SEBU7763-02

May 2007

Operation and
Maintenance
Manual
D8T Track-Type Tractor
KPZ1-Up (Machine)
J8B1-Up (Machine)

Differential Steering
 i01658146

Important Safety Information

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

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.
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. 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
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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. Caterpillar dealers have the most current information available.

When replacement parts are required for this

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

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU7763-02 3
Table of Contents

Table of Contents Operating Techniques ........................................... 88

Adjustments .......................................................... 94
Foreword ................................................................. 4
Parking .................................................................. 97
Safety Section Transportation Information .................................. 101
Safety Messages (D8T Track-Type Tractor ) .......... 6
Towing Information .............................................. 103
Additional Messages ............................................. 16
Engine Starting (Alternate Methods) ................... 108
General Hazard Information ................................. 17
Maintenance Section
Crushing Prevention and Cutting Prevention ........ 19
Cooling System Specifications ............................ 111
Burn Prevention .................................................... 20
Lubricant Viscosities and Refill Capacities .......... 112
Fire Prevention and Explosion Prevention ............ 20
Maintenance Support ........................................... 117
Fire Extinguisher Location .................................... 22
Maintenance Interval Schedule ........................... 118
Track Information .................................................. 22
Reference Information Section
Electrical Storm Injury Prevention ......................... 23
Reference Materials ............................................ 182
Before Starting Engine .......................................... 23
Index Section
Engine Starting ..................................................... 23
Index ................................................................... 183
Before Operation .................................................. 23

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

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

Parking .................................................................. 25

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

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

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

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

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

Product Information Section

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

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

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

Machine Operation ............................................... 38

Engine Starting ..................................................... 85

4 SEBU7763-02
Foreword
Foreword
Literature Information
This manual should be stored in the operator’s
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your machine. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine,
or this publication, please consult your Caterpillar
dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep
the engine and machine systems operating correctly.
As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
SEBU7763-02 5
Foreword

It is prohibited for any person engaged in the 3. Check Character (character 9)

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or
render inoperative any emission related device or
element of design installed on or in an engine or
machine that is in compliance with the regulations
(40 CFR Part 89). Certain elements of the machine
and engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may be emission related and should not be
altered unless approved by Caterpillar.
Machine Capacity
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Machines and generator sets produced before First
Quarter 2001 will maintain their 8 character PIN
format.
Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Serial Number (S/N).

Additional attachments or modifications may exceed

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

Caterpillar Product Identification

Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:

g00751314
Illustration 1

Where:

1. Caterpillar’s World Manufacturing Code

(characters 1-3)

2. Machine Descriptor (characters 4-8)

6 SEBU7763-02
Safety Section
Safety Messages

Safety Section
i02696213

Safety Messages
(D8T Track-Type Tractor )
SMCS Code: 7000; 7405

g01074770
Illustration 2
SEBU7763-02 7
Safety Section
Safety Messages

g01352591
Illustration 3

There are several specific safety messages on this

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

Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
the illustrations if the illustrations are not visible.
When you clean the safety messages, use a cloth,
water, and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
g01352573
the adhesive that secures the safety message. Loose
Illustration 4 adhesive will allow the safety message to fall.
8 SEBU7763-02
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 in the cab beneath
the left window.
g00930652
Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
Hot Fluid Under Pressure (2)
Safety Message (2) is located under the access door
to the radiator cap.
g01067344
Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.
Seat Belt (3)
Safety Message (3) is positioned on the cab post
above the differential steering control..
g01067563
A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
SEBU7763-02
Electrical Shock Hazard (4)
Safety Message (4) is located on the inside face of
the fuse panel.
g01108645
WARNING! Shock/Electrocution Hazard! Read and
understand the instructions and warnings in the
Operation and Maintenance Manual. Failure to fol-
low the instructions or heed the warnings could
cause serious injury or death.
Refer to Operation and Maintenance Manual, “Fuses
and Circuit Breakers - Replace/Reset”.
9
Safety Section
Safety Messages
High Pressure Cylinder (5)
Safety message (5) is on top right side of the valve
cover plate in the middle of the fuel tank. Safety
message (5) can also be found behind the cab seat
on the back cover plate.
g01058237
Personal injury or death can result from grease
under pressure.
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 one turn only.
If track does not loosen, close the relief valve and
contact your Caterpillar dealer.
10 SEBU7763-02
Safety Section
Safety Messages

Accumulator (6) Improper Connections for Jump

Safety Message (6) is on the accumulator cylinder
Start Cables (7)
on the right side of the hydraulic valve stack at the
Safety Message (7) is in the battery compartment.
middle of the fuel tank.

g01067366
g01024378

Explosion Hazard! Improper jumper cable connec-

High pressure cylinder. Rapid discharging from
disconnecting or disassembly can result in per-
sonal injury or death. See your Caterpillar dealer
for tools and instructions for relieving pressure or
charging. Precharge only with nitrogen gas.
tions can cause an explosion resulting in serious
injury or death. Batteries may be located in sep-
arate compartments. Refer to the Operation and
Maintenance Manual for the correct jump starting
procedure.

Refer to Operation and Maintenance Manual, “Engine

Staring with Jump Start Cables”.
SEBU7763-02
Compressed Recoil Spring (8)
Safety Message (8) is located inside the track roller
frames.
g01108669
Personal injury or death can result from a com-
pressed recoil spring being released suddenly us-
ing incorrect disassembly procedures.
A recoil spring that is still held in compression
can result in the recoil spring being released un-
expectedly with extreme force which could cause
serious injury or death.
Make sure that the correct disassembly procedure
is used, if a front track roller frame that has a crack
in the parent metal or weld connection (or a tubu-
lar section that has separated from the front of
the frame assembly) when the recoil spring is still
held in compression.
Refer to Special Instruction, SMHS8273 which
contains the disassembly procedure that must be
used to decrease the possibility of injury while
performing service on the track roller frame.
11
Safety Section
Safety Messages
Compressed Recoil Spring (9)
Safety message (9) is located inside the covers for
the guides for the track roller frames.
g01078108
Personal injury or death can result from a com-
pressed recoil spring being released suddenly us-
ing incorrect disassembly procedures.
A recoil spring that is still held in compression
can result in the recoil spring being released un-
expectedly with extreme force which could cause
serious injury or death.
Make sure that the correct disassembly procedure
is used, if a front track roller frame that has a crack
in the parent metal or weld connection (or a tubu-
lar section that has separated from the front of
the frame assembly) when the recoil spring is still
held in compression.
Refer to Special Instruction, SMHS8273 which
contains the disassembly procedure that must be
used to decrease the possibility of injury while
performing service on the track roller frame.
12 SEBU7763-02
Safety Section
Safety Messages

High Pressure Cylinder (10) Product Link (11) (if equipped)

Safety Message (10) is attached to the inside of the Safety message (11) is located in the right side of the
cover for each recoil spring compartment. cab on the rear support.

g01058237 g01108685

Personal injury or death can result from grease
under pressure.
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.
This machine is equipped with a Caterpillar
Product Link radio communication device which
must be deactivated within 6.0 m (20 ft) of a blast
zone. Failure to do so could result in serious
injury or death.
Refer to Special Instruction, REHS1642, “Operation
of the Product Link System” for additional information.

Loosen the relief valve one turn only.

If track does not loosen, close the relief valve and

contact your Caterpillar dealer.

Refer to the Operation and Maintenance Manual,

“Track - Check/Adjust” for additional information.
SEBU7763-02
Do Not Weld On The FOPS (12)
Safety message (12) is positioned on the outside
right of the cab.
g01077753
Structural damage, an overturn, modification, al-
teration, or improper repair can impair this struc-
ture’s protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. 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.
13
Safety Section
Safety Messages
Rotating Shaft (13)
This safety message (13)is located on top of
the guard which is covering the coupling for the
implement pump. The film is visible by removing the
floorplate of the cab.
g01113701
Rotatins shaft pinch hazard. The shaft under this
cover is rotating anytime the engine is running.
Contact with a rotating shaft could cause injury or
death. Keep hands away.
Falling Hazard (14) (If Equipped)
Safety message (14) is located on the rear of the
Accugrade mast at eye level.
g01108716
To prevent possible personal injury during instal-
lation and removal of the laser receivers, lower the
mast to the minimum height and use an approved
access system to reach the mounting locations of
the laser receivers at the top of the mast. Do not
climb on the blade.
14 SEBU7763-02
Safety Section
Safety Messages

Wood Chip or Waste Handling Do Not Weld On the ROPS (16)

Arrangement (15) (If Equipped) Safety Message (16) is positioned on the vertical
support of the outside right ROPS post.
If equipped, safety message (15) is located on the
right side of the radiator guard near the access slot.

g01108701

g01352487

Structural damage, an overturn, modification, al-

Activating the machine’s steering and work tools
can be hazardous when personnel are working
around the machine.
Before moving the machine, make sure the ma-
chine is on firm level ground. Engage the parking
brake. Make sure the area is clear of personnel be-
fore activating any work tool.
Failure to follow this instruction could result in
injury or death.
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 a payload, should not
exceed the mass on the certification plate.

Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.

The engine must be shut off before any maintenance

is performed. Use a wand in order to clean debris
from the fan and baffle assembly.
SEBU7763-02 15
Safety Section
Safety Messages

Do Not Operate (17)

This safety message is located on the right side
frame of the towing winch.

g01055734

Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
16 SEBU7763-02
Safety Section
Additional Messages

i01944134

Additional Messages
SMCS Code: 7405

g01023544
Illustration 5

There are several specific messages on this machine.

The location of the messages and the description of
the messages are reviewed in this section. Please
become familiarized with all messages.

Make sure that all of the messages are legible.

Clean the messages or replace the messages if
you cannot read the words. Replace the illustrations
if the illustrations are not legible. When you clean
the messages, use a cloth, water and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall. g01024657
Illustration 6
Replace any message that is damaged, or missing.
If a message is attached to a part that is replaced, NOTICE
install a message on the replacement part. Any When the steering lever is moved with the transmis-
Caterpillar dealer can provide new messages. sion in NEUTRAL or in gear, and the engine is running,
the machine will turn. Engage the steering control lock
Steering Control (1) by engaging the parking brake in order to prevent ma-
chine movement.
This message is located on the cab post above the
differential steering control. Air Conditioner (2)
SEBU7763-02
This message is located on the left side of the front
instrument panel.
g00927763
Illustration 7
This message for the air conditioner has the
appropriate information for the following services: the
air conditioner lubricant, the refrigerant charge, and
the refrigerant capacity.
Follow instruction in order to avoid engine damage.
Reference: See Operation and Maintenance Manual,
“Maintenance Interval Schedule” for all maintenance
recommendations.
Prelube (3) (if equipped)
This message is located next to the engine start
switch.
g01114731
Illustration 8
NOTICE
To operate, turn machine start switch to START po-
sition, HOLD to activate pre-lubrication system and
start engine. When adequate oil pressure is available,
pre-lubrication system will disengage, then will AU-
TOMATICALLY crank engine to start. RELEASE KEY
WHEN ENGINE STARTS.
17
Safety Section
General Hazard Information
i02443908
General Hazard Information
SMCS Code: 7000
g00104545
Illustration 9
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment. These warning tags (Special
Instruction, SEHS7332) are available from your
Caterpillar dealer.
Know the width of your equipment in order to maintain
proper clearance when you operate the equipment
near fences or near boundary obstacles.
Be aware of high voltage power lines and power
cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.
g00702020
Illustration 10
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
18 SEBU7763-02
Safety Section
General Hazard Information

Keep the equipment free from foreign material. Trapped Pressure

Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Know the appropriate work site hand signals and
the personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.
High pressure oil that is released can cause a hose to
whip. High pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury
and possible death.

Do not smoke when you service an air conditioner.

Also, do not smoke if refrigerant gas may be present.
Fluid Penetration
Inhaling the fumes that are released from a flame that
Pressure can be trapped in the hydraulic circuit long
contacts air conditioner refrigerant can cause bodily
after the engine has been stopped. The pressure can
harm or death. Inhaling gas from air conditioner
cause hydraulic fluid or items such as pipe plugs to
refrigerant through a lighted cigarette can cause
escape rapidly if the pressure is not relieved correctly.
bodily harm or death.
Do not remove any hydraulic components or parts
Never put maintenance fluids into glass containers.
until pressure has been relieved or personal injury
Drain all liquids into a suitable container.
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
Obey all local regulations for the disposal of liquids.
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
Use all cleaning solutions with care. Report all
relieve the hydraulic pressure.
necessary repairs.

Do not allow unauthorized personnel on the

equipment.

Unless you are instructed otherwise, perform

maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance Manual
for the procedure for placing the equipment in the
servicing position.

Pressurized Air and Water

Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
g00687600
personal injury. Illustration 11

When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the
nozzle is deadheaded and the nozzle is used with
an effective chip deflector and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for the following items:
SEBU7763-02
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
Asbestos Information
g00702022
Illustration 12
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
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.
19
Safety Section
Crushing Prevention and Cutting Prevention
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal
of asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
Illustration 13
g00706404
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01359664
Crushing Prevention and
Cutting Prevention
SMCS Code: 7000
Support the equipment properly before you perform
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold
up the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
Do not work beneath the cab of the machine unless
the cab is properly supported.
20 SEBU7763-02
Safety Section
Burn Prevention

Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while
the engine is running.
Never jump across the starter solenoid terminals
in order to start the engine. Unexpected machine
movement could result.
Check the coolant level only after the engine has
been stopped.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.

Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
maintenance is performed.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can 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.
i01329099
Burn Prevention
SMCS Code: 7000
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
the hydraulic tank filler cap.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i01359795
Fire Prevention and Explosion
Prevention
SMCS Code: 7000

Do not touch any part of an operating engine.

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

Coolant
When the engine is at operating temperature, the g00704000
engine coolant is hot. The coolant is also under Illustration 14
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. All fuels, most lubricants, and some coolant mixtures
are flammable.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
SEBU7763-02 21
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.

Remove all flammable materials such as fuel, oil, and

debris from the machine. Do not allow any flammable
materials to accumulate on the machine.

Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.

Do not operate the machine near any flame.

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.
g00704059
Illustration 15
Do not weld on lines or on tanks that contain
flammable fluids. Do not flame cut lines or tanks Use caution when you are refueling a machine. Do
that contain flammable fluid. Clean any such lines or not smoke while you are refueling a machine. Do
tanks thoroughly with a nonflammable solvent prior not refuel a machine near open flames or sparks.
to welding or flame cutting. Always stop the engine before refueling. Fill the fuel
tank outdoors.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
machine. Clean all electrical connections and tighten
all electrical connections.

Dust that is generated from repairing nonmetallic

hoods or nonmetallic fenders can be flammable
and/or explosive. Repair such components in a well
ventilated area away from open flames or sparks.

Inspect all lines and hoses for wear or for

deterioration. The hoses must be properly routed.
The lines and the hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.

g00704135
Illustration 16

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or
a hydrometer.
22 SEBU7763-02
Safety Section
Fire Extinguisher Location

Improper jumper cable connections can cause • Wires are exposed.

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific • Outer coverings are ballooning.
instructions.
• Flexible part of the hoses are kinked.
Do not charge a frozen battery. This may cause an
explosion. • Outer covers have embedded armoring.

Fire Extinguisher • End fittings are displaced.

Make sure that all clamps, guards, and heat shields
Make sure that a fire extinguisher is available. Be
are installed correctly. During machine operation, this
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire will help to prevent vibration, rubbing against other
parts, and excessive heat.
extinguisher regularly. Obey the recommendations
on the instruction plate.
i01834364

Ether Fire Extinguisher Location

Ether is flammable and poisonous.
SMCS Code: 7419
Use ether in well ventilated areas. Do not smoke
Make sure that a fire extinguisher is available. Be
while you are replacing an ether cylinder or while you
familiar with the operation of the fire extinguisher.
are using an ether spray.
Inspect the fire extinguisher and service the fire
extinguisher. Obey the recommendations on the
Do not store ether cylinders in living areas or in the
instruction plate.
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
Mount the fire extinguisher in the accepted location
above 49 °C (120 °F). Keep ether cylinders away
per local regulations.
from open flames or sparks.
Do not weld the ROPS structure in order to install the
Dispose of used ether cylinders properly. Do not
fire extinguisher. Also, do not drill holes in the ROPS
puncture an ether cylinder. Keep ether cylinders
structure in order to mount the fire extinguisher on
away from unauthorized personnel.
the ROPS.
Do not spray ether into an engine if the machine is
Strap the mounting plate to a leg of the ROPS in
equipped with a thermal starting aid for cold weather
order to mount the fire extinguisher, as needed. If
starting.
the weight of the fire extinguisher exceeds 4.5 kg
(10 lb), mount the fire extinguisher near the bottom of
Lines, Tubes and Hoses the ROPS. Do not mount the fire extinguisher at the
upper one-third area of the ROPS.
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent Consult your Caterpillar dealer for the proper
or damaged. procedure for mounting the fire extinguisher.

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
i01329108
Track Information
SMCS Code: 7000
Track adjusting systems use either grease or oil
under high pressure to keep the track under tension.
Grease or oil under high pressure coming out of the
relief valve can penetrate the body causing injury or
death. Do not watch the relief valve to see if grease
or oil is escaping. Watch the track or track adjustment
cylinder to see if the track is being loosened.
SEBU7763-02
The pins and bushings in a dry track pin joint
can become very hot. It is possible to burn the
fingers if there is more than brief contact with these
components.
i01122596
Electrical Storm Injury
Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator’s station during an electrical
storm, stay in the operator’s station. If you are on the
ground during an electrical storm, stay away from
the vicinity of the machine.
i01896223
Before Starting Engine
SMCS Code: 1000; 7000
Start the engine only from the operator’s
compartment. Do not short across the battery
terminals and do not short across the batteries.
Bypassing the engine neutral start system can
damage the electrical system.
Inspect the condition of the seat belt and mounting
hardware. Replace any damaged parts or worn parts.
Regardless of appearance, replace the seat belt after
three years of use. Do not use an extension for a
seat belt on a retractable seat belt.
Adjust the seat so that full pedal travel can be
achieved. Make sure that the operator’s back is
against the back of the seat.
Make sure that the machine is equipped with a
lighting system that is adequate for the job conditions.
Make sure that all lights are working properly. Before
you start the engine or before you move the machine,
make sure that no one is working on the machine,
working underneath the machine or working close
to the machine. Make sure that the area is free of
personnel.
23
Safety Section
Electrical Storm Injury Prevention
i01492207
Engine Starting
SMCS Code: 1000; 7000
If a warning tag is attached to the start switch or
attached to the controls, do not start the engine. Also,
do not move any controls.
Move all hydraulic controls to the HOLD position
before starting the engine. Move the transmission
control to NEUTRAL position.
Engage the parking brake switch.
Diesel engine exhaust contains products of
combustion. These products can be harmful to your
health. Always start the engine and always operate
the engine in a well ventilated area. If you are in an
enclosed area, vent the exhaust to the outside.
i01944266
Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
area.
Remove all obstacles from the path of the machine.
Beware of hazards such as wires, ditches, etc.
Be sure that all windows are clean. Secure the doors
and the windows in either the open position or the
shut position.
Adjust the rearview mirrors (if equipped) for best
vision close to the machine. Make sure that the
machine horn, the backup alarm (if equipped) and all
other warning devices are working properly.
Reference: Refer to Operation and Maintenance
Manual, “Daily Inspection” in this manual.
Fasten the seat belt securely.
i02773460
Visibility Information
SMCS Code: 7000
Before you start the machine, the operator shall
perform a walk-around inspection in order to ensure
that there are no hazards around the machine.
24
Safety Section
Operation
While the machine is in operation, the operator should
constantly survey the area around the machine. The
operator needs to identify potential hazards as a
hazard becomes visible around the machine.
Your machine may be equipped with mirrors or other
visual aids. An example of a visual aid is Closed
Circuit Television (CCTV). The operator should
ensure that the visual aids are in proper working
condition and that the visual aids are clean. Adjust
the visual aids for the best visibility of all areas
around the machine.
It may not be possible to provide direct visibility on
large machines to all areas around the machine.
Appropriate job site organization is required in order
to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules
and procedures that coordinates machines and
people that work together in the same area. Examples
of job site organization include the following:
• Safety instructions
• Controlled patterns of machine movement
• Controlled patterns of vehicle movement
• Restricted areas
• Operator training
• Warning symbols or warning signs on machines
or on vehicles
• A system of communication
• Communication between workers and operators
prior to approaching the machine
Modifications of the machine configuration that result
in a restriction of visibility shall be verified according
to “ISO 5006”.
i01930605
Operation
SMCS Code: 7000
Machine Operating Temperature
Range
The standard machine configuration is intended
for use within an ambient temperature range
of −40 °C (−40 °F) to 50 °C (122 °F). Special
configurations for different ambient temperatures
may be available. Consult your Caterpillar dealer for
additional information on special configurations of
your machine.
SEBU7763-02
Machine Operation
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
is running.
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
protective devices.
Before you move the machine, you must make sure
that no one will be endangered.
Do not allow riders on the machine unless the
machine has the following equipment:
• additional seat
• additional seat belt
• Rollover Protective Structure (ROPS)
Note any needed repairs during machine operation.
Report any needed repairs.
Carry work tools approximately 40 cm (15 inches)
above ground level. Do not go close to the edge of a
cliff, an excavation, or an overhang.
If the machine begins to sideslip downward on a
grade, immediately remove the load and turn the
machine downhill.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine
can tip when you cross ditches, ridges or other
unexpected obstructions.
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and
down the slopes.
Maintain control of the machine. Do not overload the
machine beyond the machine capacity.
Be sure that the hitches and the towing devices are
adequate.
Only connect the trailing equipment to a drawbar or
to a hitch.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
SEBU7763-02
Before you maneuver the machine, make sure that
no personnel are between the machine and the
trailing equipment. Block up the hitch of the trailing
equipment in order to align the hitch with the drawbar.
Maneuver the machine. Connect the machine to the
trailing equipment.
Know the maximum dimensions of your machine.
Always keep the Rollover Protective Structure
(ROPS) installed during machine operation.
i01492258
Parking
SMCS Code: 7000
Park on a level surface. If you must park on a grade,
use blocks to prevent the machine from rolling.
Apply the service brake in order to stop the machine.
Move the transmission control to NEUTRAL position
and the speed control to LOW IDLE position. Engage
the parking brake switch.
Lower all attachments to the ground.
Stop the engine.
Turn the engine start switch key to OFF position and
remove the key.
Turn the key for the battery disconnect switch to the
OFF position. Remove the key when you exit the
machine for an extended period of time.
Turning the battery disconnect switch to the OFF
position will provide the following benefits:
• Prevent battery discharge that is caused by a
battery short circuit.
• Prevent battery discharge that is caused by some
of the components.
• Prevent battery discharge that is caused by
vandalism.
i01889291
Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine immediately after the
machine has been operated under load. This can
cause overheating and accelerated wear of engine
components.
25
Safety Section
Parking
After the machine is parked and the parking brake
is engaged, allow the engine to run for five minutes
before shutdown. This allows hot areas of the engine
to cool gradually.
For more information, refer to the following topics
in the Operation Section of the Operation and
Maintenance Manual:
• “Stopping the Engine”
• “Stopping the Engine if an Electrical Malfunction
Occurs”
i01329161
Equipment Lowering with
Engine Stopped
SMCS Code: 7000
Before lowering any equipment with the engine
stopped, clear the area around the equipment of
all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind
most systems use a high pressure fluid or air to
raise or lower equipment. The procedure will cause
high pressure air, hydraulic, or some other media
to be released in order to lower the equipment.
Wear appropriate personal protective equipment and
follow the established procedure in the Operation
and Maintenance Manual, “Equipment Lowering with
Engine Stopped” in the Operation Section of the
manual.
i02659468
Sound Information and
Vibration Information
SMCS Code: 7000
Sound Level Information
The operator Equivalent Sound Pressure Level
(Leq) is 81 dB(A) when “ANSI/SAE J1166 OCT 98”
is used to measure the value for an enclosed cab.
This is a work cycle sound exposure level. The cab
was properly installed and maintained. The test was
conducted with the cab doors and the cab windows
closed.
Hearing protection may be needed when the
machine is operated with an open operator station for
extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
operated with a cab that is not properly maintained or
when the doors and windows are open for extended
periods or in a noisy environment.
26 SEBU7763-02
Safety Section
Sound Information and Vibration Information

The average exterior sound pressure level is 85
dB(A) when the “SAE J88 Jun86 - Constant Speed
Moving Test” procedure is used to measure the value
for the standard machine. The measurement was
conducted under the following conditions: distance of
15 m (49.2 ft) and “the machine moving forward in an
intermediate gear ratio”.
Sound Level Information for
Machines in European Union
Countries and in Countries that
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.

Adopt the “EU Directives”

The dynamic operator sound pressure level is 79
dB(A) when “ISO 6396:1992” is used to measure the
value for an enclosed cab. The cab was properly
installed and maintained. The test was conducted
with the cab doors and the cab windows closed.

“The European Union Physical

Agents (Vibration) Directive
2002/44/EC”
Vibration Data for Track-Type Tractors
Information Concerning Hand/Arm Vibration
Level

When the machine is operated according to the

intended use, the hand/arm vibration of this machine
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

• 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.
SEBU7763-02 27
Safety Section
Sound Information and Vibration Information

Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Machine Typical Operating Vibration Levels Scenario Factors

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

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

The Caterpillar suspension seat meets the criteria of 5. Perform the following operations smoothly.
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. This seat is tested a. Steer
with the input “spectral class EM6”. The seat has a
transmissibility factor of “SEAT<0.7”. b. Brake

The whole body vibration level of the machine varies. c. Accelerate.

There is a range of values. The low value is 0.5
meter per second squared. The machine meets the
short term level for the design of the seat in “ISO
7096”. The value is 1.61 meter per second squared
for this machine.
Guidelines for Reducing Vibration Levels on
Earthmoving Equipment
Properly adjust machines. Properly maintain
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level:
1. Use the right type and size of machine, equipment,
and attachments.
2. Maintain machines according to the
manufacturer’s recommendations.
a. Tire pressures
d. Shift the gears.
6. Move the attachments smoothly.
7. Adjust the machine speed and the route in order
to minimize the vibration level.
a. Drive around obstacles and rough terrain.
b. Slow down when it is necessary to go over
rough terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance.
a. Use machines that are equipped with
suspension systems.
b. Use the ride control system on Track-Type
Tractors.

b. Brake and steering systems c. If no ride control system is available, reduce

speed in order to prevent bounce.
c. Controls, hydraulic system and linkages
d. Haul the machines between workplaces.
3. Keep the terrain in good condition.

a. Remove any large rocks or obstacles.

28 SEBU7763-02
Safety Section
Operator Station

9. Less operator comfort may be caused by other risk i01649970

factors. The following guidelines can be effective
in order to provide better operator comfort:
a. Adjust the seat and adjust the controls in order
to achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
c. Provide breaks in order to reduce long periods
of sitting.
d. Avoid jumping from the cab.
e. Minimize repeated handling of loads and lifting
of loads.
Operator Station
SMCS Code: 7000
Any modifications to the inside of the operator
station should not project into the operator space.
The addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator space is maintained. Any item that is brought
into the cab should not project into the defined
operator space. A lunch box or other loose items
must be secured. Objects must not pose an impact
hazard in rough terrain or in the event of a rollover.
i01992325

f. Minimize any shocks and impacts during sports Guards

and leisure activities.
(Operator Protection)
Sources SMCS Code: 7000; 7150; 7325

The vibration information and calculation procedure
is based on “ISO/TR 25398 Mechanical Vibration
- Guideline for the assessment of exposure
to whole body vibration of ride on operated
earthmoving machines”. Harmonized data is
measured by international institutes, organizations
and manufacturers.
This literature provides information about assessing
the whole body vibration exposure of operators of
earthmoving equipment. The method is based on
measured vibration emission under real working
conditions for all machines.
You should check the original directive. This
document summarizes part of the content of the
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documents are based on information from the United
Kingdom Health and Safety Executive.
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.
A daily inspection of the guards is required in order to
check for structures that are bent, cracked or loose.
Never operate a machine with a damaged structure.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are recommended for your
machine.

Refer to Operation and Maintenance Manual,

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

Consult your local Caterpillar dealer for more

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

Use the following web site in order to find your local

dealer:

Caterpillar, Inc.
www.cat.com
SEBU7763-02 29
Safety Section
Guards

Rollover Protective Structure • Demolition applications

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

The ROPS/FOPS Structure (if equipped) on your Additional guards may be required for specific
machine is specifically designed, tested and certified applications or work tools. The Operation and
for that machine. Excavators are not equipped Maintenance Manual for your machine or your
with ROPS structures. Any alteration or any work tool will provide specific requirements for the
modification to the ROPS/FOPS Structure could guards. Consult your Caterpillar dealer for additional
weaken the structure. This places the operator information.
into an unprotected environment. Modifications or
attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
structure can be caused by an overturn, a falling
object, a collision, etc.

Do not mount items (fire extinguishers, first aid

kits, work lights, etc) by welding brackets to the
ROPS/FOPS Structure or by drilling holes in the
ROPS/FOPS Structure. Welding brackets or drilling
holes in the ROPS/FOPS Structures can weaken
the structures. Consult your Caterpillar dealer for
mounting guidelines.

The Tip Over Protection Structure (TOPS) is

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

Other Guards (If Equipped)

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

A front guard needs to be installed when a work

tool that creates flying objects is used. Mesh
front guards that are approved by Caterpillar or
polycarbonate front guards that are approved by
Caterpillar are available for machines with a cab or
an open canopy. On machines that are equipped with
cabs, the windshield 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:
30 SEBU7763-02
Product Information Section
General Information

Product Information Table 2

Section D8T Track-Type Tractor

Engine Power 310 hp

General Information Engine (Make and Model) Caterpillar C-15 Acert

Engine Displacement 15.2 L ()
i02769197 Engine Rated Speed 1850 RPM

Specifications Engine (No. of Cylinders) 6

3493.4 mm
SMCS Code: 1000; 7000 Height (Top of Cab) (A)
(137.5 inch)
Length of the Machine(1)
4632 mm (182 inch)
(B)
Height to Top of Rain Cap (C) 3505.4 mm (138 inch)
Ground Clearance (D) 527.9 mm (20.8 inch)
Track Gauge (E) 2083 mm (82 inch)
Width Over Trunnions (F) 3050 mm (120 inch)
Height of the Drawbar 528 mm (20.8 inch)
Width of Standard Track Shoe 560 mm (22 inch)
Length of Track on Ground 3200 mm (126 inch)
Operating Weight(2) 38488 kg (84851 lb)
Illustration 17
g01119768 (The single shank ripper and
the SU-blade are included in
the weight.)
Drawbar (Length) 325 mm (12.8 inch)
Single Shank Ripper (Length)(3) 1829 mm (72 inch)
(Length is measured from the
grouser tip with the ripper
shank in a vertical position and
the ripper tip at the ground.)
Multiple Shank Ripper 1623 mm (64 inch)
(Length)(3)
8SU Bulldozer Blade (Length)(3) 1438 mm (57 inch)
8SU Bulldozer Blade (Width) 3937 mm (155 inch)
8SU Bulldozer Blade 8.7 m3 (11.4 yd3)
(Capacity)
g00678145
Illustration 18
8U Bulldozer Blade (Length)(3) 1835 mm (73 inch)
8U Bulldozer Blade (Width) 4262 mm (168 inch)
Basic machine specifications are listed in Table 2. 8U Bulldozer Blade (Capacity) 11.7 m3 (15.3 yd3)
8A Bulldozer Blade (Length)(3) 1621 mm (64 inch)
8A Bulldozer Blade (Width) 4978 mm (196 inch)
8A Bulldozer Blade (Capacity) 4.7 m3 (6.1 yd3)
(1) The length of the machine is measured from the trunnion of
the tag link to the end of the track (standard).
(2) The weight includes the machine and the following items:
full tank of fuel, all lubricants, coolant, SU Bulldozer Blade
with tilt cylinders, single shank ripper, hydraulic controls, air
conditioner, 560 mm (22 inch) track (MS), cab with EROPS,
and operator.
(3) Add to length of the machine.
SEBU7763-02 31
Product Information Section
General Information

Intended Use
This machine is a Track-Type Tractor that is classified
as a “Tractor-dozer”. The machine is earthmoving
equipment that is described in ISO 6165:2001. The
machine propels the track forward. Also, the machine
propels the track rearward. This allows the machine
to move independently. The machine uses equipment
that is either 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
by using a drawbar.

Application and Configuration

Restrictions
Maximum approved operating weight (44794 kg
(98770 lb))

Maximum drawbar pull (67191 kg (148130 lb))

Maximum vertical drawbar load (33596 kg (74066 lb))

The maximum slope that has the proper lubrication is

100 percent or 45 degrees.

Use the machine only in environments that are not

explosive with gases.

Special attachments and operating instructions are

required for waste handling applications and other
custom configurations.
32 SEBU7763-02
Product Information Section
Identification Information

Identification Information
i02696536

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
g01057083
an operator to ride. Illustration 20

Serial Numbers identifyCaterpillar products such as Machine PIN ________________________________________________

engines, transmissions and major attachments that
are not designed for an operator to ride. Service Information Number plate (2) is located on
the left hand side of the front dash in the cab.
For quick reference, record the identification numbers
in the spaces that are provided below the illustration.

g01087470
Illustration 21
Enclosed ROPS arrangement

g01016776
Illustration 19

The plate for Machine PIN (1) is located to the left of

the transmission cover on the rear of the machine.

g01014397
Illustration 22
SEBU7763-02 33
Product Information Section
Identification Information

Service Information Number plate _____________________

The Engine Serial Number plate (3) is located on top

of the engine block, as shown.

g01057104
Illustration 26

Ripper Serial Number (7) ________________________________

Illustration 23
g01014343 The serial number plate of the winch is located on
the right side of the winch frame.
Engine Serial Number ____________________________________

The serial number plate of the bulldozer (4) is located

on the back of the blade.

g01334816
Illustration 27

g00939077
Illustration 24

g01323812
Illustration 28

Winch Serial Number _____________________________________

g01057098
Illustration 25

Bulldozer Serial Number (4) _____________________________

The serial number plate (7) for the ripper is located

on the side of the ripper frame.
34 SEBU7763-02
Product Information Section
Identification Information

Certifications FOPS Plate (6)

ROPS Plate (5)

Message (5) is positioned on the vertical support of
the outside right ROPS post.

g01077753
Illustration 30
Certification plate (FOPS)

Message (6) is positioned on the outside left canopy.

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture’s protection capability thereby voiding this
certification. Do not weld on or drill holes in the
g01023970
Illustration 29 structure. This will void the certification. Consult
Certification plate (ROPS) a Caterpillar dealer to determine this structure’s
limitations without voiding its certification.

This machine has been certified to the standards that

Structural damage, an overturn, modification, al- are listed on the certification plate.
teration, or improper repair, can impair this struc-
ture’s protective capability thereby voiding this Sound Certification
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

above.

Refer to Operation and Maintenance Manual, Illustration 31

g00933634
“Guards (Operator Protection)” for more information.
A typical example of this film is shown. Your machine may have a
different value.
SEBU7763-02 35
Product Information Section
Identification Information

If equipped, the certification film is used to verify the

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

European Union

g01062968
Illustration 32

This plate is positioned on the bottom left side of the

Machine PIN (1).

Note: The CE plate is on machines that are certified

to the valid European Union requirements at that
time.

• Power (kW)_______________________________________________
• Weight (kg)________________________________________________
• Year of Compliance_____________________________________

i01915747

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Certification Label for Emissions

The certification label (if equipped) is used to verify an
engine’s conformance to the emissions requirements
of the EPA.

This label is located on the engine oil cooler.

36 SEBU7763-02
Product Information Section
Identification Information

g00638668
Illustration 33
Typical Example (English)

g00638373
Illustration 34
Typical Example (French)
SEBU7763-02 37
Operation Section
Before Operation

Operation Section i02243194

Daily Inspection
Before Operation SMCS Code: 1000; 7000

A walk-around inspection must be done daily before

i02415882 operating the machine.

Mounting and Dismounting Reference: Refer to Operation and Maintenance

Manual, “Walk-Around Inspection” for more
SMCS Code: 7000 information.

g00037860
Illustration 35

Use steps and handholds whenever you mount

the machine. Use steps and handholds whenever
you dismount the machine. Before you mount the
machine, clean the step and the handholds. Inspect
the step and handholds. Make all necessary repairs.

