MA-CAT-D10N - 3.pdf Opt. (800-950)

18
Contour Series Seat

Disassembly and Assembly Section
15. Installseat belt retractor (11). Install the bolt that

holds seat belt retractor (11) to the seat. Install
.omfort ride sleeve (9). Install the nut and bolt
10) that holds comfoh ride sleeve (9) to the seat.
gOC275679
Illustration 38
12. Install pin (19) and retainer clip (18) on each

end of adjuster (17).
g00275676
Illustration 41
13. Lift lever (A) in order to allow the seat backrest
to pivot backward
S
Illustration 42
g00275678
Illustration 39
14. Install the seat backrest and seat pan assembly There is spring force against the seat tilt plate
(15) on upper slide plate (16). Install six bolts when the seat tilt plate is being installed.
(13) and (14). Install two bolts (12) and the
locknuts. To prevent personal injury, retain the seat tilt plate
by hand during installation.
16. Install two springs (7) in the plate. Pull up on

seat cushion tilt lever (8) and install plate (6).
Hold down plate (6) and install two cotter pins
(5).
Illustration 40 C2.t(7
S
19
Contour Series Seat
Disassembl y and Assembly Section
[1 0
Illustration 43 g00275634 Illustration 46 g0027563
17. Install bottom seat cushion (4) on the seat tilt 20. Install back extension (1) on the seat assembly.
pan. The back extension is a slip fit.
NMI
.
Illustration 44 q00275633 Illustration 47 g00713003
18.Install seat cushion (3) on the seat backrest. 21.Adjust the cable to the proper position after the
seat has been assembled. Use the adjuster (17)
in order to adjust the cable. The cable should
not be tight. A small amount of slack should be
present in the cable. The cable should move
slightly before the seat will recline.
22.Install the Contour series seat in the machine.
Illustration 45
19.Install two bushings (2) on the seat assembly.

Turn each bushing clockwise by 114 of a turn in
I Contour Seat With Lumbar
Option and Side Controls -
Disassemble
SMCS Code: 7324-015
Disassembly Procedure
0O64385.
order to ; nstall the bushings

1. Remove the contour series seat from the
machine.
20
Contour Series Seat
f•)
g00275631 çj00275688
Illustration 4.8 illustration 51
2. Remove back extension (1) from the seat 5. Remove rivets (5) in order to remove lumbar
assembly. The back extension is a slip fit. plate (4) from the seat backrest. Remove two
pins (6), two spacer blocks (7), the adjustment
rod and two cams from the seat backrest.
Illustration 49
F g0C275689
S
3. Remove two bushings (2) from the seat assembly. illustration 52
Turn each bushing counterclockwise by 1/4 of a
turn in order to remove the bushings.
There is spring force against the seat lift plate.

When the cotter pins are removed and the lever
is raised, the spring force will be released.
To prevent personal injury, retain the seat lift plate
by hand when the cotter pins are being removed.
Remove the two cotter pins and slowly release the
spring force with your hand against the seat lift
plate.
6. Use a screwdriver to carefully pry the bottom seat

cushion from seat pan assembly (9). While you
hold down seat lift plate (10), remove two cotter
c00275633 pins (8). Slowly release the spring force against
Illustration 50
seat lift plate (10). Puff up on seat cushion tilt
4. Use a screwdriver to carefully pry seat custon ever ( 11 ) and remove seat Iitt plate (10)
(3) from the seat backrest
A
21
Contour Series Seat
9. Remove pin (18) from seat back adjustment

knob (17). Remove seat back adjustment knob
(17). Remove two pins (16) from seat back
adjustment shaft (20). Slide spring (19) from seat
back adjustment shaft (20). Remove seat back
adjustment shaft (20).
Illustration 53 g00275890
7. Remove two springs (12) from seat pan assembly

(9).
qOG27693
Illustration 56
10.Remove seven bolts (22) from the seat pan

assembly. Remove two bolts (21) and the
locknuts from the brackets on both sides of the
seat. Separate seat pan assembly (9) and the
seat backrest from upper slide plate (29).
11.Remove pin (25) from fore and aft adjustment

knob (26). Remove fore and aft adjustment knob
. (26). Remove three pins (23) from fore and aft
adjustment shaft (27). Remove bracket (24), fore
gCO275e9
and aft adjustment shaft (27) and spring (28)
Illustration 54 from the seat pan assembly.
8. Remove the nut and bolt (15) that holds comfort
ride sleeve (13) to the seat. Remove comfort
ride sleeve (13). Remove the bolt that holds seat
belt retractor (14) to the seat. Remove seat belt
retractor (14).
18
E g00275694
Illustration 57
12. Remove pin (32) from seat cushion tilt knob (33).
Remove two pins (34) from seat cushion tilt shaft
(31). Slide spring (30) from the seat cushion tilt
T2T'?22 shaft Remove seat cushion tilt shaft (31) from
Iiftstraton 55
Can
0
22
Contour Series Seat
15.Remove bolt (42). Remove bolt (41) and the lock

washer. Remove right armrest (40) the spacer
and the bushing
16.Use the procedure in Step 15 to remove the left
S
armrest.
13.Relieve the spring pressure of the spring on the

back pan assembly. Remove retainer clip (35)
and pin (36) from each end of seat back angling
adjuster (37).
Illustration 61 i;)0275687
17.Remove rivet (44). Remove cable assembly (43)

from the seat pan assembly.
.
Illustration 59 13
14.Remove retainer clip (39) and cable (38) as a

unit from the spring lever. Remove retainer clip
(39) and seat back angling adjuster (37) from Illustration 62
g00275738
cable (38).
18. Remove pin (45) from slide lever/lock shaft (46).
Remove slide lever/lock shaft (46) and spring
(47) from upper slide plate (29).
go2
Illustration 60
Note: When the armrests are removed, the back

panel and springs will be removed at the same time. Illustration 63 g0027.
S
23
Contour Series Seat
19. Turn upper slide plate (29) onto the opposite

side. Remove six bolts (48), the locknuts and
tic b r ackets (49)
.
Contour Seat With Lumbar

Option and Side Controls -
Assemble
SMCS Code: 7324-016
Assembly Procedure qO0275687

Illustration 66
1. Check the condition of all parts of the contour
series seat. If any of the parts are worn or 4. Install cable assembly (43) on the seat pan
damaged, install new parts. assembly. Install rivet (44).
ON
'1@
Illustration 64 g30275739 Illustration 67
2. Install six bolts (48), the locknuts and two Note: When the armrests are removed, the back
brackets (49) on the bottom of upper slide plate panel and springs will be removed at the same time.
(29).
5. Install the bushing, the spacer and left armrest
(40). Install the lock washer and bolt (41). Install
bolt (42).
6. Use the procedure jr Step 5 to nstall the right
armrest
Illustration 65 q00275 738
3. Install slide lever/lock shaft (46) and spring (47)

on upper slide plate (29). Install pin (45) on slide
lever/lock shaft (46).
.
24
Contour Series Seat
7. Install adjuster (37) and retainer clip (39) on 10.Install spring (28), fore and aft adjustment shaft
cable (38). Install retainer clip (39) and cable
(38) as a unit on the spring lever.
(27), and bracket (24) on the seat pan assembly
Install three pins (23) in fore and aft adjustment
shaft (27). Install fore and aft adjustment knob
(26). Install pin (25) in fore and aft adjustment
[I
knob (26).
11.Install seat pan assembly (9) and the seat
backrest on upper slide plate (29). Install two
bolts (21) and the Iocknuts on the brackets on
both sides of the seat. install seven bolts (22) on
the seat pan assembly.
Illustration 69 gOO27595
8. Install pin (36) and retainer clip (35) on each end

of adjuster (37).
cIH.,_'
Illustration 72
12.Install shaft (20). Slide spring (19) onto shaft

(20). Install two pins (16) in shaft (20). Install
seat back adjustment knob (17). Install pin (lal
in seat back adjustment knob (17),
S
g00275634
Illustration 70
9. Install seat cushion tilt shaft (31) on the seat pan

assembly. Slide spring (30) onto the seat cushion
tilt shaft. Install two pins (34) in seat cushion
tilt shaft (31). Install pin (32) in seat cushion tilt
knob (33)
Illustration 73 gOC275691
13.Install seat belt retractor (14). Install the bolt that

holds seat belt retractor (14) to the seat. Install
comfort ride sleeve (13), Install the nut and bolt
(15) that holds comfort ride sleeve (13) to the
seat.
Illustration 71 g002 75693 [I

29
Contour Series Seat
:O64455
Air Suspension With Toggle
Switch Height Adjustment -
Disassemble
SMCS Code: 7324-015-AJ
1. Remove the seat assembly from the machine
Separate the seat from the air suspension.
1Q2757J4
Illustration 95
9. Install back seat cushion (6). Install three bolts The air spring of the air suspension is filled with
(5). air pressure.
Prior to disassembly, release the air pressure in
the air spring. Failure to do so could result in per-
sonal injury.
2. Use the following procedure to release the air

pressure in the air spring:
10. Install bottom seat plate (4). Install six bolts (3).
Illustration 98 gO029076
a. Connect a 24 volt power supply to two-pin

connector (6). No. 1 connector pin is positive.
Note: The air spring will completely deflate in
approximately 60 seconds.
b. Push down toggle (5). While you hold down

the toggle, apply the 24 volt power supply for
Illustration 97 g00275740 approximately 60 seconds.
11.lnstall swivel seat (1) on suspension (2). Install C. Allow the air spring to deflate without any
the swivel seat assembly in the machine, weight on the suspension.
d. Turn off the power supply when all the air has
been released
32
Contour Series Seat
14. Put identification marks on two electrical OO€44'6

connectors (31) for installation purposes.
Disconnect two electrical connectors (31). Cut Air Suspension With Toggle
tie-wraps (32) that are holding wiring harness
(26) to scissor assembly (15). Remove wiring
Switch Height Adjustment -
harness (26). Assemble
Assembly Procedure
1. Check the condition of all parts of the air
suspension. If any of the parts are worn or
damaged, install new parts.
Illustration 111
15. Remove tube (30) from fitting (33)

3
910275c
Illustration 113
2. Install two rubber bumpers (34). Apply 5N-5561

Lubrication Compound to the scissor assembly
at the point of installation for four rollers (37).
Install four bushings (39) and four rollers (37).
3. Position air compressor (35) in scissor assembly
(15). Install clamp (36) and tie-wrap (38) in order
gOO275788 to secure air compressor (35) to the scissor
Illustration 112 assembly. Tighten clamp (36) to a torque of
3.2 ± 0.6 Nm (29 ± 5 lb in).
16.Remove clamp (36) and tie-wrap (38) from air
compressor (35). Remove air compressor (35)
from scissor assembly (15).
17.Remove four bushings (39) and four rollers (3:
Remove two rubber bumpers (3)
4. Connect tube (30) to fitting (33). Make sure that

the tube is securely seated in the fitting
33
Contour Series Seat
7. Install wiring harness connection (25) and

the washer in upper housing (24). Install new
S tie-wraps on wiring harness (26) in order to
secure the wiring harness to the upper housing.
900275785
Illustration 115
5. Position wiring harness (26). Connect two

electrical connectors (31) in the original positions
Install tie-wraps (32) in order to secure wiring Illustration 118 g00275780
harness (26) to scissor assembly (15).
8. Install scissor assembly (15) in upper housing
(24) by sliding rollers (21) into the slider track.
Slide bumper (22) into the slider track in order
to secure the scissor assembly. Install two tether
belts (16), bolts (23) and the locknuts in upper
housing (24). Tighten bolts (23) to a torque of
40 ± 8 Nm (30 ± 6 lb ft).
S Ic;'
guJ
Illustration 116

the tube is securely seated in the fitting. Apply
9S-3263 Thread Lock on bolt (27). Position air
spring (29) on the scissor assembly. Install bolt
(27) in order to secure air spring (29). Tighten
bolt (27) to a torque of 4.3 ± 1 Nm (38 ± 9 lb in) Illustration 119 900275778
9. Install two bearings (17), damper (18), pin (20)

and nut (10) into lower housing (14). Tighten nut
(19) to a torque of 40 ± 8 Nm (30 ± 6 lb ft).
S Illustration 117
g00275782
34
Contour Series Seat
-
a
I : -
10. Install scissor assembly (15) into lower housing 12. Install bushing (9) into the lower housing.
(14). Connect the damper and two tether belts
(16) to lower housing (14).
g00275753
Illustration 124

