replace
i02320208
Alternator and Fan Belts -

Replace
SMCS Code: 1357-510
Refer to Disassembly and Assembly Manual , “
Alternator Belt - Remove and Install”.
i04315472
Backup Alarm - Test

SMCS Code: 7406
The backup alarm is attached to the right rear ROPS

post.
The nonadjustable backup alarm is set at the
appropriate sound level when the machine is shipped
from the factory.
i01989120
Battery - Inspect
SMCS Code: 1401-040
Tighten the battery retainers on all batteries at every
1000 hour interval.
1. Open the battery access cover.
Turn the engine start switch to the ON position in
order to perform the test. 2. Clean the top of the batteries with a clean cloth.
Keep the terminals clean and coated with
Apply the decel/brake pedal. Disengage the parking petroleum jelly. Install the terminal covers after you
brake switch. Move the transmission control lever to coat the terminals.
the REVERSE position.
3. Close the battery access cover.
The backup alarm should sound immediately. The
alarm alerts the people behind the machine that the
machine is backing up. The backup alarm should i07746330
continue to sound until the transmission control lever
is moved to the NEUTRAL position or to the Battery - Recycle
FORWARD position.
SMCS Code: 1401-535; 1401-561; 1401-510; 1401-
005; 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
SEBU8498-04 111
Maintenance Section
Battery or Battery Cable - Inspect/Replace
i04315506
Battery or Battery Cable -

Inspect/Replace
SMCS Code: 1401-510; 1401; 1401-040; 1402-510;
1402-040
Personal injury may occur from failure to prop-

erly service the batteries.
Batteries give off flammable fumes that can ex-
plode. Electrolyte is an acid and can cause per-
sonal injury if it contacts the skin or eyes.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
proper jumper cable connections can cause an
explosion.
Always wear protective glasses when working
with batteries. There are two batteries on this machine.
(1) Primary battery
(2) Secondary battery
1. Turn the engine start switch key OFF. Turn all of
the switches OFF. 4. Disconnect the negative battery cable at battery
(1). The primary battery is located behind the right
side access door.
5. Disconnect the positive battery cable at the
battery.
6. Remove the mat and the floorplate in the cab in
order to access the secondary battery. Perform
steps 4 and 5 in order to disconnect the secondary
battery.
7. Inspect the battery terminals for corrosion. Inspect
the battery cables for wear or damage.
8. Make any necessary repairs. If necessary, replace
the battery cables or the batteries.
Note: Do not exceed a change interval of 48 months

when the secondary battery carrier (strap) is
replaced.
9. Connect the positive battery cable to the battery

positive terminals.
10. Connect the negative battery cable to the battery
negative terminals.
2. Open the right rear access door. Turn the battery
disconnect switch to the OFF. Remove the key. 11. Connect the battery cable at the battery
disconnect switch.
3. Disconnect the negative battery cable from the
disconnect switch. 12. Install the key and turn the battery disconnect
switch ON.
Note: Do not allow the disconnected battery cable to
contact the disconnect switch. 13. Close the right rear access door.
112 SEBU8498-04
Maintenance Section
Belts - Inspect
i07532505 The belt deflection should not be more than

14 to 20 mm (.56 to .81 inch) under 110 N (25 lb)
Belts - Inspect of force. Use a 144-0235 Belt Tension Gauge in
SMCS Code: 1357-040; 1397-040 order to measure the tension.
Note: The deflection of the serpentine belt has the

Inspect same limit with an alternator only.
1. Park the machine on level ground. Lower the dozer Note: This machine is equipped with one belt
blade to the ground. Move the transmission control tensioner (2). The belt tensioner automatically
to the NEUTRAL position and engage the parking adjusts the belt to the correct position.
brake. Shut off the engine.
4. Close the engine enclosure.
2. Open the engine enclosure.
i03868550
Belt Tensioner - Inspect

SMCS Code: 1358-040

Typical example
Remove the belt. Refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.
Illustration 153 g01259370 Ensure that the belt tensioner is securely installed.
A/C compressor Visually inspect the belt tensioner (2) for damage.
Check that the pulley on the tensioner rotates freely
and that the bearing is not loose. Some engines have
3. Inspect the condition of the serpentine belt (1) for an idler pulley (1). Ensure that the idler pulley is
any of the following conditions: securely installed. Visually inspect the idler pulley for
damage. Ensure that the idler pulley can rotate freely
• excessive cracking and that the bearing is not loose. If necessary,
replace damaged components.
• excessive wear
Install the belt. Refer to Disassembly and Assembly,
• excessive damage “Alternator Belt - Remove and Install”.
SEBU8498-04 113
Maintenance Section
Brakes, Indicators and Gauges - Test
i04316503 If the above tests are not correctly completed, the

system will not function in the normal operating
Brakes, Indicators and Gauges mode. Consult your Caterpillar dealer for an electrical
system check. Any repairs must be made before you
- Test start the engine.
SMCS Code: 4100-081; 7000-081; 7450-081 Turn on all of the machine lights. Check for proper
Check the operation of the Caterpillar Monitoring operation. Sound the forward horn.
System. Observe the self test when you start the Move the machine forward and test the service
engine. brakes.
The system performs an automatic self test when you
turn the engine start switch to the ON position. Braking System (Test)
The self test verifies that the monitoring panel and
the display modules are operating properly.
The internal circuits, the indicators, and the gauges If the machine moves during the test, reduce the
are automatically checked. engine speed immediately, and engage the park-
ing brake.
If the machine moved while testing the brakes,
consult your Caterpillar dealer for brake inspec-
tion and repair. Damaged brakes must be re-
paired before returning the machine to operation.
Make sure that the area around the machine is clear
of personnel and clear of obstacles.
Test the brakes on a dry, level surface.
Fasten the seat belt before you test the brakes.
The operator must observe whether gauges (1),

indicators (2), and displays (3) are operating properly.
The self test lasts for approximately 3 seconds.
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)

• “X10” readout
• Symbol for the hour meter Illustration 156 g02637276
• “8.8.8.X.8.8” readout 1. Start the engine.

The pointers in the gauges point upward. Then, the 2. Raise all attachments.
pointers point to the left. Then, the pointers point to
the right. Then, the pointers point to the final 3. Use the ET service tool in order to perform the
positions. Transmission Stall Test. Refer to the Testing and
Adjusting manual for your machine for more
• The action light stays illuminated.
information.
• The action alarm sounds once for one second. 4. Reduce the engine speed to LOW IDLE. Engage
The monitoring panel is then in the normal operating the parking brake. Lower all attachments to the
mode. ground. Apply a slight down pressure. Stop the
engine.
114 SEBU8498-04
Maintenance Section
Bulldozer Power Angling Tilt Hinge Pins - Lubricate
5. Make any necessary repairs before you operate Apply lubricant to the grease fitting for the head end
the machine. of the lift cylinder (7). Repeat for the left and right side
lift cylinders.
NOTICE
If the machine moved while testing the brakes, con- Apply lubricant to the grease fittings for the pitch link
tact your Caterpillar dealer. Have the dealer inspect (8, 9).
and, if necessary, repair the service brake before re-
turning the machine to operation. i05063231
Cab Filter (Fresh Air) - Clean/

i04316818
Inspect/Replace
Bulldozer Power Angling Tilt (If Equipped)
Hinge Pins - Lubricate SMCS Code: 7342-070; 7342-040; 7342-510
SMCS Code: 6050 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.
Note: Enclosed ROPS only
1. Open left access door (1) for the filter.

Apply lubricant to the grease fitting for the head end 2. Remove filter element (2). Clean the filter element
of the tilt cylinder (1). with compressed air.
Apply lubricant to the grease fitting for the rod end of Note: Do not clean the filter elements while the filter
the tilt cylinder (2). elements are installed on the machine.
Apply lubricant to the grease fitting for the rod end of Note: Do not wash the filter element with water.
the angle cylinder (3). Repeat for the left and right
side angle cylinders. Note: Keep the filter element dry.
Apply lubricant to the grease fitting for the head end 3. Install the filter element. Close access door (1).
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.
SEBU8498-04 115
Maintenance Section
Cab Filter (Recirculation) - Clean/Inspect/Replace

Equipped)
HEPA Cab Air Intake Filter
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
Fire plow HEPA air filter element is installed on the machine.
Note: Use a soft brush to clean the outside of the Note: Do not use water in order to clean the filter
HEPA filter of dust and other particles. A gentle knock element.
on the mesh can dislodge the stuck particles. Use
compressed air to remove stuck particulates in the Note: The filter must be thoroughly dried before you
mesh. Do not use a hard brush. install the filter.
After cleaning, soak the HEPA filter in a mild 2. Replace any filter element that is worn or
germicidal solution. Allow the HEPA filter to air dry damaged.
before installing the filter.
3. Install the filter element and replace the filter cover.
Contact your Cat dealer to replace the HEPA (High-
Efficiency Particulate Air) air filter with the proper Note: Install the filter element with the filter media
equipment, as needed. toward the inside of the cavity.
i02801612 i04352110
Cab Filter (Recirculation) - Condenser (Refrigerant) -

Clean/Inspect/Replace Clean
SMCS Code: 7342-070; 7342-040; 7342-510 SMCS Code: 1805-070
Note: Clean the filter element more often in dusty
conditions. If there is a noticeable reduction in the air NOTICE
flow from the air vents, check the filter element. If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush.
Repair the fins if found defective.
116 SEBU8498-04
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
Illustration 161 g02507517 Note: This machine was filled at the factory with
Caterpillar Extended Life Coolant.
1. Remove the cover for the condenser.
If the coolant in the machine is changed to Extended
2. Inspect the condenser for debris. Clean the Life Coolant from another type of coolant, see
condenser, if necessary. Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”.
3. Use clean water to wash all of the dust and dirt
from the condenser. 1. Open the left engine access door first in order to
access the latch for the top access panel.
4. Install the cover for the condenser.
2. Open the access panel on top of the engine
i04359909 compartment in order to remove the cooling
system pressure cap.
Cooling System Coolant (ELC)
- Change
SMCS Code: 1352-044; 1395-044
NOTICE
Do not change the coolant until you read and under-
stand the cooling system information in Special Publi-
cation, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.
Failure to do so could result in damage to the cooling
system components.
NOTICE
Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
This could result in damage to cooling system
components.
If Caterpillar products are not available and commer-
cial products must be used, make sure they have
passed the Caterpillar EC-1 specification for pre-
mixed or concentrate coolants and Caterpillar
Extender.
SEBU8498-04 117
Maintenance Section
Cooling System Coolant (ELC) - Change
Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.
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 7a through
Step 7h in order to flush the cooling system
properly.
a. Close drain valve (2).
b. Fill the cooling system with clean water.
c. Install pressure cap (1).
d. Start the engine and run the engine until the
engine reaches operating temperature.
e. Stop the engine and allow the engine to cool.
f. Loosen pressure cap (1) slowly in order to
relieve any pressure in the cooling system.
g. Open drain valve (2) and allow the coolant to
drain into a suitable container.
h. Flush the radiator with clean water until the
3. Loosen cooling system pressure cap (1) slowly draining water is transparent.
when you are inside the engine compartment in 8. Close the drain valve and install the access cover
order to release the pressure from the cooling underneath the engine.
system.
9. Add the Extended Life Coolant. Refer to the
4. Remove the pressure cap. following topics:
• Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”
• Operation and Maintenance Manual,

“Capacities (Refill)”
118 SEBU8498-04
Maintenance Section
Cooling System Coolant Level - Check
10. Start the engine. Operate the engine without the

cooling system pressure cap until the water
temperature regulator opens and the coolant level
stabilizes.
11. Maintain the coolant level between the maximum
mark and the minimum mark on the expansion
tank.
Note: Refer to Operation and Maintenance Manual,

“Cooling System Coolant Level - Check” for
additional information.
12. Inspect the O-ring of the cooling system pressure

cap. If the O-ring is damaged, replace the
pressure cap.
13. Install the cooling system pressure cap.
14. Stop the engine.
15. Close the access panel on top of the engine
compartment.
16. Close the left engine access door.
2. Maintain the coolant level between minimum mark
i04646169 (B) and maximum mark (A) on expansion tank (2).
If you need to add coolant daily, check the cooling
Cooling System Coolant Level system for leaks.
- Check 3. Close the left engine access door.
SMCS Code: 1353; 1354; 1395; 7520
i04646430
1. Open the left engine access door.
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 Cat 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.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
instead of Cat ELC. This sampling includes the
following types of coolants.
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
(Caterpillar “EC−1” )
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
• Commercial heavy-duty antifreeze/coolant

SEBU8498-04 119
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Use the following guidelines for proper sampling of

NOTICE the coolant:
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam- • Complete the information on the label for the
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being sampling bottle before you begin to take the
drawn. This contaminate may cause a false analysis samples.
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers. • Keep the unused sampling bottles stored in plastic
bags.
Note: Level 1 results may indicate a need for • Keep the lids on empty sampling bottles until you
Level 2 Analysis. are ready to collect the sample.
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
• Never collect samples from the drain for a system.