Face the machine whenever you mount the machine

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

Note: Three-point contact can be two feet and one

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

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 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 compartment or when you exit the operator
compartment.
38 SEBU7763-02
Operation Section
Machine Operation

Machine Operation Fore and Aft Adjustment (1) – Pull up fore

and aft lever (1). This will allow movement
i01930019 of the seat forward or this will allow
movement of the seat back to the desired position.
Alternate Exit Release lever (1) in order to lock the seat in place.
SMCS Code: 7254; 7308; 7310
Adjusting the Angle of the Back of the
Machines with cabs are equipped with alternate exits. Seat
If a door becomes disabled, the other door can be
used as an alternate exit. Release the latch and open
the door.

i02247402

Seat
SMCS Code: 7312-025; 7324

Adjusting the Seat

The operator’s seat that is provided with this machine
is in compliance with the appropriate class of “ISO
7096”.

Note: Adjust the seat for a new operator or at the

beginning of each shift.

The operator should be seated against the seat

backrest. Adjust the seat so that the operator is g00999313
Illustration 37
allowed full travel of the pedals.
Back Angle Adjustment (2) – Lift lever
Adjusting the Fore and Aft Position of (2) and allow the seat back to tilt forward.
the Seat Push the front of the backrest in order to tilt
the seat backward. Release lever (2) at the desired
position.

Adjusting the Height of the Seat

Seats with Mechanical Suspension

g00999315
Illustration 36 Illustration 38
g01131998
SEBU7763-02
Adjustment of the Seat Height (4) – Pull
up on height adjustment lever (4) and pull
up on the seat in order to raise the height of
the seat. Pull up on height adjustment lever (4) and
push down on the seat in order to lower the height
of the seat.
Seats with Air Suspension
g00999499
Illustration 39
Adjustment of the Seat Height (6) – Push
in on the air valve knob (6) in order to raise
the height of the seat. Pull out on the air
valve knob (6) in order to lower the height of the seat.
Note: The key switch must be on in order to raise
the seat.
Weight Adjustment
Seats with Mechanical Suspension
g01001175
Illustration 40
39
Operation Section
Machine Operation
Weight Adjustment (7) – Rotate knob (7) and
observe gauge (8) in order to obtain the proper
adjustment for the weight of the operator. Turn
the knob counterclockwise in order to reduce the
stiffness of the suspension for an operator of lighter
weight. Turn the knob clockwise in order to increase
the stiffness of the suspension for an operator of a
heavier weight.
Seats With Air Suspension
The weight adjustment is automatically controlled by
adjusting the height of the seat.
Adjusting the Lumbar Support
g01001077
Illustration 41
Adjustment for the Lumbar Support
(9) – Rotate the knob (9) counterclockwise
in order to increase support for the lower
back. Rotate the knob (9) counterclockwise in order
to decrease support for the lower back.
40 SEBU7763-02
Operation Section
Machine Operation

Extension for the Back of the Seat (if Storage for the Operation and
equipped) Maintenance Manual

g01001129
Illustration 43

The Operation and Maintenance Manual should be

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

g01001125
Illustration 42
Extension for the Back of the Seat (10) – Lift up
on extension (10) in order to remove the extension.
When you install extension (10) push the
extension all the way downward. The extension
should touch the top of the seat.
i02707449
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt
when the machine was shipped from Caterpillar.
At the time of installation, the seat belt and the
instructions for installation of the seat belt meet the
SAE J386 standards. See your Caterpillar dealer for
all replacement parts.

Always check the condition of the seat belt and

the condition of the mounting hardware before you
operate the machine.

Seat Belt Adjustment for

Non-Retractable Seat Belts
Adjust both ends of the seat belt. The seat belt should
be snug but comfortable.
SEBU7763-02 41
Operation Section
Machine Operation

Lengthening the Seat Belt Shortening the Seat Belt

g00100709 g00100713
Illustration 44 Illustration 46

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

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

manner.

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

Fastening The Seat Belt

g00932817
Illustration 45

2. To remove the slack in outer loop (1), rotate buckle

(2). This will free the lock bar. This permits the
seat belt to move through the buckle.

3. Remove the slack from the outer belt loop by

pulling on the buckle.

4. Loosen the other half of the seat belt in the same g00932818
Illustration 47
manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
Fasten the seat belt catch (3) into the buckle (2).
Make sure that the seat belt is placed low across the
lap of the operator.
42 SEBU7763-02
Operation Section
Machine Operation

Releasing The Seat Belt Releasing The Seat Belt

g00100717 g00039113
Illustration 48 Illustration 50

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

Fastening The Seat Belt

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

g00867598
be used with a seat belt extension.
Illustration 49
Consult your Caterpillar dealer for longer seat belts
Pull seat belt (4) out of the retractor in a continuous and for information on extending the seat belts.
motion.

Fasten seat belt catch (3) into buckle (2). Make sure i02742390
that the seat belt is placed low across the lap of the
operator. Operator Controls
The retractor will adjust the belt length and the SMCS Code: 7300; 7301; 7451
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
SEBU7763-02 43
Operation Section
Machine Operation

Illustration 51
(1) Adjustable armrests
(2) Parking brake control
(3) Steering control lever
(4) Direction selector lever
(5) Gear selector
(6) Gauge and instrument module
(7) Service brake control
(8) Decelerator
(9) Bulldozer blade control lever
(10) Auto blade assist (switch)
(11) Reversing fan control switch (if
equipped)
g01127016
(12) Advisor monitor display (23) Front lights on ROPS
(13) Auxiliary power switch (24) Rear lights on ROPS
(14) Engine start switch (25) Action light
(15) Engine throttle (switch) (26) Ripper shank in/out lever
(16) Implement lockout control (27) Horn
(17) Bidirectional shift switch (28) Ripper auto stow switch
(18) Automatic Downshift switch (29) Ripper raise/lower
(20) Lockout Switch for the Winch or Ripper (30) Winch control lever (not shown)
Pin Puller
(21) Front lights on cylinder and backlights
(22) Work lights in fenders and light for
ripper (if equipped)
44 SEBU7763-02
Operation Section
Machine Operation

g01127026
Illustration 52
(31) Interior dome light (32) Windshield wiper control and window (33) Heating and air conditioning controls
washer control

Note: Your machine may not have all the controls 2. Move armrest (1) to the desired height.
that are described in this information section.
3. Tighten the knobs.
Adjustable Armrests (1)
Parking Brake Control (2)
NOTICE
Do not engage the parking brake while the machine is
moving unless an emergency exists.

The use of the parking brake as a service brake in reg-

ular operation causes severe damage to the parking
brake system.

g01015542
Illustration 54

Parking Brake – This switch engages the

parking brake. This switch also locks the
transmission in NEUTRAL. The machine
should not move when the parking brake switch is
engaged. When the parking brake switch is engaged,
g01107108
the parking brake indicator on the dashboard will
Illustration 53 light. Do not use the parking brake for stopping the
Left armrest machine. The transmission direction selector will still
rotate but the transmission will stay locked in neutral.
Use the following procedure in order to adjust the left
armrest and right armrest(1), if necessary.

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

armrest.
SEBU7763-02
Engaged – Raise knob (2) in order
to engage the parking brake. This will
mechanically lock the steering control. Also,
this will electrically disable the transmission controls.
The transmission will be locked in NEUTRAL.
Disengaged – Depress switch (2) in order
to disengage the parking brake.
Differential Steering Control and
Transmission Control (3) (4) (5)
g01015497
Illustration 55
Steering control lever (3) allows the steering system
and the transmission system to be simultaneously
controlled. Push down on the parking brake
knob in order to release the parking brake and
allow movement of the steering. Also, this will
enable transmission controls. The steering lever
is mechanically locked by the parking brake. The
transmission controls are electronically disabled.
Transmission Direction Selection
Rotate control (4) (transmission direction selector)
clockwise or counterclockwise in order to change the
direction of the machine.
Forward – Rotate the twist handle on the
lever forward to the FORWARD position
in order to move the transmission to
FORWARD.
Reverse – Rotate the twist handle on the
lever backward to the REVERSE position
in order to move the transmission to
REVERSE.
Neutral – Rotate the twist handle on the
lever to the NEUTRAL position in order to
move the transmission to NEUTRAL.
45
Operation Section
Machine Operation
Transmission Gear Selection
Gear Selector (5) – Press the transmission
upshift switch (5A) in order to upshift the
transmission to the next higher gear. Press
the transmission downshift switch (5B) in order to
downshift the transmission to the next lower gear.
The gauge and indicators will show the direction of
the transmission that has been selected. Also, the
selected gear is displayed on “Advisor” panel (12).
Steering Lever
The machine can be steered with the transmission in
the NEUTRAL position.
NOTICE
When the steering lever is moved with the transmis-
sion in NEUTRAL or in gear, and the engine is running,
the machine will turn. Engage the steering control lock
by engaging the parking brake in order to prevent ma-
chine movement.
g01103286
Illustration 56
When the machine is moving forward, push the
steering control lever forward for a left turn. When
the machine is moving backward, push the steering
control lever forward for a right turn. When you move
the steering control lever farther in a forward motion,
the machine will turn faster.
In order to pivot the machine in the clockwise
direction, place the transmission in NEUTRAL and
pull the steering lever backward toward the operator.
In order to pivot the machine in the counterclockwise
direction, place the transmission in NEUTRAL and
push the steering lever forward.
46 SEBU7763-02
Operation Section
Machine Operation

Table 3 Decelerator (8)

Machine travel Lever movement Machine
direction
(turn)
FORWARD PUSH LEFT
FORWARD PULL RIGHT
REVERSE PULL LEFT
REVERSE PUSH RIGHT
NEUTRAL PUSH LEFT
NEUTRAL PULL RIGHT

Gauges and Indicators (6) g01021776

Refer to Operation and Maintenance Manual,
“Monitoring System” for more information.
Service Brake Control (7)
Illustration 58
Decelerator Pedal – Use the decelerator pedal in
order to control the desired engine speed. Push
down on the pedal in order to reduce the engine
speed. Release the pedal in order to increase engine
speed. Use the pedal in order to reduce the engine
speed when you make a directional shift. Use the
decelerator pedal in order to maneuver in tight
locations.

Adjustment – The height of the decelerator pedal is

adjustable. The minimum setting for the decelerator
pedal is adjustable. Consult your Caterpillar dealer
for the adjustment procedure.

Bulldozer Joystick Control (9)

Bulldozer Blade Lift
g01107061
Illustration 57

Applying the Brake Pedal – Push the brake pedal

downward in order to apply the service brakes. Use
the brake pedal for slowing the machine and for
stopping the machine. Use the service brakes on
a downgrade in order to prevent overspeed. The
service brakes are especially needed when you
change directions on a steep slope.

Releasing the Brake Pedal – Release the brake

pedal in order to allow the machine to move.

g01073385
Illustration 59

Float (9A) – Push the lever forward

completely past the detent force in order to
activate the blade float function. The float
function is not deactivated when the lever is released
into the NEUTRAL position. When the float function
is activated the blade moves up and down with the
ground contour. The top of the “Advisor” display will
change from MANUAL to FLOAT when FLOAT is
activated.
SEBU7763-02
The float will deactivate if the lever is moved through
the NEUTRAL position to the RAISE position or the
LOWER position.
Note: The default setting for the operator is ENABLE.
The float function is enabled in “Advisor”or disabled
in “Advisor”. Refer to Operation and Maintenance
Manual, “Monitoring System” for the explanation of
the “Advisor” functions.
Lower (9B) – Push the lever forward in
order to lower the blade. Release the lever.
The lever will return to the HOLD position.
Hold (9C) – The lever will return to the
HOLD position, when you release the
lever from the RAISE position and from the
LOWER position. The movement of the bulldozer
blade stops. If the lever is released from the float
position the float function remains active.
Raise (9D) – Pull back on the lever in order
to raise the blade. Release the lever. The
lever will return to the HOLD position.
“Advisor” allows the blade response to be
automatically set. Refer to Operation and
Maintenance Manual, “Monitoring Systems” for
proper adjustment of this setting.
Bulldozer Blade Tilt (Single Tilt)
g01073394
Illustration 60
Single Tilt Control
Tilt Left (9E) – Pull the blade control lever
toward the left in order to lower the left side
of the bulldozer blade. When you release
the lever, the lever returns to the HOLD position.
Tilt Hold (9F) – When you release the
lever, the lever returns to the HOLD
position. The movement of the bulldozer
blade stops.
47
Operation Section
Machine Operation
Tilt Right (9G) – Push the blade control
lever toward the right in order to lower the
right side of the bulldozer blade. When
you release the lever, the lever returns to the HOLD
position.
Bulldozer Blade Tilt (Dual Tilt)
Dual Tilt (If Equipped)
g01130936
Illustration 61
Trigger switch ((Not Shown)) – The trigger switch
is located on the underside of the joystick. Hold the
trigger switch inward in order to operate the bulldozer
blade in single tilt mode. Release the trigger switch in
order to return the bulldozer blade to dual tilt mode.
Tilt Left (9E) – Pull the blade control lever
toward the left in order to lower the left side
of the bulldozer blade. When you release
the lever, the lever returns to the HOLD position.
Tilt Hold (9F) – When you release the
lever, the lever returns to the HOLD
position. The movement of the bulldozer
blade stops.
Tilt Right (9G) – Push the blade control
lever toward the right in order to lower the
right side of the bulldozer blade. When
you release the lever, the lever returns to the HOLD
position.
Pitch Control (Dual Tilt)
Thumb switch (9H) is used to pitch the blade forward
and backward. This blade movement changes the
performance of the blade.
48
Operation Section
Machine Operation
Pitch Back – Move the thumb lever(9H)
on the bulldozer blade control lever to the
left in order to pitch the blade backward.
When you pitch the bulldozer blade to the rear you
will improve the ability of the bulldozer blade to carry
the load.
Pitch Forward – Move the thumb lever
(9H) on the bulldozer blade control lever to
the right in order to pitch the blade forward.
When you pitch the bulldozer blade forward you will
improve the penetration of the bulldozer blade. This
will also help to dump the load. This will also help to
minimize the carryback of the material.
Bulldozer Blade (Automatic Modes)
g01385602
Illustration 62
Dual tilt mode must be selected in the Advisor
system. Activate the auto blade assist by pressing
switch (10). Buttons (9J) and (9K) can be used to
assist with changing the blade pitch. Push button (9J)
to toggle between the 3 positions of the blade pitch
that are set in Advisor.
Auto Blade Assist (10) (if equipped)
The auto blade assist moves the blade to preset
pitch positions.
Auto Blade Assist – Push the switch in
order to set the system to the ON position.
The indicator light will illuminate when the
system is active. Push the switch again in order to
turn the system OFF.
SEBU7763-02
Definitions of Auto Blade Assist (if
equipped)
Illustration 63
g01130936
The Auto blade assist has three sequences of
operation:“Carry”, “Spread”, and Load.
Carry – Press the left button on the joystick (9J) one
time in order to activate the sequence. The blade will
adjust the pitch that was set in Advisor for this portion
of the application.
Spread – Press the left button on the joystick (9J)
again in order to activate the sequence. The blade
will adjust the pitch that was set in Advisor for this
portion of the application.
Note: If the machine is equipped with the position
sensor on the lift cylinder the blade will also rise, in
addition to the change in pitch.
Load – Press the left button on the joystick (9J)
again in order to activate this sequence. The blade
will adjust the pitch that was set in Advisor for this
portion of the application. The activation of the load
sequence will recalibrate the blade. In order to
recalibrate the pitch, the blade will pitch all the way
to the back. Then, the blade will pitch forward to the
appropriate angle.
Note: You can override the auto blade assist at any
time by moving the dozer controls. The auto blade
assist will be suspended by the selection of the right
button on the joystick (9K). The auto blade assist
will resume at any time by the selection of the right
button on the joystick (9K).
Procedures for the Auto Blade Assist
Note: Be aware that this procedure will move
the dozer blade automatically. Make sure that the
hydraulic oil is warmed up before performing this
procedure.
1. Press the throttle switch in order to activate high
idle.
SEBU7763-02
2. Turn on ABA switch. The ABA switch is located
under the Advisor display monitor in front of the
bulldozer control lever.
3. Raise the blade about 2 feet off the ground.
4. Press the button on the left side of the bulldozer
control lever in order to reset the ABA. The blade
will move to zero pitch. The blade will remain there
for several seconds. Then, the blade will move to
the default setting (load position).
5. Highlight the settings on the “Home” screen. Press
the OK button.
Reference: See “Home Button” in “Monitoring
System” story for more information.
6. Highlight the setup for the implement controls.
Press the OK button.
Reference: See “Settings Menu” in “Monitoring
System” story for more information.
7. Highlight the auto blade pitch. Press the OK
button.
Reference: See the same section in “Monitoring
System” story for more information.
8. Highlight the segment of the dozing cycle in order
to adjust the change in the pitch. The dozing cycle
consists of a load segment, the carry segment,
and the spread segment.
9. Move the thumb lever on the bulldozer control
lever until the blade pitch is in the desired position.
Press the OK button.
10. Repeat steps 8 and 9 in order to change the
blade pitch in the other segments of the dozing
cycle. The new settings are active until the ignition
key is turned off.
Note: In order to save the desired settings, make
sure that you have selected an operator profile.
11. In order to save the settings of the dozer blade
pitches to the operator profile, follow the steps 10
& 11 in the Operation and Maintenance Manual,
“Creating Operator Profile”.
49
Operation Section
Machine Operation
Engine Reverse Fan (11) (if
equipped)
g01131670
Illustration 64
Fan control switch (if equipped)
If the machine is equipped with the reverse fan
function (attachment), the fan can reverse the
direction of air flow from forward to the rearward
direction. This enables the fan to purge debris from
the radiator, aftercooler cores, and engine access
doors. The purge cycle will begin automatically when
the purge interval expires or the purge cycle can
begin manually with a switch(11) on the right dash.
Reversing Fan Control – In order to
initiate the fan purge cycle, press fan
control switch (11) while the machine is
in NEUTRAL and the parking brake is released or
when the machine is in REVERSE. In order to initiate
the continuous fan purge cycle, press fan control
switch (11) while the machine is in NEUTRAL and
the parking brake is ON and hold for three seconds.
The fan will remain in a continuous purge cycle until
the switch is pressed again or the parking brake is
released.
The setting range for fan purge duration is 5 - 60
seconds. The setting range for fan purge interval is 5
- 120 minutes. See “Procedures for the Reverse Fan
Function (If Equipped)” for more information.
If the purge interval expires, a purge cycle will begin
when the track-type tractor is in a REVERSE gear or
in NEUTRAL and the parking brake is released. If the
purge interval expires and the track-type tractor is in a
FORWARD gear, starting a purge cycle is prevented.
If the purge interval expires and the track-type tractor
is in NEUTRAL with the parking brake engaged,
starting a purge cycle is prevented. A purge cycle is
prohibited until there is a shift into REVERSE gear or
the parking brake is released in NEUTRAL.
50 SEBU7763-02
Operation Section
Machine Operation

If the purge button is manually depressed, a purge Advisor Monitor Display (12)
cycle will begin when the track-type tractor is in a
REVERSE gear or in NEUTRAL and the parking
brake is released. If the purge button is manually
depressed, the request for a purge cycle will be
ignored when the track-type tractor is in a FORWARD
gear or in NEUTRAL and the parking brake is
engaged.

g01107176
Illustration 65
g01386038 Illustration 66

Top banner in Advisor Monitor Display All buttons on the left side of the Advisor monitor display are
inactive.

When a purge cycle is in progress and the Purge
Cycle Cancellation is set to OFF, the top banner in
the Advisor monitor display displays “Active”. See
illustration 65.
When a purge cycle begins, the total purge cycle
will be completed regardless of gear changes during
the purge cycle. When a purge cycle begins and the
Purge Cycle Cancellation is set to ON, the purge
cycle will stop automatically once the machine is put
into FORWARD gear. If the Purge Cycle Cancellation
occurs after 15 seconds of purge time, the purge
interval timer is held at zero. Then, the system is
able to purge the cooling system and the purge cycle
starts automatically at the next time. After three
successive attempts fail to complete more than 15
seconds of purge time, the purge interval timer is
reset to the purge interval.
See “Procedures for the Reverse Fan Function
(If Equipped)” in order to set the Purge Cycle
Cancellation.
The purge interval timer is reset upon full completion
of every purge cycle regardless of an automatic start
or manual start. The reverse fan function is disabled
when the hydraulic oil temperature is below 0 °C
(32 °F).
(12A) Gear and Direction
(12B) Dozer mode
(12C) Bidirectional shift mode
(12D) Left / Up button
(12E) Right / Down button
(12F) Back to the previous screen
(12G) Return to home menu
(12H) OK button
(12J) Display menu
(12K) Additional pull-down menu
The Advisor monitor display is located at the front
of the right side operator console. The “Advisor”
communicates with the machine electronic control
modules, sensors, and the instrument module.
Advisor provides information to the operator. The
Advisor allows the operator to have control of the
machine system. Also, the operator can monitor the
machine systems with Advisor monitor display.
Items (12A), (12B), and (12C) across the top portion
of the screen display system’s data at all times.
Some functions of the Advisor monitor display
are password protected. Refer to Operation and
Maintenance Manual, “Monitoring System” for
additional information on the Advisor monitor display.

Procedures for the Reverse Fan Function

(If equipped)
Reference: See the “Monitoring System” story in this
manual for “Procedures for the Reverse Fan Function
(If equipped)”.
SEBU7763-02 51
Operation Section
Machine Operation

Auxiliary Power Switch (13) (If Note: If the engine fails to start, the engine start
switch key must be returned to the OFF position in
Equipped) order to attempt to start the engine again.
Auxiliary Circuit – Push the rocker switch to the top
position in order to activate the auxiliary electrical Engine Throttle (15)
connector. The auxiliary electrical connector is
located on the inner face of the right fender below the
hydraulic tank. A 24 volt temporary duty light may
be connected to the 2-pin connector. A 15 AMP fuse
protects the circuit.

Note: The auxiliary circuit also serves as the switch

for the rotating beacon.

Engine Start Switch (14)

g01073346
Illustration 68

High Idle – For high idle, press the top of

the throttle switch that is right of the engine
start switch. The engine throttle is set at
the low idle speed position. Starting an engine that is
cold will cause the engine to start at a higher engine
speed. Improved combustion and reduced smoke
will occur.

Illustration 67
g01073300 Low Idle – For low idle, press the bottom of
the throttle switch to the right of the engine
OFF – Insert the engine start switch key start switch. The engine speed immediately
only from the OFF position and remove moves to low idle.
the engine start switch key only from the
OFF position. Turn the engine start switch key to
the OFF position in order to stop the engine. In the
Set Engine Throttle
OFF position, there is no power to most electrical
Set the engine throttle between low idle and high idle
circuits on the machine. The cab lights, panel lights,
in the following manner:
tail lights, working lights (if equipped) and fuel gauge
light are operational even when the engine start
1. Set the engine throttle to high idle. Push on
switch is in the OFF position.
the decelerator pedal until the desired speed is
reached.
ON – Turn the engine start switch key
clockwise to the ON position in order to 2. When the desired speed is reached, push the high
activate all of the cab circuits. idle side of the throttle switch and hold the switch
for three seconds. This will electronically lock in
START – Turn the engine start switch key the engine speed.
clockwise to the START position in order to
crank the engine. Release the key after the 3. In order to return to low idle or high idle, push
engine starts. The key will return to the ON position. the Throttle switch on the appropriate side of the
Throttle switch and release the switch.
Note: The engine start switch will start differently
if the engine is equipped with the prelube system.
Refer to Operation and Maintenance Manual, “Engine
Starting ” for more instruction.
52
Operation Section
Machine Operation
Implement Lockout Switch (16)
g01016340
Illustration 69
This switch will make all hydraulic attachment
nonfunctional.
Implement Lockout Switch – Press the
top of the switch (16) in order to deactivate
the implement controls. Press the bottom of
the switch in order to activate the implement
controls.
Note: The hydraulic shutoff control is designed to
deactivate the control levers. Depress the top of
the switch in order to deactivate the control levers.
The indicator for the implement control on the dash
panel will illuminate when the hydraulic controls are
deactivated. Deactivate the control levers before you
exit the seat or before you service the machine. The
control levers should always be deactivated when the
machine is left unattended.
Note: You may lower the implements for only a
short time after you stop the engine. The engine
start switch key must be ON in order to lower the
implements. Refer to the Article “Equipment Lowering
with Engine Stopped” in this manual.
SEBU7763-02
Bidirectional Shift (17) (Direction
Shift)
g01016340
Illustration 70
The bidirectional shift function can be selected with
the switch (17). The switch is located on the right
console. The default setting for the bidirectional shift
is OFF. Refer to theOperation and Maintenance
Manual, “Monitoring System” for more details about
the directional shift indicator. The bidirectional shift
mode is displayed on the top banner of the “Advisor”.
The autoshift function includes the following modes:
Bidirectional shift mode – The electronic
transmission system is equipped with a bidirectional
shift function for directional changes.
First gear forward to second reverse
directional shift mode – Push button (5)
once for the autoshift function. A directional
shift to the FORWARD position will always shift to
first gear. A directional shift to the REVERSE position
will always shift to second gear. This mode allows
a direct shift from the FIRST GEAR FORWARD
position to the SECOND GEAR REVERSE position.
This is the default setting for this machine.
Note: Advisor will recall the previous gear selection.
Press “OK” at the recall operator settings screen in
order to load the previous settings.
The top line of the “Advisor” panel displays the
specific bidirectional shift mode (“1F-2R, 2F-2R,
2F-1R”). For the best results, change the options with
the transmission in NEUTRAL.
SEBU7763-02 53
Operation Section
Machine Operation

Automatic Downshift (18) Automatic Downshift (LOW) – Push switch (18)

and release the switch until the indicator for the
(Downshift) automatic downshift is ON. This setting allows the
highest engine lug setpoint and the most reduction in
travel speed before an automatic downshift occurs.
The selection can be Changed in Advisor.

Automatic Downshift (MEDIUM) – Push switch

(18) and release the switch again until the indicator
for the automatic downshift is ON. This setting allows
the middle engine lug setpoint and the medium range
of reduction in travel speed before an automatic
downshift occurs. The selection can be changed in
the Advisor menu.

Automatic Downshift (HIGH) – Push switch (18)

and release the switch again until the indicator for the
g01016340 automatic downshift is ON. This setting allows the
Illustration 71
lowest engine lug setpoint and the least reduction in
travel speed before an automatic downshift occurs.
Automatic Downshift – The electronic
The selection can be changed in the Advisor menu.
transmission system is equipped with
a mode for the automatic downshift.
When the machine is powered down, the active mode
If a significant decrease in machine speed is
for the automatic downshift is kept in ECM memory.
detected, this function automatically downshifts the
When the machine is powered up, the automatic
transmission. This function works in forward and
downshift is activated in the same mode.
reverse gears. The default setting for this machine is
OFF. When the automatic downshift is activated the
default setting is medium. Light Switches (21) (22) (23) (24)
(31)
The automatic downshift switch (18) is located on
the right console of the cab. The current mode
of operation is shown by the indicator for the
automatic downshift. When the machine is started,
the transmission will be in the mode of automatic
downshift that was selected prior to shutting down
the machine. When the machine is started and the
automatic downshift is not active, push switch (18)
and release the switch. If the mode for the automatic
downshift is active, the indicator for the automatic
downshift will illuminate and the display monitor will
display “LO or HI”. Select the mode for the automatic
downshift with the transmission in NEUTRAL. If the
operation for the automatic downshift is not desired,
the machine can be operated in the manual mode.
Changes in performance for the automatic downshift Illustration 72
g01127109
can be made in “Advisor”.
Interior Dome Light (31) – This is a three-position
The operation for the automatic downshift can be switch. The dome light is OFF in the center position.
used in the following modes. Push the right side of the rocker switch in order to
enable the light to turn on when either one of the cab
Manual Shift in Automatic Downshift – The doors are open. Push the left side of the switch in
automatic downshift allows the transmission to order to turn on the dome light. See illustration 52.
downshift automatically. After a manual upshift, the
auto kickdown is prevented for two seconds. The Panel Backlights and Front Lights on
operator can make manual shifts at any time. Cylinders (21) – Press the rocker switch
to the top position in order to turn on the
Automatic Downshift (OFF) – Push switch (18) and dash panel lights and the front halogen floodlights.
release the switch in order to turn off the automatic Move the rocker switch to the middle position in order
downshift. The indicator on the front instrument panel to turn on the dash lights. Press the bottom of the
will no longer be illuminated. The manual shift mode switch in order to turn off the lights.
is then active if no autoshift indicators are on.
54 SEBU7763-02
Operation Section
Machine Operation

Work Lights on Fenders and Light for
Ripper(22) – Press the top of the switch to
the first position in order to turn on the lights
on the fender. If equipped, with a light on the ripper,
depress the switch to the second position in order to
turn on the light on the ripper.
Horn (27)
Horn – Push the knob downward in order
to sound the horn. Use the horn to alert
the personnel. Use the horn to signal the
personnel.

Note: The switch can be in the top position or

Ripper Auto Stow switch (28)
the middle position during shutdown. The fender
Push ripper auto stow switch (28) on the ripper
floodlights will remain on for a short period of time
control in order to raise the ripper to maximum height.
when the switch is left in one of these two positions.
If the machine is configured move the ripper to a full
SHANK IN position. The positions of the ripper can be
Front Lights on ROPS (23) – Press the
configured with Advisor. Refer to System Operations,
top of the switch to the first position in order
RENR8170 for more information about Advisor.
to turn on the lights on the ROPS that face
forward. If equipped, with HID lights, the lights on the
SHANK IN – Position “In”
ROPS, that face forward will use HID lights. Depress
the switch to the second position in order to light the
SHANK OUT – Position “Out”
HID lights on the cylinders.
SHANK – Unchanged position
Rear lights on ROPS (24) (if equipped)
– Press the top of the switch in order to turn While the ripper auto stow function is moving the
on the light on the ROPS that faces the rear. ripper, press the ripper auto stow switch again in
order to stop ripper movement.
Action Light (25)
Ripper Raise/Lower (29)
Action Light – The action light illuminates
when a Warning Level 2 is active. The
action light illuminates when a Warning
Level 3 is active. The action light is on the gauge
and indicators. A second action light is on the right
hand console.

Refer to the Operation and Maintenance Manual,

“Monitoring System” for more information about the
action light.

Ripper Shank In/Out Lever (26)

Shank In – Pull the front of the ripper
shank in/out lever (26) toward the operator
in order to move the shank in closer to the
machine. Release the lever. The lever will return to
HOLD position.
Hold – The ripper shank in/out lever
(26) returns to the HOLD position. Ripper
movement will stop when the lever is
released.
Shank Out – Pull the rear of the ripper
shank in/out lever (26) toward the operator
in order to move the shank out away from
the machine. Release the lever. The lever will return
to HOLD position.
Illustration 73
g01129001
RAISE – Push the top of the ripper lift
control lever (29) in order to raise the ripper.
Release the lever. The lever will return to
the HOLD position.
HOLD – The ripper lift control lever (29)
automatically returns to HOLD position.
Ripper movement will stop when the lever
is released.
LOWER – Push the bottom of the ripper
lift control lever (29) in order to lower the
ripper. Release the lever. The lever will
return to the HOLD position.
SEBU7763-02
Winch Control (30) (If Equipped)
g01129007
Illustration 74
(30) Winch control lever
Winch (Lock) – Press the switch (20) on
the console to the winch control circuit to
the stop position. This switch deactivates
the winch control lever. A light on the gauge display
will illuminate when this mode is active.
Note: Deactivate the winch control lever before you
exit the seat or before you service the machine. The
winch control lever should always be deactivated
when the machine is left unattended.
g01127181
Illustration 75
The electronic control provides variable speed
control for the winch. Slight movement in the REEL
IN position or slight movement in the REEL OUT
position results in a winch drum speed that is very
slow and controlled. As the control is moved further
from the center BRAKE ON (neutral) position, the
winch drum speed is increased proportionally. When
the control is released from the REEL IN position or
from the REEL OUT position, the control will return to
the BRAKE ON (neutral) position.
Brake On (Neutral) (30A) – The wire rope
should not move. Use this position when
you are holding a load and when the winch
is not active.
55
Operation Section
Machine Operation
Reel-In (30B) – Push the lever forward
in order to reel in the wire rope. The wire
rope should move toward the winch under
power. Release the lever. The lever will return to the
BRAKE ON (neutral) position.
Freespool (30C) – Push the control
away from the operator in order to release
the winch. The control will stay in the
DETENTED position. The wire rope will unreel by the
weight of the load. The wire rope will unreel as the
machine moves away from the load. Pull the control
from the DETENTED position. The lever will return to
the BRAKE ON (neutral) position.
Do not use drum clutch release for controlled
reelout of suspended loads.
Sudden release of load may result in injury or
death and property damage.
Use only reelout to lower loads.
Reel-Out (30D) – Pull the lever rearward
in order to reel out the wire rope. The wire
rope will reel out under power. Release the
lever. The lever will return to the BRAKE ON (neutral)
position.
Window Wiper and Window Washer
(32)
g01129013
Illustration 76
Front Windshield Wiper and Front
Windshield Washer (32A) – Turn the knob
clockwise in order to turn on the windshield
wiper. Continue to turn the knob clockwise in order to
move the windshield wipers faster. Push the knob in
order to activate the windshield washer. Spring force
returns the knob when you release the knob.
56
Operation Section
Machine Operation
The Windshield Wiper/Washer for the
left door (32B) – All of the Windshield
Wiper/Washers operate in the same
manner as Windshield Wiper/Washer (32A).
the Windshield Wiper/Washer for the
right door (32C) – All of the Windshield
Wiper/Washers operate in the same
manner as Windshield Wiper/Washer (32A).
The Windshield Wiper/Washer for the
rear window (32D) – All of the Windshield
Wiper/Washers operate in the same
manner as Windshield Wiper/Washer (32A).
Heating and Air Conditioning
Controls (33)
Fan Control (33A)
The Fan Speed Switch (33C) for the
Heating and for the Air Conditioning –
The fan speed switch controls the
four-speed blower fan motor.
OFF – Move fan speed switch (33C) to the
left position in order to stop the blower fan.
Low – Move the switch to this symbol. This
is the lowest fan speed.
Medium – Move the switch to this symbol.
This is the medium fan speed.
High – Move the switch to this symbol for
the high fan speed.
Maximum – Move the switch to this symbol
for the maximum fan speed.
Air Conditioning Switch
Air Conditioning (33A) – Depress A/C
switch (33A) in order to activate the air
conditioning system. Turn fan speed switch
(33C) to LOW, MEDIUM, HIGH or MAXIMUM speed.
Adjust temperature variable control (33B) for the
desired temperature.
SEBU7763-02
Temperature Variable Control (33B)
Temperature Variable Control (33B) –
Turn the control knob anywhere between
the blue area (left) and the red area (right).
This will control the amount of heating and the
amount of cooling.
Move temperature variable control (33B) clockwise
in order to operate the heating system. Turn the
knob toward the red area in order to increase cab
temperature. Turn the knob toward the blue area in
order to decrease the temperature.
Heating and Air Conditioning System
Operation
The Fan Control for the Heating and for
the Air Conditioning – The fan control
knob assists the functioning of the heating
and air conditioning system.
The heating and air conditioning system can perform
four functions:
Heating – Turn the fan speed switch to LOW, HIGH
or MAXIMUM speed. Adjust temperature variable
control (33B) for the desired temperature.
Air Conditioning – Activate the A/C switch. Turn
the fan speed switch to LOW, MEDIUM, HIGH or
MAXIMUM speed. Adjust the temperature variable
control for the desired temperature.
Pressurizing – When heating or cooling is not
desired, pressurize the cab in order to prevent dust
from entering.
Turn the temperature variable controls to a
comfortable stage. Turn the blower fan switch to
LOW, MEDIUM, HIGH, or MAXIMUM speed. Use the
fan speed that is needed to keep out the dust.
Defogging – Activate the air conditioning system.
Select a fan speed for the air conditioner. Use the
fan speed that is needed to remove moisture from
the air in the cab. This prevents moisture from
forming on the windshield and the windows. Adjust
the temperature control until the moisture level is
lowered. Adjust the temperature control until the
temperature of the cab is comfortable.
SEBU7763-02
Cab Door (34) (35) (36)
g01127191
Illustration 77
Front view
Pull lever (34) in order to open the cab door (35).
Fully open the door until the door latches.
g01127201
Illustration 78
Typical machine cab (Track-Type Tractor)
Some components are removed for clarity.
Pull inside top lever (36) in order to release the cab
door from the fully open position. Pull the lever that is
outside of the cab in order to close the cab door.
Alternate Exits
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.
Mirror (37)
The operator will adjust the rear view mirror in order
to get the best visibility. Adjust the mirror before you
operate the machine and after operators change.
57
Operation Section
Machine Operation
Window (39)
g01129016
Illustration 79
Open latch (39A). Then squeeze latch (39B) in order
to release the window from the CLOSED position.
Close latch (39A) in order to secure an open window.
i02703644
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-
ing, do not operate the machine until the cause
has been corrected. Machine operation with faulty
action alarms or displays could result in injury or
death as any Warning Category 3 notifications will
not be relayed to the operator.
When the engine start switch key is turned to the
ON position, the monitoring system runs a test. The
operator must observe the monitoring system during
the test to determine proper operation.
The self testing feature verifies that the modules of
the monitoring system are properly operating. The
self testing feature verifies that the display module is
properly operating.
The operator must observe the outputs in order to
determine if the modules are operating properly. This
self testing feature is three seconds long.
58
Operation Section
Machine Operation
During the self test, all status indicators on the
instrument module light.
The digital display window on the instrument module
shows the following readouts:
• Initial part number of the instrument module
• All indicators of units (Deg C, kPa, rpm, and liters)
• “X10”
• Symbol for the hour meter
• “8.8.8.X8.8” readout
The pointers in the quad gauge point upward. Then,
the pointers point to the left. Then, the pointers point
to the right. Then, the pointers point to the final
position.
• The readout of the gear shows “**”.
• The speed readout shows “888”, “MPH”, and
“km/h”.
• The rear action light “ON then OFF”
• The forward action light stays illuminated.
• The action alarm sounds once.
The monitoring panel is then in the normal operating
mode.
Action Light
g01108870
Illustration 80
Instrument module
Action Lamp (1) – There are two action
lamps. One action lamp (1) is on the
instrument module. The other action lamp
is located on the right console. The rearward action
lamp is viewed when the operator is facing rearward.
SEBU7763-02
Electrical Fault
Electrical System (2) – This indicator
indicates a malfunction in the electrical
system. If this alert indicator lights, the
system voltage is too high or too low for machine
operation.
Increase the engine speed to high idle, if the electrical
loads are high. The electric loads consist of the air
conditioning and/or the lighting. An alternator will
generate more output when the engine is at high idle.
If the alert indicator for the electrical system stops
within one minute, the electrical system is operating
normally. During the periods of low engine speeds,
the alternator is overloaded.
Modify the operating cycle. This will prevent the
electrical system from overloading. This will also
prevent the electrical system from discharging the
batteries. You can also reduce the loads on the
electrical system. Use the medium fan speed in the
cab instead of the high fan speed.
Run the engine speed at normal rpm. Run the
electrical system at a light load. If the light remains on,
drive the machine to a convenient stop. Investigate
the cause of the problem. The cause may be a loose
alternator belt, a broken alternator belt, a faulty
battery, a faulty alternator, etc.
SEBU7763-02
Status Indicators
Illustration 81
Parking Brake (3) – This status indicator
indicates that the parking brake is engaged.
If this indicator lights, disengage the parking
brake.
Float (4) – This status indicator is
illuminated when the float mode is selected.
Single Tilt (5) – This status indicator is
illuminated when the single tilt system is
activated.
Dual Tilt (6) – This status indicator is
illuminated when the dual tilt system is
activated.
This function (7) is not used. –
This function (8) is not used.
Auto Blade Assist (9) – This indicator is
illuminated when the auto blade assist is
enabled.
59
Operation Section
Machine Operation
g01356411
This function (10) is not used.
Implement Lockout (11) – This indicator
is illuminated when the implement lockout
is activated.
This function (12) is not used.
Winch Lock (13) – This status indicator is
illuminated when the winch control lever is
disabled.
Winch Low Speed (14) – This indicator
is illuminated when the winch is locked at
low speed.
Winch Freespool (15) – This indicator is
illuminated when the winch is released .
Automatic Downshift(16) – This indicator
is illuminated when the auto kickdown
operation is active.
60 SEBU7763-02
Operation Section
Machine Operation