Illustration 121 900275776
13. Install boot (8).
Illustration 122 900275755 g00291077

Illustration 125
11.Apply 9S-3263 Thread Lock on bolt (10). 14. Position fore and aft slider track (7). Install two
Position the air spring on lower housing (14). bolts (3), the washers, one bolt (2) and locknut
Install bolt (10). Tighten bolt (10) to a torque of (4). Tighten bolts (2) and (3) to a torque of
4.3 ± 1 Nm (38 ± 9 lb in). Install two shafts (13). 30 ± 7 Nm (22 ± 5 lb ft). Also, tighten locknut
Install four locknuts (11) and lock washers (12) 4)toa torque cf3O7Nm(22--5rbft)
Tighten locknuts (11) to a torque of 40 ± 8 N
(30 ± 6 1b ft). S
35
Contour Series Seat
gCO275751 g00275790
Illustration 126 Illustration 127
15.Install four slides (1). a. Connect a 24 volt power supply to two-pin

connector (1). No. 1 connector pin is positive.
16.Install the seat on the air suspension. Install the
seat assembly in the machine. Note: The air spring will completely deflate in
approximately 60 seconds.
00644683
b. Pull out on air valve knob (2). While you pull
Air Suspension with Air Valve out on the air valve knob, apply the 24 volt
power supply for approximately 60 seconds.
Knob Height Adjustment -
Disassemble c. Allow the air spring to deflate without any
weight on the suspension.
I SMCS Code: 7324-015-AJ
d. Turn off the power supply when all the air has
been released.
3. Remove boot (3).
1. Remove the seat assembly from the machine.
The air spring of the air suspension is filled with

air pressure.
Prior to disassembly, release the air pressure in
the air spring. Failure to do so could result in per-
sonal injury.
2. Use the following procedure to release the air

pressure in the air spring: g00275791
Illustration 128
4. Loosen the setscrew on knob (2). Remove nut

(5) and the lock washer.
5. Remove locknut (4) and the lock washer. Remove
the upper shaft assembly.
0
36
Contour Series Seat
I
.r.
6. Tilt upper housing (6) forward. Slide the upper 8. Remove locknut (12) and the lock washer.
housing out of scissor assembly (7). Remove the lower shaft from lower housing (13).
9. Remove screw (14) from the air spring, which is
not shown. Remove scissor assembly (7) from
lower housing (13).
I
7. Disconnect two tether belts (11) from the scissor

assembly. Remove two bearings (8) and two
g00275836
rollers (9) from the scissor assembly. Remove Illustration 133
bushing (10) from the lower housing.
10.Remove nut (17), pin (19), two bearings (15)
and damper (16) from lower housing (13)
g00275794
Illustration 131
gC'327583
Illustration 14
11.Remove two tether belts (11), two rollers (2 1 )

and two bearings (20) from scissor assembly (7).
37
Contour Series Seat
g00275840 g002 7-5,843

12. Remove two bumpers (24). Remove bolt (25) 15. Remove two bolts (39) and the washers. Remove
and air spring (26). Use a small wrench to press Locknut (37) and the washer. Remove bolt (40).
fitting (23) while you pull tube (22) out of fitting Remove slider track (38) from upper housing (6).
(23).
00644705
Air Suspension With Air Valve

Knob Height Adjustment -
Assemble
. Assembly Procedure
1. Check the condition of all parts of the air
13. Put identification marks on two electrical

connectors (29) for installation purposes
Disconnect two electrical connectors (29) and
tube assembly (27) from combination valve (28)
g00275843
Illustration 139
2. Install slider track (38) on upper housing (6).

Install bolt (40), two bolts (39), the washers,
locknut (37) and the washer. Tighten bolts (39)
and (40) to a torque of 30 ± 7 Nm (22 ± 5 lb ft).
S 14. Remove tube (32) from fitting (33). Remove

tie-wraps (31) from wiring harness (30).
Remove clamps (35) and tie-wrap (34) from air
compressor (36). Remove air compressor (36).
38
Contour Series Seat
g00275842 g00275840
3. Position air compressor (36) in the scissor 7. Connect tube (22) to fitting (23). Make sure that
assembly. Install clamp (35) and tie-wrap (34) the tube is securely seated in the fitting. Apply
in order to secure air compressor (36) to the 9S-3263 Thread Lock on bolt (25). Position air
scissor assembly. Tighten clamp (35) to a torque spring (26) on the scissor assembly. Install bolt
of 3.2 ± 0.6 Nm (29 ± 5 lb in). (25) in order to secure air spring (26). Tighten
bolt (25) to a torque of 4.3 ± 1 Nm (38 ± 9 lb in).
4. Position wiring harness (30). Install tie-wraps Install two bumpers (24).
(31) in order to secure wiring harness (30) to the
scissor assembly.
the tube is securely seated in the fitting.
g00275839
Illustration 143
8. Apply 5N-5561 Lubrication Compound to the

scissor assembly at the point of installation for

two rollers (21). Install two bearings (20), two
Illustration 141
g00275841 rollers (21), and two tether belts (11) on scissor
assembly (7).
6. Connect tube assembly (27) and two electrical
connectors (29) to combination valve (28). Make
sure that electrical connectors (29) are installed
in the original positions.
0
39
Contour Series Seat
S 'V
OR

9. Install bearings (15) and (18), damper (16), pin 13. Install bushing (10) into the lower housing. Install
(19) and nut (17) into lower housing (13). Tighten two tether belts (11) and two bearings (8). Apply
nut (17) to a torque of 40 ± 8 Nm (30 ± 6 lb ft). 5N-5561 Lubrication Compound to the scissor
assembly at the point of installation for rollers (9).
Install rollers (9) on the scissor assembly.
S
Illustration 145 qCO275 794
14. Install upper housing (6) on scissor assembly

(7).
10.Install scissor assembly (7) into lower housing

(13).
11.Apply 9S-3263 Thread Lock to screw (14). Illustration 149 g00275791
Position the air spring on lower housing (13).
S Install screw (14). Tighten screw (14) to a torque
of 4.3 ± 1 Nm (38 ± 9 lb in).
15. Install the upper shaft assembly. Install locknut
(4) and the washer. Tighten the locknut to a
torque of 40 ± 8 Nm (30 ± 6 lb ft).
12.Install the lower shaft assembly. Install locknut
(12) and the lock washer. Tighten locknut (12) to
a torque of 40 ± 8 Nm (30 ± 6 lb ft).
40
Contour Series Seat
16.Install the lock washer and nut (5). Tighten the

nut to a torque of 13.6 ± 2.7 Nm (10 ± 2 lb ft).
Apply 9S3263 Thread Lock on the setscrew of
knob (2). Install knob (2) and the setscrew. 'V® .
g00275845
Illustration 152
3. Loosen the setscrew on knob (2) and remove the

knob. Remove nut (3) and the lock washer.
Illustration 150 g0029'083
4. Remove locknut (4) and the lock washer. Remove
17.Install boot (3). the upper shaft assembly.

seat assembly in the machine.
:J'064473 1
Air Suspension With System

Air - Disassemble
^j
1. Remove the seat assembly from the machine Illustration 153 900275846
5. Tilt upper housing (6) forward. Slide the upper
housing off scissor assembly (7).
2. Remove boot (1). Illustration 154 002758
6. Remove screw (7) from the air spring, which is

not shown. .
41
Contour Series Seat
S go
7. Disconnect two tether belts (10). Remove two 10.Remove two tether belts (10). Lift up scissor
bearings (9) and two rollers (9). assembly (5) and slide the scissor assembly out
of lower housing (14)
S
Illustration 159 oCO27 3
8. Disconnect tube (1 2) from fitting (11).
11.Remove cap (15) and shaft (16) from damper
(16). Remove locknut (19), the pin, bearings (17)
and (20), and damper (18).
g07e
Illustration 157
9. Remove locknut (13) and the lock washer.

Remove the lower shaft assembly. Illustration 160 7585€
0 12.Remcve fitting (11) lower housing (14'.

from
42
Contour Series Seat
'z^
g00275857 gXi275862
13. Remove two bearings (21) and two rollers (24) 17. Remove two bolts (32) and the washers. Remove
from scissor assembly (5). Disconnect tubes (22) locknut (30) and the washer. Remove bolt (33).
and (12) from valve assembly (23). Remove slider track (31) from upper housing (6).
00644785
Air Suspension With System
Air - Assemble
Assembly Procedure
.
1. Check the condition of a parts of the air
g002751358
Illustration 162
g(20275862
Illustration 165
g00275860
Illustration 163
2. Position slider track (31) on upper housing
14.Remove two bumpers (25). Remove bolt (27) (6). Install bolt (33), two bolts (32) and the
from air spring (28). washers. Tighten bolts (33) and (32) to a torque
of 30 ± 7 Nm (22 ± 5 lb ft). Install locknut (30)
15.Disconnect tube (22) from fitting (26). Remove and the washer. Tighten locknut (30) to a torque
air spring (28) from scissor assembly (5). of 40 ± 8 Nm (30 ± 6 lb fill
16.Cut tie-wraps (29) that are holding tubes (22

and (12) to scissor assembly (5).
^j
43
Contour Series Seat
6. Apply 5N-5561 Lubrication Compound on

scissor assembly (5) at the point of installation
S for two rollers (24). Install two rollers (24) and
two bearings (21). Connect tubes (12) and (22)
to valve assembly (23).
Illustration 166 i .275510
g00275855
Illustration 169
7. Install fitting (11) in lower housing (14).
IWV
S Illustration 167 g00275856
3. Position air spring (28) on scissor assembly (5)

Apply 9S-3263 Thread Lock on bolt (27). Install
bolt (27) that holds the air spring to scissor
assembly (5). Tighten bolt (27) to a torque of
40 ± 8 Nm (30 ± 6 lb ft).
aC r :' 75855
Illustration 170
4. Position tubes (12) and (22) on scissor assembly
(5). Install new tie-wraps (29) in order to secure 8. Install two bearings (17) and (20), damper (18),
the tubes to the scissor assembly. the pin and locknut (19). Tighten locknut (19) to
a torque of 30 ± 7 Nm (22 ± 5 lb ft). Install shaft
5. Connect tube (22) to fitting (26) on air spring (7) and cap (15) on damper (18)
(28). Install two bumpers (25).
* X)
I OW 1 • -.
S Illustration 166 g00275857 Illustration 171
9. Install scissor assembly (5) into lower housing

(14). Install two tether belts (10).
44
Contour Series Seat
g:,2o51 Illustration 175 gUO275848

Illustration 172
10. Install the lower shaft assembly. Install locknut 13. Apply 9S-3263 Thread Lock on screw (7).
(13) and the lock washer. Tighten locknut (13) to Install screw (7) in order to secure the air spring,
F. torque of 40 ± 8 Nm (30 ± 6 lb if). which is not shown. Tighten the screw to a torque
of 4.3 ± 1 Nm (38 ± 9 lb in).
g002758c0
Illustration 173
11. Connect tube (12) to fitting (11).
14. Install upper housing (6) on scissor assembly
(5).
111111
12. Install two tether belts (10) and two bearings Illustration 177 g00275845
(9). Apply 5N-5561 Lubrication Compound or
the scissor assembly at the point of installation
for rollers (8). Install rollers (8) on the scissor
assembly. .
45
Contour Series Seat
15. Install the upper shaft assembly, Locknut (4) and

• the lock washer. Tighten the locknut to a torque
of 40 ± 8 Nm (30 ± 6 lb ft). Install locknut (4)
and the lock washer. Apply 9S-3263 Thread /®
Lock on the setscrew of knob (2). Install knob
(2) and the setscrew.
g00288292
Illustration 180
2. Remove fasteners (2). Remove two retainers (3)

and boot (4).
16.Install boot (1).

seat assembly in the machine.
OO6448.3
• Mechanical Suspension With

Fixed Damper - Disassemble
gCO288293
SMCS Code: 7324-015-ME Illustration 181
Table 2
Tools Needed
%6
Part
Tool Number Part Description Qty I
- A 91-1-667134-Spring Compressor
4!_
r Illustration 182 o00288294
3. Remove locknut (5). Remove upper shaft

assembly (6) from upper housing (7)
S Illustration 179 g00288290
1. Remove four slider blocks (1).