(B) and maximum mark (A). Add coolant, if
necessary.
5. Install cooling system pressure cap (1) on to
expansion tank (2). Close the access panel on top
of the engine compartment. Close the left engine
access door.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.
i04646456
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1395-554
compartment.
3. The cooling system pressure cap (1) is located on NOTICE
the top of expansion tank (2). Remove the cooling Always use a designated pump for oil sampling, and
system pressure cap slowly in order to relieve use a separate designated pump for coolant sam-
system pressure. pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
4. Obtain the coolant sample from the expansion tank drawn. This contaminate may cause a false analysis
and collect the sample into the proper sampling and an incorrect interpretation that could lead to con-
bottle. cerns by both dealers and customers.
Note: Always discard drained fluids according to

local regulations.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish a
consistent trend of data. In order to establish a
pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your
Caterpillar dealer.
120 SEBU8498-04
Maintenance Section
Cooling System Water Temperature Regulator - Clean/Replace
Obtain the sample of the coolant as close as possible

NOTICE to the recommended sampling interval. In order to
tained during performance of inspection, mainte- receive the full effect of S·O·S analysis, establish a
nance, testing, adjusting, and repair of the product. consistent trend of data. In order to establish a
Be prepared to collect the fluid with suitable contain- pertinent history of data, perform consistent
ers before opening any compartment or disassem- samplings that are evenly spaced. Supplies for
bling any component containing fluids. collecting samples can be obtained from your
Caterpillar dealer.
Service Tool Catalog” for tools and supplies suitable Use the following guidelines for proper sampling of
to collect and contain fluids on Cat products. the coolant:
Dispose of all fluids according to local regulations • Complete the information on the label for the
and mandates. sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic
bags.
• Keep the lids on empty sampling bottles until you

are ready to collect the sample.
• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.
• Never collect samples from the drain for a system.

(B) and maximum mark (A). Add coolant, if
necessary.
5. Install cooling system pressure cap (1) on to
expansion tank (2). Close the access panel on top
of the engine compartment. Close the left engine
access door.
Submit the sample for Level 2 analysis.
Illustration 167 g02789037 For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
1. Open the left engine access door. Fluids Recommendations” or consult your Caterpillar
dealer.
compartment. i05791119
3. The cooling system pressure cap (1) is located on
the top of expansion tank (2). Remove the cooling Cooling System Water
system pressure cap slowly in order to relieve Temperature Regulator -
system pressure.
Clean/Replace
4. Obtain the coolant sample from the expansion tank
SMCS Code: 1355; 1393
and collect the sample into the proper sampling
bottle. Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of
Note: S·O·S coolant samples should be pulled from problems with the cooling system.
the shunt bottle. Always discard drained fluids
according to local regulations. A new thermostat should be installed after the
cooling system has been cleaned. Install the
thermostat while the cooling system is drained or
while the cooling system coolant is drained to a level
that is below the thermostat housing.
SEBU8498-04 121
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace
i04317389
NOTICE
Failure to replace the engine's thermostat on a regu-
larly scheduled basis could cause severe engine Cutting Edges and End Bits -
damage. Inspect/Replace
SMCS Code: 6801; 6804
Note: If you are only installing a new thermostat,
drain the cooling system coolant to a level that is
below the thermostat housing.
1. Loosen the hose clamp and remove the hose from

the elbow. (The thermostat is integrated into the
elbow housing.)
2. Remove the bolts and the thermostat housing
assembly and discard.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a thermostat.
Depending on load, failure to operate with a thermo-
stat could result in either an overheating or an over-
cooling condition.
NOTICE
If the thermostat is installed incorrectly, it will cause
the engine to overheat.
3. Install the new thermostat housing assembly on 1. Raise the bulldozer blade and block up the
the engine cylinder head. bulldozer blade. When you remove the cutting
edges and the end bits, maintain the bulldozer
4. Install the hose. Tighten the hose clamp.
blade at a minimum height.
5. Top off the coolant tank with ELC coolant.
2. Remove the bolts.
3. Remove the cutting edge and the end bits.
4. Thoroughly clean all contact surfaces.
5. Inspect the opposite side of the cutting edge. If the
opposite side of the cutting edge is not worn, turn
the opposite side of the cutting edge downward
and install the cutting edge.
6. If both sides of the cutting edge are worn, install a
new cutting edge.
7. Install new end bits, as required.
8. Install all bolts and tighten the bolts to the specified
torque.
Note: Always install new bolts and nuts when
installing new cutting edges or flipping cutting edges.
Reference: For more information, refer to

Specifications, SENR3130, “Torque Specifications”.
9. Raise the bulldozer blade and remove the
blocking. Lower the bulldozer blade to the ground.
122 SEBU8498-04
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
10. After you operate the machine for a few hours,

check all bolts for the proper torque.
i04021794
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1051; 1054
NOTICE
Caterpillar recommends certified air filter cleaning
services that are available at Cat dealers. The Cat
cleaning process uses proven procedures to assure
consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element: 2. Loosen the four cover latches and remove the air
cleaner cover.
Do not tap or strike the filter element in order to re-
move dust. Note: The latches for the air cleaner housing may
Do not wash the filter element. snap open when you release the latches.
Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets,
or seals. Dirt entering the engine will cause damage
to engine components.

346-6686 Air Cleaner Group D3K2
3. Remove primary filter element (2) from air cleaner

housing (1). In order to remove the engine air filter
primary element, slide the element outward. While
you pull the element outward, rock the element.
NOTICE
Do not use a filter if the media, the gaskets, or the
seals are damaged.
4. Install clean primary filter element (2) over engine

air filter secondary element (3). Apply firm
pressure to the end of the primary element as you
gently rock the filter element. This seats the
Illustration 169 g02502123 primary element.
1. Open the engine access door on the left side of the 5. Clean cover (4) and install the cover.
machine. 6. Close the left engine access door.
SEBU8498-04 123
Maintenance Section
Engine Air Filter Secondary Element - Replace
7. Start the engine. The indicator on the gauge Do not touch the tip of the air gun to the primary air
cluster will illuminate when the filter needs filter element. Dirt could be forced further into the
attention. pleats.
Before you reuse the primary air filter element, check
Cleaning Primary Air Filter for any damage to the seals, the gaskets, and the
bellows. Discard any damaged air filter elements.
Elements
The primary air filter element can be used up to Inspecting the Primary Air Filter
three times if the element is properly cleaned and
properly inspected. When the primary air filter
Elements
element is cleaned, check for rips or tears in the filter Do not use a primary air filter element that has any
material. The primary air filter element should be tears and/or holes in the filter material. Do not use a
replaced at least one time per 2 yr period. This primary air filter element with damaged pleats,
replacement should be performed regardless of the gaskets, or seals. Discard damaged primary air filter
number of cleanings. elements.
NOTICE i04022167
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Engine Air Filter Secondary
Damaged elements will allow dirt to pass through.
Engine damage could result.
Element - Replace
SMCS Code: 1051; 1054
Visually inspect the primary air filter elements before
cleaning. Inspect the air filter elements for damage to NOTICE
the seal, the gaskets, and the outer cover. Discard Always replace the secondary element. Do not at-
any damaged air filter elements. tempt to reuse it by cleaning. Engine damage could
result.
Pressurized air is the best method to clean primary
air filter elements.
Note: Replace the secondary filter element when you
Pressurized Air service the primary element for the third time.

Direction of air flow
Pressurized air can be used to clean primary air filter

elements that have not been cleaned more than
three times. Pressurized air will not remove deposits
of carbon and oil. Use filtered, dry air with a Illustration 173 g02502123
maximum pressure of 207 kPa (30 psi).
Note: When the primary air filter element is cleaned, 1. Open the left engine access door.
always blow the air from the clean side in order to
force dirt particles toward the dirty side. This action
helps prevent damage to the paper pleats.
124 SEBU8498-04
Maintenance Section
Engine Air Filter Secondary Element - Replace

Secondary air cleaner element
2. Loosen the four cover latches and remove the air
cleaner cover. 5. Remove secondary element (3). The secondary
element is on the end of the air cleaner group
Note: The latches for the air cleaner housing may
away from the cab.
snap open when you release the latches.
6. Cover the air inlet opening. Clean the inside of the
air cleaner housing.
7. Inspect the gasket between the air inlet and the
housing. If the gasket is damaged, replace the
element.
8. Uncover the air inlet opening. Install a new
secondary element.
9. Reinstall the primary air filter element.
Reference: See “Engine Air Filter Primary Element -

Clean/Replace” for more information.
10. Install the air cleaner housing cover.
11. Close the engine access door.
346-6686 Air Cleaner Group D3K2
3. Remove primary filter element (2) from air cleaner

housing (1). In order to remove the engine air filter
primary element, slide the element outward. While
you pull the element outward, rock the element.
4. Remove housing cover to the precleaner body
assembly.
SEBU8498-04 125
Maintenance Section
Engine Air Precleaner - Clean
i04021449 agent. Then, wash the precleaner body with a

spray of water.
Engine Air Precleaner - Clean b. Blow dry the precleaner body completely.
SMCS Code: 1050
5. Install precleaner body (1) into the engine air
precleaner. Latch the precleaner body in place.
6. Install bolts (2). Tighten the bolts to 8 ± 2 N·m
(6 ± 1.5 lb ft) only.
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
i04321550
Engine Crankcase Breather

Element - Replace
SMCS Code: 1317-510-FQ
Hot oil and hot components can cause personal

Illustration 177 g02502123 injury. Do not allow hot oil or hot components to
contact the skin.
1. Open the left engine access cover.
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
NOTICE
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
Illustration 178 g02502196 for tools and supplies suitable to collect and contain
fluids on Cat products.
2. Inspect the engine air precleaner for dirt and for Dispose of all fluids according to local regulations
trash. and mandates.
3. Remove M6 bolts (2) in order to remove the The crankcase breather is a very important
integrated precleaner body (1) completely. component in order to keep your engine emissions
compliant.
4. Use pressurized air to clean the tubes. Put the
tubes on a flat surface. Direct the pressurized air • The filter element within the crankcase breather
into the tubes from the top. This operation loosens must be serviced at the prescribed service
up the dirt. interval.
a. Loosen hard deposits of dust on the precleaner • The correct filter element must be installed before
body by soaking in an appropriate cleaning the engine is operated.
126 SEBU8498-04
Maintenance Section
Engine Crankcase Breather Element - Replace
• The installation of the filter element is very

important.
• The quality of the filter element that is installed is

very important.
For information on aftermarket products, refer to
Operation and Maintenance Manual, “Engine
Description”. Within that section, refer to the title
“Aftermarket Products and Caterpillar Engines”.