Table 4
Bidirectional Shift Function(17) – This D8T High Inlet Manifold Air Temperature
indicator is illuminated when the autoshift
mode is functioning. Trip Point 80 °C 84 °C
(176 °F) (183 °F)
Warning 1 2
Gauges Level
Torque Converter Oil Temperature (18) –
This gauge indicates excessive torque Table 5
converter oil temperature. If the gauge High Engine Coolant Temperature D8T
needle reaches the red zone, the Advisor display
monitor will display a warning. If necessary, reduce Trip Point 107 °C (225 °F) 115 °C (239 °F)
the load that is on the machine until the torque Warning Level 2 3
converter oil temperature decreases.
Table 6
Fuel Level (19) – The fuel level gauge High Hydraulic Oil Temperature D8T
indicates the amount of fuel that remains
in the fuel tank. A gauge needle in the red Trip Point 102 °C (216 °F) 117 °C (243 °F)
zone indicates a low fuel level. Refill the fuel tank Warning Level 2 3
before the machine is empty of fuel.
Table 7
NOTICE
High Torque Converter Oil Temperature D8T(1)
Running out of fuel can cause engine damage. Do not
continue to operate the machine when critically low on Trip Point 129 °C (264 °F) 135 °C (275 °F)
fuel.
Warning Level 2 3
(1) This excessive oil temperature does not initiate the full forward
Hydraulic Oil Temperature (20) – The speed of the fan.
gauge indicates the temperature of the
hydraulic oil in the hydraulic oil sump for the Table 8
steering and implement circuits. This gauge indicates
High Transmission Oil Temperature D8T(1)
excessive hydraulic oil temperature. If the gauge
needle reaches the red zone, the Advisor display Trip Point 119 °C (246 °F)
monitor will display a warning. If necessary, reduce
Warning Level 2
the load that is on the machine until the hydraulic
oil temperature decreases. Move the implement
cylinders without a load, or clean the hydraulic oil Thermostat Control
cooler.
The following table shows the thermostat opening
Engine Coolant Temperature (21) – The temperatures.
water temperature regulator regulates the Table 9
coolant temperatures. This gauge indicates
excessive engine coolant temperature. If the gauge D8T Thermostatic Control
needle reaches the red zone, the Advisor display Opening Temperature 81 °C (178 °F)
monitor will display a warning. Continued operation to
of the machine during the sounding of the warning 84 °C (183 °F)
alarm or the gauge needle in the red zone may
damage the engine. Fully Open Temperature 92 °C (198 °F)

Warnings For Overheating Fan Speed

The following tables show the temperatures for All D8T tractors have a hydraulic fan drive.
the warning trip points for the following systems:
inlet manifold air temperature, engine coolant
temperature, hydraulic oil temperature, and torque
converter oil temperature.
SEBU7763-02
Fan speed will vary. The fan speed depends
on the following temperatures: inlet manifold air
temperature, engine coolant temperature, and
hydraulic oil temperature. These temperatures rise
as the load and ambient temperatures increase.
Under the condition of very light loads and cooler
ambient temperatures, the fan operates at minimum
forward speed in order to conserve fuel. As the load
and ambient temperatures increase the fan speed
increases. Under heavy load and high ambient
temperatures, the fan reaches maximum forward
speed.
Maximum Forward Speed of Fan
The fan will operate at full forward speed when any of
the temperatures that are listed in the following table
are met or the temperature is exceeded.
Table 10
Temperatures at Maximum Demand Fan Speed
Engine Coolant 98 °C (208 °F)
Temperature
Hydraulic Oil 90 °C (194 °F)
Temperature
Inlet Manifold Air 48 °C (118 °F)(1)
Temperature
(1) This temperature with the sound suppression arrangement
is 54 °C (129 °F).
Engine Speed (22)
Do not allow the engine speed to exceed 3150 rpm.
Severe engine damage may result.
The following range marks are displayed on the
tachometer (22): White zone, Yellow zone, and Red
zone.
Engine Speed (White zone) – 0 - 2700
RPM
Engine Speed (Yellow zone) – 2700 -
2850 RPM is only a visual caution. This
indicates that the machine is approaching
the Level 2 Warning.
Engine Speed (Red zone) – 2850 - 3500
rpm is a visual warning that immediate
action is required to maintain the engine
speed below the maximum allowable engine speed of
3150 rpm. A Level 2 Warning begins at 2850 rpm. A
Level 3 Warning starts at 3150 rpm. Apply the service
brake in order to reduce engine speed immediately.
Note: See the Topic “Engine Overspeed” in this
manual for more information.
61
Operation Section
Machine Operation
NOTICE
Do not exceed 3150 rpm in any situation. Overspeed-
ing when downshifting, going downhill, etc., can result
in serious damage to your engine.
Digital Display Window (23)
The digital display window (23) provides readouts
that show the following items:
• Operational hours (service hours)
• Selected gear and direction
• Ground speed
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. Service hours are displayed even with the
engine start switch key in the OFF position.
Warning Levels
The operator will be warned of immediate problems
with a machine system or impending problems with a
machine system by Advisor.
The machine monitoring system provides three
warning levels. Warning level (1) requires no
immediate action. The first level requires only
operator awareness. The system needs attention.
Warning level (2) requires a response to the
warning. Change the machine operation or perform
maintenance to the system. In all events except
engine overspeed, warning level (3) requires
immediate shutdown of the machine. Engine
overspeed requires an immediate reduction in engine
speed.
The Advisor system will display a text message for
the current highest level active event.
62 SEBU7763-02
Operation Section
Machine Operation

Table 11
Warning Operation
Warning indications(1)
Warning Front Action Rear Action Action Advisor
Category Lamp(3) Lamp(4) Alarm Monitor “Operator Action “Possible
Sounds Display Required” Result ”(2)
1 X Amber X(5) No immediate No machine
action is required. damage
The system needs occurs. Minor
attention soon. reductions
in machine
performance
may occur.
2 X Red X (4) X(5) Change machine Severe
operation or perform damage to
maintenance to the components
system. can occur.
3 X Red X (4) X (6) X(5) (7)Immediately Injury to the
perform a safe engine operator
shutdown. or severe
damage to
components
can occur.
(1) The active indicators are marked with an X.
(2) This is the possible result, if the operator takes no action.
(3) The lamp is color coded. The lamp flashes at Level 2 and 3.
(4) Rear action lamp flashes at Level 2 and 3.
(5) Advisor indicates an active fault.
(6) The action alarm sounds.
(7) Engine overspeed does not require engine shutdown. Engine overspeed requires applying the brake in order to immediately reduce
engine speed.

If an action alarm, alert indicator, or Warning
occurs, the message will override the screen that
was displayed on the CAT Advisor graphic display
module.
CAT Advisor Graphic Display
The Advisor display monitor monitors the machine
operations, diagnostic events, service intervals,
and modes of operation. Advisor is used to change
customer preferences and operation parameters.
This allows additional means for the operator to
increase machine efficiency.

Module

g01361910
Illustration 83

g01085588
Illustration 82 Monitor alert indicator – The action light
lights on the front instrument module. See
The CAT Advisor Graphic Display Module is located illustration 80. The action lamp that appears
at the front of the right side operator console. on the Advisor display monitor indicates a detected
fault by the monitoring system.
SEBU7763-02 63
Operation Section
Machine Operation

If an action alarm, alert indicator, or Warning occurs, Menu for the Operator’s Profile
the message will override the screen that was
displayed on the CAT Advisor display monitor.

Home Button
As many as five items are available to setup with
Advisor.

g01372719
Illustration 85
Operator menu

The menu for the “Operator Profile” allows the user to

perform the following changes to an operator profile:

g01356674
• selection
Illustration 84
Home menu • editing
• creating
• deleting
• saving
The user may reset a profile back to the default
settings or the user may recall the previously used
settings.
64
Operation Section
Machine Operation
An Operator Profile is a private set of preferences that
is identified by a name. Once the profile is created,
the operator may associate various items to that
profile such as the following components: implement
features and settings, display settings, and power
train settings. After all of the parameters have been
adjusted to the operator’s preference, the operator
may then save the parameters for future usage.
g01115796
Illustration 86
Upon the next restart, the user will be prompted to
recall the previous settings. Refer to Illustration 86.
Press the “OK” button within ten seconds in order to
recall the previous settings. If ten seconds pass by
the start-up, the default settings will activate.
g01104631
Illustration 87
SEBU7763-02
The “Operator Profile” menu option is entered by
selecting “Operator” from the “Home” menu. Press
the up arrow button or the down arrow button until
“Operator” is highlighted. Then press the “OK” button.
Refer to Illustration 87.
Note: The “Home Menu” can be displayed from any
screen by pressing the Home button.
The following screen will now be displayed.
g01104635
Illustration 88
The “Operator Profile” menu options and contents
contain the following components:
• Select the profile.
• Edit the name.
• Create the profile.
• Delete the profile.
• “View/save” to the current profile
• Default Set
• “Recall Previous”
Press the “UP” arrow button or the “DOWN” arrow
button until the desired category is highlighted in
order to access the “Operator Profile” menu options .
Then press the “OK” button. The following explains
the usage of each menu option.
SEBU7763-02
“Create Profile”
g01356469
Illustration 89
Engine Reverse Fan
From the “Operator Profile” menu, use the appropriate
arrow button to highlight the “Create Profile” option.
Then press the “OK” button in order to display the
“Create Profile” screen. Follow the prompts that
are on the screen in order to create a new name.
Save the new name to the existing list of profiles.
This procedure creates a profile. The “Settings”
menu can then be used to adjust parameters. These
parameters may then be associated to the new
profile by using the “View/Save Current” option.
The user profile contains these options that are able
to be modified.
• Blade response
• Blade tilt mode
• Blade float
• Auto downshift
• “Auto downshift setting”
• “Bidirectional shift configuration”
• “Bidirectional shift setting”
• “Reverse fan manual switch”
• “Ripper auto stow function”
• Measurement
• Language
65
Operation Section
Machine Operation
• Backlight intensity “night mode %”
• Backlight intensity “day mode %”
• Contrast “%”
Note: A maximum of 10 profiles may be used. The
typical display settings will allow 11 characters to the
name of profile information to be viewed.
“View/Save Current”
From the “Operator Profile” menu, use the
appropriate arrow button to highlight the “View/Save
Current” option. Then, press the “OK” button in
order to view the settings that are associated with
the current profile. This procedure will cause the
following components to be displayed on the screen:
selected profile and current settings. The displayed
settings are the current settings. Also, the settings will
reflect any overrides that are not saved to the stored
settings in memory. The operator may then exit this
display without saving the overrides to memory or the
operator may save the overrides to memory. Then,
exit the display by following the screen prompts. In
either case, the machine operation will reflect these
settings. When the settings are not saved and this
profile is recalled next, the overrides will not be active.
“Select” Profile
From the “Operator Profile” menu, use the appropriate
arrow button to highlight the “Select Profile” option.
Then press the “OK” button in order to display a
list of existing profiles. Again, use the appropriate
arrow button to highlight the desired profile. Then
press the “OK” button in order to select that profile.
This procedure will cause the selected profile and
the associated settings to be the active profile. The
machine operation will reflect these settings.
Note: A maximum of 10 profiles may be used.
“Edit” Name
From the “Operator Profile” menu, use the appropriate
arrow button to highlight the “Edit Name” option.
Then press the “OK” button in order to display a list
of existing profiles. Again, use the appropriate arrow
button to highlight the name of the desired profile.
Then press the “OK” button in order to select that
profile. Follow the prompts that are on the screen in
order to edit the selected name. Save the changes.
This procedure renames the selected profile. Also,
this keeps the settings associated with the original
name.
Note: The typical display settings will allow 11
characters to the name of profile information to be
viewed.
66 SEBU7763-02
Operation Section
Machine Operation

“Delete” Profile Display Module

From the “Operator Profile” menu, use the appropriate
arrow button to highlight the “Delete Profile” option.
Then press the “OK” button in order to display a list
of existing profiles. Again, use the appropriate arrow
button in order to highlight the profile that will be
deleted. Then press the “OK” button in order to delete
that profile. This procedure deletes the selected
profile from the list of stored profiles. This procedure
also deletes the settings that are associated with
that profile.

Default Set
From the “Operator Profile” menu, use the
appropriate arrow button to highlight the “Default Set”
option. Then press the “OK” button in order to make
the default settings active. This procedure recalls
the default settings. The default settings are then
the active settings and the machine operation will
reflect the default settings. Once the default settings
have been activated, the settings may be viewed
without saving using the “View/Save Current” option.
The default settings are not permanently associated
with the current profile unless the operator saves the
default settings to the current profile by using the
“View/Save Current” option.

“Recall Previous”
From the “Operator Profile” menu, use the appropriate
arrow button to highlight the “Recall Previous” option.
Then press the “OK” button in order to activate the
previous profile’s settings. This procedure recalls
the settings that were associated with the previous Illustration 90
g01361831
profile. This was the profile that was used before (1) Gear and Direction
the current profile was activated. The recalled (2) Dozer function
settings are then the current, or active settings. The (3) “Active” (reverse fan)
active settings are not permanently associated with (4) Auto Shift mode
(5) Left Up
the current profile. In order to make the change (6) Right Down
permanent, the operator can save the active settings (7) Back button
to the current profile by using the “View/Save Current” (8) Return to first menu (button)
option. These settings may also be viewed without (9) OK button
saving using the “View/Save Current” option. (10) Display menu
(11) Options

Items (1), (2), (3), and (4) across the top banner of
the screen contain critical information and system
data at all times.

Transmission gear and direction (1) – This display

area shows the active transmission gear and the
current direction of the machine.

Dozer mode (2) – This display area shows one of a

number of different messages such as the following
modes: the current dozer mode, the current segment
of ABA (Auto Blade Assist) or Auto Carry, the
implement status, and the status of the implement
system .
SEBU7763-02
“Active” (3) – When this message is shown, the
forward and reverse control to the engine fan is
password protected. The reverse fan function initiates
turning in the “REVERSE” speed. The automatic
mode stops the purge cycle when the machine shifts
into FORWARD speed. Manual mode will complete
the timed purge cycle if the machine shifts into
FORWARD speed.
Autoshift Mode (4) – This display area shows the
current autoshift mode that is selected. Use the switch
on the right operator console in order to select one of
the following autoshift modes: “1F-2R”, “2F-2R”, and
“2F-1R”. If no autoshift mode is selected, “Inactive”
status will show in the display area.
Five buttons on the right of the Advisor Graphical
Display Module are the user interface. Use the
buttons for the following purposes: navigation
buttons, menu buttons, and data information
Left Up (5) – This button is used for the following
purposes: navigation button, data information, and a
decrease in a setting value.
Right Down (6) – This button is used for the following
purposes: navigation button, data information, and an
increase in a setting value.
Back button (7) – This button is used to return to
the previous screen.
Return to first menu (8) – Home button
OK (9) – This button is used to make selections
on the screen . Also, use this button to confirm an
password entry or use the button to save an operator
profile.
Display Menu (10) – This display area shows the
numerous menus and submenus in order to navigate
from one screen to another screen. Also, this display
area depends on the menu or the submenu that
is selected in order to show the information in the
system, system status, and operator warnings.
Options (11) – Additional information is available
on the subject that is highlighted on the display
screen. Use the appropriate arrow button to view the
information.
Use the arrow buttons to highlight the desired
selection in order to navigate through the menus and
submenus. Then press the OK button. Also, use
the arrow buttons to highlight a mode or parameter
setting. Then, press the OK button in order to select
that option.
67
Operation Section
Machine Operation
Upon turning the engine start key to ON, the Advisor
display module will perform a self test. The first
preliminary screen asks the operator to accept the
use of the customer preferences that are still active
from the previous start-up. Press the OK button,
in a timely manner in order to use the active set of
customer preferences. Without acceptance of the
previous settings as “OK”, the default settings are
loaded into the memory 10 seconds after start-up.
A second popup screen appears when active faults
or events are reported to the Advisor display module
by any ECM. Warning information appears on the
screen and the operator must acknowledge the
warning message by pressing the OK button. Advisor
will scroll through all the warning messages that are
generated by active faults or events. The warning
messages are not cleared from system memory by
pressing the OK button. The message may reoccur
after a period of time according to the severity of the
warning information.
After all screens with warning messages are
acknowledged, the first performance monitor screen
will appear. This is the default screen.
Performance Menu
Illustration 91
g01107257
The “Performance” menu allows the operator or the
technician to view two pages of information. These
pages of information monitor critical data from the
machine systems during machine operation. This
information can only be viewed. The typical display
settings will allow 11 characters to the name of profile
information to be viewed. The “Performance” menu
uses two screens for the real time monitoring of the
following information:
68 SEBU7763-02
Operation Section
Machine Operation

Table 12
“Performance” Screen 1 of 2
Description Units
Engine Coolant °C or °F
Temperature
Engine Speed RPM
Hydraulic Oil Temperature °C or °F
Torque Converter Oil °C or °F
Temperature

Table 13

“Performance” Screen 2 of 2
Description Units
Engine Oil Pressure kPa or PSI
Inlet Air Temperature °C or °F
Fuel Level 0 - 100%
g01107277
Illustration 93
System Voltage V
When the machine is powered up, the page that
The “Performance” menu option is entered by displays “Performance 1 of 2” is the default setting.
selecting “Performance” from the “Home Menu”. (Key ON). Press the right arrow button in order to
Press the up arrow button or the down arrow button access the “Performance 2 of 2” page. Refer to
until “Performance” is highlighted in order to select Illustration 94.
the “Performance” menu. Then press the “OK”
button. Refer to Illustration 92.

Note: The “Home Menu” can be displayed from any

screen by pressing the Home button.

g01107317
Illustration 94

The arrow buttons switch the page from one screen

to another screen.

g01107297
Illustration 92

The following screen will now be displayed.

SEBU7763-02 69
Operation Section
Machine Operation

Settings Menu

g01365893
Illustration 95

The “Settings” menu allows the user to adjust Operating conditions, preferences of the operator,
parameters for the following: and requirements for efficient operation inform the
operator that adjustments to the parameters are
• Advisor display needed. The setup of the machine determines the
display of adjustable parameters. The attachments
• Implement operation on the machine are determined by the software
versions that are contained in the available ECM. The
• Operation of the power train Advisor reviews the version of the software in order
to determine the set of parameters that are displayed
• Reverse fan function and the set of parameters that are variable.

See the “Quick Reference Guide for Setting the Note: Cat ET can be used to access parameters and
Operator Profile by Using Advisor” at the end of this CAT ET can be used to change parameters.
section for more information.
70 SEBU7763-02
Operation Section
Machine Operation

The “Settings” menu option is entered by selecting
“Settings” from the “Home Menu”. Press the up arrow
button or the down arrow button until “Settings” is
highlighted in order to select the “Settings” menu.
Then press the “OK” button. Refer to Illustration 96.
Note: Press the home button in order to display the
“Home Menu”.
The “Settings” menu organizes the adjustable
parameters into four categories. These categories
have adjustable parameters. The four categories are
“Display Setup”, “Implement Setup”, “Power train
Setup” and “Engine Setup”. The menu options are
displayed on the left half of the screen, and the user
settings are displayed on the right half of the screen.
To make adjustments to the associated parameters,
press the up arrow button or the down arrow button
until the desired category is highlighted. Then press
the “OK” button in order to access the parameters
in that category. From this point, follow the screen
prompts in order to make adjustments to the available
parameters.

Display Settings
From the “Display Setup” menu, use the arrow
buttons to highlight the desired parameter. Then
press the “OK” button. This will allow access to that
parameter’s screen. Then follow the screen prompts
in order to adjust the parameter. All the parameters
in this category relate to the operator’s preferences
in regard to the Advisor display. The following
parameters may be adjusted:

Contrast – Adjust the contrast“ 0 - 100 %”.

g01107800
Illustration 96 Language – Select a language.

The following screen will now be displayed. Measurement – Select one of the following options:
Metric, English, and Imperial

Backlight in Night Mode – Adjust the level of

brightness at night.

Backlight in Day Mode – Adjust the level of

brightness during the day.

Settings for the Implements

From the “Implement Setup” menu, use the arrow
buttons to highlight the desired parameter. Then
press the “OK” button. This will allow access to that
parameter’s screen. Then follow the screen prompts
in order to adjust the parameter. All the parameters
in this category relate to the operator’s preferences
for the work tool’s operational modes. The following
parameters may be adjusted:

Blade Response – Standard, fine, fast

Illustration 97
g01376916 Blade Float – The float is ON in FORWARD. The
float is OFF in FORWARD.

The Quick Drop (D9T) – Enabled, disabled

Ripper auto stow function (If equipped) – The

function contains the following components: Ripper
raise, ripper shank in, and ripper shank out.
SEBU7763-02
Auto Blade Pitch (If equipped) – This function
performs the following operations: Loading, carrying,
and spreading.
Blade Tilt Mode for Dual Tilt (If equipped) – Single
tilt or dual tilt
The submenu for the auto pitch feature allows the
operator to adjust settings (%) for the current pitch
position and the actual pitch position for each function
(if equipped).
“Load” – The dozer blade pitch is set when the
blade is loading.
“Carry” – The setting of the dozer blade pitch is
positioned when the machine is in the carry function.
“Spread” – The setting of the dozer blade pitch
is positioned when the machine is in the spread
function.
These parameters may be adjusted in the same
fashion as the adjustable parameters from the
“Implement Setup” menu.
Settings for the Power Train
From the “Power Train Setup” menu, use the
appropriate arrow button to highlight the desired
parameter. Then press the “OK” button. This will
allow access to that parameter’s screen. Then follow
the prompts on the screen in order to adjust the
parameter. The parameters in this category relate
the operator’s preferences for operational modes of
the power train. The following parameters may be
adjusted:
Auto Downshift
• Off
• Low
• Medium
• High
Bidirectional gears (shift)
• Inactive
• “1F-2R”
• “2F-2R”
• “2F-1R” (D8T) only
71
Operation Section
Machine Operation
Settings for Engine Setup
Password Protection
Adjustment to the engine settings for engine reverse
fan is password protected. See the “Service Menu”
section in this article. Follow the instruction for
“Service Password” in order to access to the reverse
fan function.
See the “Procedures for the Reverse Fan Function
(If Equipped)” in the “Operator Controls” story in this
manual for more information.
Procedures for the Reverse Fan Function
(If equipped)
Make sure that the machine is in PARK and on level
ground. The transmission is in NEUTRAL when you
begin this procedure to set the purge cycles with the
Advisor monitor display.
1. Highlight the “Settings” on the “Home” screen.
Press the OK button.
2. Highlight the setup for the “Engine”. Press the OK
button.
3. Use the service password in order to set up the
“engine reverse fan”.
4. Set the automatic mode for the “engine reverse
fan” to “Enable”. Press the OK button.
a. If necessary, set the mode for the “engine
reverse fan” to “Disable”.
5. Turn on the fan control switch. The fan control
switch is located under the Advisor monitor display
in front of the bulldozer control lever. The fan
begins to operate in the reverse direction.
Note: The following instruction may vary with
machines. The active software that operates the
reverse fan function will determine the actual
response to the fan.
6. The operator will set the purge interval. When
the fan is active in the reverse mode, set the
purge interval. Press the fan control switch for five
seconds in order to set the interval.
a. Select the segment of the reverse fan function
which is to change.
b. Set the cycle times for the ramp up and ramp
down for the desired purge intervals.
7. The new settings are active until the ignition key is
turned off.
72 SEBU7763-02
Operation Section
Machine Operation

Note: In order to save the desired settings, make

sure that you have selected a profile.

Service Menu
SEBU7763-02 73
Operation Section
Machine Operation

g01364896
Illustration 98
74 SEBU7763-02
Operation Section
Machine Operation

Access the Service Menu The required service password must be successfully
entered. This is the only way to access the Calibration
mode or the Configuration mode.

Codes in the display screen “Diagnostics” are visible

at any time. However, logged codes cannot be
cleared until the “Service Mode” is enabled.

From the Service Menu, use the appropriate arrow

button to highlight the desired selection menu. Then,
press the “OK” button in order to display that screen.

Diagnostics

g01024789
Illustration 100
Diagnostic message screen

Illustration 100 represents a typical message. Press

the “OK” key in order to acknowledge the message.
Consult the appropriate Warning Category for the
proper instruction.
g01363437
Illustration 99
The “Diagnostics” menu option will show a complete
The Service Menu contains the following 7 categories. list of all active events, logged events, and diagnostic
codes. #
• Diagnostics
Each line that is listed contains the following
• Calibrations information about that event or that code.

• System Status MID – Module Identifier

• ECM Summary Code – Component Identifier and Failure Mode

Identifier (CID/FMI)
• Limp Home mode
Occ – Number of occurrences
• Configuration
First – Service meter hour of the first occurrence
• Service Password
Last – Service meter hours of the last occurrence
Note: The options for the Calibration mode will not
be displayed until the “Service Mode” is enabled. Act – “X” means the event or the code is currently
active.
Note: The options for the Configuration mode will not
be displayed until the “Service Mode” is enabled.
SEBU7763-02 75
Operation Section
Machine Operation

Fault Log Clearing and Fault Indication • Engine

Clearing
• Power Train
The service password must be entered in order to
clear logged codes and logged events that are “Level • Implement
I & II”.
• Advisor
Some “Level I & II” engine events will not be cleared
by using Advisor. Limp Home Menu
Note: The ECM will require the entry of the machine
password in order to clear “Level III” events that are
logged.

Calibrations
The “Calibrations” menu option is password
protected. First, you must successfully enter the
service password. Then, the screen on the “Service”
menu displays the option that is the Calibration
menu. See Illustration 98 for the options settings that
can be calibrated from this menu.

System Status

g01364333
Illustration 102

The “Limp Home” menu option allows slow

incremental movement of the following functions.

• Blade raise
• Blade tilt
• Blade pitch
• Ripper raise
• ripper shank

Illustration 101
g01364434
The “System Status” menu option allows the operator
or the technician to view the real time data from
components in the machine’s major systems.
From the Service Menu, use the appropriate arrow
button in order to highlight the appropriate function.
Then, select the “System Status”. Then, press the
“OK” button in order to access the menu for “System
Status”. This menu organizes the systems into the
following categories.
• Steering
• Winch
This movement is done without using the implement
control levers. “Limp Home” mode may be selected
by the operator or the technician in order to move
implements to a safe position. This is needed in order
to move the machine in the event of a system failure
that causes a major repair. Some examples are a
steering failure or a failure of the dozer control.
Note: If a steering fault light (“Level III” warning)
is displayed on the screen, perform the following
actions. Select an option from the alert as a direct
link to the “Limp Home” menu.
76
Operation Section
Machine Operation
From the “Service” menu, use the appropriate
arrow button to highlight the “Limp Home” option.
Then press the “OK” button in order to access the
“Limp Home” menu. This menu will display a list of
implements that may be slowly moved in increments
by using the keys on the Advisor display monitor.
To move an implement in this fashion, use the
appropriate arrow button to highlight the desired
implement function from the menu. Then press
the “OK” button in order to access that function.
This action will result in a screen that will display
instructions for moving the implement. Follow the
prompts and directions on the screen in order to
move the implement.
ECM Summary
Illustration 103
g01364435
The “ECM Summary” menu option allows the user to
display a list of all the ECM’s. Also, the corresponding
software part numbers on the machine are provided.
Configuration
The “Configuration” menu option is password
protected. First, you must successfully enter the
password. Then, the screen on the “Service” menu
displays the menu option. See Illustration 98 for the
operating functions that can be defined from this
menu.
SEBU7763-02
Service Password
The Service Password menu option allows the
technician to enter a service password of four digits.
This password allows the display of the “Calibrations”
option and the “Configuration” option from the
“Service” menu. Then, access to the options is
allowed.
Engine Reversing Fan (If equipped)
The service password allows access to the reverse
fan function, if equipped. Use the operator settings in
order to enable the engine reversing fan option. Use
the “Operator Settings” in order to disable the engine
reversing fan, if necessary.
Totals Menu Option
g01364829
Illustration 104
The “Totals” display allows the operator or the
serviceman to access lists of collected data about
machine systems. This data is useful in order to
determine when service work needs to be performed.
Also, the Cat ET service tool may be used to access
this data.
SEBU7763-02 77
Operation Section
Machine Operation

Time in Gear “Hrs” or Distance Travelled

“km/mi”
• Total hours in Neutral Coast Function
• Total forward travel distance
• Total reverse travel distance
• Operating times “1F, 2F, 3F” gear
• Operating time in “N” gear
• Operating times “1R, 2R, 3R” gear
• Power train oil filter bypass
The following “Engine Totals” information may be
viewed by using the “Totals” screens.

g01364847
Fuel Consumption
Illustration 105
• Fuel consumption “Gal/hr of L/hr”
Use the appropriate arrow button and highlight the
Totals Menu from the Home Menu. Then, press the • Fuel rate per engine load factor “%”
OK button.
• Instantaneous load factor “%”
• Total fuel consumption number “Gal or L”
• Total maximum fuel “Gal or L”

Engine Data
• Number of engine starts
• Total engine revolutions (lifetime)

Idle Modes
• Idle time “Machine hrs”
• Total fuel at idle “gal”

g01364880
Illustration 106

Use the appropriate arrow button to highlight the

desired category. Then, press the “OK” button.
The screen displays the first page of the “Totals”
information for the selected category. Use the
“Totals” information in order to view the totals in each
category only. This information may not be changed
using “Advisor”.

The following information for the power train system

(“Ptrain Totals”) may be viewed by using the “Totals”
screens.
78 SEBU7763-02
Operation Section
Machine Operation

Quick Reference Guide for Setting

the “Operator Profile” by Using
Advisor

g01155740
Illustration 107
(1) Bidirectional shift mode (5) Return (“Home Menu”) (9) Dozer control (mode)
(2) Left or Up button (6) OK button (10) Gear and Direction
(3) Right or Down button (7) Additional information (Indicator)
(4) Back to the previous screen (8) Display menu

Creating an Operator Profile
1. Turn the engine start switch key to the ON
position. The monitoring system runs a test. The
operator may start the machine.
9. Repeat step 7 and repeat step 8 for a different
category until all desired changes are made.
10. Press the “Home” button and highlight “Operator”
with the Arrow buttons. Press the OK button.

2. Push the “Home” button.
3. Use the Arrow buttons in order to highlight the
“Operator” option on the “Home” screen. Press
the OK button.
4. Highlight “Create Profile”. Press the OK button.
5. Use the arrow buttons in order to highlight a letter.
Press the OK button in order to select the letter.
This process will allow you to create a name.
Select “Accept”. Press the OK button. This saves
the name that was created.
6. Press the “Home” button and highlight the
“Settings”. Save the setting. Press the OK button.
7. Then, highlight the desired category. Press the
OK button.
8. Use the Arrow buttons in order to highlight the
desired change. Press the OK button.
11. Use the Arrow button to highlight “View/Sav Cur”.
Then save the setting. Press the OK button. View
the changes that were made to the settings. Make
sure that the changes are correct. Press the OK
button. The new settings are now saved to the
new operator profile.
Note: If changes are not saved, changes will only
remain until the tractor key is turned off.
Note: Pressing the “OK” button within ten seconds
after start-up will select last settings of the previous
operator. This selection will occur even if the previous
settings were not saved.
Recalling a Saved Profile
1. Recall the saved changes and activate the
changes by following the previous steps 2 and 3.
a. Then, highlight the “Select Profile”.
b. Press the OK button.
SEBU7763-02 79
Operation Section
Machine Operation

c. Highlight the desired profile.

d. Press the OK button.

Reference: See Operation and Maintenance Manual,

“Operator Controls” for additional information on the
operating procedures for the“Auto Blade Assist” and
for the “Engine Reverse Fan”.

Listing of Abbreviations and Terms

The Advisor Monitor Display uses abbreviations
when the display area shows the information inputs.
The following table describes the abbreviations in
full terminology.