46
Contour Series Seat

g00288338

4. Tip upper housing (7) forward and slide the 6. Remove scissor assembly (8) from lower housing
upper housing off scissor assembly (8). (11). Lift the scissor assembly and slide the
scissor assembly out of slider track (12).

g00288340
Illustration 187
7. Remove four rollers (14) and two tether belts (13).
Illustration 185 gC)O28837
i
S. Remove locknut (9) from lower shaft assembly
(10). Remove lower shaft assembly (10) from Illustration g00288343
lower housing (11).
8. Remove four bearings (16). Remove retainer (17),
two bearings (15) and (19), and damper (18)
0
47
Contour Series Seat
o cri1
0C
32 1 34 35 136
3
gOC?883i1
9. Remove pin (2 1 ) from the end of weight 11. Remove roller assembly (30) from each side of
adjustment screw (22). Turn weight adjustment suspension arm (29). Remove retaining rings
knob (25) in the negative (-) direction in order (32) and (36), washers (31), (33) and (35), and
to relieve the tension on springs (20). Remove rollers (34)
pin (24), weight adjustment knob (25), the thrust
bearing, two races, weight adjustment screw
(22) and nut (23).
I
g00288345
Illustration 190
10. Remove retaining ring (27) from each side

of height adjustment shaft (28). Remove two
off &A" 7 -
springs (20) and plastic bearings (26) from
height adjustment shaft (28).
40 ^ 471
g00288350
Illustration 194
12.Attach Tool (A) to spring assembly (37), as

shown. Use Tool (A) to remove the spring
assembly from the shaft as a unit.
S Illustration 191
13.Use Tool (A) to slowly release the compression
on spring assembly (37). Disassemble spring
assembly (37). Remove guide bushing (38),
spring (40), retainer (39) and rod assembly (41).
48
Contour Series Seat
14. Repeat Steps 12 and 13 for the spring assembly 17. Remove retaining ring (50). Use a hammer ard
on the other side of the suspension arm. a punch to remove the pin. Remove roller (49)
Remove retaining ring (47). Use a hammer and
a punch to remove the pin. Remove roller (48.) .
- and two spacers. Remove spring (52) and arm
assembly (51).
Illustration 195 rOC2R 3 5 1
15.Remove spacers (42) and (43) from shaft (28)

Remove the shaft and suspension arm (29).
g00288355
Illustration 198
18. Remove the key for the height adjustment lever.

(The key is not shown.) Remove handle (53) and
height adjustment lever (54).
3.
Illustration 196
16.Remove retaining rings (45) and (46). Use

a hammer and a punch to remove the pins
Remove cam (44) from suspension arm (29).
Illustration 199
19. Remove pin (57) from the bracket. Cut tie-wraps

(55). Remove indicator band (56).
gOO28354
Illustration 197
Illustration 200
49
Contour Series Seat
20. Remove four bolts (60), two bolts (59), the 3. Install indicator band (56) and new tie-wraps
• washers, and the locknuts from two brackets (55). Install pin (57) in the bracket.
(58). Remove two brackets (58) from upper
•nJsing 1
Suspension With
Fixed Damper - Assemble
SMCS Code: 7324-016-ME
Assembly Procedure
Table 3
Tools Needed Illustration 203 g00288355
Part
Tool Number Part Description Qty 4. Install height adjustment lever (54) and handle
(53). Install the key for the height adjustment
A 9U-6613 Spring Compressor 11 lever.
1. Check the condition of all parts of the mechanical
damaged. install new parts.
S
oXJ288354
Illustration 204
Note: Apply 5N-5561 Lubrication Compound on

the roller shafts before installation.
5. Install arm assembly (51) and spring (52). Install
2. Install two brackets (58) on upper housing (7). roller (48), two spacers, and the pin. Install
Install the washers, four bolts (60), two bolts (59), retaining ring (47). Install roller (49) and the pin.
and the locknuts on two brackets (58). Tighten Install retaining ring (50). Make sure that the
the bolts to a torque of 25 ± 6 Nm (18 ± 4 lb ft) rollers do not bind.
S
aCJ2S8352
50
Contour Series Seat
6. Install cam (44) in suspension arm (29). Install 9. Attach Tool (A) to spring assembly (37), as
retaining rings (45) and (46) and the pins. shown. Slowly compress spring assembly (37)
Use Tool (A) :o install the sprinc assemb ly or,
the shaft .
10.Repeat Steps 8 and 9 for tne spring assembly

on the other side of the suspension arm.
g00288351
0
Illustration 206
7. Install the shaft and suspension arm (29). Install 33 34

32 717 35 36
spacers (42) and (43) on shaft (28).
g0028834b
Illustration 209
IWMI
gOC2B35O
Illustration 207
Illustration 210 -
8. Install rod assembly (41), retainer (39), spring
(40) and guide bushing (38). Assemble spring
assembly (37) Note: Apply 5N-5561 Lubrication Compound on
11. Install retaining rings (32) and (36), washers
(31), (33) and (35), and rollers (34). Install roller
assembly (30) on each side of suspension arm
(29). Make sure that the rollers do not bind.
- 208
Illustration •:j00288349
.
51
Contour Series Seat
Illustration 211
900288345 Illustration 214 g00288340
12. Install two springs (20) and plastic bearings (26) Note: Apply 5N-5561 Lubrication Compound on
on height adjustment shaft (28). Install retaining the roller shafts before installation.
ring (27) on each side of height adjustment shaft
(28). 15. Install four rollers (14) and two tether belts (13).
Make sure that the rollers do not bind.

13. Install nut (23), weight adjustment screw (22),
two races, the thrust bearing, weight adjustment 16. Install scissor assembly (8) on lower housing
knob (25) and pin (24). Turn weight adjustment (11).Slide the scissor assembly into slider track
knob (25) in the positive (+) direction in order to (12).
apply tension to springs (20). Install pin (21) in
the end of weight adjustment screw (22).
0
g00288337
5 Illustration 216
900288343
Illustration 213
14. Install damper (18), two bearings (15) and (19),

and retainer (17). Install four bearings (16).
52
Contour Series Seat
17. Install lower shaft assembly (10) in lower housing 19. Install upper shaft assembly (6) in upper housing
(11). Install locknut (9) on lower shaft assembly (7). Install locknut (5).
(10).
g00288292
Illustration 221
20.Remove fasteners (2). Install boot (4) and two
18. Tip upper housing (7) forward and slide the retainers (3).
upper housing onto scissor assembly (8).
oi Y-r-;Ito

21.Install four slider blocks (1).
ciI
53
Contour Series Seat
CO4552O
Mechanical Suspension With I

Variable Damper - Disassemble
Table 4
LTools Needed
Tool
Part
Numbe
F Part Description Oty
g00288362
Spring Compressor Illustration 225
3. Remove locknut (11). Remove the lower shaft

assembly.
S illustration 223 qOO2836
g00288363
Illustration 226
4. Lift up lower housing (12). Tilt the lower housing

:irward in order to remove the lower housing from
scissor assembly (13) and from upper housing
(14) Remove the tie-wraps that are holding the
adiustable cable to upper housing (14).
U28c, 1,
Illustration 224 q_11
1. Remove four slider blocks (3). Remove four bolts

(2), two bolts (5), the via as and
from two brackets (4:
2. Remove boot (6) and t'*
a hammer and a punch to remove pin (10)
Remove knob (7). spring (8) and ball (9) g00288364
Illustration 227
S 5. Remove locknut (15) from the upper shaft

assembly. Remove the upper shaft assembly.
Slide wire cable (16) from upper housing (14).
54
Contour Series Seat
8. Cut wire cable (16) at the point of connection

to bracket (23). Remove the wire cable from
te variable damper. Use a hammer and a
punch to remove the pin from arm (22). Remove .
adjustable bracket (21). Remove arm (22),
bracket (23), two bearings (25), retainer (24) and
variable damper (20).
Note: Adjustable bracket (21) must be replaced.
The bracket will be damaged during the removal
procedure.
gU288365
Illustration 228
6. Lift up scissor assembly (13). Tilt the scissor

assembly forward and remove the scissor
assembly from upper housing (14).
Illustration 231
gOO2889
[1
g(EJ289367 9. Remove pin (27) from the end of weight
Illustration 229
adjustment screw (29). Turn weight adjustment
7. Remove two tether belts (18), four rollers (19) and knob (31) in the negative (-) direction in order
four bearings (17) from scissor assembly (13). to relieve the tension on springs (26). Remove
pin (30), weight adjustment knob (31), the thrust
bearing, two races, weight adjustment screw
(29) and nut (28).
g00288368
Illustration 230
Note: During removal of the wire cable, the wire q0028837C

cable will be cut. The wire cable will not be Illustration 232
reusable. A new wire cable must be installed during
assembly of the mechanical suspension. .
55
Contour Series Seat
10. Remove retaining ring (33) from each side

ot height adjustment shaft (34). Remove two
springs (26) and plastic bearings (32) from
7
S height adjustment shaft (34).
Illustration 236
77
;46 47
12.Attach Tool (A) to spring assembly (43), as

g002883%
shown. Use Tool (A) to remove the spring

Illustration 233 assembly from the shaft as a unit.
13.Use Tool (A) to slowly release the compression
on spring assembly (43). Disassemble spring
assembly (43). Remove guide bushing (44),
spring (46), retainer (45) and rod assembly (47).
7 7 17 1
14.Repeat Steps 12 and 13 for the spring assembly
on the other side of the suspension arm.
S 37 :
M 3 40 41 42
gOC2H
Illustration 234
11. Remove roller assembly (35) from each side of

suspension arm (36). Remove retaining rings
(42) and (38), washers (41), (39) and (37), and
rollers (40).
15.Remove two spacers (48) from shaft (34).

Remove the shaft and suspension arm (36).
illustration 235 g00288375
.
Illustration 238 .
56
Contour Series Seat
16. Remove retaining rings (50) and (51). Use

a hammer and a punch to remove the pins.
Remove cam (49) from suspension arm (36)
[1
g00288401
Illustration 241
19. Remove pin (62) from the bracket. Cut tie-wraps

gCCl288399 (60). Remove indicator band (61).
Illustration 239
17. Remove retaining ring (57) Use a hammer and G0645668

a punch to remove the pin. Remove roller (54).
Remove retaining ring (52). Use a hammer and
a punch to remove the pin. Remove roller (53)
Mechanical Suspension With
and two spacers. Remove spring (56) and arm Variable Damper - Assemble
assembly (55).
Assembly Procedure
Table 5
Tools Needed
is
Part
Tool Number Part Description Qty
9U-6613 Spring Compressor 1
1. Check the condition of all parts of the mechanical

damaged, install new parts
LCO2e84OU
Illustration 240
18. Remove the key for the height adjustment lever.

(The key is not shown.) Remove handle (58) and
height adjustment lever (59).
gOO2..iU 1
Illustration 242
2. Install indicator band (61) and new tie-wracs

(60) Install pin (62) in the bracket. .
57
Contour Series Seat
Illustration 243 gOG288400 g00288397

Illustration 246
3. Install height adjustment lever (59) and handle 6. Install the shaft and suspension arm (36). Install
(58). Install the key for the height adjustment two spacers (48) on shaft (34.
:7
ever.
IThWM$NMMo
[] 47

7. Assemble the spring assembly. Install rod

Note: Apply 5N-5561 Lubrication Compound on assembly (47), retainer (45), spring (46) and
the roller shafts before installation. guide bushing (44).
4. Install arm assembly (55) and spring (57). Install
roller (53) and two spacers. Install retaining ring
(52). Install roller (54) and the pin. Install retaining
ring (57). Make sure that the rollers do not bind.
8. Attach Tool (A) to spring assembly (43), as

shown. Slowly compress spring assembly (43).
Use Tool (A) to install the spring assembly on
. Illustration 245 gCQ288. 398
the shaft as a unit.
5. Install cam (49) in suspension arm (36). Install 9. Repeat Steps 7 and 8 for the spring assembly
retaining rings (51) and (50) and the pins. on the other side of the suspension arm.
58
Contour Series Seat
7 17 1
37 38
: 39 40
Illustration 249

0 41 42
g002883?2
g00288369
Illustration 252
12. Install nut (28), weight adjustment screw (29),

two races, the thrust bearing, weight adjustment
knob (31) and pin (30). Turn weight adjustment
knob (25) in the positive (+) direction in order to
apply tension to springs (26). Install pin (27) in
the end of weight adjustment screw (29)
Illustration 250
Note: Apply 5N-5561 Lubrication Comnound cr

10. Install retaining rings (42) and (38i, vAsnes
(41), (39) and (37), and rollers (40). Install ro le
assembly (35) on each side of suspension arn
(36). Make sure that the rollers do not bini
g00288368
Illustration 253
Note: During removal of the wire cable, the wire

cable will be cut. The wire cable will not be
reusable. A new wire cable must be installed during
assembly of the mechanical suspension.
13. Install variable damper (20), retainer (24), two
bearings (25), bracket (23) and arm (22). Install
new adjustable bracket (21). Install the pin in
g00288370 arm (22). Install a new wire cable in the variable
Illustration 251
damper. Connect wire cable (16) to bracket (23).
11. Install two springs (26) and plastic bearings (32)
on height adjustment shaft (34). Install retaining
ring (33) on each side of height adjustment shaft
(34)
Note: Adjustable bracket (21) must be replaced
The bracket will be damaged during the removal
procedure.
01
59
Contour Series Seat
Disassembly and Assembl y Section
Note: Apply 5N-5561 Lubrication Compound on 17. Install the tie-wraps in order to hold the
the roller shafts before installation. adjustable cable to upper housing (14). Tilt
the lower housing forward and slide the lower
14. Install four rollers (19), two tether belts (18) and housing onto scissor assembly (13) and onto
four bearings (17). Make sure that the rollers upper housing (14).
do not bind.
S
Illustration 258 q00288362
18. Install the lower shaft assembly. Install locknut
15. Install scissor assembly (13) on upper housing (11).
(14).
u(i028836 1
900288364 Illustration 259
liuslration 256
19. Install ball (9), spring (8) and knob (7). Install
. 16. Slide wire cable (16) into upper housing (14). pin (10).
Install the upper shaft assembly. Install locknut
(15) on the upper shaft assembly.
60
Contour Series Seat
g00288360
Illustration 260
20.Install two retainers (1) and boot (6).