(B) Alignment position
Note: The cut away from section (5) in the cap allows
access to the seal.
4. Remove the old seal (4) and install a new seal.

5. Install a new filter element into the breather body
(3) and orient the filter element so that position (A)
Illustration 179 g02477425 is aligned. Refer to illustration 179 . Align position
Typical example (A) on the filter element to position (B) on the cap.
1. Ensure that dirt cannot enter the breather

assembly. Ensure that the outside body of the
breather assembly is clean and free from damage.
Place a container under the breather assembly.
2. Rotate the cap (1) counterclockwise into the
unlocked position. Remove the cap from the body
of the breather (3).
3. Note the orientation of the filter element (2).
Remove the filter element .

Typical example
6. Install the cap (1). Rotate the cap by hand

clockwise until the cap locks into the locked
position C on the breather body.
SEBU8498-04 127
Maintenance Section
Engine Oil Level - Check
Check the System NOTICE

Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
1. Open the engine access door that is on the left

side of the machine.
(1) Connection to breather cap for the engine
(2) Oil drain
(3) Tube assembly to atmosphere
(4) Outlet
Check the system for damage. Replace any

component that is damaged. Ensure that the outlet
(4) is clear and free from obstructions.
i04358109
Engine Oil Level - Check

SMCS Code: 1302; 1318; 1326
Hot oil and components can cause personal

injury.
Do not allow hot oil or components to contact
skin.
NOTICE
Perform this maintenance with the engine stopped.
128 SEBU8498-04
Maintenance Section
Engine Oil Sample - Obtain
i04358613
Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM; 1348; 7542

2. Remove the lower service access door on left side
Illustration 185 g01165836 of the machine. Refer to Operation and
(Y) “Min” mark. (X) “Max” mark. Maintenance Manual, “General Hazard
Information” for information that pertains to
2. Check the dipstick (2) while the engine is stopped. containing fluid spillage.
Maintain the oil level between the “LOW” mark and
the “FULL” mark.
Note: Ensure that the engine is level in order to
obtain a true level indication.
Note: When you operate the machine on severe

slopes, the oil level in the engine crankcase must be
at the “FULL” mark on the dipstick.
3. Remove oil filler cap (1). If necessary, add oil.

4. Clean the oil filler cap and install the oil filler cap.
Note: For the best results, check the engine oil level
after the engine has been off for 2 hours or more. Illustration 187 g02511945
This time will allow all of the oil to drain back into the
engine crankcase. 3. Obtain the regularly scheduled oil sample.
a. Use the oil sampling valve. Refer to Special
Publication, PEHP6001, “How To Take A Good
Oil Sample”.
SEBU8498-04 129
Maintenance Section
Engine Oil and Filter - Change
Reference: See Special Publication, SEBU6250,

“Caterpillar Fluids and Recommendations” “S·O·S Oil
Analysis” and “Sampling Interval and Location of
Sampling Valve” for more information.
i04358749
Engine Oil and Filter - Change

SMCS Code: 1318
Hot oil and components can cause personal

injury.
Do not allow hot oil or components to contact
skin.
4. Open crankcase drain valve (4). Allow the oil to
drain into a suitable container.
NOTICE 5. Remove engine oil filter element (3) and discard
A 500 hour engine oil change interval is available,
the engine oil filter element properly. Make sure
provided that the operating conditions and recom-
mended multigrade oil types are met. When these re- that all of the old filter seal is removed from the
quirements are not met, shorten the oil change filter base.
interval to 250 hours, or use an S·O·S Services oil
sampling and analysis program to determine an ac- 6. Apply a thin coat of clean engine oil to the seal on
ceptable oil change interval. the new filter. Install new engine oil filter element
(3) by hand.
If you select an interval for oil and filter change that is
too long, you may damage the engine. Instructions for the installation of the filters are
printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
2. Remove the lower service access door on the left supplier of the filter.
7. Close crankcase drain valve (4). Replace the
a. Obtain the regularly scheduled oil sample, if crankcase drain access cover that is in the
necessary. crankcase guard.
See Operation and Maintenance Manual, “Engine Oil 8. Remove the oil filler cap (1). Fill the crankcase with
Sample - Obtain” for the proper procedure. new oil. See Operation and Maintenance Manual,
“ Capacities (Refill)”. Clean the oil filler cap and
install the oil filler cap.
9. Always measure the oil level with dipstick (2) in
order to ensure that the correct amount of oil was
added.
3. Remove the crankcase drain access cover, which

is in the crankcase guard.
130 SEBU8498-04
Maintenance Section
Ether Starting Aid Cylinder - Replace
4. Install the new ether starting aid cylinder. Tighten

the ether starting aid cylinder hand tight. Tighten
the cylinder retaining clamp securely.
5. Close the engine access door.
i06060041
Final Drive Oil - Change

SMCS Code: 4050

(Y) Min mark
(X) Max mark
10. On the dipstick, maintain the oil level between the

“ADD” mark and the “FULL” mark.
11. Replace the lower service access door on the left
i02624244
Ether Starting Aid Cylinder -

Replace
SMCS Code: 1456
1. Open the engine access door on the left side of the
machine. 1. Move the machine so that final drive oil level mark
(3) is horizontal. The final drive drain plug (1) is at
the bottom of the final drive.
2. Remove final drive drain plug (1) and allow the oil
to drain into a suitable container.
3. Clean drain plug (1) and replace the plug . Tighten
the drain plug to a torque of 180 ± 27 N·m
(132 ± 20 lb ft).
4. Remove oil filler plug (2). Add oil until the oil is
level with the plug threads. Refer to Operation and
Maintenance Manual, “Lubricant Viscosities” and
Operation and Maintenance Manual, “Capacities
(Refill)”.

5. Clean oil filler plug (2) and install the plug . Tighten
the oil filler plug to a torque of 300 ± 45 N·m
2. Loosen the cylinder retaining clamp. Unscrew the (220 ± 33 lb ft).
empty ether starting aid cylinder and remove the 6. Repeat this procedure for the other final drive.
empty ether starting aid cylinder.
3. Remove the used gasket. Install the new gasket
that is provided with each new ether starting aid
cylinder.
SEBU8498-04 131
Maintenance Section
Final Drive Oil Level - Check
i06060064 i06060080
Final Drive Oil Level - Check Final Drive Oil Sample - Obtain
SMCS Code: 4050 SMCS Code: 3258-008; 4050-008; 7542-008
Oil – See “Lubricant Viscosities” in this Remove the oil filler plug for the final drive. Obtain a
manual for the proper final drive oils. sample of the final drive oil by pulling a sample
through the filler plug opening.
Final Drive Oil Level Mark – Fill the final When the oil sample is completed, clean the plug and
drive with oil until the oil is level with install the plug. Tighten the oil filler plug to a torque of
this horizontal mark. 300 ± 45 N·m (220 ± 33 lb ft).
1. Position the final drive oil level mark at a horizontal Refer to Special Publication, SEBU6250, “Caterpillar
position in order to check the oil level, as shown. Machine Fluids Recommendations” “S·O·S Oil
Analysis” for information that pertains to obtaining a
2. Remove the oil filler plug in order to check the oil sample of the final drive oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
level. Sample” for more information about obtaining a
3. The oil should be level with the bottom of the plug sample of the final drive oil.
threads.
i01942475
4. Clean the plug and install the plug. Tighten the oil
filler plug to a torque of 300 ± 45 N·m Free Spool Drag - Adjust
(220 ± 33 lb ft).
SMCS Code: 5163-025
5. Repeat the procedure for the other final drive.
Adjust the free spool drag to the operator's
preference. For the correct procedure to adjust the
free spool drag, refer to Specifications, Systems
Operation, Testing and Adjusting, Disassembly and
Assembly, “Free Spool - Test” for the winch
hydrostatic systems.
132 SEBU8498-04
Maintenance Section
Front Idler Position - Check/Adjust
i05429511
NOTICE
Front Idler Position - Check/ tained during performance of inspection, mainte-
Adjust Be prepared to collect the fluid with suitable contain-
SMCS Code: 4159-036 ers before opening any compartment or disassem-
See the Testing and Adjusting manual for this
machine for the check and adjustment procedure. Refer to Special Publication, NENG2500, “Dealer
The procedure is for both the Caterpillar SystemOne to collect and contain fluids on Cat products.
undercarriages that have the center tread idler and
SALT undercarriages with a conventional idler. Dispose of all fluids according to local regulations
and mandates.
The SystemOne undercarriage and the SALT
undercarriage require shim adjustment when the If the engine does not start, air may be trapped in the
wear on the link and the bottom roller system is at fuel lines to the engine. Use the following procedure
25%, 50%, and 75%. The adjustment is based on a in order to purge air from the fuel lines.
Custom Track Service (CTS) report.
Reference: Refer to Testing and Adjusting,
Electric Lift Pump
UENR1357, “D3K2, D4K2, D5K2 Track-Type Tractor This machine is equipped with an electric lift pump.
Systems” “Front Idler Position - Check and Adjust”. The electric lift pump is located underneath the
primary fuel filter on the left side of the engine.
i04347810
Note: Do not fill fuel filters before installation in any
Fuel System - Prime circumstance. Do not open high-pressure fuel lines in
order to purge air from the fuel system.
SMCS Code: 1258
1. Ensure that the fuel system is in working order.
Personal injury or death may result from failure

to adhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
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 in-
structions may cause personal injury or death.
Note: When the engine start switch key is turned

to the ON position, priming of the fuel system
begins.
SEBU8498-04 133
Maintenance Section
Fuel System Filter (In-Line) - Replace
2. When the key switch is moved to the ON position

and there is no engine speed present, the electric
lift pump will run for 2 minutes before automatically
stopping . This operation is the automatic fuel
priming feature.
3. The engine fuel system should now be primed and
the engine should now be able to start.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Crank the engine. If the engine does not start, or if

the engine continues to misfire, additional priming
in the key ON position may be necessary. Cycle
the key switch from ON to OFF, the back to ON.
This action will restart the automatic priming
system.
5. Run the engine at the LOW IDLE position until the Illustration 196 g02502123
engine runs smoothly.
2. Open the left engine access door on the machine.
i04900092
Fuel System Filter (In-Line) -

Replace
SMCS Code: 1261-510

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
Be prepared to collect the fluid with suitable contain- Some components are removed for clarity.
ers before opening any compartment or disassem- (A) Fuel pump
bling any component containing fluids. (B) In-line fuel filter
Refer to Special Publication, NENG2500, “Dealer 3. Remove in-line fuel filter (B).
to collect and contain fluids on Cat products. 4. Install the new in-line fuel filter.
Dispose of all fluids according to local regulations 5. Clean up any fuel that remains on any surface
and mandates. area.
1. Turn off the engine.

134 SEBU8498-04
Maintenance Section
Fuel System Secondary Filter - Replace
Note: Do not start the engine until all the necessary Remove the Element
service to the fuel system section is completed. See
the Operation and Maintenance Manual, “Fuel
System - Prime” for the engine starting procedure
that follows service to the fuel system.
6. Start the engine and check the fuel system for

leaks.
7. Close the left engine access door on the machine.
i05383103
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE
Personal injury can result when using cleaner

solvents.
To help prevent personal injury, follow the in-
structions and warnings on the cleaner solvent Illustration 198 g02502123
container before using.
Note: Do not fill fuel filters before installation in any
circumstance. Do not open high-pressure fuel lines in
Personal injury or death can result from a fire. 1. The secondary fuel filter is located on the front of
the engine on the left side. Open the left engine
Fuel leaked or spilled onto hot surfaces or electri- access door.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.