Table 14
Abbreviation and Term For Advisor Monitor Display
Abbreviation Term Abbreviation Term Abbreviation Term
aba Auto Blade km kilometer rt right
Assist
act active kPa kilopascal scrn screen

autocal automatic KPH “Kilometers / sec Second

calibration Hour”
aux auxiliary kpig “kilometers secs seconds
/ Imperial
gallon”
bi-dir bidirectional kpl “kilometers / seg segment
liter”
bld blade L Liter set setting
cal calibration L/Hr “Liters / shkin shank in
Hour”
ctrl control lt left shkout shank out
cur current m Meter snr sensor

cyl cylinder max maximum snsr sensor

DC direct current Mi Miles sol solenoid

degrs degrees min minimum spd speed
dist distance mm millimeter stat status
ecm electronic mm/s “millimeters / std standard
control second”
module
eng engine mpg “miles / US steer steering
gallon”
exten extension MPH “MILES / sw switch
HOUR”
f forward mpig “miles / tc torque
Imperial converter
gallon”
fil filter n neutral tco torque
converter
output
(continued)
80 SEBU7763-02
Operation Section
Machine Operation

(Table 14, contd)

filt filter Nm Newton temp temperature
meter
forwrd forward occ occurrence term terminal
Abbreviation Term Abbreviation Term Abbreviation Term
freq frequency p/n part number trans transmission
ft feet pos position V volt
ftlb foot pound pres pressure

Gal US Gallon press pressure

Gal/Hr “US Gallons / PSI Pounds per

Hour” square inch
hi high ptrain power train
hrs hours pwr power

hyd hydraulic r reverse

IGal Imperial rel release

Gallon
IGal/Hr “Imperial ren renewal
Gallons /
Hour”
imp implement req required
in inch ret return
in/sec “inches / rev reverse
second”
init initialization rpm revolutions
per minute

i02648039 • Hardware, which includes the following, data

Product Link
(If Equipped)
SMCS Code: 7606
Product Link is a satellite communication device
that transmits information regarding the machine to
Caterpillar and to Caterpillar dealers and customers.
The device contains a Global Positioning System and
a satellite transmitter/receiver. All logged events and
diagnostic codes that are available to the Caterpillar
Electronic Technician (ET) on the CAT data link
can be sent to the satellite. Information can also
be sent to the Product Link from the satellite. The
information that is sent by the Product Link goes to
the satellite, and then to the receiving station. The
receiving station transmits the data to Caterpillar. The
information can then be sent to Caterpillar dealers
and customers.
Note: Product Link is automatically activated when
the battery disconnect switch is in the ON position.
The system consists of three main components:
module, antenna, wiring, and additional mounting
hardware.
• Satellite System and Caterpillar Network
• PC Software
This machine is equipped with a Caterpillar Prod-
uct Link communication device which must be de-
activated within 12 m (40 ft) of a blast zone. Failure
to do so could result in serious injury or death.
If the machine is required to work within 12 m
(40 ft) of a blast area, then the operator must take
one of the following precautions:
• Disconnect the Product Link module from the
power source by disconnecting the wiring harness
at the Product Link module.
• Temporarily remove the Product Link module from
the machine.
SEBU7763-02 81
Operation Section
Machine Operation

• Install an ON/OFF switch in order to allow the Reduce the engine speed when you maneuver the
Product Link module to be turned off from the machine in tight quarters or when you break over a
inside of the cab. rise.

This warning does not supersede the published Select the gear range that is necessary before you
requirements or the regulations that are found in “Title start the downgrade. Do not change gears when you
30 of the Code of Federal Regulations (CFR)”. Every are going downhill.
operation of a mine should conduct an assessment of
hazards that meets all of the requirements of “Title 30 When you drive down a grade, use the same gear
of the Code of Federal Regulations (CFR)”. This will range that is used for driving up a grade.
ensure safe operation in the storage, transportation,
loading, and blasting of explosive material. The
following specifications are provided in order to
Operating The Machine
aid in conducting assessments of hazards. These
1. Adjust the operator’s seat.
specifications are also provided in order to aid in
ensuring compliance with all local regulations: 2. Fasten the seat belt.
• The power of the transmitter for the Product Link is
5 to 10 Watts.

• The operating frequency range for the Product Link

is 148 - 150 MHz.

Refer to System Operation, Troubleshooting,

Testing and Adjusting, RENR7911, “Product Link
121SR/321SR” for more information about this
service tool.

Regulatory Compliance
g01108817
Illustration 109

3. Push down on service brake pedal (2) in order to

prevent the machine from moving.

4. Start the engine.

5. Raise all attachments enough to clear any

unexpected obstacles.

g01131982
Illustration 108

Consult your Caterpillar dealer with any questions

that concern the operation of the Product Link in a
specific country.

i02767609

Operation Information
SMCS Code: 7000 Illustration 110
g01384474

Differential steering control and transmission direction selector

To prevent injury, make sure that no maintenance
work is being performed on the machine or near the
machine. Keep the machine under control at all times
in order to prevent injury.
82
Operation Section
Machine Operation
6. Release the parking brake by pushing down on
parking brake knob (3). This unlocks the parking
brake, the transmission control, and the steering
lever.
Note: When the parking brake is set, the transmission
defaults to neutral. When the parking brake is
released the transmission will stay in neutral. To
select the direction of machine travel, return direction
selector (4) to neutral.
7. Then, move direction selector (4) to the desired
direction. Use transmission gear selector (5) to
select the desired gear.
8. Release service brake pedal (2) in order to allow
the machine to move.
g01016002
Illustration 111
Engine speed control
9. To select high idle, push in on the top of the engine
speed control switch and release. The engine
speed immediately moves to high idle.
10. To select low idle, push in on the bottom of the
engine speed control switch and release. The
engine speed immediately moves to low idle.
11. Select an intermediate speed in the following
manner:
a. Set the engine speed to high idle.
b. Select the desired engine speed with the
decelerator (1).
c. Push in on the switch of the engine speed
control and hold for three seconds in order to
lock in the engine speed. This speed is now
the maximum operating speed.
12. Change an intermediate speed in the following
manner:
SEBU7763-02
a. To return to high idle from an intermediate
engine speed, push in and release the top part
of the engine speed control switch.
b. To return to low idle from an intermediate
speed, push in and release the bottom part of
the engine speed control switch.
13. Use the differential steering control in order to
turn the machine.
14. Drive the machine forward for best visibility and
for control.
Changing Direction and Gear
NOTICE
For operator comfort and maximum service life of pow-
er train components, deceleration and/or braking is
recommended before any directional shifts are made.
Speed changes and directional changes at full engine
speed are possible.
1. In order to decrease engine speed, push down on
the decelerator pedal (1).
2. When the machine slows, shift the transmission to
the desired direction with direction selector (4).
3. Increase the engine speed by releasing the
decelerator pedal (1).
4. Select the desired gear with transmission gear
selector (5). Push button (6) for upshift. Push
button (7) for downshift.
i02209587
Battery Disconnect Switch
SMCS Code: 1411
g01115494
Illustration 112
SEBU7763-02 83
Operation Section
Machine Operation

The battery disconnect switch is on the left side of i02764675

the machine next to the battery compartment.
Engine Overspeed
SMCS Code: 1000

Do not allow the engine speed to exceed 3150 rpm.

Severe engine damage may result.

g00406959
Illustration 113

ON – To activate the electrical system,

insert the disconnect switch key and turn
the battery disconnect switch clockwise.
The battery disconnect switch must be turned to the g01383944
ON position before you start the engine. Illustration 114

OFF – To deactivate the electrical

system, turn the battery disconnect switch
counterclockwise to the OFF position.

The battery disconnect switch operates differently

than the engine start switch. When the battery
disconnect switch is in the OFF position, the electrical
system is disabled. When the engine start switch is
turned to the OFF position and the battery disconnect
switch is turned to the ON position, the battery
remains connected to the entire electrical system.

Turn the battery disconnect switch to the OFF g01383974

position and remove the disconnect switch key
when you service the electrical system or other
components on the machine.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key if you
do not operate the machine for an extended period
of a month or more. This will prevent drainage of
the battery.
Illustration 115
Engine speed that is indicated by tachometer (2) will
be displayed in rpm in digital display window (3).
A warning level 2 will occur at 2850 rpm. Warning
level 2 requires reduction of engine rpm in order to
keep the engine speed below 3150 rpm. At this level,
the following events will occur:

• Forward action lamp (1) lights with a flashing red

NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
color.
• Rearward action lamp (4) lights a flashing red color.
Note: Rearward action lamp (4) is located on the
right console. The action lamp is near the right elbow
of the operator. If the operator is facing rearward, this
will alert the operator.
84 SEBU7763-02
Operation Section
Machine Operation

A warning level 3 will occur at 3150 rpm. Warning

level 3 requires immediate reduction of engine rpm in
order to prevent severe damage to the engine. At this
level, the following events will occur:

• Forward action lamp (1) lights with a flashing red

color.

• Rearward action lamp (2) lights a flashing red color.

• The action alarm sounds.
Alter the operation of the machine. Use the service
brake in order to reduce engine speed immediately.

See the Topic “Machine on an Up Slope or Down

Slope”. This article is located in the “Bulldozing”
section of this manual.
SEBU7763-02 85
Operation Section
Engine Starting

Engine Starting
i01951496

Engine Starting
SMCS Code: 1000; 7000

ON – Turn the battery disconnect switch to

the right in order to activate all of the cab
circuits.

g01015655
Illustration 118

4. Turn engine start switch key (3) to the ON position.

The monitoring system performs an automatic
self test. The action alarm sounds and all of the
indicator lights come on briefly.

The indicator light for the parking brake will stay

on. If the implement controls are locked out the
indicator light for the hydraulic lockout will stay
on. The indicator light for the auto kickdown
will stay on until the function is unselected. The
g01015131
Illustration 116 indicator light for the parking brake stays on until
the parking brake is released. The indicator light
1. The battery disconnect switch is inside of an for the hydraulic lockout stays on until the controls
access door in the battery compartment on the are unlocked.
left side of the machine.
If the system detects a fault, check the electrical
system. Make all of the necessary repairs before
you start the engine.

If the action alarm does not sound during this test

or machine monitoring displays are not function-
ing, do not operate the machine until the cause
has been corrected. Machine operation with faulty
action alarms or displays could result in injury or
death as any Warning Category 3 notifications will
not be relayed to the operator.

g01017004
Illustration 117 5. Turn engine start switch key (3) to the START
position. Crank the engine. Release the key when
2. Move direction selector (1) to the NEUTRAL the engine starts.
position.
See the Topic “Starting With Engine Prelubrication
3. Engage parking brake (2). System”. This article is located in the “Engine
Starting” section of this manual.
86
Operation Section
Engine Starting
NOTICE
Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies
that the oil pressure is sufficient.
Ether Starting Aid
If engine coolant temperature is below 0 °C (32 °F),
the engine ECM will automatically inject ether during
engine cranking and during engine warm-up. The
duration and the amount of ether increases with
colder temperatures at start-up.
The system is automatic. Manual operation of ether
starting system is not permitted. Do not introduce
any additional ether into the inlet air system. The
additional ether may damage the engine.
For starting below −18°C (0°F), the use of the cold
weather starting aids is recommended. A fuel heater,
a jacket water heater, and extra battery capacity may
be required.
At temperatures below −23°C (−10°F), consult your
Caterpillar dealer. For information on starting the
engine in cold weather, refer to the Operation and
Maintenance Manual, SEBU5898, “Cold Weather
Recommendations for all Caterpillar Machines”.
SEBU7763-02
i02229120
Engine Starting with
Prelubrication System
SMCS Code: 1000; 7000
If equipped:
1. Move the transmission direction control lever to
the NEUTRAL position.
2. Engage the parking brake.
3. Move the implement control levers to the HOLD
position. Use the switch for hydraulic lockout
control in order to deactivate the inputs to the
hydraulic control circuit.
4. Turn the battery disconnect switch to the ON
position. The battery disconnect switch is inside of
the left engine compartment access cover on the
left side of the machine.
5. Turn the key start switch to the START position.
Hold the key in the START position. The
prelubrication system is now activated. When the
engine oil pressure sensor detects inadequate
engine oil pressure, the prelubrication system
will operate. When the engine oil pressure
sensor detects adequate engine oil pressure,
the prelubrication stops. Then, the system will
automatically crank the engine.
6. When the engine starts, release the key start
switch.
Note: If the engine is being restarted within two
minutes, the prelubrication system is bypassed.
When the key start switch is turned to the START
position, the engine will crank immediately.
i02053781
Engine and Machine Warm-Up
SMCS Code: 1000; 7000
After the engine has been started, allow the
monitoring system to complete the self test.
1. Allow a cold engine to warm up at LOW
IDLE for at least five minutes. To help the
hydraulic components to warm up faster, engage
the attachment controls and disengage the
attachment controls.
2. You can begin to operate the machine with a
reduced load.
SEBU7763-02 87
Operation Section
Engine Starting

3. When the engine coolant temperature reaches the

normal operating range and no faults are present,
you may operate the machine at full load.

4. Look at the indicators and the gauges frequently

during operation.

5. Check oil levels in the power train, the engine, and

the hydraulic systems when the oil is at operating
temperature. Maintain the oil levels to the FULL
marks.

The hydraulic oil will warm up faster, if the dozer

blade control is held in the CLOSE position for short
periods of ten seconds or less. This will allow the
hydraulic oil to reach relief pressure, 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.

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

• Allow the engine to warm up for approximately 15

minutes when the temperature is higher than 0°C
(32°F).

• Allow the engine to warm up for approximately 30

minutes or more when the temperature is below
0°C (32°F).

• More time may be required if the temperature is

less than −18°C (0°F). More time may also be
required if the hydraulic functions are sluggish.

Additional Low Idling Speed

Note: If the engine is running at low idle with the
parking brake ON and the engine coolant temperature
is below 70 °C (158.0°F) for a period of ten minutes,
the engine speed will automatically increase to 1000
RPM. This increases the heat in the jacket water.
88 SEBU7763-02
Operation Section
Operating Techniques

Operating Techniques Dozer Blade Pitch for the U-Blade

and SU-Blade
i02765096

Operating Technique
Information
SMCS Code: 7000

Gear Selection
Gear Selection – Maximize the amount of work
that is accomplished by selecting the best gear
for the load. In order to accomplish the maximum
work output, the best way is using the mode for the
automatic downshift. Illustration 120
g00522784

(1) Extended
See “Operator Controls” in this manual for more (2) Retracted
information. (3) Neutral

With certain loads, the machine will move faster in The NEUTRAL position works well in most materials
first gear instead of a higher gear. See the chart in and applications. The NEUTRAL position provides
Illustration 119. equal blade tilt to the right and to the left.

The EXTENDED position pitches the blade forward.

This improves blade penetration in materials that are
difficult to penetrate and makes for faster loading.

The RETRACTED position pitches the blade

backward. The backward pitch enhances the amount
of dozer carry.

Refer to Machine Adjustments in the Operating

Section of this manual.

Straight Dozing

g00666988
Illustration 119

General Rule For Selecting a Gear As You Are

Dozing – If the transmission is shifted into a higher
gear and the machine slows down, return to the
previous gear.

g00040620
Illustration 121

Straight Dozing – Maintain a level cut for the best

performance. Fill the bulldozer blade. Carry the load
to the dump.

• Avoid lugging or stalling the machine.

SEBU7763-02
• Avoid excessive spinning of the track.
• If turning the machine with a loaded blade is
necessary, use the bulldozer tilt cylinders instead
of the steering lever in order to steer the machine.
When you are performing levelling work, a full
bulldozer blade manages better than a partially
loaded bulldozer blade.
Slot Dozing
Illustration 122
g00040626
Slot Dozing – When you trap material in a slot, you
can carry larger loads in front of the bulldozer blade.
The depth of the slot should not be deeper than the
top corner of the bulldozer blade.
g00040622
Illustration 123
Start the slot at the dump or the spoil end and work
rearward. See Figure (A) in Illustration 123. You
can load the blade as you are moving downhill.
Also, you can then carry the load on a level surface.
The technique that is shown in Figure (B) is not as
efficient as the technique that is shown in Figure (A).
In figure (B), the machine is pushing a load uphill
and the operator does not utilize the slot. Dozing
level through the entire pit is inefficient because the
average distance for pushing the material to the
dump will be greater.
89
Operation Section
Operating Techniques
g00040628
Illustration 124
When you are digging parallel slots, the center should
be removed from the rear. This procedure permits
the operator to maintain a slot until the center is
removed. The center berm should be wide enough to
stand up without collapsing. Maximum width should
be approximately 1/3 of the bulldozer blade.
Machine on a Slope
Machine on a Side Slope
g00040630
Illustration 125
When possible, work on a slope vertically. This
method is better than working horizontally.
When you are working on banks, use caution. When
you are working on slopes, use caution. Avoid tipping
the machine.
If the machine starts to sideslip on a slope, lighten
the load and turn the machine downhill.
If you are working horizontally on a slope, start at the
top of the slope. Work downhill. Maintain a windrow
of material on the low side of the machine in order
to provide stability.
Use caution in order to not undercut the slope.
Undercutting the slope will increase the slope.
90 SEBU7763-02
Operation Section
Operating Techniques

Machine on an Up Slope or Down Slope V-Ditching – Tilt the bulldozer blade in order to start
the desired slope. Position the corner of the bulldozer
blade in the center of the ditch. Cut to the desired
depth.

Backfilling

g00641146
Illustration 126

Reduce ground speed of the machine to an

acceptable level by using the service brake prior to
initiating a steering correction.
g00040635
Illustration 128
Do not allow the engine to overspeed when you
are unloaded and moving down a slope. Watch the
Backfilling – Push the material at a 90 degree angle
tachometer and use the service brake. Use the
in order to fill a trench. When you are cutting material
service brake near the top of the slope to prevent
with the side of the blade, use caution so that the
excessive engine speed.
remaining material does not fall on the machine.
Note: When you approach engine overspeed the
forward action lamp on the instrument module will Land Clearing
flash. If the engine overspeeds at warning level 2, the
forward action lamp will flash red and the rear action
lamp will flash red color. The rearward action lamp
is on the right hand console near the elbow of the
operator seat. If the engine overspeeds at warning
level 3, the forward action lamp will flash red and
the rearward action lamp will flash red color. Also,
the warning alarm will sound. See the Topic “Engine
Overspeed” in this manual.

V-Ditching

g00040067
Illustration 129

• Beware of all dead limbs. Beware of all limbs that

are hanging overhead.

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

g00040633
Illustration 127
SEBU7763-02
g00040073
Illustration 130
• If additional leverage is needed, you can doze a
small ramp near the base of the tree. The ramp
allows the machine to make higher contact on the
tree. Push the tree in the direction of the intended
fall. Advance cautiously. The ball of the root may
hang up under the bulldozer blade. This could drag
the machine off the ramp.
Stump Removal
Illustration 131
g00561004
Stump Removal – Make sure that roots are cut or
loosened. Remove the stump by pushing or digging.
Ripping
Use FIRST gear for ripping operations. Use additional
shanks instead of increasing the speed or using a
higher gear.
Use the decelerator in order to match the drawbar
pull. Also, use the decelerator in order to prevent
spinning the track.
Rip the ground as deep as possible. Sometimes, you
may rip at partial depth. You can remove the material
in natural layers.
91
Operation Section
Operating Techniques
The sizing of the material is controlled by the depth of
the pass and by the width of the pass. If the material
will be loaded with a wheel dozer, then the size of
the material should be smaller. The material should
be still smaller, if the material will be loaded into a
scraper.
NOTICE
Do not turn or back the machine while shanks are in
the ground. Twisting strain on the shanks and tips may
cause failure.
NOTICE
Inspect the ripper tips frequently for excessive wear.
The multishank ripper is intended for high production.
Use the multishank ripper in hard, packed soil and
loosened, embedded rock. The multishank ripper is
for use in material that can be ripped with AT LEAST
two shanks. Use the multishank ripper with a single
center shank less than 20 percent of the time.
The multishank ripper is NOT intended for high
production in rock with a single center shank.
A single ripper shank in an outside pocket of the
ripper is NOT recommended. If necessary, locate the
shank in the highest position. Operate the machine
at reduced speed. The frame of the ripper is not
designed for ripping with a single outside shank at
full horsepower.
The multishank ripper is NOT intended for ripping in
deep applications. Only use shanks of the specified
length.
Use a single shank ripper when deep ripping is
required.
Packed Soil, Hardpan, Clay, Shale
or Cemented Gravel
g00040571
Illustration 132
Multishank ripper with three shanks
92
Operation Section
Operating Techniques
Three shanks work well in these materials. Use the
greatest possible number of shanks to break the
material to the desired size. However, the number of
shanks that are used should not cause the machine
to stall.
Rock with Fractures, Faults and
Planes of Weakness
g00040576
Illustration 133
Multishank ripper with two shanks
Using two shanks will cause the rocks to break out
in smaller pieces, so that the machine can manage
the job easily. When the machine begins to stall, use
only the center shank. If the tracks spin, use only the
center shank.
Single Shank Ripper
Illustration 134
g00562861
Solid Rock, Granite or “Hard-to-Rip”
Material
Use one shank in material that tends to break out in
large slabs or in large pieces.
SEBU7763-02
Adjustable Ripper
The shank on the ripper has angle adjustments and
length adjustment features.
The angle of the shank must be varied in order to
achieve the maximum performance throughout each
ripping pass.
g00040595
Illustration 135
Insert the ripper into the material that is being ripped.
Adjust the angle of the shank slightly beyond the
vertical position. This will give you the correct tip
angle for entering the material. The angle will change
because of the different materials that need to be
ripped.
g00040600
Illustration 136
Lower the ripper into the material while you move
the machine forward. When you reach the desired
ripping depth, move the shank forward in order to
achieve the correct angle for best performance. This
angle is usually between the vertical position of the
shank and the forward position of the shank.
SEBU7763-02 93
Operation Section
Operating Techniques

Push Loading

g00040603
Illustration 137
g00040056
Illustration 139
Move the ripper shank forward to the shank in
position when you pry out the lodged material. 1. Contact the push block squarely.

2. The machine should not be moving more than

5 km/h (3 mph).

3. When possible, maintain a straight push.

4. do not allow the rear of the scraper off the ground.

5. When the cut is complete, upshift the machine in

order to help the scraper get out of the cut.

g00040607
Illustration 138

Adjust the length of the shank according to the

following procedure.

1. Maintain a length of the shank so that the machine

can efficiently pull the shank through the material.

2. Maintain sufficient clearance under the lower

ripper frame. This will prevent the machine from
catching on large slabs or on large rocks that are
brought to the surface.

3. Keep the lower frame assembly as parallel to the

ground as possible. This will evenly distribute the
stress.

4. When you remove material with a scraper or with

a loader, shallow ripping is recommended.

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

direction as the scraper that is being loaded.

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

material that is being removed.

7. When you are removing material with an excavator

or with a bulldozer, deep ripping is recommended.
94 SEBU7763-02
Operation Section
Adjustments

Adjustments 2. Activate the bulldozer tilt in the FLOAT position in

order to remove the force from the tilt brace so
that the rear pin for the tilt brace can be removed
i01956788 later. Shut down the engine, leaving the bulldozer
control in FLOAT and the parking brake engaged.
Bulldozer Tilt Brace
SMCS Code: 6060; 6074

U and SU Three-Position Tilt Brace

If equipped:

g01017200
Illustration 142

3. Place a wood block between the tilt brace and

the push arm. The block should measure at least
216 mm (8.5 inch) by 216 mm (8.5 inch) by
153 mm (6.0 inch). The block will help maintain
the hole alignment between the tilt brace and the
Illustration 140
g01017195 push arm when the pin is being removed.

Pin the brace in the EXTENDED position and extend 4. Remove the pin at the tilt brace to the joint of the
the right cylinder in order to tip the bulldozer blade push arm.
forward.

Pin the brace in the RETRACTED position and

retract the right cylinder in order to tip the bulldozer
blade rearward.

g01023331
Illustration 143

5. Start the machine and activate the bulldozer tilt

control in the FLOAT position. The tilt brace will
slide forward or the tilt brace slides rearward on
g00561194
Illustration 141 the push arm. Extending the cylinder will slide the
(N) Neutral brace forward. Retracting the cylinder will slide
(E) Extended the brace rearward. Align the holes in the tilt brace
(R) Retracted and the push arm bracket and assemble the pin
to the desired location. Alignment of the push
1. Position the machine on a hard flat surface and arm may require the rotation of the push arm, if
lower the bulldozer blade to the ground. Place the clearances at the joint allow rotation.
bulldozer control in the FLOAT position. Engage
the parking brake. Remove the retainer bolts and
plates.
SEBU7763-02 95
Operation Section
Adjustments

6. Shut down the machine. Return the bulldozer

control to the HOLD position. Keep the parking
brake engaged.

7. Reinstall the retainer bolts and the retainer plate.

Note: The pin in the right arm to tilt cylinder is

retained on the side toward the track, and the pin in
the left arm to the tilt brace is retained on the outside.

Angling the Blade

If equipped:

g00561282
Illustration 145

Turn the handle to the left (counterclockwise

direction) in order to lengthen the brace. Turn the
handle to the right (clockwise direction) in order to
shorten the brace.

When length (A) of the right tilt brace and length

(A) of the left tilt brace are divided by two the sum
equals a measurement of 1373 mm (54 inch). Do not
extend either tilt brace length (A) beyond 1440 mm
(56.5 inch).

g01017216
In order to tilt the blade left, shorten the left tilt
Illustration 144 brace. Then, lengthen the right tilt brace by an equal
amount.
The bulldozer blade can be positioned to various
angles with the following instructions. To tilt the blade right, shorten the right tilt brace.
Then, lengthen the left tilt brace by an equal amount.
1. Use the lift cylinders to position the bulldozer
blade with the edges and the end bits 25 to 50 mm
(1 to 2 inch) off the ground.

2. Remove the bolts from the retainer pin (One on

each side).

3. Remove the retainer pins.

4. Pull the coupling pin out of the housing.

5. Position the bulldozer blade at the desired angle.

6. Install the coupling pins in the new positions.

7. Install the retainer pins.

8. Install the bolts.

Tilt the Blade Manually

If equipped:
96 SEBU7763-02
Operation Section
Adjustments

i01953041

Tracks
SMCS Code: 4170; 7000

g01015715
Illustration 146

NOTICE
If tracks are too tight or loose, wear of components is
accelerated.

If they appear too tight or too loose, adjust the track.

Follow the procedures in the Maintenance Section for

adjustment.
SEBU7763-02 97
Operation Section
Parking

Parking i02229132

Stopping the Engine

i01969238
SMCS Code: 1000; 7000
Stopping the Machine
NOTICE
SMCS Code: 7000 Stopping the engine immediately after it has been
working under load can result in overheating and ac-
NOTICE celerated wear of engine components.
Park on a level surface. If it is necessary to park on a
grade, block the tracks securely. Refer to the following procedure to allow the engine
to cool and to prevent excessive temperatures in the
Do not engage the parking brake while the machine is turbocharger housing, which could cause oil coking
moving unless an emergency exists. problems.

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

g01022276
Illustration 147 Illustration 148
g01124621

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

4. Lower the bulldozer blade and lower all of the
attachments to the ground. Apply slight downward
pressure.
Idling the Engine for Extended
Periods
If the machine is parked and left running for extended
periods of time, set the engine speed at an RPM that
is slightly higher than low idle. Idling the engine at a
higher RPM ensures good engine lubrication.
98 SEBU7763-02
Operation Section
Parking

i01969312 The Procedure Before The

Stopping the Engine if an Accumulator Bleeds Down
Electrical Malfunction Occurs When the engine is running, the bulldozer blade can
be lowered by pushing the work tool control forward.
SMCS Code: 1000; 7000 For a short period of time, after the engine has been
stopped, the bulldozer blade can be lowered by
If the engine does not stop after turning the engine pushing the implement control lever forward.
start switch key to the OFF position, perform the
following procedure.

1. Apply the parking brake.

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

3. Exit the cab.

4. Locate the battery disconnect switch.

g01109010
Illustration 150

Make sure that hydraulic lockout switch (1) has

not cut inputs to the hydraulic control circuit. The
implement lever and the hydraulic valves must be
active.

LOWER – Push the work tool control (2)

forward in order to lower the bulldozer
g01022298
blade. Release the lever. The lever will
Illustration 149 return to the HOLD position.
Left side machine

LOWER – Move ripper raise/lower control

OFF – Turn the key counterclockwise in
(3) in a counterclockwise direction in order
order to stop the engine. Remove the key.
to lower the ripper. Release the lever. The
lever will return to the HOLD position.

Reference: Refer to Operation and Maintenance

Manual, “Operator Controls” for further information. The Procedure After The
Note: Do not operate the machine until the
Accumulator Bleeds Down
malfunction has been corrected. After the engine has been stopped for a short
period of time the control levers will not lower the
i02229167 implements to the ground.

Equipment Lowering with There is a mechanical method that can be used to

Engine Stopped lower the attachments.

SMCS Code: 7000

Make sure that no one is endangered before you

lower the attachments.
SEBU7763-02 99
Operation Section
Parking

Lower Dozer Blade

1. Connect the drain hose to quick pressure tap (6).
Run the hose to the hydraulic tank filler neck.

2. Remove quick pressure tap (7).

3. Slowly insert bolt (5) in order to lower the dozer.

Lower Ripper
1. Remove quick pressure tap (8).

Note: The drain hose is not required.

g01118072
Illustration 151
2. Slowly insert bolt (5) in order to lower the ripper.
Remove access cover (4).
3. Return bolt (5) to the storage position and return
quick pressure tap (7).

4. Return access cover (4).

i01953131

Leaving the Machine

SMCS Code: 7000

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

block the machine.

Apply the service brake in order to stop the machine.

g01124636
Illustration 152 Move the transmission gear selector to the NEUTRAL
Lift and tilt bulldozer arrangement (front view) position. Use the engine speed control switch to
reduce the engine speed to low idle. Engage the
Relieve the pressure in the hydraulic tank. parking brake.

The dozer/ripper valves are located at the center of
the fuel tank behind the operator module (cab).
A bolt (5) with “9/16 - 18 x 64 mm” threads is stored
inside the access cover. This bolt may be used to
lower the implements.
Lower all implements to the ground.
Turn the engine start switch key to the OFF position,
and remove the key.
Turn the key for the battery disconnect switch to the
OFF position. Remove the key when you exit the
machine for an extended period of time.

g01124638
Illustration 153
Arrangement with dozer/ripper valve and auxiliary valve (front
view)
100 SEBU7763-02
Operation Section
Parking

g01014705
Illustration 154

1. When you dismount, use the steps and the

handholds. Use both hands and face the machine.
When you dismount, use three points of contact.

2. Inspect the engine compartment for debris. Clean

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

3. If the machine is parked overnight, turn off the

disconnect switch and remove the key.

4. Close and lock all cab windows. Use the vandalism

protection covers and install all the padlocks. Lock
the cab doors.

Padlocks are provided for the following areas:

• Both engine enclosures

• Radiator access cover
• Battery box and access cover to the master
switch

• Washer fluid bottle compartment

• Fuel cap
• Fuel drain
• Hydraulic tank cap
SEBU7763-02
Transportation Information
i00052187
Shipping the Machine
SMCS Code: 7000; 7500
Investigate the travel route for overpass clearances.
Make sure that there is adequate clearance for
the machine that is being transported. This is
especially true for machines that are equipped with a
ROPS/FOPS structure, a cab, or a canopy.
Remove ice, snow, or other slippery material from the
loading dock and from the truck bed before loading.
Removing ice, snow, or other slippery material will
prevent the machine from slipping as you load the
machine. Removing ice, snow, or other slippery
material will prevent the machine from slipping in
transit.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
Observe all regulations governing wide loads.
g00040011
Illustration 155
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.
6. Turn the battery disconnect switch to the OFF
position. Remove the key.
101
Operation Section
Transportation Information
7. Lock the door and lock the access covers. Attach
any vandalism protection.
8. Install the tie-downs at several locations and block
the tracks in the front and in the rear.
9. Cover the opening for the engine exhaust. Rotation
of the turbocharger without engine operation can
result in damage to the turbocharger.
Consult your Caterpillar dealer for shipping
instructions for your machine.
i02696521
Lifting and Tying Down the
Machine
SMCS Code: 7000; 7500
Improper lifting and improper tie-downs can allow
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 Main-
tenance Manual, “Lifting and Tying Down the
Machine” for the proper technique for securing
the machine. Refer to Operation and Maintenance
Manual, “Specifications” for specific weight in-
formation.
NOTICE
Improper lifting or tiedowns can allow load to shift and
can cause injury and damage.
The weights that are listed in the table below and
the following instructions describe units that are
manufactured by Caterpillar Inc.
Table 15
Approximate Machine Shipping Weight
D8T without a Ripper 34019 kg (75000 lb)
D8T shipping weight (1) 29553 kg (65153 lb)
D8T (maximum weight) 45360 kg (100000 lb)
(1) Shipping weight includes the following components: coolant,
lubricant, 20% fuel, ROPS, FOPS, and 560 mm (22 inch) (MS
shoes)
Engage the parking brake before you sling the
machine and before you secure the machine with
tie-downs.
102 SEBU7763-02
Operation Section
Transportation Information

Move the hydraulic activation control lever to the

Locked position.

Consult your Caterpillar dealer for shipping

instructions for your machine.

g00561816
Illustration 156

A – Front tie-downs (2 places) Use the front towing

eye.

B – Lifting a machine that has a ripper attached. The

ripper must be raised.

C – Lifting a machine without a ripper attached.

D – Side tie-downs (3 places) Use the inside edge

of the track.

E – Rear tie-downs (2 places) Use the drawbar, the

outer edge of the track, or the ripper. The ripper must
be lowered.

The crane should be positioned so that the machine

may be lifted in a level plane. The spreader bars
should be wide enough to prevent contact between
the crane and the machine that is being lifted.

Use properly rated cables and properly rated slings to

lift the machine. For a machine without a ripper (C),
position the slings beneath the front of the track and
beneath the rear of the track. For a machine with a
ripper (B), position the slings beneath the front of the
track and under the ripper at the rear of the machine.

Use the front towing eye to secure the front tie-down

(A). Use the inside edge of the track shoe (D) to
secure the side tie-downs. Secure the side tie-downs
on three places per side. Use the drawbar, the ripper,
or the outer edge of the track shoe (E) to secure
the rear tie-downs. Use corner protectors on sharp
corners.

Check all of the laws that govern the load

characteristics (height, weight, width, and length).
SEBU7763-02
Towing Information
i01484554
Towing the Machine
SMCS Code: 7000
Personal injury or death could result when towing
a disabled machine incorrectly.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if
it is not blocked.
Personal injury or death can result from worn wire
rope cable.
Worn or frayed cable could break causing injury.
Check the wire rope cable. If cable is worn or is
frayed install a new cable.
When the axle shafts are removed, the machine
has NO parking brakes. The machine can roll and
cause personal injury or death.
Block the tracks securely so that the machine can-
not move.
The towing connection must be rigid, or towing
must be done by two machines of the same size
or larger than the towed machine. Connect a ma-
chine on each end of towed machine.
Be sure all necessary repairs and adjustments
have been made before a machine that has been
towed to a service area, is put back into operation.
This machine is equipped with spring applied brakes.
These brakes are also oil pressure released brakes.
If the power train oil system for pressure oil is
inoperable, the brakes are applied and the machine
cannot be moved.
Do not allow an operator to be on the machine that
is being towed unless the operator can control the
steering and/or the braking. Do not attempt to tow
a machine without reading and understanding the
following procedures.
103
Operation Section
Towing Information
These towing instructions are for moving a disabled
machine for a short distance at low speed. Move the
machine at a speed of 2 km/h (1.2 mph) or less to a
convenient location for repair. These instructions are
only for emergencies.
Always haul the machine if long distance moving is
required. When any towed machine is loaded, the
machine must be equipped with a brake system that
is operable from the operator’s compartment.
Normally, the towing machine should be as large as
the disabled machine, or larger than the disabled
machine. Make sure that the towing machine has
enough brake capacity, enough weight, and enough
power. The towing machine must be able to control
both machines for the grade that is involved and for
the distance that is involved.
Do not use a chain for pulling a disabled machine.
A chain link can break. This may cause possible
personal injury. Use a wire cable with ends that have
loops or rings. Put an observer in a safe position in
order to watch the pulling procedure. A safe position
would be at a distance away from either machine that
is greater than two times the length of the towing
cable. The observer can stop the procedure, if
necessary. The procedure should be stopped if the
cable starts to break. Also, stop the procedure if the
cable starts to unravel. Stop pulling whenever the
towing machine moves without moving the towed
machine.
Shields must be provided on both machines. This
will protect the operator if either the tow line or the
bar breaks.
Before towing, make sure that the tow line or the
bar is in good condition. Make sure that the tow
line or the bar has enough strength for the towing
procedure that is involved. The strength of the towing
line or of the bar should be at least 150 percent of the
gross weight of the towing machine. This is true for
a disabled machine that is stuck in the mud and for
towing on a grade.
For towing, only attach the tow line to the tow eyes
on the frame, if equipped.
Keep the tow line angle to a minimum. Do not exceed
a 30 degree angle from the straight ahead position.
Quick machine movement could overload the tow
line or the bar. This could cause the tow line or the
bar to break. Gradual, steady machine movement will
be more effective.
104 SEBU7763-02
Operation Section
Towing Information

All situation requirements cannot be listed. Minimal
towing machine capacity is required on smooth,
level surfaces. Maximum towing machine capacity is
required on inclines or on surfaces that are in poor
condition.
Consult your Caterpillar dealer for the equipment that
is necessary for towing a disabled machine.
Running Engine
One or more towing machines must provide sufficient
control and sufficient braking when you are moving a
disabled machine downhill. This may require a larger
towing machine and additional machines that are
connected to the rear. This will prevent the machine
from rolling away out of control.
Consult your Caterpillar dealer or refer to the
machine’s Service Manual for axle shaft removal and
installation procedures.