21.Install two brackets (4), the locknuts on two
brackets (4), the washers, two bolts (5) and
four bolts (2). Tighten the bolts to a torque of
25 ± 6 Nm (18 ± 4 lb ft). Install four slider
blocks (3).
0
61
Contour Series Seat
Index Section
Index
.
M
Air Suspension With Air Valve Knob Height Mechanical Suspension.........................................4

Adjustment - Assemble........................................37 Height Adjustment..............................................6
Assembly Procedure..........................................37 Isolation..............................................................5
Air Suspension with Air Valve Knob Height Weight Adjustment.............................................5
Adjustment - Disassemble...................................35 Mechanical Suspension With Fixed Damper -
Disassembly Procedure .....................................35 Assemble.............................................................49
Air Suspension With System Air - Assemble.........42 Assembly Procedure..........................................49
Assembly Procedure..........................................42 Mechanical Suspension With Fixed Damper -
Air Suspension With System Air - Disassemble .... 40 Disassemble ........................................................ 45
Disassembly Procedure.....................................40 Disassembly Procedure..................................... 45
Air Suspension With Toggle Switch Height Adjustment Mechanical Suspension With Variable Damper -
- Assemble...........................................................32 Assemble............................................................. 56
Assembly Procedure..........................................32 Assembly Procedure.......................................... 56
Air Suspension With Toggle Switch Height Adjustment Mechanical Suspension With Variable Damper -
- Disassemble ...................................................... 29 Disassemble........................................................ 53
Disassembly Procedure.....................................29 Disassembly Procedure..................................... 53
C S
Contour Seat Air Suspension with Air Swivel Seat - Assemble.........................................27

Compressor.........................................................6 Assembly Procedure..........................................27
Connection to the Seat ......................................8 Swivel Seat - Disassemble ....................................26
Height Adjustment..............................................7 Disassembly Procedure .....................................26
S Isolation and Weight Adjustment .......................6

Contour Seat Air Suspension with Air System
Connection to the Seat ......................................10
9
Systems Operation Section ...................................4
Height Adjustment..............................................9 T
Isolation and Weight Adjustment .......................9
Contour Seat Controls...........................................11 Table of Contents...................................................3
Armrest Adjustment ...........................................11 Testing and Adjusting Section ...............................12
Contour Seat With Lumbar Option.....................11 Troubleshooting .....................................................12
Upper Back Support ..........................................11 Troubleshooting Chart ...........................................12
Contour Seat With Front Controls - Assemble.......16
Assembly Procedure..........................................16
Contour Seat With Front Controls - Disassemble.. 13
Disassembly Procedure .....................................13
Contour Seat With Lumbar Option and Side Controls
- Assemble...........................................................23
Assembly Procedure..........................................23
Contour Seat With Lumbar Option and Side Controls
- Disassemble......................................................19
Disassembly Procedure .....................................19
iii:
Disassembly and Assembly Section......................13
. Important Safety Information .................................2

CATE R PILLAR 0 SENR5296
November 1993
h
o F (^^ no
D9N, D9R, DION & DI IN

Cab Supplement
S

D9N: MR: Dl ON: DuN:
6XJ1-UP 8BL1 -UP 3SK1 -UP 4HK1 -UP
7TL1 -UP
0
Important Safety Information
Most accidents involving 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 other persons.
The hazards are identified by the Safety Alert Symbol" and followed by a "Signal Word" such as
WARNING" as 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, explaining the hazard, 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 not specifically recommended by Caterpillar is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain the complete and most current information before starting any job. Caterpillar
dealers have the most current information available. For a list of the most current publication form
numbers available, see the Service Manual Contents Microfiche, REG1139F.
I
Index
0 Cab
Disconnect batteries before performance of any

service work.
S
Cab Supplement 3 Index
Disassembly & Assembly
Cab S
Remove Cab 7301-011
.
0.909
3. Disconnect windshield washer hoses at the check

valve joint (3). Put identification marks on the hoses
for correct installation.
1. Attach appropriate lifting device to ROPS (1).

J1 I
j.t
A
ia i .
-I
4. Remove two bolts (4) and cover (5).
I
Typical Example
2. Remove mounting bolts (2) from each side of ROPS

(1). Remove ROPS from machine. The weight of the
LL,a /K
ROPS is approximately 781 kg (1720 lb).
NOTE: There are twelve mounting bolts on the 09N
and D1ON. There are sixteen mounting bolts on the
D1 IN.
J Mill
5. Disconnect two electrical connectors (6). Reposition

wiring harnesses (7) out of the way.
S
Cab Supplement 4 Disassembly & Assembly
U
P_j I
:
6. Remove three bolts and washers (8) that connect 10. Remove three threshold bolts and washers (14)
cab to dash. from each side of the cab.
-'..
t
IN'
1
to
7. Remove bolts (9) and air condition vents (10) from

both sides of cab. Remove bolts (11) and covers
i. -. 1!J
NOTICE
:
Be sure all bolts, wiring harnesses, and hose assem-

(12) from both sides and rear of cab.
blies have been disconnected or removed before se-
parating cab from operator station.
10. Attach lifting straps and appropriate lifting device

to cab (15) as shown. Carefully remove cab (15)
from operator station. The weight of the cab is
approximately 500 kg (1100 lb).
NOTE: Remove protective bolt caps if necessary.

8. Remove fifteen bolts and washers (13).
9. Remove floor mat from cab.
.

Install Cab 7301-012
I I't!I1LH1
I
!==== iJL=
1
3. Install three bolts and washers (3). Do not tighten

bolts at this time. Loosen three bolts (4) on dash
1. Loosen three bolts (1) on each side of the threshold. plate assembly.
Check the condition of threshold seal. If seal is worn
or damaged. use new parts for replacement. Apply
1 E2487A Sealant between the platform joint plate
and threshold plate as required.
/®
S
4. Install fifteen bolts and washers (5). Do not tighten
bolts at this time.
2. Attach lifting straps and appropriate lifting device to

cab (2) as shown. Carefully install cab with seals
attached on operator station. Be sure seals are
properly aligned. I 1'
2
-I
S. Install three threshold bolts and washers (6) on each

side of cab. Do not tighten bolts at this time. Apply
1E2487A sealant as required to this joint.
.

6. All cab mounting bolts can now be tightened in the
I
d
following order:
a. Tighten fifteen (5).
b. Tighten three dash plate assembly bolts (3).
c. Tighten three dash plate assembly bolts (4).
d. Tighten six threshold bolts (6).
e. Tighten six threshold bolts (1).
9. Install cover (14) and bolts (13).

O^J
/ \ 10. Install floor mats in cab.
is
7. Install air condition vents (8) and bolts (7) to both
sides of cab. Install covers (10) and bolts (9) to both
sides and rear of cab.
11. Connect four windshield washer hoses at the

check valve joint (15).
I
8. Reposition wiring harnesses (11) and connect
wiring connectors (12).
12. Attach appropriate lifting device to ROPS (16) and

position it on machine.
is

Cab Supplement Disassembly & Assembly
JII
.
I.
C65?I?
13. Install mounting bolts (17). Tighten the mounting

bolts to a torque of 1350 ± 160 N • m (1000 ±
120 lb ft).

CATERPILLAR 5 1 SEBU601 8-03
September 1990
0 0(@ 013
[P u(DR (^^
no
rJ EñJ1EN©®
9 (5i flu E10
DION
Track-Type Tractor
S
2YD1 -UP
0
Table of Contents
S
General Maintenance Section
Foreword .2 General Torque
Specifications .................................................60
Important Safety Information ..............................3
Recommendations and
Safety................................................................. Specifications .................................................62
Towing..............................................................11 Lubricant Viscosity Recommendations .........70
Fire Suppression System (If Equipped) ............14 Refill Capacities .............................................70
Product Identification and Lubrication and Maintenance Interval Chart .. 71
Serial Number Locations ..................................17
WhenRequired ..............................................72
Operation Section
Every 10 Service Hours or Daily ....................79
Operator's Compartment .................................18
Every 50 Service Hours or Weekly ................85
Machine Controls .............................................29
Every 250 Service Hours or Monthly .............88
Implement Controls ..........................................31
Every 500 Service Hours or 3 Months ...........92
Before Starting the Engine ...............................35
Every 1000 Service Hours or 6 Months .........99
Starting the Engine ..........................................40
p After Starting the Engine .................................45

Moving and Stopping the Machine ..................45
Every 2000 Service Hours or 1 Year ............102
Every 3000 Service Hours or 2 Years ..........106
Parking the Machine ........................................48

Operating Adjustments ....................................49
Operating Techniques ......................................52
Transportation Hints .........................................59
1
Foreword

I
This guide contains operation instructions and
lubrication and maintenance information.
The operation section is a reference for the new
operator and a refresher for the experienced one
Read - study - and keep it handy.
Photographs or 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 Wu e service hour meter to determine servicing
it,
capabilities. intervals. Calendar intervals shown (daily, weekly,

monthly, etc.) may be used instead of service hour
The maintenance section is a guide to equipment meter intervals if they provide more convenient
care. The illustrated, step-by-step instructions are servicing schedules and approximate the indicated
grouped by servicing intervals. Items without service hour meter reading. Recommended
specific intervals are listed under "When Required." service should always be performed at the interval
Items in the "Lubrication and Maintenance Interval
I
that occurs first.
Chart" are referenced to detailed instructions that
follow. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Lubrication and Maintenance
Interval Chart" may 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, Every 50 Service Hours or Weekly and
Every 10 Service Hours or Daily.
Some photographs or illustrations in this
publication show details or attachments that may
be different from your machine. Also, guards and
covers may have been removed for illustrative
purposes.
Continuing improvement and advancement of
product design may have caused changes to your
machine which are not included in this publication.
Whenever a question arises regarding your
machine, or this publication, please consult your
Caterpillar dealer for the latest available
information.
FRA
Important Safety Information
S Most accidents involving 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 other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word such as
"WAR NING as 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, explaining the hazard, 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 not specifically recommended by Caterpillar is used. you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements. adjustments,
illustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain The complete and most current information before starting any job. Caterpillar
dealers have the most current information available. For a list of the most current publication form
numbers available, see the Service Manual Contents Microfiche, REG1 139F.
S
3
Safety
Warning Signs and Labels