Some components are removed for clarity.
SEBU8498-04 135
Maintenance Section
Fuel System Secondary Filter - Replace
2. Place a suitable container under the fuel filter in

order to catch any fuel that might spill. Clean up
any spilled fuel. Clean the outside of secondary
fuel filter (A).
7. Rotate the filter element counterclockwise and

remove the filter element (5). Clean the filter bowl.
Illustration 200 g02789133 Note: Replace fuel screen (B) on the same schedule
as secondary fuel filter (A).
3. Make a temporary Mark (C) across the filter before
the assembly is removed. Install a suitable tube
onto drain (4). Open the drain valve (3). Rotate the
drain valve counterclockwise. Two full turns are
required. Loosen vent screw (1).
4. Allow the fuel to drain into the container. Remove
the tube.
5. Tighten the vent screw (1) securely.
6. Remove the filter bowl (2). Rotate the filter
assembly counterclockwise in order to remove the
assembly.
136 SEBU8498-04
Maintenance Section
Fuel System Water Separator - Drain
Reference: See Operation and Maintenance 7. Close the left engine access door.
Manual, “Fuel System (In-Line) Filter - Replace” for
instructions. i04317467
Install the Element Fuel System Water Separator -

Drain
SMCS Code: 1263-543; 1263

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
NOTICE
The water separator can be under suction during nor-
mal engine operation. Ensure that the drain valve is
tightened securely to help prevent air from entering
the fuel system.
1. Locate the thread in the filter element (7) onto the NOTICE
threads (8). Spin on the element. Do not tighten. Care must be taken to ensure that fluids are con-
2. Lubricate the O ring seal (6) with clean engine oil. nance, testing, adjusting, and repair of the product.
Do NOT fill the filter bowl (2) with fuel before the Be prepared to collect the fluid with suitable contain-
filter assembly is installed.
3. Do not use a tool in order to install the filter
assembly. Tighten the assembly by hand. Install
the filter bowl (2) and align with your temporary to collect and contain fluids on Cat products.
Marks.
4. Prime the fuel system. Refer to the Operation and and mandates.
Maintenance Manual, “Fuel System - Prime” for
more information.
5. Start the engine. Check for leaks.
6. The primary filter element must be replaced at the
same time as the secondary filter element. Refer
to the Operation and Maintenance Manual , “Fuel
System Water Separator - Replace”.
SEBU8498-04 137
Maintenance Section
Fuel System Water Separator - Replace
7. Close the access door.

If the engine fails to start, change the fuel filter. If
there is a power loss, change the fuel filter.
i05399033
Fuel System Water Separator -

Replace
SMCS Code: 1263
Personal injury or death may result from failure

Illustration 203 g02476878 to adhere to the following procedures.
When the water separator element for the fuel Fuel leaked or spilled onto hot surfaces or electri-
system needs to be drained, an indicator light on the cal components can cause a fire.
dash will be illuminated. The water separator is
located in the compartment on the left side of the Clean up all leaked or spilled fuel. Do not smoke
machine. while working on the fuel system.
Note: Do not fill fuel filters before installation in any Turn the disconnect switch OFF or disconnect
circumstance. Do not open high-pressure fuel lines in the battery when changing fuel filters.
1. Open the left engine access door. NOTICE

2. Place a suitable container under the water tained during performance of inspection, mainte-
separator in order to catch any fuel that might spill. nance, testing, adjusting, and repair of the product.
Clean up any spilled fuel. Be prepared to collect the fluid with suitable contain-
to collect and contain fluids on Cat products.
and mandates.
Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.
3. Place a suitable container under the water
Note: This primary fuel filter has vent screw (1). separator in order to catch any fuel that might spill.
Clean up any spilled fuel. Clean the outside body
3. Install a suitable tube onto drain (2). Loosen vent of the filter assembly.
screw (1).
4. Make a temporary Mark (A) across the filter before
4. Open drain (2). Allow the fluid to drain into the the assembly is removed.
container.
5. Tighten drain (2) by hand pressure only. Remove
the tube and dispose of the drained fluid in a safe
place.
6. Tighten vent screw to 6 N·m (53 lb in).
138 SEBU8498-04
Maintenance Section
Fuel System Water Separator - Replace
9. Rotate the filter element counterclockwise and

remove the filter element (5). Clean the filter bowl.
Install the Element
5. Install a suitable tube onto drain (3). Open the

drain valve (2). Rotate the drain valve
counterclockwise. Two full turns are required.
Loosen vent screw (1).
Note: Two complete rotations of the valve will
release the valve from the filter element.
6. Allow the fuel to drain into the container. Remove

the tube and install the valve into the filter element.
Engage the threads of the valve into the filter
element. Do not secure the valve.
7. Tighten the vent screw (1) securely . Remove the
wiring harness from connection (4).
1. Locate the thread in the filter element (8) onto the

threads (9). Spin on the element. Do not tighten.
2. Lubricate the O ring seal (7) with clean engine oil.
Do NOT fill the bowl with fuel before the assembly
is installed.
3. Do not use a tool in order to install the filter
assembly. Tighten the filter bowl (6) by hand.
Install the filter bowl (6) and align with your
temporary marks (A).
4. Tighten the drain valve (2) securely. Remove the
container and dispose of the fuel in a safe place.
Install the wiring harness to connection (4).
8. Remove the filter bowl (6). Use a standard filter
strap wrench and rotate the filter assembly 5. Turn the fuel supply valve to the ON position.
counterclockwise to remove the assembly. Prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.
6. Start the engine. Check for leaks.
SEBU8498-04 139
Maintenance Section
Fuel Tank Cap - Clean
7. The secondary filter element must be replaced at i04358874

the same time as the primary filter element. Refer
to the Operation and Maintenance Manual , “Fuel Fuel Tank Water and Sediment
System Secondary Filter - Replace”. - Drain
8. Close the left engine access door. SMCS Code: 1273
i04358834
Fuel Tank Cap - Clean

SMCS Code: 1273
1. Slowly, remove fuel tank cap (1) in order to relieve

pressure.
2. Remove plate (2). The drain valve for the fuel tank
is located on the center of the machine below the
Fuel tank cap (1) is located on the left side on the fuel tank.
rear of the machine.
1. Clean fuel tank cap (1) and the surrounding area.
2. Remove the fuel tank cap and disassemble the
fuel tank cap.
3. Inspect the seal for damage. Replace the seal, if
necessary. Lubricate the seal on the fuel tank cap.
4. Replace the element on the fuel tank cap.
5. Assemble the fuel tank cap and install fuel tank
cap (1).
3. Perform the following procedure for a machine with

a winch (if equipped). Remove plate (3). The drain
valve for the fuel tank is located on the left side of
the machine beneath the fuel tank.
Note: Drain the fuel underneath the fuel tank when a

rear attachment is installed on the machine.
140 SEBU8498-04
Maintenance Section
Fuel Tank Water and Sediment - Drain
Some components are removed for clarity. Bottom view
4. Open drain valve (4). Allow the water and the 2. Remove plate (2) under the rear of the machine to
sediment to drain into a suitable container. Close access the remote drain valve for the fire plow
drain valve (4). machine. The drain valve for the fuel tank is
located toward the rear and right side of the
i05056269 machine underneath the fuel tank.
Fuel Tank Water and Sediment

- Drain
(Equipped with Winch or Other
Rear Attachment)
SMCS Code: 1273
Perform the following Fuel Tank and Water
Sediment - Drain" procedure every two weeks for
fire suppression tractors.
Fire Plow Only

Drain valve (3) shown open
3. Remove drain cap from drain line (4). Make sure

that an appropriate drain hose is connected to
drain line (4). Open drain valve (3) . Allow the
water and the sediment to drain into a suitable
container.
1. Slowly, remove fuel tank cap (1) in order to relieve

pressure.
SEBU8498-04 141
Maintenance Section
Fuses - Replace
Note: The fuse panel for this machine is equipped

with all of the available options.
The fuse panel is located on the front panel next to
the right side of the seat.
In order to change the fuses, remove the cover to the
fuse block in the following manner.
• Push the locking tabs on the cover toward the

center of the fuse block.
• Pull the cover away from the fuse block.

Drain valve (3) shown closed
4. Close drain valve (3), remove drain hose and

replace cap on drain line (4). Place the drain hose
into the machine and install plate (2).
i04318020
Fuses - Replace
SMCS Code: 1417
Fuses – Fuses protect the electrical system from
damage that is caused by overloaded circuits.
Replace the fuse if the element separates. If the
element of a new fuse separates, check the circuit.
Repair the circuit, if necessary.

NOTICE
Replace the fuses with the same type and size only. Enclosed ROPS fuse panel
Otherwise, electrical damage can result. (1) Fuse block 1
(2) Fuse block 2
If it is necessary to replace fuses frequently, an elec-
trical problem may exist. Contact your Caterpillar
dealer Enclosed ROPS Fuse Panel
Machine with an enclosed Rollover Protection
System (cab)
Fuse Block 1
Condenser fan 1 (F1) – 20 Amp
Mini breaker
Condenser fan 2 (F2) – 20 Amp

mini circuit breaker
Window wiper for the front window and

front window washer pump (F3) – 15
Amp
Illustration 216 g02506957 Window wiper for the left door (F4) – 15
Access for the fuse panel Amp
142 SEBU8498-04
Maintenance Section
Fuses - Replace
Window wiper for the right door (F5) – 15 Fuse Block 2

Amp
Note: Mini circuit breakers protect the electrical
Rear window wiper and rear window system from damage that is caused by overloaded
washer pump (F6) – 15 Amp circuits. Replace the mini circuit breakers if the
blower fan motor or condenser fans are intermittent
or inoperable. Repair the circuit or replace the
Engine stop (F7) – 15 Amp (engine component, if necessary.
electrical system)
ECM 1 Machine/Service Port (F1) – 15
Amp
Lighting switches (F8) – 10 Amp
Key start switch (F2) – 10 Amp

Power Pitch Blade (9) – 15 Amp
Horn (F3) – 10 Amp

Fuel Pump (F10) – 15 Amp
ECM 2 Attachments (F4) – 15 Amp

Front lights (F11) – 15 amp
Radio (F5) – 10 Amp

Front attachment lights (F12) – 15 Amp
Spares – One 10 Amp (F6), three 15 Amp

(F7, F8, F9) and one 20 Amp (F10) fuses
Rear working lights (F13) – 15 Amp
Open ROPS Fuse Panel

Blower (low, medium) (F14) – 15 Amp
Machine with an Open Rollover Protection System
Power Port (F15) – 10 Amp
Dome light/radio (F16) – 10

Amp
Blade Control 1 (F17) – 15 Amp
Seat (F20) – 20 Amp

SEBU8498-04 143
Maintenance Section
Fuses - Replace
Seat (F20) – 20 Amp
Fuse Block 2 (OROPS)

Note: Mini circuit breakers protect the electrical
system from damage that is caused by overloaded
circuits. Replace the mini circuit breakers if the
blower fan motor or condenser fans are intermittent
or inoperable. Repair the circuit or replace the
Illustration 218 g02508656 component, if necessary.
ECM 1 Machine/Service Port (F1) – 15
Fuse Block 1 (OROPS) Amp
Engine stop (F7) – 15 Amp (engine
electrical system) Key start switch (F2) – 10 Amp
Lighting switches (F8) – 10 Amp

Horn (F3) – 10 Amp
Power Pitch Blade (9) – 15 Amp

ECM 2 Attachments (F4) – 15 Amp
Fuel Pump (F10) – 15 Amp

Spares – Two 10 Amp (F5, F6), three 15
Amp (F7, F8, F9) and one 20 Amp (F10)
fuses
Front lights (F11) – 15 amp
Fuse Panel Behind Cab
Front attachment lights (F12) – 15 Amp There is an additional fuse panel behind the cab
inside the right access door.
Rear working lights (F13) – 15 Amp
Blower (low, medium) (F14) – 15 Amp
Power Port (F15) – 10 Amp
Dome light/radio (F16) – 10