For the second method, use a brake release

If the engine is running, the machine can be towed for
a short distance under certain conditions. The power
train and the steering system must be operable.
Tow the machine for a short distance only. For
example, pull the machine out of mud or pull the
machine to the side of the road.
The operator on the towed machine must steer the
machine in the direction of the tow line.
Carefully follow all instructions that are outlined in
the Towing Information. Ensure that the instructions
are followed exactly.
Stopped Engine or Drive Line
Defect
pump. If a brake release pump is used to tow the
machine, the brakes can not be applied with the
service brake pedal or with the parking brake control.
If the brake release pump is used and you need to
apply the brakes, the brakes must be applied with the
brake release pump that is being used.
Note: The axles must not be removed when you use
a brake release pump.
Connection of Brake Release Pump
Note: This machine is free to move. This machine is
free to roll away. This machine has no braking ability
with the parking brake or with the service brake when
both brakes have been released.

You can move the machine when the engine is not The pressure hoses from the pump connect to the
operable. You must use a brake release pump or you brake valve. The pump takes oil from the sump of the
must remove the axle shafts. brake release pump. Then, the pump pressurizes the
brake piston cavity in order to release the brake.
You can use a brake release pump or you can
remove the axle shafts in order to tow the machine,
if the engine is stopped and if the drive line is not
damaged.

If an internal transmission or a drive line failure is

suspected, remove the axle shafts.

For the first method, remove the axle shafts.You

may remove the axle shafts from the final drives in
order to tow the machine. This will make the machine
brakes inoperable and the machine can move freely.
The towed machine will be totally dependent on the
towing machine for control and for braking.

If you are towing a machine without axle shafts,

you may not be able to use the implements to stop
the machine. The implement hydraulic system is
pilot controlled. With an inoperable engine or an
inoperable hydraulic pump, the accumulator pressure
will bleed off rapidly. The implement controls will
not operate when there is no pressure in the
accumulator. The implements can not be lowered
with the implement control lever in order to stop a
towed machine when there is no pressure in the
accumulator.
SEBU7763-02 105
Operation Section
Towing Information

g00775200 g00775222
Illustration 157 Illustration 158
(1) FT1973 Adapter Gp
(2) 8T-0855 Pressure Gauge 1. The main pressure hose connects to 9J-6190
(3) 8T-0477 Relief Valve Adapter Union, 04-6683 Nipple, 5P-8018
(4) Handle
(5) 6V-5016 Ball Valve
Adapter Union, 8M-0547 Elbow, and 5P-2909
(6) FT1845 Brake Release Pump Plug. Plug the pressure hose at the connection
(7) 123-0525 Brake Release Adapter with a 5P-2909 Plug. The components are
(Not shown) 5P-2909 Plug indicated by shaded area (A).

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

4. Adjust the opening pressure of the relief valve.

NOTICE
Possible brake piston seal damage could result with-
out checking relief valve. Opening pressure must be
checked and adjusted before connection is made.
Set the pressure to 3030 ± 70 kPa (440 ± 10 psi).
5. Turn the handle on bypass valve (5) to the open
position in order to relieve the pressure in the
pump and in the hose.
106 SEBU7763-02
Operation Section
Towing Information

Connection for the Pump

g00545389
Illustration 161
(8) Brake control valve
(9) Brake valve ports

3. Remove the seat and the floorplate from the

operator’s station.

4. Remove the pressure test fittings from the top of

g00775205
Illustration 159 brake valve ports (9).

1. Remove the components that were used to plug
the pressure hose. The components are 9J-6190
Adapter Union, 04-6683 Nipple, 5P-8018
Adapter Union, 8M-0547 Elbow, and 5P-2909
Plug. The components are indicated by shaded
area (A).
5. Install one 123-0525 Adapter (7) into each of the
brake valve ports.
6. Connect the FT1973 Adapter to the 123-0525
Adapters.
7. Route the pressure hose through the rear, around
the side, and through the door of the cab. Connect
the pressure hose to the pump. Install the pump
temporarily on the platform.

8. Replace the floorplate and the seat.

9. Place the brake release pump in front of the

operator.

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

g00775209
Illustration 160
(1) Pump adapter
(7) Brake release adapter

2. Connect FT1973 Adapter (1) to the pump

pressure hose. The adapter will be downstream
from the relief valve.
SEBU7763-02 107
Operation Section
Towing Information

Brake Release Brake Engagement

g00775217 g00775217
Illustration 162 Illustration 163
(5) Bypass valve (5) Bypass valve

1. Turn bypass valve handle (5) to the closed
position.
2. Initially, rapidly move the pump handle. This will
produce a large volume of oil flow.
3. The brake piston seal must be fully seated. The
seating of the seal is evident by a sudden rise in
the oil pressure.
When the seal is properly seated, the pressure
rises to the relief valve setting. The setting is
3030 ± 70 kPa (440 ± 10 psi).
Open bypass valve (5) in order to apply the brakes.
This will completely dump the oil.
The brake system can only be applied by turning
the bypass valve. The service brake pedal and the
steering levers do not function.
After towing, remove the brake release pump. Repair
the machine. Install the floorplate and the seat.
Consult your Caterpillar dealer for towing a disabled
machine.

4. Now, the machine can be towed.

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

Partial brake engagement could occur and can result

in brake damage.

Brakes must be fully released when towed machine is

moving.
108
Operation Section
Engine Starting (Alternate Methods)
Engine Starting (Alternate
Methods)
i01953305
Engine Starting with Jump
Start Cables
SMCS Code: 1000; 7000
Batteries give off flammable fumes which can ex-
plode.
To avoid injury or death, do not strike a match,
cause a spark, or smoke in the vicinity of a battery.
Failure to properly service the batteries may cause
peronal injury.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
machine.
Do not smoke when checking battery electrolyte
levels.
Electrolyte is an acid and can cause personal in-
jury if it contacts skin or eyes.
Always wear eye protection when starting a ma-
chine with jump start cables.
Improper jump start procedures can cause an ex-
plosion resulting in personal injury.
Always connect the battery positive (+) to battery
positive (+) and the battery negative (−) to battery
negative (−).
Jump start only with an energy source with the
same voltage as the stalled machine.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the
energy source is connected.
SEBU7763-02
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
This machine has a 24 volt starting system. Use only
the same voltage for jump starting. Use of a welder or
higher voltage damages the electrical system.
Refer to Special Instruction, Battery Test Procedure,
SEHS7633, available from your Caterpillar dealer, for
complete testing and charging information.
Use of Jump Start Cables
When the auxiliary start receptacles are not available,
use the following procedure.
1. Place the transmission control on the stalled
machine in the NEUTRAL position. Engage the
parking brake switch. Lower all attachments to the
ground. Move all controls to the HOLD position.
2. On a stalled machine, turn the start switch key to
the OFF position. Turn off the accessories.
3. On a stalled machine, turn on the battery
disconnect switch.
4. Move the machines together in order for the cables
to reach. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
5. Stop the engine on the machine that is the
electrical source. When you use an auxiliary
power source, turn off the charging system.
6. Check the battery caps for correct placement
and for correct tightness. Make these checks on
both machines. Make sure that the batteries in
the stalled machine are not frozen. Check the
batteries for low electrolyte.
SEBU7763-02
g01015884
Illustration 164
(1) Battery disconnect switch
(2) Positive cable
(3) Positive cable terminal
(4) Negative cable terminal
(5) Negative cable
NOTICE
Do not allow positive cable clamps to contact any met-
al except for battery terminals.
Note: Some positive cables and some covers for
positive terminals are red for correct identification.
7. Connect the positive jump start cable to the
positive cable terminal of the discharged battery.
8. Batteries in series may be in separate
compartments. Use the terminal that is connected
to the starter solenoid. Trace this cable in order
to make sure that the cable is connected to the
starter.
9. Connect the positive jump start cable to the
positive terminal of the electrical source. Use the
procedure from Step 7 in order to determine the
correct terminal.
10. Connect one end of the negative jump start cable
to the negative terminal of the electrical source.
11. Make the final connection. Connect the negative
cable to the frame of the stalled machine. Make
this connection away from the battery, the fuel, the
hydraulic lines, or moving parts.
12. Start the engine on the machine that is the
electrical source. Also, you can energize the
charging system on the auxiliary power source.
109
Operation Section
Engine Starting (Alternate Methods)
13. Allow the electrical source to charge the batteries
for two minutes.
14. Attempt to start the stalled engine. Refer to
Operation and Maintenance Manual, “Engine
Starting”. See the beginning of this topic. Allow
the electrical source to charge the batteries for
two minutes.
15. Immediately after the stalled engine starts,
disconnect the jump start cables in reverse order.
i01953306
Engine Starting with Auxiliary
Start Receptacle
SMCS Code: 1000; 1463; 7000
g01114158
Illustration 165
A permanent auxiliary start receptacle is standard on
this machine. The receptacle is always available for
jump starting. The receptacle is located on the left
side of the engine next to the air cleaner housing.
There are two cable assemblies that can be used
to jump the stalled machine. You can jump the
machine from another machine that is equipped
with this receptacle or an auxiliary power pack. Your
Caterpillar dealer can provide the correct cable
lengths for your application.
1. Place the transmission control in the NEUTRAL
position on the stalled machine. Engage the
parking brake. Lower all attachments to the
ground.
2. On the stalled machine, turn the start switch key
to the OFF position. Turn all accessories to the
OFF position.
3. Turn the battery disconnect switch ON.
110 SEBU7763-02
Operation Section
Engine Starting (Alternate Methods)

4. Move the machine that is used for the electrical

source close to the stalled machine. The cables
must reach. DO NOT ALLOW THE MACHINES
TO COME INTO CONTACT WITH EACH OTHER.

5. Stop the engine on the machine that is used for

the electrical source. When you use an auxiliary
power source, turn the charging system to the
OFF position.

6. On the stalled machine, connect 9S-3664 Cables

to the auxiliary start receptacle.

7. Connect the other end of this cable to the electrical

source.

8. Start the engine on the machine that is used for

the electrical source. If you are using an auxiliary
power pack, turn the charging system to the ON
position.

9. Allow the electrical source to charge the batteries

for two minutes.

10. Attempt to start the stalled engine. Refer to the

Articles on“Engine Starting” in this manual.

11. Immediately after the stalled engine starts,

disconnect the jump start cable from the electrical
source.

12. Disconnect the other end of this cable from the

stalled machine.
SEBU7763-02
Maintenance Section
Cooling System
Specifications
i02240514
Model Specific Coolant
Information
SMCS Code: 1000
NOTICE
Adding coolant to an overheated engine could result in
damage to the engine. Allow the engine to cool before
adding coolant.
If the machine is to be stored in, or shipped to, an area
with freezing temperatures, the cooling system must
be protected to the lowest outside (ambient) temper-
ature.
The engine cooling system is normally protect-
ed to a minimum of−29°C (−20°F) with Caterpillar
Antifreeze, when shipped from the factory unless
special requirements are defined.
NOTICE
Frequently check the specific gravity of the coolant to
ensure proper freeze protection and anti-boil protec-
tion.
NOTICE
Never use water alone as a coolant. Water alone is
corrosive at engine operating temperatures and does
not provide adequate anti-boil protection.
NOTICE
All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
Extended Life Coolant (ELC) is used at the factory for
the D9TTrack-Type Tractor .
Reference: Refer to Service Manual, SEBU6250,
“Caterpillar Machine Fluids Recommendations”,
“Cat Extended Life Coolant (ELC)”. See the section
“ELC Cooling System Maintenance” in order to
maintain your cooling system. However, maintaining
an ELC cooling system is preferred. Also, see the
topics“Coolant Recommendations” and “S·O·S
Coolant Analysis”.
111
Maintenance Section
Cooling System Specifications
The following problems may indicate a need to check
the cooling system:
• Engine overheating
• A strong, unusual odor from the coolant
• Contamination of the cooling system
• A change in the color of the coolant
• Foaming within the radiator
Air pockets can form in the cooling system if the
cooling system is filled at a rate that is greater than
20 L (5 US gal ) per minute.
After you drain the cooling system and after you refill
the cooling system, operate the engine. Operate
the engine without the radiator cap until the coolant
reaches normal operating temperature and the
coolant level stabilizes. Make sure that the coolant is
maintained to the proper level.
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
For more detailed information, refer to the following
publication: Special Publication, REHS1063, “Special
Instruction - Know Your Track-Type Tractor Cooling
System”.
Many engine failures are related to the cooling
system. Cooling system failures include the following
problems: overheating, leakage of the water pump,
plugged radiators, and cylinder liner pitting. These
failures could be avoided with proper cooling system
maintenance. Maintenance of the engine coolant is
important to the engine life and to the performance.
Maintaining the quality of the engine’s coolant is as
important as maintaining the quality of the engine’s
fuel and lubricating oil.
Coolant is normally composed of three elements:
• Water is used for transferring heat from the engine
to the atmosphere.
• Additives are used for corrosion protection.
• Glycol is used for anti-boil protection and antifreeze
protection.
112 SEBU7763-02
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities and

Refill Capacities
i02547347

Lubricant Viscosities
SMCS Code: 7581

Selecting the Viscosity

Ambient temperature is the temperature of the air
in the immediate vicinity of the machine. This may
differ due to the machine application from the generic
ambient temperature for a geographic region. When
selecting the proper oil viscosity for use, review both
the regional ambient temperature and the potential
ambient temperature for a given machine application.
Generally, use the higher temperature as the criterion
for the selection of the oil viscosity. Generally, use the
highest oil viscosity that is allowed for the ambient
temperature when you start the machine. Refer to
the “Lubricant Viscosities for Ambient Temperatures”
tables and the associated footnotes for guidance. In
arctic applications, the preferred method is to use
properly sized machine compartment heaters and a
higher viscosity grade oil. Thermostatically controlled
heaters that circulate the oil are preferred.

The proper oil viscosity grade is determined by the

minimum outside ambient temperature. This is the
temperature when the machine is started and while
the machine is operated. In order to determine the
proper oil viscosity grade, refer to the “Min” column
in the table. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer
to the “Max” column in the table in order to select
the oil viscosity grade for operating the machine at
the highest temperature that is anticipated. Unless
specified otherwise in the “Lubricant Viscosities for
Ambient Temperatures” tables, use the highest oil
viscosity that is allowed for the ambient temperature
when you start the machine.

Machines that are operated continuously should

use oils that have the higher oil viscosity in the final
drives and in the differentials. The oils that have the
higher oil viscosity will maintain the highest possible
oil film thickness. Consult your dealer if additional
information is needed.
SEBU7763-02 113
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities for Ambient

Temperatures
Table 16

Lubricant Viscosities for Ambient Temperatures

Compartment or Oil Type and °C °F

Application Oil Viscosities
System Classification Min Max Min Max
SAE 60 −7 50 19 122
Cat FDAO(1)(2)
Moderate Usage commercial FD-1(1) SAE 50 −15 32 5 90
or Intermittent Cat TDTO
Operation Cat TDTO-TMS SAE 30 −25 15 −13 59
commercial TO-4
Cat TDTO-TMS(3) −35 15 −31 59
Final Drive
Cat FDAO(1)(2) SAE 60 −25(4) 50 −13(4) 122
Severe Usage commercial FD-1(1)
or Continuous Cat TDTO SAE 50 −33(4) 14 −27(4) 58
Operation (Multiple Cat TDTO-TMS SAE 30 −40(4) 0 −40(4) 32
Shifts/ Day) commercial TO-4
Cat TDTO-TMS(3) −40(4) 0 −40(4) 32
SAE 75W-90 −30 40 −22 104
End Pin Joints for SAE 75W-140 -30 45 -22 113
Cat GO
the Equalizer Bar,
Cat Synthetic GO(5)
Bogie Cartridge Normal SAE 80W-90 −20 40 −4 104
commercial API
Pins, and Track
GL-5 gear oil SAE 85W-140 −10 50 14 122
Pins
SAE 90 0 40 32 104
SAE 0W-20(6) −40 10 −40 50
SAE 0W-30(7) −40 20 −40 68
Power Shift SAE 5W-30(7) −30 20 −22 68
Cat TDTO
Transmissions
commercial TO-4
and Winches Normal SAE 10W −20 10 −4 50
Cat TDTO-TMS
(mechanical
Cat Arctic TDTO SAE 30(8) 0 35 32 95
drive)
SAE 50(8)(9) 10 50 50 122
Cat TDTO-TMS(3)(8) −10 35 14 95
SAE 0W-20 −40 40 −40 104
Cat HYDO SAE 0W-30 −40 40 −40 104
Cat DEO
SAE 5W-30 −30 40 −22 104
Cat MTO
Cat TDTO SAE 5W-40 −30 40 −22 104
Cat TDTO-TMS
Cat DEO SYN SAE 10W −20 40 −4 104
Cat Arctic DEO SYN
Hydraulic SAE 30 10 50 50 122
Normal Cat Arctic TDTO
Systems
Cat ECF-1 SAE 10W-30 −20 40 −4 104
Cat BIO HYDO
(HEES) SAE 15W-40 −15 50 5 122
API CG-4
Caterpillar MTO −25 40 −13 104
API CF
commercial TO-4 Cat BIO HYDO
commercial BF-1(10)(11) −25 43 −13 110
(HEES)(10)(11)
Cat TDTO-TMS(3) −15 50 5 122
(continued)
114 SEBU7763-02
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 16, contd)

Lubricant Viscosities for Ambient Temperatures

Compartment or Oil Type and °C °F

Application Oil Viscosities
System Classification Min Max Min Max
SAE 0W20(6) −40 10 −40 50
SAE 0W30(7) −40 20 −40 68
Cat TDTO SAE 5W30(7) −30 20 −22 68
Winches
Normal Cat TDTO-TMS
(hydraulic drive) SAE 10W −20 10 −4 50
commercial TO-4
SAE 30(8) 0 43 32 110
Cat TDTO-TMS(3)(8) −10 35 14 95
SAE 0W-20 −40 10 −40 50
SAE 0W-30 -40 30 −40 86
Cat DEO Multigrade
SAE 0W-40 −40 40 −40 104
Cat DEO SYN
Cat Arctic DEO SAE 5W-30 −30 30 −22 86
Engine
Normal SYN (12)
Crankcase SAE 5W-40 −30 50 −22 122
Cat ECF-1(13)
API CG-4
SAE 10W-30 −18 40 0 104
Mulitgrade(14)
SAE 10W-40 −18 50 0 122
SAE 15W-40 −15 50 5 122
SAE 0W-20(6) −40 0 −40 32
SAE 0W-30(7) −40 10 −40 50
SAE 5W-20(7) −35 0 −31 32
Track Roller
Cat TDTO
Frame SAE 10W −30 0 −22 32
Cat TDTO-TMS
Recoil Spring Normal
Cat Arctic TDTO SAE 30 −20 25 −4 77
Pivot Shaft
commercial TO-4
Bearings
SAE 40 10 40 14 104
SAE 50 0 50 32 122
Cat TDTO-TMS(3) −25 25 −13 77
(continued)
SEBU7763-02 115
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 16, contd)

Lubricant Viscosities for Ambient Temperatures

Compartment or Oil Type and °C °F

Application Oil Viscosities
System Classification Min Max Min Max

Cat DEO SAE 30 −20 25 −4 77

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

(1) Cat FDAO or commercial FD-1 are the preferred oil types to maximize gear and bearing life. Do not use Cat FDAO or FD-1 in compartments
containing clutches and/or brakes. Cat TDTO, Cat TDTO-TMS, or commercial TO-4 oil types must be used in any compartment containing
friction material unless specified otherwise by Caterpillar.
(2) Cat FDAO (Final Drive and Axle Oil) (exceeds the FD-1 specification requirements)
(3) Cat TDTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the TO-4M multigrade specification requirements).
(4) WARM-UP Required - Exercise the final drives for several minutes with the engine at partial throttle in order to warm up the oil prior to
production operation.
(5) Cat Synthetic GO is an SAE 75W-140 viscosity grade oil.
(6) First Choice: Cat Arctic TDTO - SAE 0W-20. Second Choice: Oils of full synthetic base stock that do not have viscosity index improvers and
do meet the performance requirements of the TO-4 specification for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE
0W-20, SAE 0W-30, and SAE 5W-30. Third Choice: Oils that contain a TO-4 additive package and a lubricant viscosity grade of SAE
0W-20, SAE 0W-30, or SAE 5W-30.
(7) First Choice: Oils of full synthetic base stock that do not have viscosity index improvers and do meet the performance requirements of the
TO-4 specification for the SAE 30 viscosity grade. Typical viscosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. Second Choice:
Oils with a TO-4 type additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30.
(8) Except for the hydraulic drive winch gear case. Use SAE 30 viscosity grade for 0°C (32°F) to 43°C (110°F) or Cat TDTO-TMS for −20°C
(-4°F) to 50°C (122°F).
(9) Do not use SAE 50 viscosity grade oil in ICM controlled transmissions. Do not use SAE 50 viscosity grade oil for the hydraulic drive
winch case.
(10) Commercial biodegradable hydraulic oil must meet the Caterpillar BF-1 specification. The listed ambient temperature range is for
the current Cat BIO HYDO (HEES), not for commercial BF-1 oil.
(11) Refer to the machine Operation and Maintenance Manual or contact your local Caterpillar dealer before using Cat BIO HYDO (HEES) or
commercial BF-1 oil.
(12) Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil.
(13) API CI-4, API CI-4 PLUS, and API CH-4 oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid
specification - 1) are met. API CI-4, API CI-4 PLUS, and API CH-4 oils that have not met the requirements of Caterpillar’s ECF-1
specification may cause reduced engine life.
(14) API CG-4 oils are acceptable for use in all Caterpillar machine diesel engines. When API CG-4 oils are used, the oil change interval
should not exceed 250 hours. API CG-4 oils that also meet API CI-4, API CI-4 PLUS, or API CH-4 must also meet the requirements
of the Caterpillar ECF-1 specification.
116 SEBU7763-02
Maintenance Section
Lubricant Viscosities and Refill Capacities

i01956951 Ecology Drains

Capacities (Refill) Table 18

Ecology Drain (Components)

SMCS Code: 7560
Location (Drain) Needed Component
Table 17
Coolant None
Approximate Refill Capacities
12.7 mm (0.5 inch)
Compartment or Imperial Transmission pipe with 1/2-14 NPTH
Liters US gal
System gallon thread
Cooling System 76.8 20.3 16.9 12.7 mm (0.5 inch)
Fuel Tank 643.5 170 141.6 Torque Converter pipe with 1/2-14 NPTH
thread
Engine Crankcase
37.9 10 8.3 25.4 mm (1 inch) pipe with
and Filter Engine Oil
1-11 1/2 NPTH thread
Power Train Oil
155 41 34 126-7914 Oil Drain
System and Filters
Coupling
Hydraulic Tank Oil 75.0 19.8 16.5 Hydraulic Tank or
25.4 mm (1 inch) pipe with
Final Drive (each) 12.5 3.3 2.8 1-11 1/2 NPTH thread
Recoil Spring 4C-8563 Oil Drain
65 17.2 14.3
Compartment (each) Coupling
Winch Sump Bevel Gear Case or
15 4 3.3 25.4 mm (1 inch) pipe with
(PA110VS)
1-11 1/2 NPTH thread
Pivot Shaft 40 10.6 8.8

Note: When you are operating on severe slopes
(greater than 25 degrees or greater than 47 percent),
the quantity of oil in the power train can be increased
by as much as 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.
Note: For severe slope operation, engine oil should
be maintained on the full mark. The engine should
never be overfilled with oil.
i01822901
S·O·S Information
SMCS Code: 7542
S·O·S Services is a highly recommended process
for Caterpillar customers to use in order to minimize
owning and operating cost. Customers provide
oil samples, coolant samples, and other machine
information. The dealer uses the data in order to
provide the customer with recommendations for
management of the equipment. In addition, S·O·S
Services can help determine the cause of an existing
product problem.

Refer to Special Publication, SEBU6250, “Caterpillar

Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.

Refer to the Operation and Maintenance Manual,

“Maintenance Interval Schedule” for a specific
sampling location and a service hour maintenance
interval.

Consult your Caterpillar dealer for complete

information and assistance in establishing an S·O·S
program for your equipment.
SEBU7763-02 117
Maintenance Section
Maintenance Support

Maintenance Support
i01821998

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. The following steps should be followed
in order to weld on a machine or an engine with
electronic controls.

1. Turn off the engine.

2. Turn the battery disconnect switch to the OFF

position. If there is no battery disconnect switch,
remove the negative battery cable at the battery.

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

NOTICE
Do NOT use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.

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.
118 SEBU7763-02
Maintenance Section
Maintenance Interval Schedule

i02704014 Hydraulic System Oil Level - Check ................... 160

Indicators and Gauges - Test .............................. 161
Maintenance Interval Schedule Pivot Shaft Oil Level - Check .............................. 162
Seat Belt - Inspect .............................................. 166
SMCS Code: 7000 Transmission System Oil Level - Check ............. 174
Walk-Around Inspection ...................................... 177
Ensure that all safety information, warnings, and
instructions are read and understood before any Every 50 Service Hours or Weekly
operation or any maintenance procedures are
performed. Bulldozer Tilt Brace and Tilt Cylinders -
Lubricate ........................................................... 123
The user is responsible for the performance of Cab Filter (Recirculation) - Clean/Inspect/
maintenance, including all adjustments, the use of Replace ............................................................. 124
proper lubricants, fluids, filters, and the replacement Ripper Linkage and Cylinder Bearings -
of components due to normal wear and aging. Failure Lubricate ........................................................... 165
to adhere to proper maintenance intervals and Track Pins - Inspect ............................................ 170
procedures may result in diminished performance of
the product and/or accelerated wear of components. Every 250 Service Hours
Use mileage, fuel consumption, service hours, or Belt - Inspect/Adjust/Replace .............................. 121
calendar time, WHICH EVER OCCURS FIRST, Engine Oil Sample - Obtain ................................ 139
in order to determine the maintenance intervals. Engine Oil and Filter - Change ........................... 140
Products that operate in severe operating conditions Equalizer Bar End Pins Oil Level - Check .......... 144
may require more frequent maintenance. Final Drive Oil Level - Check .............................. 146
Track - Check/Adjust ........................................... 168
Note: Before each consecutive interval is performed, Winch Fairlead Rollers - Lubricate ...................... 178
all maintenance from the previous interval must be Winch Oil Level - Check ..................................... 178
performed.
Initial 500 Hours (for New Systems, Refilled
When Required Systems, and Converted Systems)
Battery or Battery Cable - Inspect/Replace ........ 120 Cooling System Coolant Sample (Level 2) -
Bottom Guard (Power) - Clean ........................... 122 Obtain ............................................................... 128
Cooler Cores and A/C Condenser - Clean ......... 125 Electronic Unit Injector - Inspect/Adjust .............. 135
Cutting Edges and End Bits - Inspect/Replace ... 135 Engine Valve Lash - Check/Adjust ...................... 143
Engine Air Filter Primary Element - Clean/ Engine Valve Rotators - Inspect ......................... 143
Replace ............................................................. 135 Winch Oil and Breather - Change/Clean ............ 178
Engine Air Filter Secondary Element - Replace .. 137
Engine Air Precleaner - Clean ............................ 137 Every 500 Service Hours
Ether Starting Aid Cylinder - Replace ................. 145
Fuel System - Prime ........................................... 150 Engine Crankcase Breather - Clean ................... 138
Fuses and Circuit Breakers - Replace/Reset ...... 155 Engine Oil and Filter - Change ........................... 140
Oil Filter - Inspect ................................................ 162 Final Drive Oil Sample - Obtain .......................... 147
Radiator Pressure Cap - Clean/Replace ............ 163 Fuel System Primary Filter - Clean/Replace ....... 151
Ripper Tip and Shank Protector - Inspect/ Fuel System Secondary Filter - Replace ............ 153
Replace ............................................................. 165 Fuel Tank Cap Filter and Strainer -
Winch Wire Rope - Install ................................... 179 Replace/Clean .................................................. 154
Window Washer Reservoir - Fill .......................... 180 Hydraulic System Oil Filters - Replace ............... 159
Window Wipers - Inspect/Replace ...................... 180 Hydraulic System Oil Sample - Obtain ............... 160
Windows - Clean ................................................. 180 Recoil Spring Compartment Oil Level - Check ... 163
Steering Charge Filter - Replace ........................ 167
Every 10 Service Hours or Daily Transmission Breather - Clean ........................... 171
Transmission System Oil Sample - Obtain ......... 175
Backup Alarm - Test ............................................ 120 Transmission and Torque Converter Oil Filters -
Braking System - Test ......................................... 123 Replace ............................................................. 176
Cab Filter (Fresh Air) - Clean/Inspect/Replace ... 124
Cooling System Coolant Level - Check .............. 132 Every 1000 Service Hours
Engine Oil Level - Check .................................... 138
Fuel System Primary Filter (Water Separator) - Lift Cylinder Yoke Bearings - Lubricate ............... 161
Drain ................................................................. 152 Rollover Protective Structure (ROPS) - Inspect .. 166
Fuel Tank Water and Sediment - Drain ............... 154 Transmission System Oil and Screens -
Horn - Test .......................................................... 156 Change/Clean ................................................... 172
SEBU7763-02 119
Maintenance Section
Maintenance Interval Schedule

Winch Oil and Breather - Change/Clean ............ 178

Every 2000 Service Hours

Final Drive Oil - Change ..................................... 145
Final Drive Seal Guard Packing - Replace ......... 148
Hydraulic System Oil - Change ........................... 156
Hydraulic System Oil Filter (Pilot) - Replace ....... 157
Radiator Guard Pin Joint - Inspect ...................... 163
Track Roller Frame - Inspect .............................. 170
Track Roller Frame Guides - Inspect .................. 170

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 128
Engine Air Filter Primary Element - Replace ...... 137
Refrigerant Dryer - Replace ................................ 164

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 167

Every 4000 Service Hours

Electronic Unit Injector - Inspect/Adjust .............. 135
Engine Valve Lash - Check/Adjust ...................... 143
Engine Valve Rotators - Inspect ......................... 143

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 131
Cooling System Water Temperature Regulator -
Replace ............................................................. 134

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 129
120 SEBU7763-02
Maintenance Section
Backup Alarm - Test

i01957816 i02196906

Backup Alarm - Test Battery or Battery Cable -

SMCS Code: 7406-081 Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1401; 1402-040;
In order to test the alarm for proper functioning, turn
the engine start switch to the ON position. 1402-510

Battery Inspect

g01017699
Illustration 166

g01117295
Apply the service brake. Release the parking brake. Illustration 168
Move the transmission direction selector to the
REVERSE position. 1. Open the battery access covers. The battery
access covers are located on the left side of the
The backup alarm should start to sound immediately. machine outside the operator compartment.
The backup alarm will continue to sound until the
transmission gear selector is moved to the NEUTRAL
position or to the FORWARD position.

g01117315
Illustration 169

2. Tighten the battery retainers. Clean the top of the

Illustration 167
g01017684 batteries with a clean cloth. Keep the terminals
clean and coated with petroleum jelly. Install the
The backup alarm is on the rear of the machine. terminal covers after you coat the terminals.

The nonadjustable backup alarm is set at the 3. Close the battery access covers.
appropriate sound level when the machine is shipped
from the factory. Battery Recycle
Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

locations:
SEBU7763-02 121
Maintenance Section
Belt - Inspect/Adjust/Replace

• A battery supplier
• An authorized battery collection facility
• Recycling facility

Battery Disconnect Switch

1. Turn the engine start switch key to the OFF
position. Turn all of the switches to the OFF
position.

2. Turn the battery disconnect switch to the OFF

position. Remove the key.

3. Disconnect the battery cable at the battery

disconnect switch. The battery disconnect switch
is inside the left access cover next to the cab.

4. Disconnect the negative battery cable at the

battery. g01117063
Illustration 170
5. Replace the disconnect switch, the battery cables,
or the batteries, as required.

6. Connect the negative battery cable at the battery.

7. Connect the negative battery cable at the battery

disconnect switch.

8. Install the key and turn the battery disconnect

switch to the ON position.

i02229215

Belt - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510

Your engine is equipped with a serpentine belt

that drives the alternator and the air conditioner
compressor, if equipped.
g01017579
This engine is equipped with a belt tightener that Illustration 171
automatically adjusts the belt to the correct tension. Front and left side view
(1) Belt tensioner
(2) Alternator (reference only)
Inspect (3) Air conditioner compressor (reference only)
(4) Serpentine belt
1. Park the machine on level ground. Lower the (5) Idler pulley (reference only)
dozer blade to the ground. Move the transmission (6) Alternator guard (reference only)
control to the NEUTRAL position and engage the
parking brake. Shut off the engine. 4. Inspect the condition of serpentine belt (4).
Replace the serpentine belt if excessive wear or
2. Turn the battery disconnect switch to the OFF cracking has occurred. Wear due to belt slippage
position. indicates that the belt tensioner possibly needs
to be replaced.
3. Open the engine access doors on the right side.
5. Close the engine access doors.
122 SEBU7763-02
Maintenance Section
Bottom Guard (Power) - Clean

6. Turn the battery disconnect switch to the ON

position.

Replace
1. Park the machine on level ground. Lower the
dozer blade to the ground. Move the transmission
control to the NEUTRAL position and engage the
parking brake. Shut off the engine.

2. Turn the battery disconnect switch to the OFF

position.

3. Open the engine access doors.

4. Turn belt tensioner (1) in order to release the
tension from the belt with a square drive.
5. Remove the belt.
6. Install the new belt.
7. Close the engine access doors.
g01131971
Illustration 172
The power guard control is located in a compartment
on the left fender in front of the fuel tank.
The power guard control opens the bottom guards
for easier access during cleaning.

8. Turn the battery disconnect switch to the ON

position.

i02248240

Bottom Guard (Power) - Clean

SMCS Code: 7153-070

NOTICE
Do not operate the machine with the guard in the
lowered position. Damage to the machine or actuator g01131976
Illustration 173
could result.
NOTICE
Do not activate switches for power guard control with-
out removing the bolts from the guard. Damage to the
The guard is heavy. Personal injury or death may actuator could result.
result from being struck by or trapped under the
guard. Do not allow anyone to work near or un- 1. Position a jack under the bottom guard in order to
der the machine when the guard is being raised or lower the guard. The head of the jack should not
lowered. be touching the guard.

2. Remove the bolts from the bottom guard and

move switch (1) downward in order to lower the
guard.

If the guard lowers completely onto the jack, it is

possible that the actuator has failed. Use the jack
to support the guard and lower the guard to the
ground.

3. If the guard remains supported above the jack,

remove the jack.

4. Lower the guard to the lowest position.

SEBU7763-02
5. Remove all foreign debris from the underside of
the engine compartment.
6. Move the switch upward in order to raise the
guard.
7. Position the jack under the guard prior to replacing
the bolts. The head of the jack should not be
touching the guard.
8. Install the bolts.
i01958206
Braking System - Test
SMCS Code: 4100-081; 4267-081
If the machine moves during the test, reduce the
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 repaired
before returning the machine to operation.
Note: The machine can drive through the brakes
in first gear.
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.
1. Start the engine.
2. Raise all attachments.
g01017767
Illustration 174
3. Depress the brake pedal.
123
Maintenance Section
Braking System - Test
4. Release the parking brake.
5. While the brake pedal is depressed, move the
directional control to the SECOND SPEED
FORWARD position.
6. Gradually increase the engine speed to full load
speed. The machine should not move.
7. Move the directional control to the NEUTRAL
position.
8. Reduce the engine speed to LOW IDLE. Engage
the parking brake. Lower all attachments to the
ground. Apply a slight down pressure. Stop the
engine.
NOTICE
If the machine moved while testing the brakes, contact
your Caterpillar dealer. Have the dealer inspect and,
if necessary, repair the service brake before returning
the machine to operation.
i02229253
Bulldozer Tilt Brace and Tilt
Cylinders - Lubricate
SMCS Code: 6050-086
Lubricate the two fittings with CAT multipurpose type
grease with molybdenum disulfide (MPGM).
g01117177
Illustration 175
One fitting is located at the left front brace assembly
or left tilt cylinder (if equipped).
The other fitting is located at the rod end of the right
tilt cylinder.
124 SEBU7763-02
Maintenance Section
Cab Filter (Fresh Air) - Clean/Inspect/Replace

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

2. The filter element can be cleaned by using

pressure air. Use a maximum air pressure of
g01117220 205 kPa (30 psi). Direct the air from the clean side
Illustration 176
to the dirty side.
All of the locations for the grease fittings on the angle blade are
shown here.
3. Look through the filter toward a bright light. Inspect
the element for damage. Inspect the gaskets for
The angle blade has an additional grease fitting that damage. Replace damaged filters.
needs to be greased with MPGM.
4. Install the filter element.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more 5. Close the access covers.
information about MPGM.
Note: Clean the filters more often in dusty conditions.
i02229287

Cab Filter (Fresh Air) - i01971627

Clean/Inspect/Replace Cab Filter (Recirculation) -

SMCS Code: 7342-040; 7342-070; 7342-070-FI;
Clean/Inspect/Replace
7342-510; 7342-510-FI SMCS Code: 7342-040; 7342-070; 7342-510

The recirculation filter is positioned to the left of the

operator’s seat in the cab.

g01118586
Illustration 177

1. Open the access cover to the filter element. The

filter cover is on the left side of the machine next Illustration 178
g01023431
to the battery compartment.
Top view of the inside of cab

1. Unscrew the bolt to the cover of the recirculation

filter and remove the cover. Remove the
recirculation filter element.
SEBU7763-02 125
Maintenance Section
Cooler Cores and A/C Condenser - Clean

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

2. The recirculation filter element can be cleaned by

using pressure air. Use a maximum air pressure
of 205 kPa (30 psi). Direct the air from the clean g01385727
Illustration 179
side to the dirty side.
Air conditioner condenser behind the aftercooler
3. Look through the filter toward a bright light. Inspect (2) Aftercooler core
the element for damage. Inspect the gaskets for (3) Hydraulic oil cooler core
(4) Radiator cores (AMOCS)
damage. Replace damaged filters.
(5) A/C condenser core

4. Install the recirculation filter element. Make sure

that the filter element is centered. If the filter is not
centered the system will not function properly.
Note: Clean the filters more often in dusty conditions.
Remote A/C Condenser Core
In some machine arrangements, the a/c condenser
core is remotely located. A remote mounted a/c
condenser core is cooled by fans with electric drive.

i02771652

Cooler Cores and A/C

Condenser - Clean
SMCS Code: 1064-070; 1353-070; 1374-070;
7320-070

Cooler Cores
The following cooler cores are cooled by the hydraulic
fan that is located in the radiator guard at the front
of the track-type tractor.
g01117118
Illustration 180
Aftercooler core – The aftercooler core cools the
Air conditioner condenser on the right side of the machine
inlet manifold air to the engine.