I
There are several specific safety signs on your WARNING: To avoid possible weakening of the
machine. Their exact location and description of Falling Object Protective Structure (FOPS), consult
the hazard are reviewed in this section. Please a Caterpillar dealer before altering the FOPS in any
take the time to familiarize yourself with these way. The protection offered by the FOPS will be
safety signs. reduced if it has been subjected to structural
damage.
Make sure that you can read all safety signs.
Clean or replace these if you cannot read the
words or see the pictures. When cleaning the
labels use a cloth, water and soap. Do not use
solvent, gasoline, etc.
You must replace a label if it is damaged, missing
or cannot be read. If a label is on a part that is
replaced, make sure a new label is installed on the
replaced part. See your Caterpillar dealer for nev,
labe l s.
WARNING: Do not onerate or work on this

machine unless you have read and understand the
instructions and warnings in the Operation and Located on the outside of the cab.
Maintenance guide. Failure to follow the
instructions or heed the warnings could result in
injury or death. Contact any Caterpillar dealer for WARNING: To avoid possible weakening of this
I
replacement guides. Proper care is your ROPS. consult a Caterpillar dealer before altering
responsibility. this ROPS in any way. The protection offered by
this ROPS will be impaired if it has been subjected
to structural damage or has been involved in an
overturn incident.
Located in the operators compartment
Located on the HOPS.
4
S
General
WARNING: High Pressure Cylinder. Do not Attach a DO NOT OPERATE' or similar warning
remove any parts until all pressure has been tag to start switch or controls before servicing or
relieved to avoid possible personal injury. Relieve repairing the machine. These tags, Form
pressure by opening relief valve one turn SEHS7332, are available from your Caterpillar
maximum. See the Operation and Maintenance dealer.
Guide for track adjustment procedure.
Perform all maintenance unless otherwise
specified as follows:
the machine on level ground.
wer all implements to the ground.
'e transmission control lever in NEUTRAL.
e parking brake engaged.
The engine stopped.
The start switch key removed.
The disconnect switch oft and
Located on both track roller frames. the key removed.
S WARNING: Discharge of fire suppression agent

Wear a hard hat, protective glasses and other
protective equipment as required by job
conditions.
on personnel can result in serious injury or death.
Do not wear loose clothing or jewelry that can
Turn off disconnect switch and remove any catch on controls or other parts of the machine.
emergency starting power source before working
on machine. See Operation Guide for instructions. Make certain all protective guards and covers are
secured in place on the machine.
Keep the machine, especially the deck, walkways
and steps, free of foreign material, such as debris,
oil, tools and other items which are not part of the
machine.
Secure all loose items such as lunch boxes, tools
and other items which are not part of the machine.
Know the hand signals and who gives them.
Accept signals from one person only.
Located in the cab.
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5
I
Crushing or Cutting Prevention
Never put maintenance fluids into glass Never attempt adjustments while the machine is
containers. moving or the engine is running unless otherwise
specified.
Report all needed repairs.
Support equipment and implements properly when
Do not allow unauthorized personnel on the working beneath them. Do not depend on
machine. hydraulic cylinders to hold it up. Any implement
can fall if a control is moved, or if a hydraulic line
Pressure air can cause personal injury. When breaks.
using pressure air for cleaning, wear a protective
face shield and protective clothing. Where there are implement linkages, the clearance
in the linkage area will increase or decrease with
Asbestos Information movement of the implement.
Caution should be used to avoid breathing dust Stay clear of all rotating and moving parts.
that may be generated when handling
components containing asbestos fibers. If this Keep objects away from moving fan blades. They
dust is inhaled, it can be hazardous to your health. will throw or cut any object or tool that falls or is
Components in Caterpillar products that may pushed into them.
contain asbestos fibers are brake pads, brake
band and lining assemblies, clutch plates and Do not use a kinked or frayed wire rope cable.
some gaskets. The asbestos used in these Wear gloves when handling the wire rope cable.
components is usually bound in a resin or sealed
in some way. Normal handling is not hazardous as Retainer pins, when struck with force, can fly out
long as airborn dust whic,h contains asbestos is and injure nearby persons.
not generated.
Wear protective glasses when striking a retainer
If dust which may contain asbestos is present, pin to avoid injury to your eyes.
there are several common sense guidelines that
should be followed. Chips or other debris can fly off objects when
struck. Make sure no one can be injured by flying
1.Never use compressed air for cleaning. debris before striking any object.
2. Avoid brushing or grinding of asbestos Track adjusting grease and oil are under high
containing materials. pressure. Grease or oil coming out of the relief
valve under pressure can penetrate the body
3. For clean up, use wet methods or a vacuum causing injury or death.
equipped with a high efficiency particulate air
(HEPA) filter. Do not watch the relief valve to see if grease is
escaping. Watch the track or track adjustment
4. Use exhaust ventilation on permanent cylinder to see if the track is being loosened.
machining jobs. Loosen the relief valve one turn only.
5.Wear an approved respirator if there is no other
way to control the dust.
6. Comply with applicable rules and regulations for
the work place (for example in the U.S.A., OSHA
requirements as set forth in 29 CFR 1910.1001).
7. Follow environmental rules and regulations for
disposal of asbestos.
8. Avoid areas where asbestos particles may be in
the air.
I
6
ROPS Remove the cooling system filler cap slowly to
relieve pressure.
A ROPS is designed to provide operator crush
protection in a rollover by controlled bending of its Cooling system conditioner contains alkali that can
structural members. cause personal injury. Avoid contact with the skin
and eyes and do not drink.
ROPS performance requirements in rollovers are
specified by regulations in several countries. Any Allow cooling system components to cool before
modification to a ROPS such as welding on or draining.
drilling holes in the structural members for the
purpose of mounting brackets or installing other Hot oil and components can cause personal injury.
devices will affect the ROPS capability to provide Do not allow hot oil or components to contact the
the required crush protection. skin.
Therefore, any modification or repair without At operating temperature, the hydraulic tank is hot
Caterpillar's specific approval will void the ROPS and can be under pressure.
certification. The certification cannot be renewed
by repair of the ROPS, since certification requires The pins and bushings in a dry track pin joint can
a destructive test. become very hot. It is possible to burn the fingers
if there is more than brief contact with these
Certain repairs and modifications can be made components.
without voiding the ROPS certification if correctly
done. Contact your Caterpillar dealer before Remove the hydraulic tank filler cap only after the
S making any modifications or repairs to ensure that

such will not void the ROPS certification.
engine has been stopped and the filler cap is cool
enough to remove with your bare hand.
Bum Prevention Remove the hydraulic tank filler cap slowly to

relieve pressure.
At operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines to Relieve all pressure in air, oil, fuel or cooling
heaters or the engine contain hot water or steam. systems before any lines, fittings or related items
Any contact can cause severe burns. are disconnected or removed.
C ^i t2cK tne coolant level only after the engine has Battery electrolyte contains acid that can cause
been stopped and the filler cap is cool enough to injury. Avoid contact with the skin and eyes.
remove with your bare hand.
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7
I
Fire or Explosion Prevention
All fuels, most lubricants and some coolant Lines, Tubes and Hoses
mixtures are flammable.
Do not bend or strike high pressure lines. Do not
Do not smoke while refueling or in a refueling area. install bent or damaged lines, tubes or hoses.
Do not smoke in areas where batteries are Repair any loose or damaged fuel and oil lines,
charged, or where flammable materials are stored. tubes and hoses. Leaks can cause fires. Contact
your Caterpillar dealer for repair or replacement.
Batteries in series may be located in separate
compartments. When using jumper cables always Check lines, tubes and hoses carefully. Do not
connect positive (+) cable to positive (+) terminal use your bare hand to check for leaks. Tighten all
of battery connected to starter solenoid and connections to the recommended torque. Replace
negative (-) cable from external source to starter if any of the following conditions are found.
negative (-) terminal. (If not equipped with starter
negative terminal, connect to engine block.) 1. End fittings damaged, displaced or leaking.
See the "Operation Section" of this guide for 2. Outer hose covering chafed or cut and wire
specific instructions. reinforcing exposed.
Clean and tighten all electrical connections. Check 3. Outer hose covering ballooning.
daily for loose or frayed electrical wires. Have all
loose or frayed electrical wires tightened, repaired 4. Evidence of kinking or crushing of the flexible
or replaced before operating the machine. part of the hose.
Keep all fuels and lubricants stored in properly 5. Armouring embedded in the outer hose cover
marked containers and away from all unauthorized Make sure that all clamps, guards and heat shields
persons. are installed correctly to prevent vibration, rubbing
Store all oily rags or other flammable material in a against other parts and excessive heat during
protective container, in a safe place. operation.
Ether is flammable. Do not smoke while changing Shields, which protect hot exhaust components
ether cylinders. from oil or fuel spray in the event of a line, tube or
seal failure, must be installed correctly.
Use ether only in well ventilated areas.
Do not weld or flame cut on pipes or tubes that
Keep ether cylinders out of the reach of contain flammable fluids. Clean them thoroughly
unauthorized persons. with nonflammable solvent before welding or flame
cutting on them.
Do not store replacement ether cylinders in living
areas or in the operator's compartment. Remove all flammable materials such as fuel, oil
and other debris before they accumulate on the
Do not store ether cylinders in direct sunlight. machine.
Discard cylinders in a safe place. Do not puncture
or burn cylinders. Do not expose the machine to flames, burning
brush, etc., if at all possible.
Repair any loose or damaged fuel and oil lines,
tubes and hoses. Leaks can cause fires.
I
8
0
Mounting and Dismounting Starting the Engine
EL1
SOL
Mount and dismount the machine only where Do not start the engine or move any of the
steps and/or handholds are provided. controls if there is a "DO NOT OPERATE" or similar
warning tag attached to the start switch or
Use both hands and face the machine, when controls.
mounting and dismounting.
Move all implement controls to the HOLD position
Never get on or off a moving machine. Never jump before starting the engine.
off the machine.
Move the transmission control lever to NEUTRAL.
Do not try to climb on or off the machine when
I carrying tools or supplies. Use a hand line to pull
equipment up onto the platform.
Preparing to Start the Engine
Engage the parking brake.
Start and operate the engine in a well ventilated
area only. In an enclosed area, vent the exhaust to
the outside.
Start the engine only from the operator's station.
Never short across the starter terminals or across Preparing to Operate the Machine
the batteries, as this could bypass the engine
neutral-start system as well as damage the Clear all personnel from the machine and the area.
electrical system. Clear all obstacles from the path of the machine.
Inspect the condition of the seat belt and Beware of hazards such as wires, ditches, etc.
mounting hardware. Replace any damaged or
worn parts. Replace the seat belt regardless of Be sure all windows are clean. Secure the doors
appearance, after three years of use. and windows in either the open or shut position.
Adjust the seat so that full brake pedal travel can For best vision, especially close to the machine,
be obtained with the operators back against the adjust the rear view mirror.
seat back. Make sure the machine horn, the backup alarm
Make sure the machine is equipped with a lighting and all other warning devices are working
system as required by conditions. properly.
Make sure all lights are working properly. Fasten the seat belt securely.
Make sure no one is working on, underneath or Check for proper operation of all controls and
close to the machine before starting the engine or protective devices while moving slowly in an open
beginning to move the machine. Make sure the area.
I area is free of personnel.
9
I
Operating the Machine
Operate the machine only while seated. Connect trailing equipment to a drawbar or hitch
only.
Operate the controls only with the engine running.
Never straddle a wire rope cable or similar device,
The operator must satisfy himself that no one will nor allow others to do so.
be endangered before moving the machine.
No personnel should be between the machine and
Do not allow riders on the machine unless trailing equipment when maneuvering to connect
additional seat, seat belt and rollover protection them. Block the tongue or hitch of trailing
are provided. equipment to align it with the drawbar or hitch.
Report any needed repairs noted during operation. Parking the Machine
Carry implements close to the ground, Park on a level surface. If necessary to park on a
approximately 40 cm (15 in) above ground level. grade, block the machine.
Stay a safe distance from the edge of cliffs, Apply the service brake to stop the machine.
overhangs and slide areas.
Move the transmission control lever to NEUTRAL.
If the machine begins to sideslip on a grade,
immediately dispose of the load and turn the Engage the parking brake.
machine downhill.
Lower all implements to the ground and apply
Be careful to avoid the condition which could lead
to tipping when working on hills, banks or slopes,
and when crossing ditches, ridges or other
obstructions.
slight down pressure.
Stop the engine. I
Turn the start switch key to OFF and remove the
Work up and down slopes, rather than sideways, key.
whenever possible. Turn the disconnect switch key to OFF and
Keep the machine under control and do not work remove the key to service the machine. Lock all
it over its capacity. protected compartments when leaving the
machine for an extended period.
Be sure hitch points and the towing device are
adequate.
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10
Towing
Do not use a chain for pulling. A chain link may