Amp
144 SEBU8498-04
Maintenance Section
Hydraulic System Oil - Change
Glow plugs (C1) – 50 Amp
ECM Engine (C2) – 30 Amp
i04355469

SMCS Code: 5050
Note: S·O·S oil analysis must be performed at every

500 service hours or 3 months in order to extend the
Illustration 219 g02507158 hydraulic oil change interval. The normal hydraulic oil
Enclosed ROPS machine change interval is every 2000 service hours or 1 year.
By performing S·O·S oil analysis, the hydraulic oil
change interval may be extended to 4000 service
hours or 2 years. If S·O·S oil analysis is not available,
the hydraulic oil change interval must remain at every
2000 service hours or 1 year.
At operating temperature, the hydraulic tank is

hot and under pressure.
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to con-
tact skin.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to
Illustration 220 g02508516 touch with your bare hand. Remove the filler cap
Open ROPS machine slowly in order to relieve pressure.
First pair (A) – Two 60 Amp fuses Operate the machine for a few minutes in order to
warm the hydraulic system oil.
Second pair (B) – One 60 Amp fuse and one 40
Amp fuse Park the machine on level ground. Lower all
attachment to the ground. Move the parking brake
Third pair (C) – One 50 Amp fuse and one 30 Amp switch to the ENGAGED position. Stop the engine.
fuse
Note: The Hystat transmission and the hydraulic
This panel has six fuses. In order to change these system use a common tank.
fuses, push down on the locking tab on the fuse
cover. Pull the cover away from the back of the cab. NOTICE
Main cab fuse 1 (A1) – 60 Amp tained during performance of inspection, mainte-
Unswitched battery fuse (A2) – 60 Amp bling any component containing fluids.
Main cab fuse 2 (B1) – 60 Amp to collect and contain fluids on Cat products.
and mandates.
High speed blower (B2) – 40 Amp
SEBU8498-04 145
Maintenance Section
3. Hook a hose up to the drain valve of the hydraulic

tank and drain the hydraulic oil into a suitable
container.
4. Install the oil drain access cover on the bottom
plate .
5. Change the hydraulic system filters. Refer to
Operation and Maintenance Manual, “Hydraulic
System Oil Filter - Replace”.
6. Fill the hydraulic system oil tank. Refer to
Operation and Maintenance Manual, “Lubricant
Viscosities” and Operation and Maintenance
Manual, “Capacities (Refill)”.
Left view of hydraulic tank (oil filler cap)
7. Install the hydraulic cap.

8. Start the engine and run the engine for a few
1. Remove hydraulic tank filler cap that is above the minutes.
access door on the rear of the machine, if
equipped.

Location of sight gauge
9. Open the right rear access door.
2. Remove the oil drain access cover on the bottom
plate.
146 SEBU8498-04
Maintenance Section
Hydraulic System Oil Filter - Replace
Right side view of hydraulic tank

(1) Full mark
1. Hydraulic filter (1) is located on the left side of the
(2) “ADD” mark machine. Open the access door on the left side of
the machine.
10. View the sight gauge inside the right rear access
2. Remove both filter elements with a strap type
door. Maintain the hydraulic oil level above the
wrench, if equipped. Winch filter (2) is for the
“ADD” mark (2) on the sight gauge. Add oil, if
optional winch attachment.
necessary.
3. Clean the filter element mounting bases. Remove
Note: The oil must be free of bubbles. If bubbles are any part of the filter element gasket that remains
present in the oil, air is entering the hydraulic system. on the filter element mounting bases.
Inspect the suction hoses and the hose clamps.
4. Apply a light coat of oil to the gasket of the new
11. Stop the engine. filter elements.
12. If necessary, tighten any loose clamps and any 5. Install the new filter elements by hand.
loose connections. Replace any damaged hoses.
Note: Instructions for the installation of the filters are
13. Close the access door. printed on the side of each Caterpillar spin-on filter.
For non-Caterpillar filters, refer to the installation
i04355635 instructions that are provided by the supplier of the
filter.
Hydraulic System Oil Filter -
Replace
SMCS Code: 5068
Note: The hystat transmission and the hydraulic

system use a common tank.

Location of sight gauge
6. Open the right rear access door.

SEBU8498-04 147
Maintenance Section
Hydraulic System Oil Level - Check
Right side view of hydraulic tank Location of sight gauge

(1) Full mark
(2) “ADD” mark 2. Open the right rear access door.
7. View the sight gauge inside the right rear access

“ADD” mark (2) on the sight gauge. Add oil, if
necessary.

Right side view of hydraulic tank
(1) Full mark
(2) “ADD” mark
Illustration 230 g02510456 3. View the sight gauge inside the right rear access
8. Inspect the gasket on the cap for damage. Replace “ADD” mark (2) on the sight gauge.
the gasket, if necessary.
9. Install the cap .
i04356115
Hydraulic System Oil Level -

Check
SMCS Code: 5056; 7479

1. Park the machine on a level surface before you

check the hydraulic system oil level.
148 SEBU8498-04
Maintenance Section
Hydraulic System Oil Sample - Obtain
Left view of hydraulic tank Sampling valve (1) for the hydraulic system oil is
located on the filter base of the hydraulic oil filter for
the hydraulic system.
Sampling valve (2) for the hydraulic system oil is
located on the filter base of the winch oil filter for the
hydraulic system, if equipped.
Machine Fluids Recommendations” “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the hydraulic oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the hydraulic oil.
i04642249
Illustration 234 g01259742 Hydraulic Tank Breather -

4. Remove hydraulic tank filler cap and add hydraulic
Replace
oil, if necessary. SMCS Code: 5050-510-BRE; 5056-510-BRE; 5118-
510
5. Clean the cap. Install the cap.
The breather filters for the hydraulic tank are located
i04356125 inside the rear “C” posts.
Hydraulic System Oil Sample -

Obtain
SMCS Code: 5095-008

SEBU8498-04 149
Maintenance Section
Oil Filter - Inspect
Spread apart the pleats and inspect the element for

metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This condition could be caused by friction
and by normal wear. Consult your Cat dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage to
Illustration 236 g02787021 engine bearings, to the crankshaft, and to other
parts. This occurrence can result in larger particles in
Two breather assemblies
unfiltered oil. The particles could enter the lubricating
(A) Front view system and the particles could cause damage.
(B) Left view
Open the rear access doors on both sides of the i03182603

machine. Remove the hydraulic lines with the
breather filters. Replace both of the old breather Radiator Core - Clean
filters with a new breather assembly. Make sure that
the hoses are not clogged or kinked. Install each SMCS Code: 1353; 1805; 1810
hydraulic line and breather filter to the original
Inspect the radiator for these items: damaged fins,
position.
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
i04653512
Oil Filter - Inspect

SMCS Code: 1318; 3067; 5068
Inspect a Used Filter for Debris

(1) Radiator core
(2) Hydraulic oil cooler

The element is shown with debris.
150 SEBU8498-04
Maintenance Section
Radiator Pressure Cap - Clean/Replace
i04359492
Radiator Pressure Cap - Clean/

Replace
SMCS Code: 1353-070-Z2; 1353-510-Z2

The radiator grill for the fire plow is shown, if
equipped.
You can use compressed air, high pressure water, or

steam to remove dust and other debris from the
radiator core. However, the use of compressed air is
preferred.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.

Personal injury can result from air pressure.
Personal injury can result without following prop- 1. Open the access panel on top of the engine
er procedure. When using pressure air, wear a compartment.
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction of
the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move
the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.
See Special Publication, SEBD0518, “Know Your
Cooling System” for the complete procedure for
cleaning the radiator core.
2. Slowly loosen pressure cap (1) in order to release

pressure from the cooling system.
SEBU8498-04 151
Maintenance Section
Ripper - Inspect/Replace
3. Remove the pressure cap. 7. Lower the ripper to the ground.

4. Inspect the pressure cap for damage, for deposits,
or for foreign material. Clean the pressure cap with
Shank
a clean cloth. Replace the pressure cap if the cap
is damaged.
5. Install the pressure cap.
i01574318
Ripper - Inspect/Replace
SMCS Code: 6808-510; 6812-510
Tips
When the ripper shank is worn or damaged, replace

the ripper shank.
1. Raise the ripper. Place blocking under the ripper.
Lower the ripper onto the blocking. The ripper
should be high enough so that the ripper shank
can be removed. Do not place the ripper too high.
2. If the shank is worn or damaged, remove cotter pin
(3). Then drive out pin (4). Remove shank (5).

3. Install the new shank and pin (4).
4. Install cotter pin (3).
When the ripper tip is worn close to the shank,
replace the ripper tip. If the tip is too blunt, the tip will 5. Raise the ripper and remove the blocking.
not penetrate properly.
1. Raise the ripper. Place blocking under the ripper.
Lower the ripper onto the blocking. The ripper
should be high enough so that the ripper tip can be
removed. Do not place the ripper too high.
2. If the ripper tip is worn, drive out pin (1). Remove
tip (2) and the shank pin retainer.
3. Clean the shank pin retainer and the pin.
4. Install the new tip and the retainer.
5. Install pin (1) from the opposite side of the retainer.
6. Raise the ripper and remove the blocking.
152 SEBU8498-04
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate
6. Lower the ripper to the ground. i05399089
i02519439 Rollover Protective Structure

Ripper Linkage and Cylinder (ROPS) - Inspect
SMCS Code: 7325
Bearings - Lubricate
SMCS Code: 5352; 6300; 6313

Inspect the Rollover Protective Structure (ROPS) for
bolts that are loose or damaged. Replace any
damaged bolts and any missing bolts with original
1. Lubricate the two fittings (1) for the upper link pin replacement parts only.
on each side of the ripper.
Note: Apply oil to all bolt threads for the ROPS
2. Lubricate two fittings (2) at the top of the cylinder. before you install the ROPS bolts.
Lubricate two fittings (3) at the bottom of the
cylinder. Do not weld reinforcement plates to the ROPS in
order to straighten the ROPS. Do not weld
3. Lubricate two fitting (4) on each side for the lower reinforcement plates to the ROPS in order to repair
link. the ROPS.
Consult your Cat dealer for inspection of any
potential damage or repair of any damage to any
Operator Protective Structure, including ROPS,
FOPS, TOPS, OPS, and OPG. Refer to Special
Instruction, SEHS6929, “Inspection, Maintenance,
and Repair of Operator Protective Structures (OPS)
and Attachment Installation Guidelines for All
Earthmoving Machinery” for more information.
i04423622
Seat Belt - Inspect

SMCS Code: 7327
Always inspect the condition of the seat belt and the
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
SEBU8498-04 153
Maintenance Section
Seat Belt - Replace

Typical Example
(1) Date of installation (retractor)
Typical example (2) Date of installation (buckle)
(3) Year of manufacture (tag) (fully extended web)
Inspect buckle (1) for wear or for damage. If the (4) Year of manufacture (underside) (buckle)
buckle is worn or damaged, replace the seat belt.
Consult your Cat dealer for the replacement of the
Inspect seat belt (2) for webbing that is worn or seat belt and the mounting hardware.
frayed. Replace the seat belt if the webbing is worn
or frayed. Determine age of new seat belt before installing on
seat. A manufacture label is on belt webbing and
Inspect all seat belt mounting hardware for wear or imprinted on belt buckle. Do not exceed install by
for damage. Replace any mounting hardware that is date on label.
worn or damaged. Make sure that the mounting bolts
are tight. Complete seat belt system should be installed with
new mounting hardware.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for Date of installation labels should be marked and
the seat belt extension. affixed to the seat belt retractor and buckle.
Contact your Cat dealer for the replacement of the Note: Date of installation labels should be
seat belt and the mounting hardware. permanently marked by punch (retractable belt) or
stamp (non-retractable belt).
Note: The seat belt should be replaced within 3 years
of the date of installation. A date of installation label If your machine is equipped with a seat belt
is attached to the seat belt retractor and buckle. If the extension, also perform this replacement procedure
date of installation label is missing, replace belt within for the seat belt extension.
3 years from the year of manufacture as indicated on
belt webbing label, buckle housing, or installation
tags (non-retractable belts).
i06891605
Seat Belt - Replace

SMCS Code: 7327-510
The seat belt should be replaced within 3 years of the
date of installation. A date of installation label is
attached to the seat belt retractor and buckle. If the
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on
belt webbing label, buckle housing, or installation
tags (non-retractable belts).
154 SEBU8498-04
Maintenance Section
Track - Check/Adjust
i05032254 idler. Measure the distance from the straight

edge to the grouser tip at the lowest point of
Track - Check/Adjust sag.
SMCS Code: 4170-036; 4170-025 b. Place a tight string or a straight edge on top of
the grousers between the carrier roller and
Check sprocket. Measure the distance from the
straight edge to the grouser tip at the lowest
point of sag.
4. Total the two measurements. Refer to Table 15 in
order to determine the correct sag.
Table 15
Minimum Target Maximum
D3K2, D4K2, 50 mm 60 mm 70 mm
D5k2 (2.0 inch) (2.36 inch) (2.75 inch)
5. If this dimension is not correct, adjust the track.