Hydraulic oil cooler core – The hydraulic oil cooler

core cools hydraulic oil.

Radiator core – The AMOCS radiator cores cool

the engine coolant.

A/C Condenser Core – The air conditioning

condenser core cools the refrigerant in the air
conditioning system.

g01117129
Illustration 181
Air conditioner condenser on the top of the machine
126 SEBU7763-02
Maintenance Section
Cooler Cores and A/C Condenser - Clean

Inspect Clean
Note: Adjust the frequency of inspection according to
the effects of the operating environment.
Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Radiator cores, aftercooler cores, hydraulic oil cooler

cores, and a/c condenser cores needed to be cleaned
regularly. Adjust the frequency of cleaning according
to the effects of the operating environment.

Blow out the cores with compressed air. Move the

air nozzle in a systematic pattern so that the air
flow covers the whole core that includes areas in
the corner. Clean the middle space between the
aftercooler core and the a/c condenser core. Also,
clean the space between the hydraulic oil cooler and
g01385726 the AMOCS radiator cores.
Illustration 182

Use a bent copper tube that is approximately 1/4 -3/8

Turn off the engine.
inch diameter as an extension to the air nozzle. This
will facilitate cleaning of the middle spaces.
Open both of engine access doors (1).
Do not use steam or high pressure water for cleaning
Inspect the cooling system for the following
frequently. If steam or high pressure water is required
conditions: coolant leaks, oil leaks, damaged fins,
to dislodge any debris that is held deep in the
and tubes. Inspect the following parts of the cooling
cores, make sure that the cleaning is thorough. This
systems: air lines, connections, and clampsfor
may require partial removal or total removal of the
damage .Make repairs for damage, if necessary.
hydraulic oil cooler and the air conditioner condenser
for better access. Incomplete cleaning with water
Note: If parts of the aftercooler system may appear
may cause remaining debris to harden in place. Use
to be damaged or if parts of the aftercooler system
lights and wire probes in order to ensure that the
are repaired, a leak test is highly recommended.
cleaning is thorough and complete. If the debris has
Refer to Special Instruction, SEHS8622, “Using the
hardened in the center of the cores, these cores may
FT1984 Air-to-Air Aftercooler Leak Test Group”. The
need to be removed for thorough cleaning.
FT-1984 Aftercooler Testing Group can be used for
aftercoolers that have hoses with an inside diameter
If you use a degreaser and steam for removal of oil
of 102 mm (4.00 inches) or 114 mm (4.50 inches).
and grease, wash the core with detergent and hot
water. Thoroughly rinse the core with clean water. Dry
For more detailed information on testing and
the cores completely before operating the machine
inspection, see Special Publication, SEBD0518,
in the work mode.
“Know Your Cooling System”.
Dry
If steam or water is used to clean the cores, make
sure that the cores are completely dry before the
track-type tractor is put back to work.

Use compressed air to blow dry the wet cores, the

engine, engine access doors, and the hood.

Close both engine access doors.

SEBU7763-02
If the machine is in a clean environment, start the
engine and allow the fan to run until the cooling
system has completely dried. Allow the machine to
sit overnight before operating the machine in the
work mode.
Wood Chip or Waste Handling
Arrangement (If Equipped)
Cooler Cores
The wood chip and waste handling arrangements
have a remote mounted a/c compressor, and a single
plane of the following cores: hydraulic oil cooler
core, AMOCS radiator cores, and aftercooler core.
Additionally, these arrangements have a hydraulic
fan that reverses the direction of air flow in order to
purge debris.
Clean
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
NOTICE
Pressurized air: To avoid possible engine damage,
shut off engine before performing maintenance to
clean the cooling system. Install air nozzle into
access slot before starting air supply. Read and un-
derstand Operation and Maintenance Manual.
In applications with high levels of airborne debris,
a regular schedule for cleaning the cooling cores
must be established. The frequency of cleaning
and the cleaning method must be tailored to the
specific debris accumulation on the job site. In order
to maintain clean cores, the cleaning will need to be
done at least daily. Cleaning may be needed on a
more frequent basis. The clean out schedule must be
followed even when ambient temperatures are low.
This will prevent debris accumulation in the cores
and future plugging.
127
Maintenance Section
Cooler Cores and A/C Condenser - Clean
Access to the cores is through the engine access
doors from the rear of the cores which results in
blowing air in the same direction as the normal air
flow through the fan. The wood chip and Waste
Handling arrangements offer two options for blowing
air in the opposite direction of normal fan air flow.
First, the reverse fan function has a continuous
reverse mode. This allows prolonged periods of the
reverse flow while the machine is parked. Next, slots
are provided in both sides of the radiator guard for
use with a 307-6728 Air Nozzle which concentrates
air flow backward through the cores.
Blow out the cores with compressed air. Move the
air nozzle in a systematic pattern so that the air flow
covers the whole core that includes the areas in the
corners. Do not use steam or high pressure water
for cleaning frequently. If steam or high pressure
water is required to dislodge any debris that is held
deep in the cores, make sure that the cleaning is
thorough. This may require opening radiator doors
and removing debris guards for access. Incomplete
cleaning with water may cause remaining debris
to harden in place. Use lights and wire probes in
order to ensure that the cleaning is thorough and
complete. If the debris has hardened in the center
of the cores, these cores may need to be removed
from the machine for thorough cleaning. If steam or
water pressure is used to clean the cores, make sure
that the pressure is controlled in order to prevent the
fins from bending.
If you use a degreaser or special cleaning agents,
wash the core with detergent and hot water.
Thoroughly rinse the core with clean water. Dry the
cores completely before operating the machine in
the work mode.
Dry
If steam or water is used to clean the cores, make
sure that the cores are completely dry before the
track-type tractor is put back to work.
Use compressed air to blow dry the wet cores, the
engine, engine access doors, and the hood.
Close both engine access doors.
If the machine is in a clean environment, start the
engine and allow the fan to run continuously in the
reverse mode until the cooling system has completely
dried. Allow the machine to sit overnight before
operating the machine in the work mode.
Typical Cleaning Procedure That Uses
Compressed Air
The wood chip and waste handling arrangements
have special cleaning features.
128
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• continuous reverse fan function
• 307-6728 Air Nozzle in access slots in the radiator
guard
These tools can be used to develop a cleaning
process that best suits your application. One possible
sequence for cleaning is outlined below.
g01385729
Illustration 183
1. At the proper cleaning area, park the machine in
NEUTRAL and engage the parking brake.
2. Depress the fan control switch and hold for
three seconds in order to enter the continuous
reverse mode. Run the fan in the reverse mode
continuously for 2 minutes.
3. Turn off the engine. Make sure that the fan has
stopped rotation.
4. Open both of engine access doors (1). Use a
regular air nozzle to clean the cores from the rear
side. Blow off the hood, engine access doors, and
the entire engine compartment. On machines that
are equipped with the woodchip arrangement,
open the grill doors and blow off the radiator guard
shelf.
5. Open the cover to access slot (6) on both sides
of the radiator guard. Insert the 307-6728 Air
Nozzle into the access slot on the right side of the
machine in order to clean the cores on the left
side of the machine.
Note: Cleaning the cores from the opposite side of
the machine allows better cleaning in the corners.
6. Turn on the air supply.
SEBU7763-02
Note: Do not activate the air supply until you have
inserted the air nozzle into the access slot. Use the
work tool safely.
7. Move the air nozzle in a pattern in order to clean
the cores from the front side of the cores. Blow out
the cores on the left side of the cooling system.
8. Turn off the air supply when the nozzle cleaning of
the left side cores is completed.
9. Remove the air nozzle from the access slot. Close
the access cover.
10. Repeat Steps 5 through 9 from the left side of the
machine in order to clean the cores on the right
side of the machine.
11. Use a regular air nozzle in order to blow off the
cores from the rear and clean the entire engine
compartment.
12. Close both of the engine access doors.
13. Restart the engine. Operate the fan in the forward
direction continuously for 2 minutes.
14. Reverse the air flow. Operate the fan in the
reverse mode continuously for 2 minutes.
15. Return to operating the machine in work mode.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. Modify the
typical cleaning procedure above for optimal results,
as needed.
i02111232
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Level 2 Analysis
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
SEBU7763-02 129
Maintenance Section
Cooling System Coolant (ELC) - Change

Submit the sample for Level 2 analysis.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Testing the coolant can be done at your Caterpillar
dealer. Caterpillar S·O·S Coolant Analysis is the best
way to monitor the condition of your coolant and your
cooling system. S·O·S Coolant Analysis is a program
that is based on periodic samples. See Operation
and Maintenance Manual, SEBU6250, “Caterpillar
Machine Fluid Recommendations”, “S.O.S Coolant
Analysis” for more information.
Perform a Coolant Analysis (Level 2) at initial 500
hours for systems that contain extended life coolant
(ELC). Perform the analysis yearly after the initial
500 hours.
i02762742
Cooling System Coolant (ELC)
- Change
SMCS Code: 1395-044
For information about adding an extender to your
cooling system, see the Topic “Cooling System
Coolant Extender (ELC) - Add” in this manual or
consult your Caterpillar dealer.
NOTICE
Make sure you read and understand the information
in the topics Safety and Cooling System Specifica-
tions for all information pertaining to water, antifreeze
and supplemental coolant additive requirements be-
fore you proceed with maintenance of the cooling sys-
tem.
To Drain the Cooling System
The filler cap is located inside the access door on the
top of the radiator guard.

g01113455
Illustration 185

g01017880
Illustration 184

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

engine at low idle speed.

2. Open the left side engine compartment. Remove

the protective cap from the sampling valve.

3. Obtain a sample. For additional information

about coolant analysis, see Special Publication,
SEBU6250, “Caterpillar Machine Fluids
Recommendations” or consult your Caterpillar
dealer.

4. Replace the protective cap. Close the left side

engine compartment.
130 SEBU7763-02
Maintenance Section
Cooling System Coolant (ELC) - Change

Note: If you change to an ELC from another type

Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
1. Slowly loosen filler cap (1) in order to relieve
system pressure. Remove the filler cap.
2. Remove right access cover (2) and left access
cover (3) for the coolant drain. One cover is
located on the front right side of the machine,
bottom guard. The other cover is on the left side
of the machine, bottom guard.
of coolant, use a Caterpillar cleaning agent to flush
the cooling system. After you drain the cooling
system, thoroughly flush the cooling system with
clean water. All of the cleaning agent must be
removed from the cooling system. Refer to the
Topic “Cat Extended Life Coolant (ELC)” in Operation
and Maintenance Manual, SEBU6250.
6. Close the drain valves and install the plug.
7. Replace the access covers.
8. Add the ELC solution. See the following topics in
this publication:
• Cooling System Specifications
• Capacities (Refill)
Note: Caterpillar antifreeze contains additives. If
you are using Caterpillar antifreeze, do not add the
supplemental coolant additive at this time. Also,
do not change the supplemental coolant additive
element at this time.
9. Start the engine. Run the engine without the filler
cap until the thermostat opens and the coolant
level stabilizes.

g01017961
Illustration 186

3. Direct the drain hoses into suitable containers. g00475722

4. Open the drain valve. Allow the coolant to drain
into a suitable container.
5. Flush the system with water. Flush the system
until the draining water is clear.
Illustration 187
10. Look into filler tube (1). Maintain coolant level
between area (2) and area (3) of the filler tube.
Adding coolant above this area of the filler tube will
cause the coolant to overflow the cooling system.

Note: If the cooling system is already using ELC, 11. If the gasket is damaged, replace the filler cap.
cleaning agents are not required to be used at Install the filler cap.
the specified coolant change interval. Cleaning
agents are only required if the system has been 12. Stop the engine.
contaminated by the addition of some other type of
coolant or by cooling system damage. Clean water is
the only cleaning agent that is required when ELC is
drained from the cooling system.
SEBU7763-02
g01117259
Illustration 188
13. Clean the radiator cores with compressed air. You
may need to use water in order to remove debris.
14. Allow the radiator cores to dry completely before
operating the machine in the work mode.
Reference: See Operation and Maintenance
Manual, “Cooler Cores and A/C Condenser
- Clean” for information on a typical cleaning
procedure.
For additional information about the cooling
system coolant, see Operation and Maintenance
Manual, SEBU6250, “Caterpillar Machine Fluids
Recommendations”, “Cat Extended Life Coolant
(ELC)” or consult your Caterpillar dealer.
i02111126
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1395-538
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
131
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Table 19
“Cat ELC Extender” and the Cooling System Capacity
Recommended
Cooling System Capacity Amount of “Cat
ELC Extender”
84 L to 114 L (22 to 30 US gal) 2.15 L (72 oz)
When a Caterpillar Extended Life Coolant (ELC)
is used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
determined by the cooling system capacity.
For additional information about adding an extender,
see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your
Caterpillar dealer.
Extended Life Coolant (ELC)
Extender
Use a 8T-5296 Coolant Conditioner Test Kit to
check the concentration of the coolant.
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
g01018030
Illustration 189
132
Maintenance Section
Cooling System Coolant Level - Check
1. The filler cap is located inside the access door on
the top, left side of the radiator guard. Loosen the
radiator cap slowly in order to relieve pressure.
Remove the radiator cap.
2. It may be necessary to drain some coolant from
the radiator so that Extender can be added to the
cooling system.
Note: Always discard drained fluids according to
local regulations.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpillar
machines.
Dispose of all fluids according to local regulations and
mandates.
3. Add 2.15 L (72 oz) of Extender to the cooling
system.
4. Start the engine. Run the engine without the filler
cap until the thermostat opens and the coolant
level stabilizes. Check for leaks.
g00475722
Illustration 190
5. Look into filler tube (1). If necessary, add premixed
coolant in order to correct the coolant level.
Maintain the coolant level between area (2) and
area (3) of the filler tube. Adding coolant above
this area of the filler tube will cause the coolant to
overflow the cooling system.
6. Replace the radiator cap if the cap gasket is
damaged. Install the radiator cap.
SEBU7763-02
i02762816
Cooling System Coolant Level
- Check
SMCS Code: 1353-535-FLV; 1395-535-FLV
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
This machine’s radiator has a surge tank. There
is no top tank in this cooling system. The surge
tank has a filler cap and a sight glass. It is not
necessary to remove the filler cap in order to check
the coolant level. The sight glass is inside the engine
compartment that is on the front left side of the
machine. The filler cap is beneath the access door
that is on the top left side of the radiator guard.
g01075680
Illustration 191
1. Observe the sight glass in order to verify the level
of the coolant. If the coolant completely covers the
sight glass, the coolant level is okay. If the coolant
level is visible in the sight glass, the coolant is low.
Add coolant in order to fill the system.
SEBU7763-02 133
Maintenance Section
Cooling System Coolant Level - Check

Note: The factory fill is Extended Life Coolant

(ELC). Refer to Operation and Maintenance
Manual, SEBU6250, “Caterpillar Machine Fluids
Recommendations” for additional information.
Maintaining the system as ELC is preferred. See
the sections “Coolant Recommendations” and “ELC
Cooling System Maintenance”.

g01117259
Illustration 194

Use compressed air, high pressure water, or steam

to remove dust and debris from the radiator core.
However, the use of compressed air is preferred.

Allow the radiator cores to dry completely before

Illustration 192
g01075619 operating the machine in the work mode.

2. If it is necessary to add coolant, remove the filler Wood Chip or Waste Handling
cap slowly in order to relieve the pressure.
Arrangement (If Equipped)
Clean the Radiator Cores

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

g00475722
Illustration 193
3. Look into filler tube (1). Maintain the coolant level
between area (2) and area (3) of the filler tube.
Adding coolant above this area of the filler tube
will cause the coolant to overflow the cooling
system. If you need to add coolant daily, check the
cooling system for leaks.
than 205 kPa (30 psi) for cleaning purposes.
NOTICE
Pressurized air: To avoid possible engine damage,
shut off engine before performing maintenance to
clean the cooling system. Install air nozzle into
access slot before starting air supply. Read and un-
derstand Operation and Maintenance Manual.

4. Inspect the filler cap and the filler cap seal for
debris, for foreign material, or for damage. Clean
the filler cap with a clean cloth. Replace the
radiator cap if the filler cap is damaged.

5. Install the filler cap.

6. Inspect the radiator core for debris. Clean the

radiator core, if necessary.
134
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Illustration 195
g01382652
Wood chip or waste handling arrangement (if equipped)
Some components are removed for clarity.
Use 307-6728 Air Nozzle (1) (not shown) in order to
clean debris from the cooling system. Use the work
tool safely.
1. Turn off the engine.
a. Make sure that the fan has stopped rotation.
2. Open the cover to the access slot (2) on the right
side of the radiator guard.
3. Insert the air nozzle into the slot.
4. Turn on the air supply.
5. Move the air nozzle in a sufficient pattern to clean
debris from the cooling system which includes the
radiator cores.
a. Turn off the air supply when the nozzle cleaning
is completed.
6. Remove the air nozzle from the slot. Close the
access cover.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core, if necessary. Stop
the engine. Inspect the core for cleanliness. Repeat
the cleaning, if necessary.
SEBU7763-02
i01958847
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510
NOTICE
Failure to replace the engine’s thermostat on a regu-
larly scheduled basis could cause severe engine dam-
age.
NOTICE
Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of
problems with the cooling system.
A new thermostat should be installed after the cooling
system has been cleaned. Install the thermostat while
the cooling system is completely drained or while the
cooling system coolant is drained to a level that is
below the thermostat housing.
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.
Reference: Refer to Disassembly and Assembly,
“Water Temperature Regulator - Remove” and
Disassembly and Assembly, “Water Temperature
Regulator - Install” for more information. Fill the
engine cooling system. Refer to Operation and
Maintenance Manual, “Caterpillar Machine Fluids
Recommendations” and Operation and Maintenance
Manual, “Capacities (Refill)”.
SEBU7763-02
i01959143
Cutting Edges and End Bits -
Inspect/Replace
SMCS Code: 6801-040; 6801-510; 6804-040;
6804-510
g01018242
Illustration 196
1. Raise the bulldozer blade and block up the
bulldozer blade. When you remove the cutting
edges and the end bits, maintain the bulldozer
blade at a minimum height.
2. Remove the bolts. Then remove the cutting edge
and the end bits.
3. Thoroughly clean all contact surfaces.
4. 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 outward
and install the cutting edge.
5. If both sides of the cutting edge are worn, install a
new cutting edge section.
Note: When the cutting edge is within 10 mm
(0.4 inch) of the bottom of the support, change the
cutting edge. Do not allow wear to occur on the
support.
6. If the bottom edge or the outside edge of the end
bit is worn, install a new end bit.
Note: When the end bit is within 10 mm (0.4 inch) of
the bottom of the support, change the end bit. When
the end bit is within 10 mm (0.4 inch) of the outside
edge of the support, change the end bit. Do not
allow any wear to occur on the support.
7. Install all bolts and tighten the bolts to a
torque of 1150 ± 150 N·m (850 ± 110 lb ft).
Refer to Specifications, SENR3130, “Torque
Specifications”, “Torques for Ground Engaging
Tools”.
135
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace
8. Raise the bulldozer blade and remove the
blocking. Lower the bulldozer blade to the ground.
9. After you operate the machine for a few hours,
check all bolts for proper torque.
i02061807
Electronic Unit Injector -
Inspect/Adjust
SMCS Code: 1290-025; 1290-040
The Electronic Control module produces high
voltage. To prevent personal injury make sure the
Electronic Control Module is not powered and the
unit injector solenoids are disconnected.
NOTICE
The camshafts must be correctly timed with the crank-
shaft before an adjustment of the unit injector lash
is made. The timing pins must be removed from the
camshafts before the crankshaft is turned or damage
to the cylinder block will be the result.
The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.
Adjust the electronic unit injector at the same interval
as the valve lash adjustment.
Refer to your machine’s Service Manual or your
Caterpillar dealer for the complete adjustment
procedure.
i02229305
Engine Air Filter Primary
Element - Clean/Replace
SMCS Code: 1051-070; 1051-510-PY; 1054-070-PY;
1054-510-PY
NOTICE
Service the primary filter element only when the alert
indicator for the intake air filter is flashing. Do not open
the filter compartment unless it is time for service.
Opening the filter compartment can cause dirt to get
into the clean side of the filter housing.
136
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
NOTICE
Extremely short air filter life can result if the preclean-
er system malfunctions. If air filter life is drastically re-
duced from typical for the operating conditions, con-
sult your Caterpillar Dealer. The exhaust system dust
ejector for the strata tube precleaner must pull a min-
imum vacuum of 508 mm (20 inch) of water.
NOTICE
Service the engine air filters with the engine stopped.
Engine damage could result.
NOTICE
Always leave the secondary filter element in place
while you clean the primary element, or while you
clean the air cleaner housing.
NOTICE
Do not use the filter for longer than one year.
1. Open the engine compartment’s access door, if
equipped.
g00470852
Illustration 197
2. Remove the air cleaner cover (1). Pull out in order
to remove the element.
3. Remove the primary filter element (2) from the air
cleaner housing.
4. Mark the secondary filter element in order to show
that the primary filter element has been serviced.
The secondary filter element should be replaced
when the primary filter element is serviced for the
third time. Refer to Operation and Maintenance
Manual, “Engine Air Filter Secondary element -
Replace”.
SEBU7763-02
g00470857
Illustration 198
5. Clean the inside of the air cleaner housing. Keep
the secondary filter element in place while you
clean the housing.
6. If the primary filter element has not been cleaned
six times, inspect the primary filter element. If
the primary filter element has been cleaned six
times, replace the primary filter element. Proceed
to Step 9.
7. Inspect the primary filter element. Inspect the
filter element for holes and for tears by looking
through the filter element. Look toward a bright
light. Inspect the element for damaged gaskets or
for dented metal parts. Replace damaged filters.
Always crush damaged filter elements. Properly
discard the filter elements. If you replace the
primary filter element, proceed to step 9.
8. If the primary filter element is not damaged and
the element has not been previously cleaned six
times, clean the element. The filter element can
be cleaned by using pressure air. Use a maximum
air pressure of 205 kPa (30 psi). Direct the air
from the clean side to the dirty side. In order to
show that the filter element has been cleaned,
mark the element. The primary filter element can
be cleaned up to six times.
NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets, or seals. Do not wash the filter elements.
9. Push the filter element firmly in order to properly
seat the element. Write the date on the element, if
the primary element is replaced.
10. Install the air cleaner cover.
11. Close the access door, if equipped.
SEBU7763-02 137
Maintenance Section
Engine Air Filter Primary Element - Replace

i01505166

Engine Air Filter Primary

Element - Replace
SMCS Code: 1054-510-PY

NOTICE
Do not use the filter for longer than one year.

Refer to Operation and Maintenance Manual, “Engine

Air Filter Primary Element-Clean/Replace” in this
publication.
g00470240
Illustration 199
Write the date on the element, if the element is
replaced.
5. Remove the secondary filter element. Pull out in
order to remove the element.
i01454983
6. Install a new secondary filter element. Push
Engine Air Filter Secondary the element firmly in order to properly seat the
Element - Replace element. Write the date on the element, if the
element is replaced.
SMCS Code: 1051-510-SE; 1054-510-SE
7. Install the primary filter element and the air cleaner
housing cover.
NOTICE
Always replace the secondary filter element. Never 8. Close the engine access door, if equipped.
attempt to reuse it by cleaning.

The secondary filter element should be replaced at the i01959145

time the primary element is serviced for the third time.
Engine Air Precleaner - Clean
The secondary filter element should also be replaced
if the yellow piston in the filter element indicator en- SMCS Code: 1050-070
ters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.

NOTICE
The filter should be kept in service for no longer than
one year.

NOTICE
Always leave the secondary filter element in place
while you clean the air cleaner housing.

1. Open the engine access door, if equipped.

2. Remove the air cleaner housing cover.
3. Remove the primary filter element. Refer to
Operation and Maintenance Manual, “Engine Air
Filter Primary Element - Clean/Replace”.
4. Clean the inside of the air cleaner housing.
g01018245
Illustration 200
1. Inspect the screen in engine air precleaner (1) that
sits above engine hood (3) for dirt accumulation.
2. Loosen retainer (2) and remove the screen.
3. Clean the screen with compressed air or water.

4. Replace the screen.

138 SEBU7763-02
Maintenance Section
Engine Crankcase Breather - Clean

i02760299 14. Close the left access door.

Engine Crankcase Breather -
Clean i01959267

Engine Oil Level - Check

SMCS Code: 1317-070
SMCS Code: 1302-535-FLV; 1326-535-FLV
1. Stop the engine. Open the left access door.

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.

NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.

1. Open the engine access door (if equipped) on the

g01124723
Illustration 201 left side of the machine.
Top view

2. Loosen the hose clamps on the outlet hose from

the breather. Remove the hose from the breather
assembly.

3. Remove the clamp from the base of the breather

assembly.

4. Lift up on the breather assembly, in order to

remove the assembly.

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

cover seal if the cover seal is damaged.
g01025526
Illustration 202
6. Clean the breather in a clean nonflammable
solvent.

7. Shake the breather until the breather is dry. You

may also use pressure air to dry the breather.

8. Check the condition of the hose. Make sure that

the inside of the hose is unobstructed. Replace
the hose if the hose is damaged. g00489186
Illustration 203
9. Install breather assembly (2).

10. Install clamp (3).

11. Install the hose and breather outlet hose clamps

(1).

12. Open the doors to the radiator grill. Examine the

g00489188
bottom of the breather. Remove any debris that is Illustration 204
clogging the breather tube.

13. Close the doors to the radiator grill.

SEBU7763-02
2. Check the “LOW IDLE” side of dipstick (1)
while the engine is running. The oil should be
at operating temperature. Maintain the oil level
between the “ADD” mark and the “FULL” mark.
This is the only accurate way to check the oil level.
Check the “ENGINE STOPPED” side of the
dipstick while the engine is stopped. The oil should
be cold. Maintain the oil level between the “LOW”
mark and the “FULL” mark. This method should
be used as reference only, before the engine is
started.
Note: When you operate the machine on severe
slopes, the oil level in the engine crankcase must
be at the “FULL” mark on the “LOW IDLE” side of
dipstick (1).
3. Remove oil filler cap (2) and add oil, if necessary.
4. Clean the oil filler cap and install the oil filler cap.
5. Close the engine access door (if equipped).
i02489844
Engine Oil Sample - Obtain
SMCS Code: 1348-554-SM; 1348; 7542
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
139
Maintenance Section
Engine Oil Sample - Obtain
Obtain the sample of the engine oil as close as
possible to the recommended sampling interval. The
recommended sampling interval is every 250 service
hours. In order to receive the full effect of S·O·S oil
analysis, you must establish a consistent trend of
data. In order to establish a pertinent history of data,
perform consistent oil samplings that are evenly
spaced.
1. Before you obtain an oil sample, operate the
machine until the oil is warm and the oil is well
circulated.
2. Open the engine access door (if equipped) on the
left side of the machine.
g01025758
Illustration 205
3. Remove the protective cap.
4. Obtain a sample of the engine oil from the engine
oil sampling valve. The sampling valve is located
in the engine compartment on the left side of the
machine. Refer to Special Publication, SEBU6250,
“S·O·S Oil Analysis” for information that pertains
to obtaining a sample of the engine oil. Refer to
Special Publication, PEHP6001, “How To Take
A Good Oil Sample” for more information about
obtaining a sample of the engine oil.
Note: In order to obtain an oil sample from the engine
compartment, it may be necessary to increase the
engine’s speed. Normally, the oil sample is taken at
low idle. If the flow rate is too low, increase engine
speed to high idle in order to obtain the oil sample.
5. Replace the protective cap.
6. Close the engine access door (if equipped).
For additional information about oil sampling, see
Operation and Maintenance Manual, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.
140 SEBU7763-02
Maintenance Section
Engine Oil and Filter - Change

i02771121 Table 20

Engine Oil and Filter - Change D8T Series

Engine Oil Change Interval(1)
SMCS Code: 1308; 1318-510 Operating Conditions
Normal(2) Severe
Selection of the Oil Change Interval
Multigrade Fuel Altitude
High Sulfur above
Oil Type Load
NOTICE from 1830 m
Factor(3)l 0.3% (6000 ft)
This machine is equipped with an engine that meets
EPA Tier III, Euro Stage II, or MOC Step 2 emission to
regulations. A 500 hour engine oil change interval is 0.5%
available, provided that operating conditions and rec- Cat DEO
ommended multigrade oil types are met. When these 500 hr 500 hr 500 hr 250 hr(5)
Preferred
requirements are not met, shorten the oil change
interval to 250 hours, or use an S·O·S oil sampling ECF-1
10.0
and analysis program to determine an acceptable oil minimum 500 hr 500 hr 500 hr 250 hr(5)
change interval. TBN(3)
Preferred
If you select an interval for oil and filter change that is
too long, you may damage the engine. ECF-1
250
TBN(4) 500 hr 500 hr 250 hr(5)
hr(4)
below 10.0
CAT oil filters are recommended.
250
API CG-4 500 hr 250 hr(4) 250 hr(5)
hr(4)
Abnormally harsh operating cycles or harsh
(1) The standard oil change interval for the D8T is every 500
environments can shorten the service life of
hours. If the operating conditions, fuel rates, and recommended
the engine oil. Arctic temperatures, corrosive oil types for your engine are listed in the table20 are met. The
environments, or extremely dusty conditions traditional oil change interval for engines is 250 hours. The
may require a reduction in engine oil change standard oil change interval in this machine is 500 hours, if the
intervals from the recommendations in Table 20. operating conditions and recommended oil types that are listed
Also refer to Manual, SEBU5898, “Cold Weather in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
Recommendations for all Caterpillar Machines”. Poor permitted for other machines. Refer to the applicable Operation
maintenance of air filters or of fuel filters requires and Maintenance Manuals for the other machines.
reduced oil change intervals. See your Caterpillar (2) Normal conditions include these factors: Fuel sulfur below

dealer for more information if this product will
experience abnormally harsh operating cycles or
harsh environments.
0.5%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
(3) Load factors are defined as a function of fuel consumption rate.
High load factors can shorten the service life of your engine oil.
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average fuel
consumption of your D8T exceeds 51 L (13.5 US gal) per hour,
follow the “High Load Factor” recommendations in Table 20. To
determine average fuel consumption, measure average fuel
consumption for a period of 50 to 100 hours. If the application
of the machine is changed, the average fuel consumption may
change.
(4) In order to verify an oil change interval of 500 hours, refer to
“Program A” below.
(5) Use “Program B” below to determine an appropriate interval.

Adjustment of the Oil Change Interval

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

Program A

Verification for an Oil Change Interval of 500 Hours

SEBU7763-02 141
Maintenance Section
Engine Oil and Filter - Change

This program consists of three oil change intervals of

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

• Change to a preferred oil type in Table 20. Open the engine access door on the left side of the
Program B machine.

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oil

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

If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade oil type in the listing above.
g01025579
Illustration 206
References
If the machine is equipped with a high speed oil
Reference: Form, PEDP7035, “Optimizing Oil change, use a 126-7539 Nozzle.
Change Intervals”

Reference: Form, PEDP7036, “S·O·S Fluid Analysis”

Reference: Form, PEHP7076, “Understanding the

S·O·S Oil Analysis Tests”

Procedure for Changing the Engine

Oil and Filter

Hot oil and components can cause personal in-

jury.
g00490801
Illustration 207
Do not allow hot oil or components to contact
skin. 1. Remove two bolts in order to remove the
crankcase drain access cover, which is in the
crankcase guard.
142
Maintenance Section
Engine Oil and Filter - Change
g00670611
Illustration 208
2. Remove the 4P-0520 Plug Adapter from the
drain valve, if equipped.
3. Install a 25.4 mm (1.00 inch) pipe into the drain
valve. The pipe requires a 1-11 1/2 NPTF pipe
thread.
4. Open the drain valve. Allow the oil to drain into a
suitable container. A drain hose may be attached
to the pipe to aid in draining.
5. When the oil has completed draining from the
crankcase, close the drain valve. Remove the
pipe. Install the 4P-0520 Plug Adapter. Install the
access cover.
g01025590
Illustration 209
6. Remove engine oil filter element (1) and discard
the engine oil filter element properly. Make sure
that all of the old filter seal is removed from the
filter base.
7. Apply a thin coat of oil to the seal on the new filter.
8. Install the new engine oil filter element by hand.
SEBU7763-02
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.
9. Remove oil filler cap (3). Fill the crankcase with
new oil. See the topic Operation and Maintenance
Manual, “Capacities (Refill)” in this manual. Clean
oil filler cap (3) and install the oil filler cap.
10. To ensure that the correct amount of oil was
added, always measure the oil level with the
dipstick (2).
g00489188
Illustration 210
11. Check the “ENGINE STOPPED” side of the
dipstick while the engine is stopped. The oil should
be cold. Maintain the oil level between the “LOW”
mark and the “FULL” mark. This method should
be used as reference only, before the engine is
started.
g00489186
Illustration 211
12. Check the “LOW IDLE” side of the dipstick
while the engine is running. The oil should be
at operating temperature. Maintain the oil level
between the “ADD” mark and the “FULL” mark.
This is the only accurate way to check the oil level.
13. Install the access cover for the crankcase drain.
For additional information about oil types, see Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations” or consult your Caterpillar dealer.
SEBU7763-02 143
Maintenance Section
Engine Valve Lash - Check/Adjust

i02763245

Engine Valve Lash -

Electrical shock hazard. The electronic unit injec-
Check/Adjust tor system uses 90-120 volts.
SMCS Code: 1102-025; 1102

To prevent possible injury, do not use the starter

motor to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring valve clearance.

g00941949
Electrical shock hazard. The electronic unit injec- Illustration 212
tor system uses 90-120 volts.
1. Start the engine. Run the engine at low idle.
NOTICE
Operation of Caterpillar engines with improper valve
adjustments will reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.

NOTICE
Measure the valve clearance with the engine stopped.
To obtain an accurate measurement, allow at least 20
minutes for the valves to cool to engine cylinder head
and engine block temperature.

Check the valve bridge before setting the valve lash.
Ensure that the valve bridge is seated equally on
both valve stems.
Refer to your machine’s Service Manual or your
Caterpillar dealer for the complete valve adjustment
procedure.
i02763340
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
g00038585
Illustration 213
2. Watch the top surface of each valve rotator.
Whenever an inlet valve closes or an exhaust
valve closes, each valve rotator should turn.
3. If a valve rotator fails to rotate, consult your
Caterpillar dealer for service.
Note: Caterpillar recommends replacing valve
rotators that are operating improperly. An improperly
operating valve rotator will shorten valve life because
of accelerated wear on the valves.