break causing possible personal injury. Use a wire
rope cable with loop or ring ends. Use an observer
Personal injury or death could result when tow- in a safe position to stop the pulling procedure if
ing a disabled machine incorrectly. cable starts to break or unravel. Stop pulling
whenever the pulling machine moves without
Block the machine to prevent movement be- moving the towed machine.
fore releasing the brakes. The machine can roll
free if it is not blocked. Keep the tow line angle to a minimum. Do not
exceed a 300 angle from the straight ahead
Follow the recommendations below, to proper- position.
ly perform the towing procedure.
Quick machine movement could overload the tow
line or bar and cause it to break. Gradual and
smooth machine movement will work better.
This machine is equipped with spring applied, Normally, the towing machine should be as large
hydraulic pressure released brakes. If the engine as the disabled machine. Satisfy yourself that the
or power train hydraulics are inoperable, the towing machine has enough brake capacity,
brakes are applied and the machine can not be weight and power, to control both machines for
moved. Unless, a brake release pump is used. the grade and distance involved.
These towing instructions are for moving a To provide sufficient control and braking when
disabled machine a short distance, only a few feet moving a disabled machine downhill, a larger
at low speed, no faster than 2 km/h (1.2 mph), to towing machine or additional machines connected
a convenient location for repair. These instructions to the rear could be required. This will prevent it
are for emergencies only. Always haul the machine from rolling uncontrolled.
if long distance moving is required.
The different situation requirements cannot be
Shielding must be provided on the towing given, as minimal towing machine capacity is
machine, to protect the operator if the tow line or required on smooth level surfaces to maximum on
bar should break. inclines or poor surface conditions.
Do not allow operator on the machine being To move the machine when the engine is not
towed, unless the operator can control the operable, a provision has been made to attach a
steering and/or braking. brake release pump.
Before towing, make sure the tow line or bar is in The pressure hose from the pump connects to the
good condition and has enough strength for the steering clutch and brake valve. The pump takes
towing situation involved. Use a towing line or bar oil from the sump of the pump and pressurizes the
with a strength of at least 1.5 times the gross brake valve to release the brakes.
weight of the towing machine, for a disabled
machine stuck in mud or when towing on a grade.
Attach cable to towing eye on front if pulling
forward, or attach to drawbar pin or ripper if pulling
to the rear.
11
I
Brake Release Pump - Connecting
Machine Pump Connection (Typical Example)
Machine brakes can be released for towing by use

of a 8T5337 Portable Hydraulic Pump Group (1), a
5P3415 Fitting (2) with a 3D2824 0-ring (3) and a 1. Remove floor plate.
321268 Elbow (4).
2. Place pump group on the machine platform.
Before Connection Pump Test
3. Remove hydraulic tank cap and filler screen.
NOTICE 4. Remove the dust cap from the tank adapter
and install adapter into the hydraulic tank filler
Possible brake piston seal damage could result
without checking relief valve. Opening pressure
must be checked and adjusted before connection
opening.
I
is made.
1. Plug the main pressure hose.

2. Open bypass valve (5) (UP position).
3. Depress the shutoff override button (6) and
hold while starting the engine. This temporarily
disarms the low pressure shutoff feature.
4. Close the bypass valve (5) (DOWN position) to 5. Remove any one of the three 9S4183 Plugs in
build up pressure. the steering valve center manifold marked BRK.
Install 5P3415 Fitting with 3D2824 0-ring and
5. Release the shutoff override button when 321268 Elbow. Connect the pressure hose to the
pressure on the Switchgage (7) exceeds the fitting.
minimum setting.
NOTE: There is no indicator movement on the 6. Install floor plate. Leave bolts out as necessary
Switchgage until minimum setting is exceeded. to allow room for hose.
6. Observe relief valve opening pressure.

7. Adjust relief valve opening to 2825 ± 35 kpa
(410 ± 5 psi).
12
Brake Release/Brake Engagement
Brake Release
NOTICE
1. Open bypass valve (UP position).
2. Depress the shutoff override button when If pump group engine stops, do not continue tow-
pressure on the Switchgage exceeds the minimum ing. Extensive brake damage can result.
setting.
3. Close the bypass valve (DOWN position) to
build up pressure. After towing, remove the pump group. Repair
4. Release the shutoff override button when machine and install the floor plate.
pressure on the Switchgage exceeds the minimum
setting. Check hydraulic oil level. Maintain level between
the ADD and the FULL marks on the sight gauge.
5. When minimum setting is exceeded, brakes Consult your Caterpillar dealer for the equipment
should be fully released and machine can be necessary for towing a disabled machine.
towed.
Brake Engagement
Push the brake pedals down to apply the brakes.
S
13
Fire Suppression System
(If Equipped) I
System Description
Do not expect the system to put out the fire
completely. Back-up fire fighting equipment should
be available.
Fire suppression agents may create hazards to
people if discharged on them. The fire suppression system will not suppress fires
outside the machine. It will not suppress fires in
Halon Agent can cause dizziness, reduced co- the operator's compartment.
ordination and reduced vision after exposure.
If symptoms persist after exposure, consult a The fire suppression system includes a detection
physician. circuit, an operator warning system, automatic
discharge of agent, and engine shutdown when
Dry chemical agent will reduce visibility and the machine is stopped with the parking brake
can irritate eyes, skin and nasal passages. If engaged. The system has a built-in diagnostic
the agent gets into eyes, flush thoroughly with capability. This allows the system to continuously
water, then consult a physician. In case of skin monitor the fire detection circuitry, the discharge
contact, wash all exposed areas with soap and electrical circuit, the engine shutdown wiring, and
water. If irritation persists, after inhalation or the electronic control itself.
skin contact, consult a physician.
The operator's compartment contains a system
The fire suppression system will not be able to monitor and a manual system actuator. The
suppress a fire unless the nitrogen actuators system monitor is located above the dash within
and agent cylinders are fully charged. the operator's vision. The manual actuator is
The nitrogen and agent cylinders must be re-
charged if the system has been activated.
located on the right side of the operator's seat.
System Monitor I
Consult your Caterpillar dealer for recharging
information.
NOTE: To prevent vandalism or accidental

discharge of the system during shipping, a cable
and a padlock are installed to secure the lock pin C))
in each nitrogen actuator. These two parts must
be removed to permit manual actuation. A small
plastic flag seal must stay on the lock pin. This
seal is broken by the operator when pulling the
lock pin to manually discharge the system. The monitor has two Iighs (1) and (2) ana a pur
type switch (3) mounted on the face of the unit.
The purpose of the fire suppression system is to The warning light (1) is red and is activated when
suppress an oil, fuel or debris fire, long enough to the system detects a fire. The system fault light (2)
allow the operator to leave the machine. is yellow. It is activated whenever the system
control module detects a fault with the system. A
fault can include such things as low actuator
cylinder pressure, a broken lead in the detection
circuit, a defective release solenoid, low agent
cylinder pressure, or a number of other system
problems.
I
14
S
Whenever the system fault light (2) comes on, the System Operation
machine and engine should be stopped and the
system fault found and repaired. Otherwise, the The system will operate at any time, even when
fire suppression system may not function if a fire the machine is not being operated or not even
should occur. running. When the key switch is off, the operator
warning will not occur because power is not
The test switch (3) on the monitor is used to test supplied to the monitor panel. However, the rest of
the operator warning system and the engine the system will function properly as long as the
shutdown circuit. The following test should be service disconnect switch is turned to ON.
conducted at the start of each shift.
1.Disengage the parking brake.
2.Start the engine.
3. Push test switch (3).
The red warning light will flash and the warning
horn will sound as long as the switch is pushed.
The engine should continue to run. If the engine
stops, there is a defective (shorted out) parking
brake switch. The machine should not be operated
until the system is repaired and a successful test
of the system is made.
S With the key start switch in the ON position, the

NOTICE monitor panel is activated. The fire warning light
will flash and the warning horn will sound
The heat detecting ability will be impaired if the intermittently should a fire occur.
heat sensors are covered, painted, dirty, or The control module will operate a solenoid on the
damaged. automatic actuator. This releases stored nitrogen
which is carried to the agent cylinder. It acts on a
piston in the agent cylinder valve which causes a
burst disc to be ruptured. This releases the agent,
Cover the heat sensors while painting the causing it to be dispersed through the nozzles
machine. Be sure any paint protection covers are located in the engine compartment and under the
removed from the sensors before first operating a operator's compartment floorplate.
new or repainted machine. At the time the nitrogen actuator is energized, the
Clean the sensors monthly to remove dirt and fire suppression control will also activate the
debris. Replace them if they are dented or engine shutdown solenoid to stop the engine.
damaged. NOTE: The engine will shut down only if the
Fire heat sensors are located on the machine at parking brake is engaged.
various locations. They signal the fire detection The fire warning horn will sound intermittently and
monitor in the operator's compartment whenever a the fire indicator will flash until ten seconds after
temperature above 193°C (380°F) is sensed. the last heat sensor opens. The parking brake
must be engaged, if not done so when the
warning first started.
S
15
I
Actuation from the Operator's Station
1. Stop the machine and engage parking brake Manual Actuation Outside Cab
2. Stop the engine to stop the fan and fuel and
hydraulic pumps.
M
The actuator is located on the fender on the right
front side.
Remove the pin in the actuator assembly. Push
the knob in to actuate the system. The agent
3. Remove pin (1) in the actuator assembly. Push should discharge.
knob (2) in to actuate the system. The agent
should discharge. Pressurized nitrogen from either actuator is used
to trigger the discharge of the fire suppression
4. Dismount and move away from the machine to agent cylinders.
protect against possible personal injury due to the
fire. Use follow-up fire fighting equipment. After Discharging the System
5. If the system did not discharge the agent when The engine may be restarted immediately after
actuated from the operator's station, actuate the agent discharge, if it is necessary to move the
system on the right front fender, using the same machine.
procedure.
Before returning the machine to normal service,
The engine may be restarted immediately after have needed repairs made. Find and correct the
agent discharge if it is necessary to move the cause of the fire. Have the fire suppression system
machine. nitrogen actuator cylinders and the agent cylinders
recharged.
The yellow fault indicator light will flash to indicate
low or no pressure in the actuator and agent
cylinders. After the cylinders have been recharged,
a flashing yellow light will indicate that a second
fault exists. The system should be repaired as
necessary to insure that an operable system is in
place before operating the machine.
I
16
Product Identification and
Serial Number Locations
The Product Identification Number (PIN) will be

used to identify powered earthmoving equipment
that is designed for an operator to ride. The PIN
will have the same prefixes and continue in the
sequence as the current Serial Numbers.
Caterpillar products such as earthmoving
equipment not designed for an operator to ride
(scrapers, engines, transmissions, etc.) are
identified by Serial Numbers. Also. most major
Caterpillar attachments are identified by Serial
Numbers.
For quick reference, record the identification Engine Serial Number.
numbers in the spaces provided below the
photographs.
kill
I
Dozer Blade Serial Number___________________
Combined Number Plate_____________________
Ripper Serial Number.
Product Identification Number (PIN)
I Transmission Serial Number.
17
Operation Section
Operator's Compartment
Electronic Monitoring System (EMS)

I
The Electronic Monitoring System (EMS) consists Panel Test Switch - With the engine
of a fault alarm, a fault light (1) and a monitoring stopped, move test switch UP. All
panel (2) with individual indicators for each indicators should come on and the fault
machine system listed on the panel. O light should blink until the switch is
released. Release the switch. It will
The EMS is designed to alert the operator of an return to the off position.
immediate or impending problem in one or more of
the machine systems covered.
EMS Functional Test
To ensure the proper opçration of the EMS, check If any of the indicators or the fault light do not
the system daily. come on, have the electrical system checked and
all necessary repairs made before starting the
engine.
If all the indicators and the fault light did come on,
start the engine. Repeat the panel test with the
engine running. Move the test switch UP. All
A
indicators and the fault light should come on
again. The fault alarm should also sound.
f
If any of the indicators or the fault light do not
come on or the fault alarm does not sound, stop
the engine. Have the electrical system and any
machine system for which the indicator did not
come on, inspected. Have all necessary repairs
made before starting the engine again.
The disconnect switch muSt cc uN
supply electrical power to the operator's
compartment for the EMS to function.
Q
I
18
S
EMS Warning Levels
The EMS provides three warning levels. The first Warning Level 2
level requires only operator awareness. The
second warning level needs operator response. At this level, the indicator and the fault light will
The third warning level requires immediate come on. It requires a change in machine
shutdown of the machine. The following topics operation to reduce excessive temperature in one
group the machine systems by EMS warning or more of the systems.
levels.
2. Coolant Temperature - Indicates
Warning Level 1 excessive coolant temperature. If this
indicator comes on, pull the machine to
At this level, only the indicator will come on. It Q a convenient stop. Investigate the
requires that the operator is aware that a machine cause. Do not operate the machine if the indicator
system needs attention. Failure of these systems stays on, and the fault light blinks.
will not cause serious damage to machine
components.
3. Power Train Oil Temperature -
Indicates excessive
è converter/transmission oil temperature.
Q If this indicator comes on, reduce load
on the machine. If the indicator stays on, pull to a
convenient stop. Investigate the cause. Do not
operate the machine if the indicator stays on and
S the fault light blinks.
4. Hydraulic Oil Temperature -