If the track appears to be too tight or too loose,
proceed to “Track Adjustment”.
Track Adjustment
Check the track adjustment. Check for wear and for
excessive dirt buildup.
If tracks are too tight, wear of the components will
accelerate. If tracks are too loose, wear of the Do not remove any parts until all pressure has
components will accelerate. been relieved to avoid possible personal injury.
Relieve pressure by opening relief valve one turn
1. Move the machine forward for a distance of two maximum. See maintenance guide for track ad-
times the length of the machine. Allow the justment procedure.
machine to stop without the use of the service
brake. Shut off the engine.
2. Stand on the track between the front idler and the
track carrier roller in order to produce as much Grease is under high pressure.
track sag as possible.
Grease coming out of the relief valve under pres-
sure can penetrate the body causing injury or
death.
Do not watch the relief valve to see if grease is es-
caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened.
Loosen the relief valve only one turn.
1. Move the machine forward for a distance of two

times the length of the machine. Allow the
machine to a stop without the use of the service
brakes. Shut off the engine. Adjust the tracks while
you are in the typical operating conditions for the
machine. If packing conditions prevail on the job,
the tracks should be adjusted with packing
material.
3. Measure the track sag in two places on each track.
a. Place a tight string or a straight edge on top of Note: Perform Steps 2 through 6 on both sides of the
machine.
the grousers between the carrier roller and front
SEBU8498-04 155
Maintenance Section
Track Pins - Inspect

Outer cover removed
6. Install the outer cover for the track adjusting
2. Remove the cover for the track adjusting mechanism.
mechanism.
7. Repeat the procedure for the other track.
i06565539
Track Pins - Inspect

SMCS Code: 4175
Fingers can be burned from hot pins and

bushings.
The pins and bushings in a dry joint can become
very hot. It is possible to burn the fingers if there
is more than brief contact with these
components.
Use the recommendations to extend the life of the
3. Remove protection guard (4) for fill and relief valve undercarriage. Use the recommendations to avoid
excessive downtime.
(5).
4. By using a manual grease gun, add multipurpose 1. During the machine operation, listen for unusual
squeaking and for unusual squealing. This noise
grease (MPGM) through fill and relief valve (5) to
can indicate a dry joint.
tighten the track. To loosen the track, turn fill and
relief valve (5) counterclockwise until the idler 2. Check the machine for dry joints weekly. Check for
reverses and the track relaxes. Then, close fill and dry joints immediately after machine operation.
relief valve (5) at the proper track sag dimension After machine operation, use a 164-3310
listed in Table 15 . Infrared Thermometer to check the pins for dry
joints. Make a mark on any dry track pin that is too
5. Install protection guard (4) over fill and relief valve
hot.
(5).
Consult your Caterpillar dealer Custom Track Service
expert if you detect dry joints or leaks. Your
Caterpillar dealer Custom Track Service expert can
perform track inspection.
156 SEBU8498-04
Maintenance Section
Trunnion - Adjust
i02539528
Trunnion - Adjust
SMCS Code: 6060-025-TI

1. Assemble the cap for the trunnion without shims. Trunnion bolts
2. Tighten the bolts and maintain equal spacing on
each side. 7. Tighten the bolts in the following order: 1, 2, 3 and
4.
3. Measure the gap.
i04319828
4. Remove the cap for the trunnion.
5. Add shims in order to fill in the gap. Use the same Winch Cable - Inspect
number of shims on both sides. Then add one
SMCS Code: 5154-040; 5163-040
additional shim to each side.
6. Tighten the bolts.
Bolts . . . . . . . . . . . . . . 530 ± 70 N·m ((390 ± 52 lb ft)) Wear leather gloves when handling the winch
cable.
1. Move the winch control lever to the FREE SPOOL

position.
SEBU8498-04 157
Maintenance Section
Winch Cable - Replace
2. Unreel the winch cable by manually pulling the i04825744

winch cable.
3. Inspect the entire cable for fraying or kinking. If
Winch Drum Bearing -
fraying or kinking is present, replace the winch Lubricate
cable. SMCS Code: 5159-086-BD
i03186277
Winch Cable - Replace

SMCS Code: 5154-510; 5163-510
Wear leather gloves when handling the winch

cable.
NOTICE
Unroll the wire rope cable from the spool. Never lift
the wire rope off the spool in coils.
NOTICE
Use the correct size ferrule for the winch cable in or-
der to attach the winch cable to the load drum. Never
use a knot in order to secure the winch cable to the
load drum.
Table 16
Line Load
Wire Rope Diameter Load Drum(1)
Recommended 16 mm (0.63 inch) 113 m (371 ft)
Optional 19 mm (0.75 inch) 78 m (256 ft)

(1) Capacity
Table 17
Winch Capacity
Apply lubricant to the fittings for the winch drum.
Winch Bare Drum Full Drum
Maximum Line Pull 18144 kg (40000 lb) 11340 kg (25000 lb)
Maximum Line 40 m/min (131 ft/ 63 m/min (207 ft/

Speed min)(1) min)(1)
(1) Maximum line speed is the no-load speed at maximum line pull.
For the correct procedure to replace the winch cable,

refer to Specifications, Systems Operation, Testing
and Adjusting, Disassembly and Assembly, “Cable -
Remove and Install” for the winch hydrostatic
systems.
158 SEBU8498-04
Maintenance Section
Winch Fairlead Rollers - Lubricate
i04461002 4. Refill the winch to the proper level. Install plug (2).
Winch Fairlead Rollers - i04359709
Lubricate Winch Oil Filter - Replace

SMCS Code: 5163-086-RLR
SMCS Code: 5177-510

Apply lubricant to all six of the fairlead grease fittings.
1. Open the access door on the left side of the
i06060110 machine in order to access the winch oil filter. The
winch oil filter is located next to the hydraulic oil
Winch Oil - Change filter.
SMCS Code: 5163-044; 5163 2. Use a strap type wrench to remove the oil filter.
Clean the filter base and dispose of the used filter
1. Park the machine on level ground. properly.
3. Apply a thin coat of oil to the seal of the new filter.
Install a new winch oil filter by hand.
Note: Instructions for the installation of the filters are
printed on the side of each Caterpillar spin-on filter.
For non-Caterpillar filters, refer to the installation
instructions that are provided by the supplier of the
filter.
4. Close the access door.

(1) Oil drain plug
(2) Oil filler plug
2. Remove drain plug (1) and allow the oil to drain in

a suitable container.
Note: To help drain the oil, remove oil filler plug (2).
3. Install plug (1) after all of the oil has been drained.
Tighten plug (1) to a torque of 180 ± 27 N·m
(133 ± 20 lb ft).
SEBU8498-04 159
Maintenance Section
Winch Oil Level - Check
i06060184 i05812007
Winch Oil Level - Check Winch Oil Sample - Obtain

SMCS Code: 5163; 5163-535-FLV SMCS Code: 5163-008; 7542-008
(1) Drain plug Remove the filler plug for the winch. Obtain a sample
(2) Oil filler plug and oil level check
of the winch oil by pulling a sample through the filler
plug opening.
1. Position the machine on a flat, level surface.
2. Inspect the winch for leaks. Repair any leaks. Machine Fluids Recommendations” “S·O·S Oil
3. Remove oil level check plug (2) for a quick check Analysis” for information that pertains to obtaining a
sample of the winch oil. Refer to Special Publication,
of the oil level. PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the
Note: The oil must be filled to the bottom of the port winch oil.
of the oil level check plug.
i04461095
4. Fill the winch case with oil until the oil is at the
proper level.
Winch Vent Plug - Clean
5. Install plug (2). Tighten to a torque of 180 ± 27 N·m
SMCS Code: 5163-070-VN
(133 ± 20 lb ft).
1. Remove the vent plug.

2. Clean the vent plug in a suitable solvent.
3. Install the vent plug.
160 SEBU8498-04
Maintenance Section
Window Washer Reservoir - Fill
Note: Do not replace the vent plug with a solid plug. i04359812
Damage to the winch will occur.
Window Wipers - Inspect/
i04359769
Replace
Window Washer Reservoir - SMCS Code: 7305-510; 7305-040
Fill
SMCS Code: 7306-544-KE
NOTICE
When operating in freezing temperatures, use Cater-
pillar or any commercially available nonfreezing win-
dow washer solvent.
Inspect the front window wiper blade, the right

window wiper blade, the left window wiper blade, and
the rear window wiper blade. Replace any wiper
blades that are damaged or worn. Replace any wiper
blades that streak the window.
i04360149
Windows - Clean
SMCS Code: 7310; 7340
Use commercially available window cleaning
solutions to clean the windows.
Clean the outside of the windows from the ground,

Illustration 265 g01259545 unless handholds are available.
Window Washer – Open the access door

on the left side of the machine. Open the
fluid bottle cap in order to fill the washer
fluid bottle.
SEBU8498-04 161
Maintenance Section
Windows - Clean

Typical example
Cleaning Methods
Aircraft Window Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
Soap and Water

Use a clean sponge or a soft cloth. Wash the
windows with a mild soap or with a mild detergent.
Also use plenty of lukewarm water. Rinse the
windows thoroughly. Dry the windows with a moist
chamois or with a moist cellulose sponge.
Stubborn Dirt and Grease