Note: If a damaged valve rotator is not replaced,

When inspecting the valve rotators, protective
glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil
or spray.
some valve face guttering could result. Metal particles
from the valve could fall into the cylinder. This could
cause damage to the piston head and to the cylinder
head.
144 SEBU7763-02
Maintenance Section
Equalizer Bar End Pins Oil Level - Check

i01251387 4. Check the oil level. Oil level (4) should be at the
top of the hex head on the fitting.
Equalizer Bar End Pins Oil
Level - Check 5. If the oil level is low, apply the gear oil through
fitting (3) until the gear oil reaches oil level (4) at
SMCS Code: 7206-535 the top of the hex head on the fitting. Remove
any excess oil. This will maintain a volume of air.
The gear oil must be applied with a 7H-1680
NOTICE
Lubrication Pump or a suitable grease gun. Use
Apply gear oil through the fittings with a hand oper-
75W-90 API GL-5, 80W-90 API GL-5, 85W-140
ated lubrication pump or a suitable grease gun. Use
API GL-5, or 90 API GL-5 gear oil. The gear oil
of pressure operated lubricating equipment damages
has excellent load carrying capacity.
the seals.
6. Be sure that seals (1) are not pushed out. Push
NOTICE back the seals if the seals are pushed out.
Before and after the equalizer bar end pin is filled with
gear oil, seal (1) must be flush with the equalizer bar. If 7. Install plug (2).
the seals are not flush, damage to the seals can result
by overfilling. Note: MPGM GREASE IS ALLOWED ONLY
FOR A FAILED SEAL. THE SEAL SHOULD
BE REPLACED AS SOON AS POSSIBLE. THE
COMBINATION OF GEAR OIL AND MPGM IS NOT
HARMFUL TO THE MACHINE.

When you operate the machine in arctic conditions,

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

g00586840
Illustration 214

g00586858
Illustration 215

1. Clean the areas that are around the end pin with a
high pressure wash. Inspect the condition of the
seal (1).

2. Check the area for oil leakage. Be sure that the

seal is in a neutral position.

3. Remove plug (2).

SEBU7763-02
i01959542
Ether Starting Aid Cylinder -
Replace
SMCS Code: 1456-510-CD
Breathing ether vapors or repeated contact of
ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
areas or in the operator’s compartment.
Do not store ether cylinders in direct sunlight or
at temperatures above 49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.
Keep ether cylinders out of the reach of unautho-
rized personnel.
To avoid possible injury, be sure the brakes are ap-
plied and all controls are in Hold or Neutral when
starting the engine.
g01018416
Illustration 216
1. Open the engine access door (if equipped) on
the left side of the machine. The ether canister
is mounted inside the compartment on the side
of the engine.
145
Maintenance Section
Ether Starting Aid Cylinder - Replace
g01018418
Illustration 217
2. Loosen the retaining clamp. Remove the old
canister by turning the canister counterclockwise.
3. Remove the old gasket. Install the new gasket.
4. Install the new canister. Turn the canister
clockwise. Hand tighten the canister. Tighten the
clamp around the canister.
5. Close the engine access door (if equipped).
i01959689
Final Drive Oil - Change
SMCS Code: 4050-535-FLV
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
146 SEBU7763-02
Maintenance Section
Final Drive Oil Level - Check

i01959718

Final Drive Oil Level - Check

SMCS Code: 4050-535-FLV

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.

g01018450
Illustration 218

1. Position one final drive so that oil level mark (1) is

horizontal. The drain plug (3) will point downward.

2. Remove oil filler plug (2).

3. Remove drain plug (3). Allow the oil to drain into a

suitable container.

4. Inspect the drain plug seal. Replace the drain plug

seal if the drain plug seal is damaged.

5. Clean the drain plug and install the drain plug. g01018451
Illustration 219
6. Fill the final drive with oil to the bottom of the filler
plug opening. See Operation and Maintenance 1. Position one final drive so that oil level mark (1) is
Manual, “Capacities Refill”. horizontal with the oil filler plug (2).

7. Inspect the condition of the seal of the filler plug. 2. Remove oil filler plug (2).
Replace the plug seal if the plug seal is damaged.
Wipe the magnet in order to clean the plug. Install 3. The oil level should be at the bottom of the filler
the plug. plug opening. Add oil, if necessary.

8. Repeat Step 1 to Step 7 in order to change the oil 4. Wipe the magnet in order to clean the plug.
in the other final drive.
5. Install oil filler plug (2).
For additional information about final drive oil, see
Special Publication, SEBU6250, “Caterpillar Machine 6. Repeat Step 1 to Step 5 in order to check the oil
Fluids Recommendations” or consult your Caterpillar level in the other final drive.
dealer.
SEBU7763-02 147
Maintenance Section
Final Drive Oil Sample - Obtain

i02229659

Final Drive Oil Sample - Obtain

SMCS Code: 3258-008; 4011-008; 4050-008;
4050-SM; 4070-008; 4070-554-SM; 7542-008

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g01117789
Illustration 220
2. Remove the cover plate.
3. Obtain an oil sample. The use of a sampling gun
that is inserted into the sump is the preferred
method for obtaining a sample.
Note: Do not use the drain stream method to obtain
a sample of the final drive oil. A stream of dirty oil
from the bottom of the compartment will contaminate
the sample. Likewise, never dip an oil sample from
an oil container or pour a sample from a used filter.

Dispose of all fluids according to local regulations and
mandates.
Obtain the sample of final drive oil as close as
possible to the recommended sampling interval. The
recommended sampling interval is every 500 service
hours. In order to receive the full effect of S·O·S oil
analysis, you must establish a consistent trend of
data. In order to establish a pertinent history of data,
perform consistent oil samplings that are evenly
spaced.
If the machine is operated under a high load
and/or under high temperature conditions,
sample all fluids at the 250 hour interval.
4. Install the cover plate.
Reference: Refer to, “Lubricant Viscosities” in the
Maintenance Section of this manual for the correct
fluid for your machine.
Reference: Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”,
“S·O·S Oil Analysis” for information that pertains
to obtaining a sample of the final drive oil. Refer
to Special Publication, PEHP6001, “How To Take
A Good Oil Sample” for more information about
obtaining a sample of the final drive oil.

1. Run the machine until operating temperature has

been reached. The sample must be at operating
temperature in order to take an accurate sample.
148 SEBU7763-02
Maintenance Section
Final Drive Seal Guard Packing - Replace

i02774981

Final Drive Seal Guard Packing

- Replace
(If Equipped)
SMCS Code: 4052-510

The design of the seal guard has a packing that

prevents debris from entering the area of the
Duo-Cone Seal Gp. The close fit and tolerances limit
the size of the debris that can enter the labyrinth seal
to 2 mm (0.079 inch). The labyrinth seal changes
the direction of the debris four times. Contact may
be made at the packing after the fourth time. The
packing material is impregnated with silicone oil.
Therefore, it is not necessary to fill the cavity for the
packing with grease. The packing is held in place
by retainers that can be removed. This allows the
replacement of the packing without removing the final
drive. The packing has a split that allows the packing Illustration 222
g00939529
to be placed over the spindle.
Cross section view of seal guard
(6) Retainer
Replacement of the Packing (7) Inner packing
(9) Outer packing
(D) 2 mm (0.079 inch)

2. Inspect the packing and the seal guard for

evidence of leaking through the packing. Remove
packing (6) and (9) from seal guard (3). Oil
leakage through the packing would indicate
leakage of the Duo-Cone Seal Gp in the final
drive. Inspect the Final Drive for oil leakage
through the Duo-Cone Seal Gp. If oil is leaking
through the seal, replace the Duo-Cone Seal
Gp. Refer to the Service Manual.

Table 21
Required Parts
Part Qty Description
Number
137-9810 2 Seal (packing)
129-1928 1 Grease

g00939700
Illustration 221 Note: Each final drive seal guard requires two
(4) Bolt 137-9810 Seals (packing). The sections of packing
(5) Washer are installed on top of each other in the groove of
(6) Retainer
the seal guard.
1. Remove bolts (4) and washers (5). Remove
retainers (6).
SEBU7763-02
g00941695
Illustration 223
(7) Inner packing
(8) Joint in the inner packing
(A) Diameter (A)
3. Install inner packing (7). Place a thin film of
129-1928 Grease on diameter (A). Stretch the
packing during installation. Smooth the packing
and keep the packing uniform. Minimize the joint
(8) at the ends of the inner packing (7).
149
Maintenance Section
Final Drive Seal Guard Packing - Replace
g00940433
Illustration 224
(9) Outer packing
(10) Joint in the outer packing
(A) Diameter (A)
(B) 180 degrees
4. Install the outer packing (9). Offset the joint in
the inner packing (8) and the outer packing
(10) at 180 degrees. Stretch the packing during
installation. Smooth the packing and keep the
packing uniform. Minimize the joint (10) at the
ends of the outer packing (9).
150 SEBU7763-02
Maintenance Section
Fuel System - Prime

1. Turn the ignition switch to the “OFF” position.

g01124784
Illustration 226

2. Twist valve (1) in order to open the air purge valve.

3. Hold the switch for the electric fuel priming pump

Illustration 225
g00939660 (2) in order to be in the ON position. Allow the fuel
priming pump to run until fuel without air flows
(4) Bolt
(5) Washer through the air purge valve (1).
(6) Retainer
(9) Outer packing 4. Release the switch for the fuel priming pump in
(10) Joint in outer packing order to be in the OFF position.
(11) Joint in retainers
(C) 90 Degrees from joint in outer packing to joint in retainers
Note: This process will prime the fuel system
Note: The joint (10) in the outer packing (9) must be regardless of the location of the air in the lines.
offset 90 degrees (C) to the joints (11) in the retainers
(6). 5. Twist valve (1) in order to close the air purge valve.

5. Assemble retainers (6) to seal guard (3) with
washers (4) and bolts (5). The clearance at area
(D) should be 2 mm (0.079 inch).
6. Repeat steps 3 through 5 in order to replace the
packing on the other final drive, if necessary.
i02229667
Fuel System - Prime
SMCS Code: 1258
If the engine does not start, air may be trapped in the
fuel lines to the engine. Use the following procedure
in order to purge air from the fuel lines.
Electric Fuel Priming Pump
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
The electric fuel priming pump is located in the
engine compartment on the left side of the machine.
6. Hold the switch for the electric fuel priming
pump (2) in order to be in the ON position for 20
seconds. This will allow the air to be completely
removed from the system.
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.
7. Start the engine. If you cannot start the engine,
the engine needs more priming. If the engine
continues to misfire or to smoke, more priming is
necessary. Repeat step 6 if the engine will not
start.
Note: The electric fuel priming pump will only operate
if the engine start switch key is in the OFF position.
Shut off the engine before any additional priming.
8. Run the engine at the LOW IDLE position until the
engine runs smoothly.
Note: Do not activate the priming pump while you
crank the engine.
SEBU7763-02 151
Maintenance Section
Fuel System Primary Filter - Clean/Replace

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for information
on replacing the filter.

i01969411

Fuel System Primary Filter -

Clean/Replace
SMCS Code: 1260-070; 1260-510

Personal injury or death can result from a fire. Illustration 227

g01113804

Fuel leaked or spilled onto hot surfaces or electri- 2. Open the engine access door on the left side of
cal components can cause a fire. the machine.
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
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01022363
Illustration 228
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies 3. Drain water separator bowl (3) into a suitable
suitable to collect and contain fluids on Caterpillar container and remove the bowl from the bottom
products. of the filter element. Clean the water separator
bowl and inspect the seal. If the seal is worn or
Dispose of all fluids according to local regulations and damaged, install a new seal.
mandates.
4. Remove filter element (2). Properly discard the
NOTICE filter element.
Do not fill fuel filter with fuel before installing the fuel
filter. Contaminated fuel causes accelerated wear to 5. Clean the filter base. Be sure that all of the old
fuel system parts. seal is removed.

6. Coat the seal of the new filter element with clean

1. Turn the red lever (1) in order to shut off fuel diesel fuel.
supply.
7. Install the new filter element hand tight until the
seal of the filter contacts the base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter base.

Note: There are rotation index marks on the filter

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filter, use the
rotation index marks as a guide.
152 SEBU7763-02
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain

Note: Tighten the filter according to the instructions

that are printed on the filter. Use the index marks as a NOTICE
guide. For non-Caterpillar filters, use the instructions Do not allow dirt to enter the fuel system. Thoroughly
that are provided with the filter. clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
Note: You may need to use a Caterpillar strap nected fuel system component.
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

8. Coat the seal of the water separator bowl with

clean diesel fuel. Install the water separator bowl
to the filter element.

9. Turn the red lever (1) in order to resume the fuel

supply.

10. Prime the fuel system. See the Topic “Fuel

System - Prime” in this manual.

11. Start the engine and run the engine. Check filter g01022350
Illustration 229
(2) and water separator bowl (3) for leaks.

12. Close the engine access door.

i01969397

Fuel System Primary Filter

(Water Separator) - Drain
SMCS Code: 1263-543

Fuel leaked or spilled onto hot surfaces or elec-

g00104007
trical components can cause a fire. To help pre- Illustration 230
vent possible injury, turn the start switch off when (1) Element
changing fuel filters or water separator elements. (2) Bowl
Clean up fuel spills immediately. (3) Drain

Bowl (2) should be monitored daily for signs of water.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
If water is present, drain the water from the bowl.
1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Dispose of the water properly.
2. Close drain (3).

Refer to Special Publication, NENG2500, “Caterpillar NOTICE

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.
SEBU7763-02 153
Maintenance Section
Fuel System Secondary Filter - Replace

i01969432

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.
g01113804
Clean up all leaked or spilled fuel. Do not smoke Illustration 231
while working on the fuel system.
1. Turn the red lever (1) in order to shut off fuel
Turn the disconnect switch OFF or disconnect the supply.
battery when changing fuel filters.
2. Open the engine access door on the left side of
the machine.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

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

Dispose of all fluids according to local regulations and

mandates.
g01022384
Illustration 232

NOTICE 3. Remove the secondary fuel filter (2). Discard the

Do not fill fuel filters with fuel before installing them. fuel filter properly.
Contaminated fuel will cause accelerated wear to fuel
system parts. 4. Clean the filter base. Make sure that all of the old
seal is removed.
Before you replace the secondary fuel filter element,
replace the primary fuel filter element. See the Topic 5. Install the Fuel Filter. Coat the seal of the new
“Fuel System Primary Filter - Replace” in this manual. filter with clean diesel fuel.

6. Install the new filter by hand. When the seal

contacts the base, tighten the filter according to
the instructions on the filter.

Rotation index marks are positioned on the filter

at 90 degree intervals. Use these rotation index
marks as a guide when you tighten the filter.

7. Turn lever (1) in order to resume fuel supply.

8. Prime the fuel system. See the Topic “Fuel System

- Prime” in this manual.

9. Close the engine access door.

154 SEBU7763-02
Maintenance Section
Fuel Tank Cap Filter and Strainer - Replace/Clean

i01969542 5. Inspect the tank cap seal. If the seal is damaged,

replace the seal.
Fuel Tank Cap Filter and
Strainer - Replace/Clean 6. Replace the filter assembly, the valve, the gaskets,
and the screws. Use a 9X-2205 Cap Filter Kit.
SMCS Code: 1273-070-STR; 1273-070-Z2
7. Install the strainer.

8. Install the fuel cap. Rotate the fuel cap clockwise

until three tabs (7) drop into the slots in the
adapter. Rotate lever (5) clockwise until the lever
stops. Lower lever (5) over locking tab (6).

Fast Fill Fuel Adapter (If Equipped)

See illustration 233.

Machines that are equipped with a fast fill fuel adapter

(2) have identical fuel caps as systems without a
fast fill fuel adapter. Use the same procedure for
g01022482
changing the filter in the two systems.
Illustration 233

The fuel tank is located on the rear of the machine. i02770686

The filler cap (1) is on the left side of the machine
next to the ROPS. Fuel Tank Water and Sediment
- Drain
Only vented fuel caps have filters. Machines without
the fast fill fuel adapter require a vented fuel cap. SMCS Code: 1273-543-M&S

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

g01110732 Dispose of all fluids according to local regulations and

Illustration 234
mandates.
1. Lift lever (5) in order to remove the fuel tank filler
cap. Turn the lever counterclockwise until the
lever stops. Lift the cap straight up in order to
remove the cap.

2. Remove the fuel strainer from the filler neck.

3. In order to replace the filter assembly, remove two

screws that secure filter assembly (4) to the fuel
cap. Remove filter assembly (4), valve (3), and
the gaskets.

4. Wash the cap and the strainer in a clean,

nonflammable solvent.
g01113920
Illustration 235
SEBU7763-02 155
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset

The drain valve is under the fuel tank at the rear of

the machine.

1. Open the drain valve with the yellow handle. Allow

the water and the sediment to drain into a suitable
container.

2. Close the drain valve.

i02606338

Fuses and Circuit Breakers -

Replace/Reset
g01018359
SMCS Code: 1417-510; 1420-529; 1420 Illustration 237
(A) Open fuse box
Fuses – Fuses protect the electrical (B) Open fuse panel
system from damage that is caused by
overloaded electrical circuits. Replace Fuse listing:
a fuse if the element separates. If the fuse of
a particular electrical system requires frequent ROPS floodlights (1) – 15 Amp
replacement, check the electrical circuit. Repair the
electrical circuit, if necessary. Ripper floodlights (2) – 15 Amp

ECM engine monitoring (3) (Power train ECM) –

NOTICE 15 Amp
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage Rear ROPS floodlights (4) – 15 Amp
could result.
Auxiliary (5) – 10 Amp
NOTICE
Spare 1 (6) – 20 Amp
If it is necessary to replace fuses frequently, an elec-
trical problem may exist.
GPS/Radio Transmission Antenna (7) – 15 Amp
Contact your Caterpillar dealer.
Seat, Ripper, or Implements (8) – 15 Amp

Standard Converter (9) – 10 Amp

Spare 2 (10) – 15 Amp

“AccuGrade” (11) – 15 Amp

Wipers (12) – 15 Amp

Ignition Key (13) – 10 Amp

Fender Floodlights (14) – 15 Amp

Horn (15) – 15 Amp

g01118158
Illustration 236 CAES Display (16) – 10 Amp
Open the cover for access to the circuit breakers and Secondary Brake (17) – 10 Amp
the fuses. This is inside the operator station below
the left armrest above the floorplate. Unswitched Auxiliary (18) – 15 Amp

Product Link (19) – 10 Amp

Advisor Panel (20) – 15 Amp

156 SEBU7763-02
Maintenance Section
Horn - Test

Implement ECM (21) – 15 Amp

NOTICE
Implement ECM (22) – 15 Amp Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Engine ECM (23) – 20 Amp ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
24 VA − 12 VA Converter (24) (Attachment) – 20 ing any compartment or disassembling any compo-
Amp nent containing fluids.

Cover (25) – Fuse panel Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
Fuse (26) – 175 Amp suitable to collect and contain fluids on Caterpillar
products.
Fuse cover (27) – Plastic
Dispose of all fluids according to local regulations and
Power outlet (28) – 12 Volt mandates.

Starting/Charging Analyzer (29) (Plug) – 70-pin

Connector Operate the machine in order to warm the oil.

HVAC blower (30) (Reset button) – 15 Amp Park the machine on level ground. Lower the
bulldozer blade and the ripper to the ground and
Fuse Puller (31) – Auto Stop apply slight downward pressure. Engage the parking
brake and stop the engine.

i02054663 1. Make sure that all work tools are lowered to the
ground.
Horn - Test
SMCS Code: 7402-081

Test the horn on a daily basis. Press downward on

the horn button in order to sound the horn. If the horn
does not sound, make the necessary repairs before
you operate the machine.

i02229763

Hydraulic System Oil - Change

SMCS Code: 5050-044
g01022926
Illustration 238
Cross section view

At operating temperature, the hydraulic tank is hot

2. Remove hydraulic tank filler cap (1) slowly in order
and under pressure.
to relieve any pressure.
Hot oil and components can cause personal in-
3. Wash the filler strainer and the filler cap in a clean
jury. Do not allow hot oil or components to contact
nonflammable solvent.
skin.
4. Remove oil drain plug cover (3) that is under the
Remove the filler cap only when the engine is
hydraulic tank.
stopped, and the filler cap is cool enough to
touch with your bare hand. Remove the filler cap
slowly to relieve pressure.
SEBU7763-02
g01022927
Illustration 239
(4) Oil drain plug.
(5) Sight gauge
5. Remove the oil drain plug. The oil drain plug is
located under right fender (4).
6. Attach a hose to a 126-7914 Swivel. Install the
swivel and the hose into the drain plug opening. A
pipe nipple 10 cm (4 inch) and a hose can also be
used. Use a 25.4 mm (1 inch) pipe with 1-11 1/2
NPTF threads. Do not tighten the pipe.
7. Rotate the swivel clockwise in order to open the
internal drain valve. Allow the oil to drain into a
suitable container.
8. Remove the swivel. The valve for the hydraulic
tank will close.
9. Clean the drain plug and install the drain plug.
Tighten the drain plug to a torque of 68 ± 7 N·m
(50 ± 5 lb ft). Install the oil drain plug cover.
10. Change the hydraulic system filters. Case
drain filter (2) is shown. See the Operation and
Maintenance Manual, “Hydraulic System Oil
Filters - Replace”.
11. Install the filler strainer.
12. Fill the hydraulic oil tank. See the Operation and
Maintenance Manual, “Capacities (Refill)” in order
to determine the amount of hydraulic oil that is
needed to fill the hydraulic oil tank.
13. Inspect the filler cap gasket. Replace the gasket if
damage or wear is evident.
14. Install the filler cap.
15. Start the engine. Run the engine for a few
minutes.
157
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace
g01022619
Illustration 240
The arrow indicates the “FULL” mark.
Enlarged view of the sight gauge
16. Maintain the oil level to the “FULL” mark in the
sight gauge. Check with the attachments on the
ground and with cold oil. Add oil, if necessary.
17. Stop the engine.
For additional information about hydraulic system
oil, see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your
Caterpillar dealer.
i02214240
Hydraulic System Oil Filter
(Pilot) - Replace
SMCS Code: 5068-510-PS; 5068-510; 5092-510
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 contact
skin.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to
touch with your bare hand. Remove the filler cap
slowly in order to relieve pressure.
Pilot Hydraulic Oil Filter
1. Lower the bulldozer and the ripper to the ground.
Turn off the engine.
158 SEBU7763-02
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace

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

Install a new pilot hydraulic oil filter hand tight until
the seal of the pilot hydraulic oil filter contacts the
base. Note the position of the index marks on the
filter in relation to a fixed point on the filter base.

Note: There are rotation index marks on the pilot

hydraulic oil filter that are spaced 90 degrees or 1/4
of a turn away from each other. When you tighten the
pilot hydraulic oil filter, use the rotation index marks
as a guide.

6. Tighten the filter according to the instructions

g01075799
Illustration 241
2. The hydraulic tank is located on the right side of
the machine. Depress the button on breaker relief
valve (1) next to the filler cap (2) in order to relieve
any tank pressure. Remove the filler cap.
that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

7. Install the access cover.

8. Start the engine.

g01117647
Illustration 242

3. Remove access cover (3) at the rear of the fuel

tank.

g01022619
Illustration 244

9. Maintain the hydraulic oil to the “FULL” mark in the

sight gauge that is on the outside of the hydraulic
tank.

10. Install hydraulic tank filler cap (2).

11. Install access cover (3).

12. Stop the engine.

For additional information about hydraulic systems,

Illustration 243
g01117748 refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your
Rear view
Caterpillar dealer.
4. Remove spin-on type filter (4) that is the pilot
hydraulic oil filter. The pilot hydraulic oil filter
is attached below the accumulator manifold.
Properly discard the filter element.
SEBU7763-02 159
Maintenance Section
Hydraulic System Oil Filters - Replace

i02769408 4. Remove case drain filter (3) and properly discard

the case drain filter.
Hydraulic System Oil Filters -
Replace 5. Clean the strainer, the filter housing, and the oil
filler cap in a clean, nonflammable solvent.
SMCS Code: 5068-510
6. Install a new case drain filter.

7. Install the strainer, the cover, and the four bolts.

Hot oil and components can cause personal in-
jury.

Do not allow hot oil or components to contact

skin.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01103238
Illustration 246
Refer to Special Publication, NENG2500, “Caterpillar
Steering charge filter
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products. 8. Change the steering charge filter.

Dispose of all fluids according to local regulations and Reference: See “Steering Charge Filter - Change”
mandates. in this manual for more information.

9. Fill the hydraulic system with new oil. See

1. Lower the bulldozer and the ripper to the ground. Operation and Maintenance Manual, “Capacities
Turn off the engine. (Refill)”. Install hydraulic oil filler cap (1).

Reference: See Operation and Maintenance 10. Start the engine.

Manual, “Stopping the Machine” for additional
information.

g01022619
Illustration 247
g01076258
Illustration 245 11. Maintain the oil level to the “FULL” mark in the
sight gauge for the hydraulic oil tank. Check with
2. On the right side of the machine, remove hydraulic the attachments on the ground and cold oil. Add
oil filler cap (1) in order to relieve the tank oil, if necessary.
pressure. Remove the filler strainer.
12. Stop the engine.
3. Remove four bolts (2) in order to remove the cover
from the case drain filter. 13. Close the access door.
160
Maintenance Section
Hydraulic System Oil Level - Check
For additional information about hydraulic system
oil, see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your
Caterpillar dealer.
i01969751
Hydraulic System Oil Level -
Check
SMCS Code: 5056-535-FLV; 7479
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 contact
skin.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to
touch with your bare hand. Remove the filler cap
slowly in order to relieve pressure.
Lower the bulldozer and the ripper to the ground.
Place the ripper shanks in the vertical position.
The hydraulic tank is on the right rear side of the
machine.
g01022619
Illustration 248
1. Maintain the oil level to the “FULL” mark in the
sight gauge. Check the oil level when the oil is
cold. Verify that the oil level is below the “FULL”
mark before you remove the filler cap.
2. If the hydraulic system requires additional
hydraulic oil, remove the filler cap slowly in order
to relieve the pressure. Add oil through the filler
tube.
3. Clean the filler cap and install the filler cap.
SEBU7763-02
i01960922
Hydraulic System Oil Sample
- Obtain
SMCS Code: 5095-008
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
g01018666
Illustration 249
Obtain a sample of the hydraulic oil from the sampling
valve. The sampling valve is located behind the
access door on the right side of the cab. Remove
the protective cap from the oil sampling port that is
above the steering charge filter. Refer to Special
Publication, SEBU6250, “S·O·S Oil Analysis” for
information that pertains to obtaining a sample of the
oil. Refer to Special Publication, PEHP6001, “How To
Take A Good Oil Sample” for more information about
obtaining a sample of the oil.
SEBU7763-02 161
Maintenance Section
Indicators and Gauges - Test

For additional information about hydraulic system • “X10” readout

oil, see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your • Symbol for the hour meter
Caterpillar dealer.
• “8.8.8.X.8.8” readout
i01961867
The pointers in the gauges point upward. Then, the
Indicators and Gauges - Test pointers point to the left. Then, the pointers point
to the right. Then, the pointers point to the final
SMCS Code: 7450-081; 7490-081 positions.

• The speed readout shows “188”, “MPH”, and

“km/h”.

If the action alarm does not sound during this test
or machine monitoring displays are not function-
ing, do not operate the machine until the cause
has been corrected. Machine operation with faulty
action alarms or displays could result in injury or
death as any Warning Category 3 notifications will
not be relayed to the operator.
Check the operation of the Monitoring System.
Observe the self test when you start the engine.
The system performs an automatic self test when
you turn the engine start switch to the ON position.
The self test verifies that the monitoring panel and
the display modules are operating properly.
The internal circuits, the indicators, and the gauges
are automatically checked.
• The action light stays illuminated.
• The action alarm sounds once.
The monitoring panel is then in the normal operating
mode.
If the above tests are not correctly completed, the
system will not function in the normal operating
mode. Consult your Caterpillar dealer for an electrical
system check. Any repairs must be made before you
start the engine.
Turn on all of the machine lights. Check for proper
operation. Sound the forward horn.
Stop the engine.
Make any necessary repairs before you operate the
machine.

i01959914

Lift Cylinder Yoke Bearings -

Lubricate
SMCS Code: 5102-086-BD

g01113652
Illustration 250

The operator must observe the indicators and the

gauges in order to determine whether gauge module
(1), action light (2), alert indicators (3), and the LCD
display (4) are operating properly. The self test lasts
for approximately three seconds.

During the self test, all alert indicators flash. Illustration 251
g01018514

The digital display shows the following readouts:

• All indicators of units (Deg C, kPa, rpm, and liters)

162 SEBU7763-02
Maintenance Section
Oil Filter - Inspect

The fittings are on the left front side of the machine i01960073
and on the right front side of the machine. Lubricate
the bearings by applying grease to the two fittings. Pivot Shaft Oil Level - Check
Use MPGM Grease.
SMCS Code: 4153-535-FLV

i02106227

Oil Filter - Inspect

SMCS Code: 1318-507; 3067-507; 5068-507

Inspect a Used Filter for Debris

g01118433
Illustration 253

Oil must be visible through the sight gauge.

g00100013
Illustration 252
The element is shown with debris.

Use a filter cutter to cut the filter element open.

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 Illustration 254
g01018551
be used to differentiate between ferrous metals and
Front view
nonferrous metals.

Ferrous metals can indicate wear on steel parts and Open the access door to the battery box on the left
on cast iron parts. fender.

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 could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
To fill the reservoir, add oil through the dipstick
opening.
Maintain the oil level to the FULL mark on the dipstick.
Note: The initial fill of pivot shaft may trap air in the
tube. The level of the oil may fall as air escapes.
The reservoir must be filled several times in order to
remain consistently full.

Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
SEBU7763-02 163
Maintenance Section
Radiator Guard Pin Joint - Inspect

i01107744

Radiator Guard Pin Joint -

Inspect
SMCS Code: 7155-040

1. Park on a level surface.

2. Raise the bulldozer blade.

g01018567
Illustration 256
Rear view

1. Open the access cover to the radiator cap on

top of the radiator guard. Unlock the cover, if
necessary.

2. Slowly remove the radiator cap in order to relieve

system pressure.

Illustration 255
g00584863
3. Install the magnetic base of a dial indicator on the
main frame of the machine. Place the tip of the
indicator on the bottom edge of the radiator guard
directly beneath one of the pins.
3. Inspect the radiator cap for damage, for deposits,
or for foreign material. Clean the radiator cap
with a clean cloth. Replace the radiator cap if the
radiator cap is damaged.
4. Install the radiator cap.

4. Lower the bulldozer blade. Apply sufficient down

i01960703
pressure in order to raise the front of the machine
off the ground. Recoil Spring Compartment
5. If the travel of the indicator is more than 1 mm Oil Level - Check
(0.04 inch), replace the pin and replace the
bushing. SMCS Code: 4158-535

6. Check the other three pin locations. Contact your

Caterpillar dealer for service.
Hot oil and components can cause personal in-
jury.
i01960442

Radiator Pressure Cap - Do not allow hot oil or components to contact

skin.
Clean/Replace
SMCS Code: 1353-070-Z2; 1353-510-Z2

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
164 SEBU7763-02
Maintenance Section
Refrigerant Dryer - Replace

i01957783

Refrigerant Dryer - Replace

SMCS Code: 7322-510; 7322-535

Personal injury can result from contact with refrig-

erant.

Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.

Illustration 257
g01018614 Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
1. Remove all of the debris around the cover plate dicate the system is empty of refrigerant.
on the top of the track roller frame.
Always use precaution when a fitting is removed.
2. Remove the cover plate for the oil filler. Observe Slowly loosen the fitting. If the system is still un-
the level of the oil. der pressure, release it slowly in a well ventilated
area.

Personal injury or death can result from inhaling

refrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
death.

Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-

Illustration 258
g01110810 erly remove the refrigerant from the air condition-
ing system.
3. Maintain the oil level above the top of the track
adjusting cylinder (1). Do not fill the oil above the
track adjustment valve (2).

4. Install the cover plate.

5. Repeat the procedure for the other recoil

compartment.

g01118524
Illustration 259

The in-line dryer is located under the cab on the left

hand side of the machine.

The in-line dryer is accessible by removing the floor

panel in the cab.
SEBU7763-02 165
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate

i01286780

Ripper Linkage and Cylinder

Bearings - Lubricate
SMCS Code: 6313-086-BD, L4

g01017640
Illustration 260

Note: The “R-134a” refrigerant dryer should be

replaced annually. Extremely humid operating
conditions may require more frequent replacement of
the dryer. The dryer should also be replaced if the air
conditioning system has been leaking or if the system
has been opened for service repair.

Reference: For the correct procedure, refer to

Air Conditioning and Heating Service Manual,
SENR5664 or the Disassembly and Assembly
Manual for your machine.

Note: A qualified mechanic should replace the

components of the refrigerant system since special
tooling and training are required.

g00681900
Illustration 261

Lubricate twelve grease fittings (six per side). Use

MPGM Grease.

i00925689

Ripper Tip and Shank Protector

- Inspect/Replace
SMCS Code: 6808-040; 6808-510; 6810; 6812-040;
6812-510

If equipped:
166 SEBU7763-02
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect

i01961853

Rollover Protective Structure

(ROPS) - Inspect
SMCS Code: 7325-040

g00550432
Illustration 262

When the ripper tip is worn close to the shank,

replace the ripper tip. When the shank protector is
worn close to the shank, replace the shank protector.
If the tip is too blunt, the tip will not penetrate properly.
g01019290
Illustration 263
1. Raise the ripper. Place blocking under the ripper.
Front view
Lower the ripper onto the blocking. The ripper
should be high enough so that the ripper tip or the
Inspect both sides of the Rollover Protective Structure
shank protector can be removed. Do not place the
(ROPS) for bolts that are loose or damaged. Replace
ripper too high.
any damaged bolts and any missing bolts with
original replacement parts only. Tighten the ROPS
2. If the ripper tip is worn, drive out the pin. Remove
bolts to a torque of 1400 ± 200 N·m (1030 ± 150 lb ft).
the tip and the shank pin retainer.
Note: Apply oil to all bolt threads for the ROPS
3. Clean the shank pin retainer and the pin.
before you install the ROPS bolts.
4. Install the new tip and the retainer.
Do not weld reinforcement plates to the ROPS
in order to straighten the ROPS. Do not weld
5. Install the pin from the opposite side of the
reinforcement plates to the ROPS in order to repair
retainer.
the ROPS.
6. If the shank protector is worn, drive out the pins.
If the ROPS has any cracks in the welds, in the
Remove the shank protector.
castings, or in any metal section, consult your
Caterpillar dealer for repairs.
7. Clean the pin retainers and the pins.

8. Install the new shank protector and the retainers. i02429589

9. Install the pins from the opposite side of the
retainer.
10. Raise the ripper and remove the blocking.
11. Lower the ripper to the ground.
Seat Belt - Inspect
SMCS Code: 7327-040; 7520
Always check the condition of the seat belt and the
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
SEBU7763-02 167
Maintenance Section
Seat Belt - Replace

g01152685
Illustration 265

Illustration 264
g00932801
Typical example
Check the seat belt mounting hardware (1) for wear
or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
bolts are tight.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.

Inspect the seat belt (3) for webbing that is worn or

frayed. Replace the seat belt if the seat belt is worn
or frayed.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
i02429594
Seat Belt - Replace
SMCS Code: 7327-510
i02773461
Steering Charge Filter -
Replace
SMCS Code: 431F
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.

Within three years of the date of installation or within

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
168
Maintenance Section
Track - Check/Adjust
g01103238
Illustration 266
1. Open the access door on the right side of the cab.
2. Remove the steering charge filter. Discard the
used filter element properly. Make sure that all of
the old filter seal is removed from the filter base.
3. Clean the filter base with a clean cloth.
4. Install the new filter element by hand.
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.
i01961509
Track - Check/Adjust
SMCS Code: 4170-036
g01015715
Illustration 267
Check the track adjustment. Check the track for wear
and for excessive dirt buildup.
SEBU7763-02
Grease is under high pressure.
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. Allow the machine
to coast to a stop without the use of the service
brakes. Adjust the tracks while you are in the
machine’s typical operating conditions. If packing
conditions prevail on the workplace, the tracks
should be adjusted without removing the packed
material.
2. To measure the sag in the track, stretch a string
over the grousers that are between the sprocket
and the front idler. Take the measurement from
the string to the top of the grouser at the maximum
measurement. Dimension (A) is the maximum
distance between the string and the grouser.
g01109482
Illustration 268
If a machine does not have carrier rollers, the sag in
the track is measured between the sprocket and the
front idler. The correct adjustment of dimension (A) is
115 ± 10 mm (4.5 ± .4 inch).
SEBU7763-02 169
Maintenance Section
Track - Check/Adjust

g01118207 g01019116
Illustration 269 Illustration 271

If the machine is equipped with a carrier roller,
calculate the average of dimension (B) and dimension
(C). The correct average value is 65 ± 10 mm
(2.6 ± 0.4 inch).
Loose Track Adjustment
2. Add multipurpose grease (MPGM) through
track adjustment valve (1). Add the MPGM until
dimension (A, B, C) is correct.
3. Operate the machine back and forth in order to
equalize the pressure. Allow the machine to coast
to a complete stop. Do not use the brakes.