Indicates excessive hydraulic oil
' temperature. If this indicator comes on,
reduce load on the machine. If the
indicator stays on, pull to a convenient stop.
*A 1. Alternator - Indicates the alternator

is malfunctioning. If this indicator comes
on, pull to a convenient stop. Investigate
Q cause (loose or broken belt, etc.).
the
Investigate the cause. Do not operate the machine
if the indicator stays on and the fault light blinks.
Do not operate the machine until the cause has Warning Level 3
been corrected.
At this level, the indicator and the fault light will
come on and the fault alarm will sound. It requires
immediate shutdown of operation to prevent injury
to the operator and/or severe damage to the
system and/or the machine.
S
19
a
Gauges
5. Engine Oil Pressure - Indicates low If temperatures are excessive, stop operation of
oil pressure. If this indicator comes on, the machine. Slow the engine to 3/4 of high idle,
the fault alarm should sound and the to reduce the excessive temperature.
Q fault light should blink. Stop the machine
immediately. Stop the engine and investigate the The EMS panel lights should come on when the
cause. Do not operate the machine until the cause temperatures are excessive.
has been corrected.
1. Engine Coolant Temperature - If
the gauge indicator reaches 107°C
6. Power Train Oil Filters - Indicates (225°F), it indicates the temperature is
the oil filter is clogged. If this indicator too high.
- comes on, the fault alarm should sound
and the fault light should blink. Stop the
machine immediately. Stop the engine and 2. Hydraulic Oil Temperature - If the
investigate the cause. Do not operate the machine gauge indicator reaches 110°C (2300F),
until the cause has been corrected. ' it indicates the temperature is too high.
7. Coolant Flow - When this light 3. Power Train Oil Temperature - If

comes ON, STOP the engine. It the gauge indicator reaches 129°C
indicates a FAILURE, water pump, hose, (2650F), it indicates the temperature is
radiator, etc. The fault light will FLASH
and the fault alarm will SOUND. © too high.
20
S
Engine Start Switch Starting Aid - Ether
__1'•.
_ft
hat
0
4.
Starting Aid - Push the knob in to
NOTICE inject a metered amount of ether.
Do not turn the switch key to OFF when the

engine is running to avoid electrical system
damage.
NOTICE
S Governor lever must be pushed forward past the

detent to stop the engine. If the engine does not
Inject ether ONLY while cranking the engine. Use
the ether sparingly. Excessive ether can cause
piston and ring damage. Use ONLY when tem-
start, return the key to OFF, before returning it to peratures are below 0°C (32°F) for cold weather
START. starting purposes.
1. Turn the key to OFF to disconnect
the electrical circuits, except for the
dash, front lights, dome light, and back-
Q up alarm (when transmission selector is Service Hour Meter
in reverse).
2. Turn the key to ON to connect the

electrical circuits.
3. Turn the key to START to start or

crank the engine. Release the key after
- the engine starts. It will return to ON.
Q
Service Hour Meter - Indicates Inc
The disconnect switch key must be on, to start the total number of hours the engine has
engine. operated. Use it to determine service
Q intervals.
21

Light Switches Windshield Wiper/Washer
t1'I
Front Lights and Dash Panel Lights - - Front Windshield Wiper/Washer (1) -
(1) - Move the switch up to the first Turn the knob to the right to turn on the
=D
click to turn the front lights on. This also wiper. First click is low speed. Second
Q turns the gauge lights on. Move the click is high speed.
switch all the way up to turn the dash
panel lights on.
Left Hand Door Windshield
I
' y W
iper/Washer (2), Right Hand Door
Windshield Wiper/Washer (3) or Rear
Windshield Wiper/Washer (4) -
Rear Lights (2) and Side Lights (3) - Operates the same as item 1.
Move the switch up to turn the lights on.
A separate switch on right side rear console, next - - -

to fuses, can be used to add additional lights, etc.
Dome Light
Rotate the windshield washer pointer to the

window that requires washing. Push (1), (2), (3) or
(4) knob to spray the windshield. Pointer is located
on cab ceiling.
iflt1:.Ji L.JOiHe L..grlL -

down to turn the light on.
Q
4
S
Windshield Washer Fluid Bottle Heating and Air Conditioning Controls
The washer fluid bottle is located on the Fan Speed Switch - This switch
left rear side of the machine next to the controls the three speed blower fan
cab. Look in the bottle to check motor.
quantity. Q
First Speed (I) - Move the switch to this symbol

for lowest fan speed.
Second Speed (II) - Move the switch to this
symbol for a medium fan speed.
Third Speed (III) - Move the switch to this symbol
for highest fan speed.
Remove the bottle cap to add fluid.

Use Caterpillar windshield washer fluid or a
commercially available windshield washer fluid to
prevent system from freezing.
S
23
Heating and Air Conditioning System Operation
The Heating and Air Conditioning system can
perform four functions:
1. Heating - Move the control to
heating. Move the blower fan switch to
FIRST, SECOND or THIRD speed.
Q - Adjust the control knob for the desired
temperature.
2. Cooling - Move the control to air

1. This switch activates the heat or air conditioning. Move the blower fan
conditioning. switch to FIRST, SECOND or THIRD
O speed. Adjust the control knob for the
Off - Move the switch to this symbol to desired temperature.
turn off all controls.
3. Pressurizing - Pressure inside of
the cab will help keep dust out, when
heating or cooling is not desired.
Heating - Move the switch to this
symbol to activate.
Move the heating and air conditioning controls to
I
OFF. Move blower fan to either FIRST, SECOND or
THIRD speed, depending on the volume of air
Air Conditioning - Move the switch to needed to keep out dust.
this symbol to activate.
4. Defogging - It is possible to use the
heating system, with the air conditioning
system, to remove moisture from the air
Q in the cab. This will prevent moisture
2. Heating and Air Conditioning from forming on the windshield and windows.
Variable - Turn the knob anywhere
between LOW (left) and MAXIMUM heat
(right.) Move the blower fan switch to desired speed. Turn
on the air conditioning switch. Adjust the knob
control until moisture level is lowered, the
temperature is comfortable and windshield and
side windows are free of moisture.
24
S
Fuses
Q -
4. Horn Fuse, 12 Volt Converter and
Dual Tilt and Pin Puller If Equipped -
1 O 24 Volt to 12 Volt Converter and
wire located behind seat.
5. Back-up Alarm Fuse - 1 O
Panel/Gauges Fuse - 1 OA
NOTICE 06. EMS
Always replace fuses with the correct ampere

rating to avoid electrical system damage.
7. Hour Meter Fuse - 1 O
0 Fuse - Replace any fuse if the element

is broken and/or the circuit it is in does
not function. Fuses and their ampere
ratings are listed below.
1. Windshield Wiper/Washer Fuse -

15A
2. Rear Light Fuse - 1 O
8. Spare Accessory Fuse - (Live circuit - just

add fuse and correct size wire to the fuse holder.)
- 15A
3. Side Light Fuse - 1 O
9. Switch Accessory Fuse - This is for switch
(10). The pin connector is located under the
right fender. - 15A
S
25
I
Circuit Breakers
Circuit Breaker Reset - Push the button in to 1. Accessory

reset the circuit breaker. If working properly,
button will remain depressed. If button does not
stay in, or comes out shortly after being reset,
have appropriate electrical circuit checked. Front
0
lights have a automatic reset.
2. Dash Main
1. Heater and Air Blower Motor
Reset
3. Alternator
I
2. Fire Suppression (If Equipped)
Horn
3. Key Start
Horn - Push the knob down to sound

the front horn. The horn is used to alert
people in front of the machine.
Q

Seat Adjustment Seat Belt
Always check the condition of the seat belt and

mounting hardware before operating the
machine.
Replace the seat belt at least once every three
years, regardless of appearance. A date label,
to determine the age of the belt, is sewn onto
each belt.
1. Push down on the seat height level lever to

release the lock. Move the seat down, or allow it to
rise to the desired height. Release the lever to lock
the seat.
2. Pull up the fore-aft lever. Slide the seat forward
or back to the desired position. Release the lever
to lock the seat.
S 3. Pull up the seat angle lever. Adjust the seat

cushion to the desired angle. Release the lever to
lock the seat cushion.
4. Turn the knob clockwise while seated to
increase or counterclockwise to decrease the
stiffness of suspension. Adjust so that the yellow Inspect for worn or frayed webbing.
rod in the indicator is just flush with tube while
seated. Bounce on the seat a few times and Check for worn or damaged buckle or anticreep
check rod again. slide on each half of the belt. Replace the belt,
buckle or slides if they are worn or damaged.
Adjust the seat belt buckle to fit the operator. See
"Adjust Seat Belt." Inspect the belt mounting hardware. Replace any
damaged or worn hardware. Keep the mounting
5. Raise the backrest up and move it to the bolts tight.
desired position. Lower it to lock it into position.
0
I
Adjust Seat Belt
Adjust both ends of the belt. The belt should be To Shorten the Belt
snug but comfortable.
To Lengthen the Belt
1. With the belt fastened, pull on the outer loop to

L\ tighten the belt.
1. With the belt unfastened, move the antcreep
slide toward the buckle.
Fe
i
I
2. Move the anticreep slide toward the anchor

end of the belt to take up the slack in the outer
loop.
2. To remove the slack in outer loop (1), rotate
buckle (2) to free the lock bar. This permits the 3. Adjust the other half of the belt in the same
belt to move through the buckle. manner.
3. Pull on the buckle until the slack is removed 4. Readjust the belt if it does not fit snugly with
from the outer belt loop. the buckle in the center.
4. Loosen the other half of the belt in the same
manner. Readjust the belt if it does not fit snugly
with the buckle in the center.
28
Machine Controls

Windows and Doors Brake Pedal
Lift latch (1) to slide the windows. Squeeze latch Brake Pedal Applied - Push the brake
(2) to release window from the closed position. pedal down to apply the brakes, and
slow or stop the machine. Use the
@ brakes on a downgrade to keep the
engine from overspeeding.
Brake Pedal Released - Release the brake pedal

to allow the machine to move, or increase ground
speed.
S Governor and Decelerator
Move the lock to lock or unlock the cab door from

inside.
1. Governor Lever - Pull the iever

back for higher engine rpm. Push the
.) lever forward to slow the engine. Push
the lever forward to the detent position
for low idle. Push the lever all the way forward
through the detent to stop the engine.
2. Decelerator Pedal - Push down on the pedal

to override the governor control and reduce the
engine speed. Use the pedal to reduce engine
S rpm when making directional shifts.
29

I
Steering Clutch/Brake Control Parking Brake
There are two steering clutch/brake control levers Parking Brake - This lever engages the
The lever on the left, controls the left steering parking brake and locks the
clutch and brake. The lever on the right controls transmission lever in NEUTRAL. The
the right steering clutch and brake. Q machine should not move when
engaged. Do not use for stopping the machine.
1. Left Steering Clutch/Brake Lever -
Pull the left lever back to steer the
machine to the left. The rate of steering Unlocked - Pull the lever up to release
Q is controlled by how far the lever is the parking brake.
pulled back.
When a slight lever pressure is felt while pulling it