Wash the windows with a good grade of naphtha, of
isopropyl alcohol, or of Butyl Cellosolve. Then, wash
the windows with soap and with water.
Polycarbonate Windows (If

equipped)
Wash polycarbonate windows with a mild soap or
detergent. Never use a cleaning solvent on
polycarbonate windows.
Wash polycarbonate windows with warm water and a
soft sponge, or damp cloth. Never use a dry cloth or
paper towels on polycarbonate windows.
Rinse the windows with a sufficient amount of clean
water.
162 SEBU8498-04
Warranty Section
Warranty Information
Warranty Section 3. New non-road diesel engines installed in

construction machines conforming to the South
Korean regulations for construction machines
Warranty Information manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
i06044323 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 liters per cylinder (including applicable emission standards for the warranty
Tier 1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) The aftertreatment system can be expected to
operated and serviced in the United States and function properly for the lifetime of the engine
Canada, including all parts of their emission (emissions durability period) subject to prescribed
control systems (“emission related components”), maintenance requirements being followed.
are:
A detailed explanation of the Emission Control
a. Designed, built, and equipped so as to conform, Warranty that is applicable to new non-road and
at the time of sale, with applicable emission stationary diesel engines, including the components
standards prescribed by the United States covered and the warranty period, is found in a
supplemental Special Publication. Consult your
Environmental Protection Agency (EPA) by way authorized Cat dealer to determine if your engine is
of regulation. subject to an Emission Control Warranty and to
obtain a copy of the applicable Special Publication.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
SEBU8498-04 163
Reference Information Section
Reference Materials
Reference Information • Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog”
Section • Special Publication, SEBU7803, “Grade Control
System”
Reference Materials • Special Publication, SEBU6981, “Emissions
Control Warranty Information”
i05399099
• Operation and Maintenance Manual, SEBU8257,
Reference Material “The European Union Physical Agents (Vibration)
Directive 2002/44/EC”
SMCS Code: 1000; 7000
The following literature can be obtained from any Cat “AccuGrade - Laser System ”
dealer:
• Special Publication, SEBD0518, “Know Your “AccuGrade - GPS (CD700) ”
Cooling System”
• Safety Manual, SEBU5311, “Crawler Tractor/
• Special Publication, SEBD0970, “Coolant and Loader Safety Manual AEM Form CLT80-1 ”
Your Engine”
• Specifications, SENR3130, “Torque
• Service Magazine, SEBD1587,28 October 1985, Specifications”
“What ROPS/FOPS Certification Means”
• Service Manual, RENR2014, “Caterpillar
• Special Instruction, SEHS6929, “Inspection, Monitoring System”
Maintenance, and Repair of Operator Protective
Structures (OPS) and Attachment Installation • Service Manual, KENR5640, “D3K, D4K, and D5K
Guidelines For All Earthmoving Machines, If Track-Type Tractor (Tier IV Interim)”
Equipped”
• D3K2 Parts Manual, SEBP5912,
• Special Publication, SEBD0717, “Diesel Fuels and S/N: KFF1–UP; KLL1–UP; GAE1–UP
Your Engine”
• Special Instruction, SEHS7392, “Storage of Diesel S/N: KMM1–UP; KRR1–UP
Engines”
• Special Instruction, SEHS7633, “Battery Test S/N: KWW1–UP; KYY1–Up; TRF1–Up
Procedure”
Operation and Maintenance Manuals are available in
• Special Instruction, SEHS7633, “6V-2150 Starting/ other languages. Consult your Caterpillar dealer for
Charging Analyzer Group” information about obtaining these Operation and
Maintenance Manuals.
• System Operation, Troubleshooting, Testing and
Adjusting, RENR8143, “Product Link PL522/523” Additional Reference Material
• Special Instruction, REHS2368, “An Installation ASTM D2896, “TBN Measurements” This reference
Guide for the Product Link PL522/523” can normally be obtained from your local
technological society, from your local library, or from
• Special Instruction, REHS1642, “Operation of the your local college.
Product Link System”
SAE J313, “Diesel Fuels” This reference can be
• Special Instruction, SEHS9031, “Storage found in the SAE handbook. Also, this publication
Procedure for Caterpillar Products” can be obtained from your local technological society,
from your local library, or from your local college.
• Special Publication, SEBU5898, “Cold Weather
Recommendations for All Caterpillar Machines” SAE J754, “Nomenclature” This refence can normally
be found in the SAE handbook.
• Special Publication, SEBD0640, “Oil and Your SAE J183, “Classification” This reference can
Engine” normally be found in the SAE handbook.
• Special Publication, SEBU6250, “Caterpillar Engine Manufacturers Association, “ Engine Fluids
Machine Lubricant Recommendations” Data Book”
164 SEBU8498-04
Caterpillar Approved Work Tools
Engine Manufacturers Association (Table 18, contd)

Two North LaSalle Street, Suite 2200 Blade width XL LGP XL LGP XL LGP
Chicago, Illinois, USA 60602 3
E-mail: [email protected] VPAT (2)1.52 m X
(1.99 yd3) 2646 mm
(312) 644-6610
(104.2 inch)
Facsimile: (312) 827-8737
VPAT 1.66 m3 X
The “Society of Automotive Engineers (SAE) (2.17 yd3) 3149 mm
Specifications” can be found in your SAE handbook. (124 inch)
This publication can also be obtained from the
following locations: local technological society, local VPAT 1.42 m3 X X
library and local college. If necessary, consult SAE at (1.86 yd3) 2921 mm
the following address: (115 inch)
VPAT 1.98 m3 X
SAE International (2.59 yd3) 2782 mm
400 Commonwealth Drive (109.5 inch)
Warrendale, PA, USA 15096-0001
Telephone (724) 776-4841 VPAT 1.85 m3 X
(2.42 yd3) 3149 mm
The International Organization for Standardization (124 inch)
(ISO) offers information and customer service
VPAT 2.19 m3 X
regarding international standards and standardizing
(2.86 yd3) 2886 mm
activities. ISO can also supply information on the (113.6 inch)
following subjects that are not controlled by ISO:
national standards, regional standards, regulations, VPAT 2.34 m3 X
certification and related activities. Consult the (3.06 yd3) 3220 mm
member of ISO in your country. (126.7 inch)
International Organization for Standardization VPAT 2.19 m3 X

(ISO) (2.86 yd3) (Forestry
1, rue de Varembé product) 2886 mm
(113.6 inch)(3)
Case postale 56
CH-1211 Genève 20 VPAT 2.09 m3 X
Switzerland (2.73 yd3) 2921 mm
Telephone +41 22 749 01 11 (115 inch)
Facsimile +41 22 733 34 30
Rear Work Tool
E-mail [email protected]
web site http://www.iso.ch Small Track-Type X X X X X X
Tractor Ripper
i07489788
Small Track-Type X X X X X X
Caterpillar Approved Work Tractor Retrieval
Winch
Tools Premium Winch X X X X X X
SMCS Code: 6700; 7007
D3K2 Mulcher X X
Only use Caterpillar approved work tools on this (1) All front work tools are approved for all models that are shown.
machine. The chart indicates factory recommendation for usage.
(2) VPAT blade is variable pitch, power angle and tilt
(3) Includes brush guard and thicker moldboard liner
Note:
Do not use a Caterpillar work tool on a machine that See “Specifications” in this manual for additional
is not approved by Caterpillar. information on the machine specifications or
Table 18 configurations.
Caterpillar Approved Work Tools Contact your Caterpillar dealer concerning specific
work tools that are approved by Caterpillar for this
Front Work Tool(1) D3K2 D4K2 D5K2
machine. Consult your Caterpillar dealer for an
updated list of approved work tools.
(continued)
SEBU8498-04 165
Decommissioning and Disposal
i03989612
Decommissioning and
Disposal
SMCS Code: 1000; 7000
When the product is removed from service, local
regulations for the product decommissioning will
vary. Disposal of the product will vary with local
regulations. Consult the nearest Cat dealer for
additional information.
166 SEBU8498-04
Index Section
Index
A Capacities (Refill) .......................................... 106
Caterpillar Approved Work Tools................... 164
Additional Messages ....................................... 14
Condenser (Refrigerant) - Clean....................115
Adjustments..................................................... 85
Cooling System Coolant (ELC) - Change ......116
Alternate Exit ................................................... 44
Cooling System Coolant Level - Check..........118
Cooling System Coolant Sample (Level 1) -
Equipped)................................................... 44
Obtain ...........................................................118
Hammer (If Equipped) ................................. 45
Cooling System Coolant Sample (Level 2) -
Rear Window with Lever (If Equipped) ........ 44
Obtain ...........................................................119
Rear Window with Ring Seal (If
Cooling System Water Temperature
Equipped)................................................... 44
Regulator - Clean/Replace .......................... 120
Alternator and Fan Belts - Replace ................110
Crushing Prevention and Cutting Prevention.. 20
Cutting Edges and End Bits ............................ 87
B Cutting Edges and End Bits - Inspect/
Backup Alarm .................................................. 72 Replace ....................................................... 121
Backup Alarm - Test .......................................110
Battery - Inspect .............................................110 D
Battery - Recycle ............................................110
Daily Inspection ............................................... 42
Battery Disconnect Switch .............................. 72
Declaration of Conformity................................ 40
Checking the Battery Disconnect System ... 72
Decommissioning and Disposal.................... 165
Battery or Battery Cable - Inspect/Replace.... 111
Diesel Particulate Filter Regeneration ............ 71
Before Operation ....................................... 26, 42
DPF Light On ............................................... 71
Before Starting Engine .................................... 26
Regeneration ............................................... 71
Belt Tensioner - Inspect..................................112
Soot Level Monitoring.................................. 71
Belts - Inspect.................................................112
Inspect ........................................................112
Brakes, Indicators and Gauges - Test ............113 E
Braking System (Test) ................................113 Electrical Storm Injury Prevention ................... 25
Bulldozer Blade Pitch ...................................... 85 Emissions Certification Film ............................ 41
Manual Adjustment of Bulldozer Blade Emissions Warranty Information ................... 162
Pitch ........................................................... 85 Engine Air Filter Primary Element - Clean/
Power Adjustment of Bulldozer Blade Replace ....................................................... 122
Pitch ........................................................... 86 Cleaning Primary Air Filter Elements ........ 123
Bulldozer Power Angling Tilt Hinge Pins - Inspecting the Primary Air Filter
Lubricate.......................................................114 Elements .................................................. 123
Burn Prevention............................................... 20 Engine Air Filter Secondary Element -
Batteries....................................................... 21 Replace ....................................................... 123
Coolant ........................................................ 21 Engine Air Precleaner - Clean....................... 125
Induction System ......................................... 21 Engine and Machine Warm-Up ....................... 84
Oils............................................................... 21 Engine Crankcase Breather Element -
Replace ....................................................... 125
C Check the System...................................... 127
Engine Oil and Filter - Change ...................... 129
Cab Filter (Fresh Air) - Clean/Inspect/
Engine Oil Level - Check............................... 127
Replace (If Equipped)...................................114
Engine Oil Sample - Obtain........................... 128
Engine Starting.......................................... 26, 83
Equipped)..................................................115
Starting Aid (If Equipped) ............................ 83
Cab Filter (Recirculation) - Clean/Inspect/
Engine Starting (Alternate Methods)............... 98
Replace ........................................................115
SEBU8498-04 167
Index Section
Engine Starting with Jump Start Cables ......... 98 Fuse Panel Behind Cab............................. 143
Use of Jump Start Cables............................ 98 Open ROPS Fuse Panel ........................... 142
Engine Stopping .............................................. 28
Equipment Lowering with Engine Stopped ..... 29 G
(Electrohydraulic Implement Valve)............... 89 General Hazard Information............................ 17
Dead Engine Lower ..................................... 89 Containing Fluid Spillage............................. 19
Ether Starting Aid Cylinder - Replace ........... 130 Dispose of Waste Properly .......................... 20
Fluid Penetration ......................................... 18
Inhalation ..................................................... 19
F
Pressurized Air and Water........................... 18
Final Drive Oil - Change ................................ 130 Trapped Pressure ........................................ 18
Final Drive Oil Level - Check......................... 131 General Information ........................................ 34
Final Drive Oil Sample - Obtain..................... 131 Guards............................................................. 32
Fire Extinguisher Location............................... 25 Guards (Operator Protection)
Fire Prevention and Explosion Prevention...... 21 Other Guards (If Equipped) ......................... 32
Battery and Battery Cables.......................... 23 Rollover Protective Structure (ROPS), Falling
Ether ............................................................ 24 Object Protective Structure (FOPS) or Tip
Fire Extinguisher.......................................... 24 Over Protection Structure (TOPS)............. 32
General ........................................................ 21
Lines, Tubes, and Hoses ............................. 24 H
Wiring........................................................... 23
Fire Safety ....................................................... 24 Hydraulic System Oil - Change ..................... 144
Foreword ........................................................... 4 Hydraulic System Oil Filter - Replace ........... 146
California Proposition 65 Warning ................. 4 Hydraulic System Oil Level - Check.............. 147
Certified Engine Maintenance ....................... 5 Hydraulic System Oil Sample - Obtain.......... 148
Literature Information .................................... 4 Hydraulic Tank Breather - Replace ............... 148
Machine Capacity .......................................... 5
Maintenance .................................................. 4 I
Operation ....................................................... 4
Identification Information ................................. 36
Product Identification Number ....................... 5
Important Safety Information............................. 2
Safety............................................................. 4
Free Spool Drag - Adjust............................... 131
Front Idler Position - Check/Adjust................ 132 L
Fuel System - Prime ...................................... 132 Leaving the Machine ....................................... 91
Electric Lift Pump....................................... 132 Lifting and Tying Down the Machine ............... 95
Fuel System Filter (In-Line) - Replace .......... 133 Tie-Down Points For Fire Plow Machines (If
Fuel System Secondary Filter - Replace ...... 134 Equipped)................................................... 95
Install the Element ..................................... 136 Lubricant Viscosities (Fluids
Remove the Element ................................. 134 Recommendations) ..................................... 100
Fuel System Water Separator - Drain ........... 136 Biodiesel .................................................... 105
Fuel System Water Separator - Replace ...... 137 Coolant Information ................................... 105
Install the Element ..................................... 138 Diesel Fuel Recommendations ................. 104
Remove the Element ................................. 137 Engine Oil .................................................. 100
Fuel Tank Cap - Clean................................... 139 Fuel Additives ............................................ 105
Fuel Tank Water and Sediment - Drain ......... 139 General Information for Lubricants............ 100
Fuel Tank Water and Sediment - Drain Hydraulic Systems..................................... 101
(Equipped with Winch or Other Rear Selecting the Viscosity............................... 100
Attachment) ................................................. 140 Special Applications .................................. 103
Fire Plow Only ........................................... 140 Special Lubricants ..................................... 103
Fuses - Replace ............................................ 141 Transmission, Axles, Final Drive ............... 102
Enclosed ROPS Fuse Panel ..................... 141
168 SEBU8498-04
Index Section
Lubricant Viscosities and Refill Capacities ... 100 Air Conditioning and Heating Control (2)..... 50
Air Suspension Seat (25)............................. 67
M AM/FM/CD Radio (7) (If equipped).............. 61
Armrest Adjustments (1).............................. 50
Machine Operation .......................................... 44 Bulldozer Control (11) .................................. 62
Maintenance Interval Schedule..................... 108 Cab Door Release Lever (8)........................ 61
Every 10 Service Hours or Daily................ 108 Cab Door Release Lever (9)........................ 61
Every 100 Service Hours or 2 Weeks........ 108 Control Panel for the AccuGrade Machine
Every 12 000 Service Hours or 6 Years..... 108 Control (Laser and GPS) (If equipped) ..... 68
Every 1500 Service Hours......................... 109 Decelerator/Brake Pedal (4) ........................ 56
Every 2000 Service Hours......................... 109 Engine Start Switch (10).............................. 61
Every 250 Service Hours or Monthly ......... 108 Engine Throttle Control (13) ........................ 63
Every 3 Years............................................. 109 Gauges and Indicators (5) ........................... 57
Every 3000 Service Hours......................... 109 Heated Joystick Switch (20) (If Equipped) .. 66
Every 50 Service Hours or Weekly............ 108 Hydraulic Lockout (15)................................. 65
Every 500 Service Hours ........................... 109 Mirror (6) ...................................................... 61
Every 500 Service Hours or 1 Year ........... 109 Parking Brake Switch (14) ........................... 64
Every 500 Service Hours or 6 Months....... 109 Pocket in Seat Back (27) ............................. 68
Initial 250 Service Hours............................ 108 Power Receptacle (26) ................................ 68
Initial 500 Hours (for New Systems, Refilled Right Operator Console............................... 63
Systems, and Converted Systems) ......... 109 Stable Blade Control (16) ............................ 65
When Required.......................................... 108 Steering and Transmission Control (3)........ 51
Maintenance Section..................................... 100 Vandalism Guard (10A) (If Equipped) ......... 62
Maintenance Support .................................... 107 Winch Controls or Ripper Controls (21) ...... 66
Mirror ............................................................... 47 Window Wiper and Window Washer (17) (18)
Mirror Adjustment ........................................ 47 (19) (If Equipped) ....................................... 65
Monitoring System........................................... 73 Operator Station .............................................. 32
Alert Indicators............................................. 73
Compact Instrument Cluster........................ 75
P
Functional Test............................................. 73
Gauges ........................................................ 75 Parking ...................................................... 27, 88
Indicators ..................................................... 74 Plate Locations and Film Locations ................ 36
Menu Screens.............................................. 76 Certifications ................................................ 38
Warning Categories ..................................... 73 European Union........................................... 39
Mounting and Dismounting ............................. 42 Product Identification Plates ........................ 36
Sound Certification ...................................... 38
O Prestart Checks............................................... 82
Product Information Section............................ 34
Oil Filter - Inspect .......................................... 149 Product Link .................................................... 77
Inspect a Used Filter for Debris ................. 149 Data Broadcasts .......................................... 78
Operation......................................................... 27 Operation in a Blast Site for Product Link
Machine Operating Temperature Range ..... 27 Radios ........................................................ 78
Operation ..................................................... 27
Operation Information ..................................... 79
R
Hydrostatic Drive Operating Principle ......... 79
Operating Principle for the Winch................ 80 Radiator Core - Clean ................................... 149
Using the Winch........................................... 81 Radiator Pressure Cap - Clean/Replace....... 150
Warm-Up Procedure for the Winch ............. 81 Reference Information Section ..................... 163
Operation Section............................................ 42 Reference Material ........................................ 163
Operator Controls............................................ 49 Additional Reference Material ................... 163
Additional Features of Fire Suppression Reference Materials ...................................... 163
Arrangement (If Equipped) ........................ 68 Ripper - Inspect/Replace............................... 151
SEBU8498-04 169
Index Section
Shank......................................................... 151 Engine Start Switch Key ON or OFF ........... 88