4. Remeasure dimension (D).

Tight Track Adjustment

1. Loosen relief valve (2) by one turn of 360 degrees.
Allow the grease to escape.

2. Close the relief valve.

3. Add MPGM through track adjustment valve (1).

Add grease until dimension (A, B, C) is correct.

4. Install the access cover.

g01019107
Illustration 270

Bolt Torque for Track Shoes

NOTICE
Do not attempt to tighten track when dimension
(D) is 174 mm (6.8 inch) or more. The hard bottom
attachment can be tightened to the point were (D)
is no more than 152 mm (6.0 inch)Contact your
Caterpillar dealer for track service or instructions.
1. Remove the access cover.
The torque requirement for track shoe bolts is
650 ± 70 N·m (480 ± 50 lb ft). Tighten the bolts for
an additional 120 degrees. If you are using bolts
with a master link, tighten the bolts to a torque of
650 ± 70 N·m (480 ± 50 lb ft). Then, tighten the bolts
for an additional 120 degrees.
170 SEBU7763-02
Maintenance Section
Track Pins - Inspect

i01967541 i02039992

Track Pins - Inspect Track Roller Frame - Inspect

SMCS Code: 4175-040-PN SMCS Code: 4151-040

Fingers can be burned from hot pins and bush-

ings.

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 in order to extend the life

of the undercarriage. Use the recommendations in
order to avoid excessive downtime.
g01049034
Illustration 273

Inspect the track roller frame (3) for leaks. Check the
seal for the pivot shaft (2) for oil leaks. Check the
idlers (1) and track rollers (4) for leaks. Inspect the
seal for the recoil spring (5) for oil leaks.

i01967485

Track Roller Frame Guides -

Inspect
SMCS Code: 4177-040
g01021628
Illustration 272
Measure the rotational movement of the front roller
1. During the machine operation, listen for unusual frame relative to the rear roller frame.
squeaking and for unusual squealing. This can
indicate a dry joint.

2. Check the machine for dry joints weekly. Check

for dry joints immediately after machine operation.
After machine operation, lightly touch the end of
each track pin or bushing. Touch the track pin
or the track bushing with the back of your hand.
Make a mark on any dry track pin joint that is very
hot to the touch.

3. Do not hit the ends of the track pins with a sledge

hammer in order to loosen the track joints.

NOTICE Illustration 274

g01021588
Striking the end of a track pin introduces a significant
Some components are removed for clarity.
amount of end play into the track joint and can result
in early failures.
1. Raise the front of the machine with the hydraulics
of the dozer. Place a 100 mm (4 inch) block under
Consult your Caterpillar dealer’s Custom Track the outside edge of a track grouser. Place the
Service expert if you detect dry joints or leaks. Your block near the track idler. Lower the machine onto
Caterpillar dealer’s Custom Track Service expert can the block.
perform track inspection.
SEBU7763-02 171
Maintenance Section
Transmission Breather - Clean

4. Put a mark on the tubular section of the front roller

frame. This mark should correspond with the mark
on the rear roller frame. Measure the distance
between the two marks on the front roller frame.

If the distance between the two marks is greater

than 4.5 mm (.18 inch), inspect the track roller frame
guides for wear.

Repeat the entire procedure for the other side of the

machine.

NOTICE
Never build up the track roller frame guides with hard-
Illustration 275
g01021579 face welding. This will cause serious wear damage to
the guide slots in the front track roller frame.
2. Use a grease pencil to make a mark on the tubular
section of the front roller frame. Make a mark
on the rear of the roller frame. This mark should
correspond with the mark that is on the tubular
section.

g00785460
Illustration 278

If dimension (X) is less than 45.3 mm (1.78 inch),

replace the track roller frame guides. Consult your
Caterpillar dealer for information or for service.
g01021605
Illustration 276
Some components are removed for clarity.
i02771281

3. Raise the front of the machine with the hydraulics

of the dozer. Place the block under the inside edge
Transmission Breather - Clean
of the same track grouser. Lower the machine SMCS Code: 3030-070
onto the block.

g01019203
g01021583
Illustration 279
Illustration 277
Some components are removed for clarity.
172 SEBU7763-02
Maintenance Section
Transmission System Oil and Screens - Change/Clean

1. Open the access cover for the transmission filler

tube on the right side of the cab. The breather
attaches to the filler tube on top of a 90 degree
elbow. Unscrew and remove the breather.

2. Clean the breather in clean, nonflammable

solvent.

3. Install the breather and close the cover.

i02694959

Transmission System Oil and

Screens - Change/Clean g01118275
Illustration 280
SMCS Code: 3030
Open the left engine compartment in order to locate
the high speed oil change arrangement.

Use a 126-7538 Nozzle if the machine is equipped

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 contact
skin.
with the high speed oil change arrangement. This
arrangement removes oil from the sump in the bevel
gear case. The high speed oil change does not
remove oil from the torque converter or from the
transmission case.

Remove the filler cap only when the engine is

stopped, and the filler cap is cool enough to
touch with your bare hand. Remove the filler cap
slowly to relieve pressure.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00484767
Illustration 281
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies 1. Remove the plug from the drain in the bevel gear
suitable to collect and contain fluids on Caterpillar case. Install a 4C-8563 Swivel into the valve.
products. Clamp a hose to the swivel. A 25.4 mm (1 inch)
pipe and hose can be used. Use a 25.4 mm
Dispose of all fluids according to local regulations and (1 inch) pipe with 1-11 1/2 NPTF threads. Do not
mandates. tighten the pipe.

2. Turn the swivel or pipe clockwise in order to open

Drain the Oil and Change the the internal drain valve. Allow the oil to drain into a
Transmission Oil Filter Elements suitable container.

Operate the machine in order to warm the power 3. Remove the rear bottom guard.
train oil. The machine must be level. Lower the
attachments with slight down pressure.

See the Operation and Maintenance Manual,

“Transmission and Torque Converter Oil Filters -
Replace” in this manual for the procedure to change
the filters.
SEBU7763-02 173
Maintenance Section
Transmission System Oil and Screens - Change/Clean

11. Close the drain valve in the torque converter.

Close the drain valve in the transmission case.

12. Remove the hoses and remove the pipes from

the drains.

13. Remove the swivel or remove the pipe from the

drain in the bevel gear case. The drain valve will
close.

14. Clean the oil drain plugs and install the oil drain
plugs.

Clean Screens
g00484821
Illustration 282
Screens should be removed and cleaned when the
4. Remove plug (2) from the drain valve in the torque oil is drained. Drain the oil into a suitable container
converter. Install a 12.7 mm (.5 inch) pipe into the before removing any screen.
drain valve. Use a 12.7 mm (0.50 inch) pipe with
1/2-14 NPTF threads.

5. Clamp a hose to the pipe in order to drain the oil

into a suitable container.

6. Open drain valve (1) and drain the oil into a

suitable container.

g01124858
Illustration 284

1. Remove torque converter scavenge line (7).

Remove the screen.

g01023184
Illustration 283

7. Remove the access cover (3) to the drain for the

transmission (not shown). Remove plug (6) in the
guard for access to the drain valve.

8. Remove plug (5) from the drain valve in the

transmission. Install a 12.7 mm (.5 inch) pipe into
the transmission valve. Use a 12.7 mm (0.50 inch)
pipe with 1/2-14 NPTF threads. Clamp a hose to
the pipe in order to drain the oil into a suitable g01356854
container. Illustration 285

9. Open drain valve (4) and drain the oil into a 2. Remove cover (8) from the transmission scavenge
suitable container. screen. Remove the screen.

10. Change the filter element. See the Topic

“Transmission System Oil Filter-Replace” in this
manual.
174 SEBU7763-02
Maintenance Section
Transmission System Oil Level - Check

5. Maintain the oil level within the “OPR ZONE

16L” marks on the dipstick. The engine should
be running at low idle. The power train should
be at operating temperature. See Operation and
Maintenance Manual, “Transmission System Oil
Level - Check” for more information.

6. Clean oil filler cap (5). Install the oil filler cap.

7. Install the rear bottom guard.

For additional information about transmission system

oil, see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your
g01356715
Caterpillar dealer.
Illustration 286
(A) Right side view
(B) Front view i02112969

3. Remove cover (10), the seal, and four bolts from Transmission System Oil Level
the main suction line that is next to the power train - Check
oil pump (9). Remove main suction screen (11) .
SMCS Code: 3080-535
4. Inspect the O-ring seal. If the seal is damaged,
replace the seal.

5. Clean the three screens in clean, nonflammable

solvent. Hot oil and components can cause personal in-
jury.
6. Install the screens. Install the covers.
Do not allow hot oil or components to contact
skin.
Fill With Oil
1. Open the access door for the filler cap. The filler
cap is located on the right side of the machine
next to the hydraulic oil tank.

g01019160
Illustration 288
Some components are removed for clarity.

The transmission oil dipstick is behind the access

Illustration 287
g01351984 door on the right side of the operator’s station.
Some components are removed for clarity.
Open the access door and check the transmission
oil level.
2. Remove oil fill cap (13).

3. Fill the bevel gear case with oil. See Operation

and Maintenance Manual, “ Capacities (Refill)”.

4. Always measure the oil with the dipstick (12).

SEBU7763-02
Hot Oil
g00493905
Illustration 289
Use the “TRANSMISSION IN NEUTRAL, ENGINE
AT LOW IDLE, AND OIL AT OPERATING
TEMPERATURE” side of the dipstick (2). Check
when the transmission is in NEUTRAL and the
engine is running at LOW IDLE. The oil should be at
operating temperature. Maintain the oil level between
the “OPERATING ZONE” marks. This is the only
accurate way to check the oil level.
Cold Oil
Illustration 290
g00493912
Check the “ENGINE STOPPED COLD OIL” side of
dipstick (2) while the engine is stopped. Maintain the
oil between the “OPERATING ZONE” marks. This
method should be used as reference only.
Note: When you are operating the machine on severe
slopes, the quantity of oil in the transmission can be
increased up to 10 percent. When you are operating
with the increased oil quantity, prolonged operation
in some machines can cause high transmission oil
temperatures. After the work on the severe slopes
has been completed, drain the excessive oil quantity
from the bevel gear case.
1. If the oil level on dipstick (2) indicates that oil is
needed, remove filler cap (1) and add the oil.
2. Clean the filler cap and install the filler cap.
3. Close the access door.
175
Maintenance Section
Transmission System Oil Sample - Obtain
i01960903
Transmission System Oil
Sample - Obtain
SMCS Code: 3030-008
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Obtain the sample of the transmission oil as close
as possible to the recommended sampling interval.
The recommended sampling interval is every 500
service hours. In order to receive the full effect of
S·O·S oil analysis, you must establish a consistent
trend of data. In order to establish a pertinent history
of data, perform consistent oil samplings that are
evenly spaced.
g01019134
Illustration 291
1. Open the access door on the right side of the cab.
176 SEBU7763-02
Maintenance Section
Transmission and Torque Converter Oil Filters - Replace

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

g01018659 Dispose of all fluids according to local regulations and

Illustration 292
mandates.
(Some components are removed for clarity.)

2. Remove the protective cap from the sampling port. The transmission oil filters are located on the right
side of the machine behind the access cover that
3. Obtain a sample of transmission oil. Refer to faces front of the machine.
Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining Note: The Caterpillar recommended filters are
a sample of the transmission oil. a special high efficiency design. Use only the
recommended filter.
4. After you take a sample, remove the cap with
the tube and the probe from the bottle. Discard
the cap with the tube and the probe. Install the
sealing cap that is provided with 169-8373 Fluid
Sampling Bottle.

5. Replace the protective cap.

6. Close the access door and secure the door.

For additional information about transmission system

oil, see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your
Caterpillar dealer.
g01023030
Illustration 293
i02763393
1. Open the access door above the right fender.
Transmission and Torque Remove drain plugs (1) in order to remove a small
Converter Oil Filters - Replace amount of oil. Use a wrench in order to remove
filter housings (2).
SMCS Code: 3067-510
2. Remove the filter elements and properly discard
the filter elements.

3. Clean the filter element housings and clean filter

Hot oil and components can cause personal in- bases (3) with a clean cloth.
jury.
4. Inspect the seals. If the seals are damaged,
Do not allow hot oil or components to contact replace the seals.
skin.
5. Install new filter elements. Install the filter element
housing covers.

6. Start the engine.

SEBU7763-02
g01023041
Illustration 294
Some components are removed for clarity.
7. Check the oil.
HOT OIL:
Use the “TRANSMISSION IN NEUTRAL, ENGINE
AT LOW IDLE, AND OIL AT OPERATING
TEMPERATURE” side of the dipstick (4). Check
when the transmission is in NEUTRAL and the
engine is running at LOW IDLE. The oil should
be at operating temperature. Maintain the oil level
between the “OPERATING ZONE” marks. This is
the only accurate way to check the oil level.
COLD OIL:
Check the “ENGINE STOPPED COLD OIL” side
of the dipstick (4) while the engine is stopped.
Maintain the oil between the “OPERATING ZONE”
marks. This method should be used as reference
only.
8. Remove filler cap (5). If necessary, add oil.
9. Clean the filler cap and install the filler cap.
10. Close the access door.
i02236117
Walk-Around Inspection
SMCS Code: 1000; 7000
A thorough, regular visual inspection of the machine
is necessary to maintain machine performance,
availability, and safety. Make the inspection at the
beginning of every shift or make the inspection after
every 10 hours.
177
Maintenance Section
Walk-Around Inspection
Methodically inspect all exposed, easily accessible
areas of the machine for the following items:loose
fasteners, missing parts, damaged parts, cracked
parts, broken parts, worn parts, debris buildup, oil
leaks, coolant leaks, and fuel leaks.
Initiate corrective action for fluid leaks, damaged
parts, excessively worn parts, loose fasteners, and
missing parts.fluid leaks, damaged parts, excessively
worn parts, loose fasteners, and missing parts.
Remove accumulated trash, dirt, grease, or oil from
the tractor.
During this general machine inspection, give special
focus to the following items.
• Inspect the tracks, track roller frames, idlers, and
rollers for oil leaks, and excessive wear. Visually
evaluate the tightness of the track. See the Topic
“Tracks Check/Adjust” in this manual.
• Inspect the final drives for debris that may be
wrapped around the drive. Check duo-cone seals
for oil leaks, and sprocket segments for wear.
• Inspect the GET (ground engaging tool(s))
(bulldozer and ripper) and other wear surfaces for
excessive wear and damage.
• Inspect the linkage for the bulldozer and inspect the
linkage for the ripper. Also, inspect the fasteners
for the linkage.
• Inspect exposed guards, shields, and covers.
• Inspect the winch for oil leaks.
• Inspect the implement hydraulic cylinders for
damaged rods or bent rods and for leaks.
• Inspect exposed hoses and hose couplings for
damage, wear, and leaks.
• Inspect the radiator for debris buildup, coolant
leaks, and damaged fins and tubes.
• Inspect the aftercooler for debris buildup, coolant
leaks, and damaged fins and tubes.
• Inspect the fan for damage to the blades or for oil
leaks.
• Inspect the lights for broken bulbs and for broken
lenses. Inspect light guards and shields for
damage.
• Inspect exposed wiring and connectors for damage
and wear.
• Inspect steps and handholds for damage and
cleanliness.
178 SEBU7763-02
Maintenance Section
Winch Fairlead Rollers - Lubricate

• Inspect the precleaner screen for debris buildup. PA140VS

• Inspect the engine compartment for fluid leaks,
buildup of debris or trash, loose fasteners, worn
hoses, and damaged wiring.

• Inspect the crankcase guard under the engine for

debris buildup.

• Inspect the rollover Protective Structure (ROPS)

for damage. Inspect the Falling Object Protective
Structure (FOPS) for damage. Consult your
Caterpillar dealer for necessary repairs.

• Inspect the operator compartment for cleanliness.

g01076215
Refer to the Operation and Maintenance Manual, Illustration 296
“Maintenance Interval Schedule” for the list of the
daily maintenance. 1. Remove oil level plug (2) in order to check the oil
level. The oil level should be maintained to the
bottom of the level plug hole.
i02112864
2. If necessary, remove oil filler plug (1) and add oil.
Winch Fairlead Rollers -
Lubricate Check for oil leaks around the covers and around
the hoses. Repair any oil leaks.
SMCS Code: 5163-086
i02773475
If equipped:
Winch Oil and Breather -
Change/Clean
SMCS Code: 5163-044

If equipped:

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

g01076211 skin.
Illustration 295

Lubricate the five fittings. Use MPGM Grease.

i02112874

Winch Oil Level - Check

SMCS Code: 5163-535-FLV

If equipped:
SEBU7763-02 179
Maintenance Section
Winch Wire Rope - Install

PA140VS i02094238

Winch Wire Rope - Install

(If Equipped)
SMCS Code: 5163-012

Personal injury or death can result from worn wire

rope cable.

Worn or frayed cable could break causing injury.

Check the wire rope cable. If cable is worn or is

g01076796 frayed install a new cable.
Illustration 297

1. Remove oil filler plug (1).

PA140VS
2. Remove drain plug (3) on the bottom of the winch.
Allow the oil to drain into a suitable container. The cable is attached to the drum on the winch with
a cable ferrule. The ferrule is placed into a socket
3. Inspect the plug seal. If necessary, replace the on the drum.
plug seal.
Use the following table to order the cable.
4. Clean drain plug (3) and install the drain plug.
Table 22
5. Remove oil level plug (2). Wire Cable

6. Fill the oil compartment until oil is visible at the Wire Rope Recommended Holding Capacity
Diameter Ferrule
bottom of the opening for oil level plug (2). See
Operation and Maintenance Manual, “Capacities 25 mm (1 inch) L-8 91 m (300 ft)
(Refill)”.
29 mm J-9 84 m (276 ft)
(1.13 inch)
7. Clean the vent plug that is in filler plug (1). Use a
clean nonflammable solvent. 32 mm J-10 59 m (193 ft)
(1.25 inch)
8. Install oil filler plug (1).

9. Run the engine at low idle. Maintain the oil level

so that the oil level is visible at the bottom of the
opening for oil level plug (2).

10. Install the oil level plug.

g01076208
Illustration 298

1. Put the cable in a straight line behind the tractor.

2. Install the ferrule end into the socket.

3. Reel in the cable.

180 SEBU7763-02
Maintenance Section
Window Washer Reservoir - Fill

i01961420 i02770681

Window Washer Reservoir - Window Wipers -

Fill Inspect/Replace
(If Equipped) (If Equipped)
SMCS Code: 7306-544 SMCS Code: 7305-040; 7305-510

NOTICE
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
window washer solvent.

g01018994
Illustration 300

Inspect the front windshield wiper blade, the right

windshield wiper blade, the left windshield wiper
blade, and the rear windshield wiper blade. Replace
any wiper blades that are damaged or worn. Replace
any wiper blades that streak the windshield.

i01083628

g01018997
Illustration 299
Windshield Washer – The washer fluid
bottle is on the left side of the cab on the
front post, as shown. Open the access
cover. Remove the fluid bottle cap in order to fill the
washer fluid bottle.
Windows - Clean
SMCS Code: 7310-070; 7340-070
If equipped:
Use commercially available window cleaning
solutions to clean the windows.
To clean the outside of the rear window from the
inside of the cab, remove the sliding section of the
rear window. Use the following procedure in order to
remove the sliding section of the rear window.

g00039956
Illustration 301
SEBU7763-02 181
Maintenance Section
Windows - Clean

1. Lift latch (1) in order to slide the small window.

Squeeze latch (2) in order to move the window
from the CLOSED position.

2. Move handle stop (3) to the UP position. To move

the handle stop to the UP position, lift the handle
and rotate the handle simultaneously. Rotate the
handle until the handle is vertical.

3. Move the small section of the window to opening

(4) in the upper window channel.

4. Tilt the top of the window toward the inside of the

cab. Remove the window.

5. Stay inside the cab in order to clean the outside

of the rear window.

6. After cleaning, install the sliding section of the rear

window.
182
Reference Information Section
Reference Materials
Reference Information
Section
Reference Materials
i02748866
Reference Material
SMCS Code: 1000; 7000
Reference Material by Caterpillar
The following literature can be obtained from any
Caterpillar dealer:
• Special Publication, SEBD0518, “Know Your
Cooling System”
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Special Instruction, TIBU5046, “Hydraulic Fan
System & Overheating Issues on D8T and D9T”
• Special Instruction, SEHS6929, “Inspection,
Maintenance and Repair of Rollover Protective
Structures (ROPS) and Attachment Installation
Guidelines”
• Service Magazine, SEBD1587, 28 October 1985,
“What ROPS/FOPS Certification Means”
• Special Publication, SEBU5898, “Cold Weather
Recommendations For All Caterpillar Equipment”
• Special Publication, SEBD0640, “Oil and Your
Engine”
• Special Publication, SEBU6250, “Caterpillar
Machine Lubricant Recommendations”
• Operation and Maintenance Manual, SEBU8257,
“The European Union Physical Agents (Vibration)
Directive 2002/44/EC”
• Special Instruction, SMBU6981, “Emissions
Control Warranty Information”
• Service Manual, SENR5664
• Service Manual, SENR8320
• Parts Manual, SEBP3654
SEBU7763-02
• Safety Manual, SEBU5311
• Special Publication, PECP9067, “One Safe
Source”
• Special Publication, PEHP7076, “Understanding
the S·O·S Oil Analysis Test”
• Special Publication, PEHP6001, “How to Take a
Good Oil Sample”
• System Operations, RENR8170, “Machine
Monitoring System for D8T, D9T, and D10T”
Operation and Maintenance Manuals are available
in other languages. Consult your Caterpillar dealer
for information about obtaining these Operation and
Maintenance Manuals.
Additional Reference Material
ASTM D2896, “TBN Measurements” This can
normally be obtained from your local technological
society, from your local library, or from your local
college.
SAE J313, “Diesel Fuels” This can be found in the
SAE handbook. Also, this publication can be obtained
from your local technological society, from your local
library, or from your local college.
SAE J754, “Nomenclature” This can normally be
found in the SAE handbook.
SAE J183, “Classification” This can normally be
found in the SAE handbook.
Engine Manufacturers Association “Engine Fluids
Data Book”
Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
(312) 827-8700
E-Mail: ema@enginemanufacturers.org
Facsimilie
(312) 827-8737
i01631981
Decommissioning and
Disposal
SMCS Code: 1000; 7000
When the machine is removed from service, local
regulations will vary. Disposal of the machine will vary
with local regulations. Consult the nearest Caterpillar
dealer for additional information.
SEBU7763-02
Index
A Cooling System Water Temperature Regulator -
Additional Messages ............................................. 16
Adjustments........................................................... 94
Alternate Exit ......................................................... 38
B
Backup Alarm - Test ............................................ 120
Battery Disconnect Switch..................................... 82
Battery or Battery Cable - Inspect/Replace ......... 120
Battery Disconnect Switch ............................... 121
Battery Inspect ................................................. 120
Battery Recycle................................................ 120
Before Operation ............................................. 23, 37
Before Starting Engine .......................................... 23
Belt - Inspect/Adjust/Replace .............................. 121
Inspect ............................................................. 121
Replace............................................................ 122
Bottom Guard (Power) - Clean ............................ 122
Braking System - Test.......................................... 123
Bulldozer Tilt Brace ............................................... 94
Angling the Blade............................................... 95
Tilt the Blade Manually....................................... 95
U and SU Three-Position Tilt Brace................... 94
Bulldozer Tilt Brace and Tilt Cylinders -
Lubricate ............................................................ 123
Burn Prevention..................................................... 20
Batteries............................................................. 20
Coolant............................................................... 20
Oils..................................................................... 20
C Ether Starting Aid............................................... 86
Cab Filter (Fresh Air) - Clean/Inspect/Replace.... 124
Cab Filter (Recirculation) - Clean/Inspect/
Replace.............................................................. 124
Capacities (Refill) ................................................. 116
Ecology Drains.................................................. 116
Cooler Cores and A/C Condenser - Clean .......... 125
Clean................................................................ 126
Cooler Cores.................................................... 125
Wood Chip or Waste Handling Arrangement (If
Equipped)....................................................... 127
Cooling System Coolant (ELC) - Change............ 129
To Drain the Cooling System ........................... 129
Cooling System Coolant Extender (ELC) - Add... 131
Extended Life Coolant (ELC) Extender............ 131
Cooling System Coolant Level - Check ............... 132
Wood Chip or Waste Handling Arrangement (If
Equipped)....................................................... 133
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................ 128
Level 2 Analysis ............................................... 128
Cooling System Specifications ............................. 111
183
Index Section
Replace.............................................................. 134
Crushing Prevention and Cutting Prevention ........ 19
Cutting Edges and End Bits - Inspect/Replace.... 135
D
Daily Inspection ..................................................... 37
Decommissioning and Disposal .......................... 182
E
Electrical Storm Injury Prevention ......................... 23
Electronic Unit Injector - Inspect/Adjust............... 135
Emissions Certification Film .................................. 35
Certification Label for Emissions........................ 35
Engine Air Filter Primary Element - Clean/
Replace.............................................................. 135
Engine Air Filter Primary Element - Replace ....... 137
Engine Air Filter Secondary Element - Replace .. 137
Engine Air Precleaner - Clean ............................. 137
Engine and Machine Warm-Up ............................. 86
Idling .................................................................. 87
Engine Crankcase Breather - Clean.................... 138
Engine Oil and Filter - Change ............................ 140
Procedure for Changing the Engine Oil and
Filter ............................................................... 141
Selection of the Oil Change Interval ................ 140
Engine Oil Level - Check ..................................... 138
Engine Oil Sample - Obtain ................................. 139
Engine Overspeed................................................. 83
Engine Starting ................................................ 23, 85
Engine Starting (Alternate Methods) ................... 108
Engine Starting with Auxiliary Start Receptacle .. 109
Engine Starting with Jump Start Cables .............. 108
Use of Jump Start Cables ................................ 108
Engine Starting with Prelubrication System........... 86
Engine Stopping .................................................... 25
Engine Valve Lash - Check/Adjust ...................... 143
Engine Valve Rotators - Inspect .......................... 143
Equalizer Bar End Pins Oil Level - Check ........... 144
Equipment Lowering with Engine Stopped...... 25, 98
The Procedure After The Accumulator Bleeds
Down ................................................................ 98
The Procedure Before The Accumulator Bleeds
Down ................................................................ 98
Ether Starting Aid Cylinder - Replace.................. 145
F
Final Drive Oil - Change ...................................... 145
Final Drive Oil Level - Check ............................... 146
Final Drive Oil Sample - Obtain ........................... 147
184
Index Section
Final Drive Seal Guard Packing - Replace (If
Equipped) .......................................................... 148
Replacement of the Packing ............................ 148
Fire Extinguisher Location ..................................... 22
Fire Prevention and Explosion Prevention ............ 20
Ether .................................................................. 22
Fire Extinguisher ................................................ 22
Lines, Tubes and Hoses .................................... 22
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 4
Caterpillar Product Identification Number ............ 5
Certified Engine Maintenance.............................. 4
Literature Information........................................... 4
Machine Capacity ................................................ 5
Maintenance ........................................................ 4
Operation ............................................................. 4
Safety................................................................... 4
Fuel System - Prime ............................................ 150
Electric Fuel Priming Pump.............................. 150
Fuel System Primary Filter - Clean/Replace ....... 151
Fuel System Primary Filter (Water Separator) -
Drain .................................................................. 152
Fuel System Secondary Filter - Replace ............. 153
Fuel Tank Cap Filter and Strainer -
Replace/Clean ................................................... 154
Fast Fill Fuel Adapter (If Equipped) ................. 154
Fuel Tank Water and Sediment - Drain ............... 154
Fuses and Circuit Breakers - Replace/Reset ...... 155
G Listing of Abbreviations and Terms .................... 79
General Hazard Information .................................. 17
Asbestos Information ......................................... 19
Containing Fluid Spillage ................................... 18
Dispose of Waste Properly ................................ 19
Fluid Penetration................................................ 18
Pressurized Air and Water ................................. 18
Trapped Pressure .............................................. 18
General Information............................................... 30
Guards (Operator Protection) ................................ 28
Other Guards (If Equipped)................................ 29
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip Over
Protection Structure (TOPS) ............................ 29
H Oil Filter - Inspect ................................................ 162
Horn - Test ........................................................... 156
Hydraulic System Oil - Change ........................... 156
Hydraulic System Oil Filter (Pilot) - Replace ....... 157
Pilot Hydraulic Oil Filter.................................... 157
Hydraulic System Oil Filters - Replace ................ 159
Hydraulic System Oil Level - Check .................... 160
Hydraulic System Oil Sample - Obtain ................ 160
Identification Information ....................................... 32
SEBU7763-02
Important Safety Information ................................... 2
Indicators and Gauges - Test............................... 161
L
Leaving the Machine ............................................. 99
Lift Cylinder Yoke Bearings - Lubricate ............... 161
Lifting and Tying Down the Machine.................... 101
Lubricant Viscosities............................................. 112
Lubricant Viscosities for Ambient
Temperatures .................................................. 113
Selecting the Viscosity ...................................... 112
Lubricant Viscosities and Refill Capacities ........... 112
M
Machine Operation ................................................ 38
Maintenance Interval Schedule ............................ 118
Maintenance Section ............................................ 111
Maintenance Support ........................................... 117
Model Specific Coolant Information...................... 111
Monitoring System................................................. 57
Action Light ........................................................ 58
CAT Advisor Graphic Display Module................ 62
Display Module .................................................. 66
Functional Test................................................... 57
Gauges .............................................................. 60
Home Button ...................................................... 63
Menu for the Operator’s Profile.......................... 63
Performance Menu ............................................ 67
Quick Reference Guide for Setting the “Operator
Profile” by Using Advisor.................................. 78
Service Menu ..................................................... 72
Settings for Engine Setup .................................. 71
Settings for the Power Train .............................. 71
Settings Menu .................................................... 69
Status Indicators ................................................ 59
Totals Menu Option ............................................ 76
Warning Levels .................................................. 61
Mounting and Dismounting.................................... 37
O
Inspect a Used Filter for Debris ....................... 162
SEBU7763-02
Operating Technique Information .......................... 88
Adjustable Ripper............................................... 92
Backfilling........................................................... 90
Dozer Blade Pitch for the U-Blade and
SU-Blade.......................................................... 88
Gear Selection ................................................... 88
Land Clearing..................................................... 90
Machine on a Slope ........................................... 89
Packed Soil, Hardpan, Clay, Shale or Cemented
Gravel............................................................... 91
Push Loading ..................................................... 93
Ripping............................................................... 91
Rock with Fractures, Faults and Planes of
Weakness ........................................................ 92
Single Shank Ripper .......................................... 92
Slot Dozing......................................................... 89
Straight Dozing .................................................. 88
Stump Removal ................................................. 91
V-Ditching .......................................................... 90
Operating Techniques............................................ 88
Operation............................................................... 24
Machine Operating Temperature Range............ 24
Machine Operation............................................. 24
Operation Information............................................ 81
Changing Direction and Gear ............................ 82
Operating The Machine ..................................... 81
Operation Section.................................................. 37
Operator Controls .................................................. 42
Action Light (25)................................................. 54
Adjustable Armrests (1) ..................................... 44
Advisor Monitor Display (12).............................. 50
Auto Blade Assist (10) (if equipped) .................. 48
Automatic Downshift (18) (Downshift)................ 53
Auxiliary Power Switch (13) (If Equipped).......... 51
Bidirectional Shift (17) (Direction Shift) .............. 52
Bulldozer Joystick Control (9) ............................ 46
Cab Door (34) (35) (36) ..................................... 57
Decelerator (8) ................................................... 46
Differential Steering Control and Transmission
Control (3) (4) (5) ............................................. 45
Engine Reverse Fan (11) (if equipped) .............. 49
Engine Start Switch (14) .................................... 51
Engine Throttle (15) ........................................... 51
Gauges and Indicators (6) ................................. 46
Heating and Air Conditioning Controls (33) ....... 56
Horn (27)............................................................ 54
Implement Lockout Switch (16).......................... 52
Light Switches (21) (22) (23) (24) (31)............... 53
Mirror (37) .......................................................... 57
Parking Brake Control (2) .................................. 44
Ripper Auto Stow switch (28)............................. 54
Ripper Raise/Lower (29) .................................... 54
Ripper Shank In/Out Lever (26) ......................... 54
Service Brake Control (7)................................... 46
Winch Control (30) (If Equipped) ...................... 55
Window (39)....................................................... 57
Window Wiper and Window Washer (32) .......... 55
Operator Station .................................................... 28
185
Index Section
P
Parking ............................................................ 25, 97
Pivot Shaft Oil Level - Check............................... 162
Plate Locations and Film Locations....................... 32
Certifications ...................................................... 34
European Union ................................................. 35
Product Identification Plates .............................. 32
Sound Certification............................................. 34
Product Information Section .................................. 30
Product Link (If Equipped) ..................................... 80
Regulatory Compliance...................................... 81
R
Radiator Guard Pin Joint - Inspect ...................... 163
Radiator Pressure Cap - Clean/Replace ............. 163
Recoil Spring Compartment Oil Level - Check .... 163
Reference Information Section ............................ 182
Reference Material .............................................. 182
Additional Reference Material.......................... 182
Reference Material by Caterpillar .................... 182
Reference Materials ............................................ 182
Refrigerant Dryer - Replace................................. 164
Ripper Linkage and Cylinder Bearings -
Lubricate ............................................................ 165
Ripper Tip and Shank Protector - Inspect/
Replace.............................................................. 165
Rollover Protective Structure (ROPS) - Inspect .. 166
S
S·O·S Information ................................................. 116
Safety Messages (D8T Track-Type Tractor )........... 6
Safety Section ......................................................... 6
Seat ....................................................................... 38
Adjusting the Seat.............................................. 38
Seat Belt ................................................................ 40
Extension of the Seat Belt ................................. 42
Seat Belt Adjustment for Non-Retractable Seat
Belts ................................................................. 40
Seat Belt Adjustment for Retractable Seat
Belts ................................................................. 42
Seat Belt - Inspect ............................................... 166
Seat Belt - Replace.............................................. 167
Shipping the Machine .......................................... 101
Sound Information and Vibration Information ........ 25
Sound Level Information .................................... 25
Sound Level Information for Machines in European
Union Countries and in Countries that Adopt the
“EU Directives” ................................................. 26
Sources.............................................................. 28
“The European Union Physical Agents (Vibration)
Directive 2002/44/EC” ...................................... 26
Specifications ........................................................ 30
Intended Use...................................................... 31
Steering Charge Filter - Replace ......................... 167
Stopping the Engine .............................................. 97
Idling the Engine for Extended Periods ............. 97
186 SEBU7763-02
Index Section

Stopping the Engine if an Electrical Malfunction Windows - Clean ................................................. 180

Occurs ................................................................. 98
Stopping the Machine............................................ 97

Table of Contents..................................................... 3
Towing Information .............................................. 103
Towing the Machine............................................. 103
Brake Engagement .......................................... 107
Brake Release ................................................. 107
Connection for the Pump ................................. 106
Connection of Brake Release Pump................ 104
Relief Valve Setting.......................................... 105
Running Engine ............................................... 104
Stopped Engine or Drive Line Defect............... 104
Track - Check/Adjust ........................................... 168
Bolt Torque for Track Shoes ............................ 169
Loose Track Adjustment .................................. 169
Tight Track Adjustment .................................... 169
Track Information................................................... 22
Track Pins - Inspect............................................. 170
Track Roller Frame - Inspect ............................... 170
Track Roller Frame Guides - Inspect................... 170
Tracks.................................................................... 96
Transmission and Torque Converter Oil Filters -
Replace.............................................................. 176
Transmission Breather - Clean ............................ 171
Transmission System Oil and Screens -
Change/Clean.................................................... 172
Clean Screens ................................................. 173
Drain the Oil and Change the Transmission Oil
Filter Elements ............................................... 172
Fill With Oil....................................................... 174
Transmission System Oil Level - Check .............. 174
Cold Oil ............................................................ 175
Hot Oil .............................................................. 175
Transmission System Oil Sample - Obtain .......... 175
Transportation Information .................................. 101

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

Walk-Around Inspection ...................................... 177

Welding on Machines and Engines with Electronic
Controls .............................................................. 117
Winch Fairlead Rollers - Lubricate ...................... 178
Winch Oil and Breather - Change/Clean ............. 178
PA140VS.......................................................... 179
Winch Oil Level - Check ...................................... 178
PA140VS.......................................................... 178
Winch Wire Rope - Install (If Equipped) .............. 179
PA140VS.......................................................... 179
Window Washer Reservoir - Fill (If Equipped)..... 180
Window Wipers - Inspect/Replace (If Equipped).. 180
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:
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