Tips ............................................................ 151 Stopping the Machine...................................... 88
Ripper Linkage and Cylinder Bearings -
Lubricate...................................................... 152 T
Ripper Tip and Shank Protector ...................... 86
Rollover Protective Structure (ROPS) - Table of Contents .............................................. 3
Inspect ......................................................... 152 Towing Information .......................................... 97
Towing the Machine......................................... 97
Track - Check/Adjust ..................................... 154
S
Check......................................................... 154
S·O·S Information ......................................... 106 Track Adjustment....................................... 154
Safety Messages............................................... 6 Track Information ............................................ 25
Blade and Mast............................................ 13 Track Pins - Inspect....................................... 155
Do Not Operate (1) ........................................ 9 Transportation Information .............................. 92
Do Not Operate (10) (Winch)....................... 12 Trunnion - Adjust ........................................... 156
Do Not Weld On the ROPS/FOPS (3) ........... 9
High Pressure Cylinder (7) ...........................11 V
High Pressure Fuel Lines (6)........................11
Hot Fluid Under Pressure (8)........................11 Visibility Information ........................................ 26
Improper Connections for Jump Start Cables
(9)................................................................11 W
Laser ............................................................ 12
Warranty Information..................................... 162
No Ether in Air Inlet (5) ................................ 10
Warranty Section ........................................... 162
Product Link (4) (if equipped) ...................... 10
Welding on Machines and Engines with
Seat Belt (2) ................................................... 9
Electronic Controls ...................................... 107
Safety Section ................................................... 6
Winch Cable - Inspect ................................... 156
Seat ................................................................. 45
Winch Cable - Replace.................................. 157
Seat Belt .......................................................... 46
Winch Drum Bearing - Lubricate ................... 157
Extension of the Seat Belt ........................... 47
Winch Fairlead Rollers - Lubricate ................ 158
Seat Belt Adjustment for Retractable Seat
Winch Oil - Change ....................................... 158
Belts ........................................................... 46
Winch Oil Filter - Replace.............................. 158
Seat Belt - Inspect ......................................... 152
Winch Oil Level - Check ................................ 159
Seat Belt - Replace ....................................... 153
Winch Oil Sample - Obtain ............................ 159
Shipping the Machine...................................... 92
Winch Vent Plug - Clean ............................... 159
Calculating the Mass of the Machine........... 92
Window Washer Reservoir - Fill .................... 160
Slope Operation .............................................. 28
Window Wipers - Inspect/Replace ................ 160
Sound Information and Vibration
Windows - Clean ........................................... 160
Information..................................................... 29
Cleaning Methods...................................... 161
Cab Internal Clearance................................ 31
Polycarbonate Windows (If equipped) ...... 161
Sound Level Information.............................. 29
Sound Performance for Machines that are
Offered in European Union Countries and in
Countries with the “EU Directives”............. 29
Sources........................................................ 31
“The European Union Physical Agents
(Vibration) Directive 2002/44/EC”.............. 29
Specifications .................................................. 34
Intended Use ............................................... 35
Stopping the Engine ........................................ 88
Stopping the Engine if an Electrical
Malfunction Occurs........................................ 88
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
SEBU8498 CAT, CATERPILLAR, LET’S DO THE WORK, their respective
©2019 Caterpillar logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat
All Rights Reserved “Modern Hex” trade dress as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used
without permission.
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Scan to find and purchase genuine Cat® parts and related

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents General Information ........................................ 34

Identification Information ................................. 36

Safety Section Operation Section

Before Operation ............................................. 42

Track Information ............................................ 25 Maintenance Section

Before Starting Engine .................................... 26 Maintenance Support .................................... 107

Engine Starting................................................ 26 Maintenance Interval Schedule..................... 108

Before Operation ............................................. 26 Warranty Section

Visibility Information ........................................ 26 Warranty Information..................................... 162

Operation......................................................... 27 Reference Information Section

Parking ............................................................ 27 Reference Materials ...................................... 163

Slope Operation .............................................. 28 Index Section

Engine Stopping .............................................. 28 Index.............................................................. 166

Equipment Lowering with Engine Stopped ..... 29

Sound Information and Vibration Information . 29

Operator Station .............................................. 32

Guards (Operator Protection) ......................... 32

Product Information Section

Foreword Whenever a question arises regarding your machine,

It is prohibited for any person engaged in the

Product Identification Number

There are several specific safety messages on this

Replace any safety message that is damaged or

Do Not Operate (1)

Illustration 7 g02391415 Illustration 8 g01108685

Product Link (4) (if equipped) No Ether in Air Inlet (5)

Illustration 9 g01055438 Illustration 11 g01357122

Hot Fluid Under Pressure (8)

Pressurized system: Hot coolant can cause seri-

Illustration 13 g01055411 Illustration 14 g01055734

Refer to Operation and Maintenance Manual,

Illustration 15 g01282876 Illustration 16 g01282878

Blade and Mast

There are several specific messages on this

Required Engine Oil (2)

Do not step on the angle cylinders. Follow this

Refer to Operation and Maintenance Manual, Radio (4)

Batteries in Parallel Configuration (7)

General Hazard Information

Operating the machine while distracted can result

Know the width of your equipment to maintain proper

When you perform maintenance above ground level,

Pressurized Air and Water

Obey all local regulations for the disposal of liquids.

Always use a board or cardboard when you check for

• Never use compressed air for cleaning.

• Avoid grinding materials that contain asbestos.

Crushing Prevention and

Induction System Do not smoke while checking the battery electrolyte

Clean all accumulations of flammable materials such

Never store flammable fluids in the operator • Abrasion

• Flexible parts of the hoses are kinked. Fire Safety

Note: Locate fire extinguishers and how to use a fire

If you find that you are involved in a machine fire, i01834364