I
back, the lever will be entering the braking
position.
Pull the lever all the way back to brake the left
track for a pivot turn.
2. Right Steering Clutch/Brake Lever
- Pull the right lever back to steer the
machine to the right. The rate of
Q steering is controlled by how far the
lever is pulled back.
When a slight lever pressure is felt while pulling it Locked - Push the lever down to
back, the lever will be entering the braking engage the parking brake. This will also
position. lock the transmission lever in NEUTRAL.
Pull the lever all the way back to brake the right
track for a pivot turn.
30
Implement Controls
S
Transmission Dozer Blade Height
1
L.
Transmission Direction and Speed 1. Float - Push the lever all the way
Selector - This lever controls forward into detent for blade float. In
transmission NEUTRAL (N), and three this position, the blade will move up and
Q speeds forward (F) or reverse (R). Move Q down following the ground contour.
the lever to the desired direction and speed.
The lever will remain in the float position (detent)
The parking brake lever must be up to allow until manually pulled out of detent position. The
selector movement. lever will then return to HOLD.
p Back-up Alarm
J
2. Lower - Push the lever forward to
lower the blade. Release the lever and it
will return to HOLD.
3. Hold - Release the lever from raise

- or lower, and it will return to HOLD. The
blade movement will stop.
OQO
4. Raise - Pull the lever back to raise

the blade. Release the lever and it will
- return to HOLD.
Back-up Alarm - The alarm will sound
-- when the transmission lever is in the
• ZT reverse position. It is used to alert
' people behind the machine that it is
backing up.
The alarm will sound anytime the disconnect is

turned to ON, and lever is on the reverse side of
console.
31

I
Dozer Blade Tilt - Standard Dozer Blade Dual Tilt - If Equipped
1. Tilt Left - Pull the lever to the left to 1. Float - Push the lever all the way
lower the blade to the left. Release the forward into detent for blade float. In
I! lever and it will return to HOLD. this position, the blade will move up and
Q down following the ground contour.
2. Tilt Hold - Release the lever and it The lever will remain in the float position (detent)
J will return to HOLD. The blade
movement will stop.
until manually pulled out of detent position. The
lever will then return to HOLD.
3. Tilt Right - Push the lever to the

2. Lower - Push the lever forward to
lower the blade. Release the lever and it
will return to HOLD.
q
right to lower the blade to the right.
Release the lever and it will return to
OO HOLD.
3.. Hold - Release the lever from raise
or lower, and it will return to HOLD. The
-j blade movement will stop.
QO
4. Raise - Pull the lever back to raise

the blade. Release the lever and it will
return to HOLD.
32
I
Ripper
Use the toggle switch on top of control grip for 1. Raise - Move the lever to the left to
speed and hydraulic force before tilting blade left raise the ripper. Release the lever and it
or right. Move the toggle rearward for faster tilt E will return to HOLD.
speed. Move the toggle forward for slower tilt O
speed and greater blade force. Use for prying a
rock loose, etc. Rearward and forward tilt speeds
are not affected by the toggle switch. 2. Hold - Release the lever and it will
return to HOLD. The ripper movement
1. Tilt Left - Pull the lever to the left to 9 will stop.
lower the blade to the left. Q
p
3. Lower - Move the lever to the right
= to lower the ripper. Release the lever
2. Tilt Hold - Release the lever from and it will return to HOLD.
- any position and it will return to HOLD
The blade movement will stop.
Q1
Q
4. Shank In - Move the lever forward
to move the shank in closer to the
3. Tilt Right - Push the lever to the machine. Release the lever and it will
right to lower the blade to the right. ØI return to HOLD.
5. Shank Out - Move the lever

rearward to move the shank out away
Tilt Rearward - Hold the trigger in on from the machine. Release the lever and
the control grip. Move the lever to it will return to HOLD.
position (1) to tilt the blade back. Tilting
O the blade to the rear improves the ability
of the blade to carry the load.
Tilt Forward - Hold the trigger in on the

" control grip. Move the lever to position
(3) to tilt the blade forward. Tilting the
I blade forward improves blade

penetration. it also helps dump the load.
33

Ripper Pin Winch
1. Shank Pin In - Full the toggle up and toward

you to engage the ripper shank pin. Move the
toggle to HOLD, to stop the ripper shank pin
movement. Do not move the control lever to FREE SPOOL
position with a load on the line.
2. Shank Pin Hold - Move the toggle to the The load will be released uncontrolled and can
center, and ripper shank pin movement will stop. result in personal injury or death.
3. Shank Pin Out - Pull the toggle up and push
it away from you to disengage the ripper shank
pin. Move the toggle to HOLD, to stop the ripper
shank pin movement. 1. Free Spool (If Equipped) - Push the
button on top of control. Move the lever
Use the toggle to move the pin in the ripper shank to this position to free the spool. Cable
from inside the cab. Use for adjusting the shank can now be pulled out by hand.
height.
2. Brake Off Detent - The lever will
remain in this position until moved
manually. The resistance of the winch
mechanism makes it impossible to
unreel the cable by hand.
3. Brake Off - Move the lever to this

- position to release the winch brake.
Release the lever and it will return to
BRAKE ON. The cable will unreel by the
weight of the load, or when the machine moves
away from the load, if it is heavy enough.
4. Brake On - The cable should not

move. Use this position when towing,
holding load or when winch is not in
Q use.
I
34
Before Starting the Engine
I
Walk-Around Inspection
5. Reel In - Move the lever to this
position to reel in the cable. The cable
should move toward the winch under
Q power. Release the lever and it will Hot oil and components can cause personal
return to BRAKE ON. injury. Do not allow hot oil or components to
contact skin.
At operating temperature, the engine coolant is
6. Reel Out - Pull the lever to this hot and under pressure.
position to reel out the cable. The cable
will reel out under power. Release the Steam can cause personal injury.
lever and it will return to BRAKE ON.
Check the coolant level only after the engine
has been stopped and the fill cap is cool
Inching (Fine Control Operation) enough to touch with your bare hand.
The winch control valve, located inside the winch Remove the fill cap slowly to relieve pressure.
case, can be adjusted to suit operational needs. 4
two-position sequence valve is contained within Cooling system conditioner contains alkali.
the winch control valve group. This valve provides Avoid contact with the skin and eyes to prevent
"no-inch" position for general winching, and an personal injury.
"inch" position for more severe reel outline control
p
applications.
The inching sequence valve affects the reel-out
function only. It has no effect on reel-in modulation For your own safety and maximum service life of
capabilities. the machine, make a thorough walk-around
inspection before mounting the machine to start
All winches are set at the 'no-inch" position when the engine.
shipped from the factory.
Look around and under the machine for such
See "Winching" in the "Operating Adjustments" items as loose bolts, trash build-up, oil or coolant
section of this guide. leaks, broken or worn parts. Inspect the condition
of the implements and the hydraulic components.
Reel Out (Inching Out) - Pull the lever
slowly into position (6) at low engine
rpm. Control the cable line speed with
Q the engine governor control.
I
35
I
1. Inspect the implements for damage or 7. Inspect and repair any engine compartment
excessive wear. Repair if damaged. leaks. Check around all seals and covers.
2. Inspect implement cylinders and linkage for 8. Inspect steps and handholds for condition and
damage or excessive wear. Repair if damaged. cleanliness. Repair or clean if necessary. Inspect
the Rollover Protective Structure (ROPS) for
3. Inspect and replace lights, broken bulbs and damage. See your Caterpillar dealer for repairs if
lenses. necessary.
4. Remove trash build-up in and around the 9. Inspect and repair any hydraulic system leaks.
engine and under the floorplate. Also remove any Inspect hoses, seals and around flanges.
dirt build-up on top of the crankcase guard.
10. Inspect and repair any final drive leaks.
5. Inspect and repair any cooling system leaks.
Check the hoses, radiator fins, radiator cap and
the drain area.
6. Inspect the engine precleaner screens for dirt
build-up. Remove any dirt or debris.
36
S
11. Be sure covers and guards are firmly in place. 16. Inspect the seat belt and mounting for
Inspect for damage or for loose and missing bolts. excessive wear and damage. Replace if damaged.
12. Inspect and repair any transmission leaks.
Check around the seals and covers. Also, check
the hoses around the transmission.
13. Inspect and repair damaged and excessively
worn tracks. Tighten any loose bolts and replace
p any that are missing.

Look for leaks between the major and minor
bogies, bogie shafts and the roller frames.
If leakage exists consult your Caterpillar dealer for
inspection, lubrication and, if necessary, repair
instructions.
17. Make sure the horn, back-up alarm, lights,
guards, shield, etc., are in proper working order.
14. Inspect operators compartment for

cleanliness and remove all trash and dirt build-up.
15. Inspect and repair the instrument panel when 18. Brake pedal can be adjusted closer or farther
broken gauges and lights are found. from operator's seat for comfort. See your
I Caterpillar dealer for adjustment procedure.
37
I
Pre-Start Checks
^e IN
'..
Val-
1. Maintain the engine oil level between the ADD 3. Maintain the power train system oil level
and the FULL mark on the dipstick. between the ADD and the FULL marks on the
dipstick.
Maintain the pivot shaft oil level between the ADD
and FULL marks in the reservoir. Do not add oil
above FULL mark to avoid oil overflow as oil
ff- warms. Check for leaks if frequently low. Close the
cover.
'itjLi1. .......1.
WiW
2. Open the ieft side access cover.
,
4. Maintain the hydraulic implement oil level
between the ADD and the FULL mark in the sight
gauge.
I
38
S
47^ a N 7
5. Remove the coolant fill cap. 9. Open the fuel drain valves. Drain moisture ana
sediment, as required, from the fuel tank.
6. Maintain the engine coolant above the low level
plate.
\3$
p U
7. Remove the fuel fill cap.

El 10. Service -,ne air filter elements when the yellow
piston enters the red area in the indicators.
8. Maintain the fuel level to the FULL mark on the

dipstick.
S
39
Starting the Engine
I
Above 0°C (32°F)
LII
L
11. Adjust the seat to allow full brake pedal travel 1. Move the transmission control lever into
with the operator's back against seat back. NEUTRAL.
12. Adjust the mirror to allow proper viewing from
the seat to see close behind the machine.
'I
2. Engage the parking brake.
13. Adjust the seat belt to fit snug.

I
¼
3. Move he implement control levers to tne
HOLD position.
40
S
` --- ` a
.2
4. Pull the governor control lever back tnrough toe 7. Turn the start switch key to START. Release
stop engine detent. Then return it to the LOW IDLE the switch key when the engine starts.
position.
Below 0°C (32°F)
1. Follow steps 1 through 6 for "Above 000
(32°F)."
5. Turn the start switch key to the ON position.
2. Turn the start switcn key to START.
NOTICE
Inject starting aid (ether), ONLY while cranking

the engine to avoid engine damage.
Use sparingly, excessive ether can cause piston
and ring damage.
6. The engine oil pressure, coolant flow and the Use ether for cold starting purposes only.
alternator lights should come on.
41
I
Starting with Jumper Cables
Batteries give off flammable fumes that can

explode.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow jump
cable ends to contact each other or the
machine.
Do not smoke when checking battery electro-
lyte levels.
3. Push the starting aid (ether) knob and release. Electrolyte is an acid and can cause personal
4. Use additional starting fluid every two seconds injury if it contacts skin or eyes.
until engine starts. Always wear eye protection when starting a
5. Release the start switch key when the engine machine with jump cables.
starts. Improper jump procedures can cause an ex-
6. Use starting aid every two seconds after the plosion resulting in personal injury.
engine starts, until the engine is running smoothly Always connect battery positive (+) to battery
positive (+) and battery negative (-) to battery
negative (-).
I
NOTICE Jump only with a battery source and with the
same voltage as the stalled machine.
After every 30 seconds of engine cranking, allow Turn off all lights and accessories on the
two minutes for the starting motor to cool before stalled machine. Otherwise, they will operate
cranking again. when the jump source is connected.
For starting below —18°C (0°F), use of additional

cold weather starting aids is recommended. A NOTICE
coolant heater, fuel heater or extra battery
capacity may be required.
When starting from another machine, make sure
At temperatures below —23°C (-10°F), consult the machines do not touch. This could prevent
your Caterpillar dealer, or refer to the "Cold damage to engine bearings and electrical circuits.
Weather Recommendations Operation &
Maintenance Guide," Form SEBU5898, available Turn on (close) the disconnect switch prior to the
from your Caterpillar dealer. boost connection to prevent damage to electrical
components on the stalled machine.
42
I
Machines with Auxiliary Start Receptacles
Some Caterpillar products may be equipped with
auxiliary start receptacles as standard. All other
machines can be equipped with a parts service
receptacle. A permanent receptacle is then always
available for jump starting.
Two mating cable assemblies are also available to
jump the stalled machine from another machine
also equipped with this receptacle or an auxiliary
power pack. Your Caterpillar dealer can provide
the correct cables in lengths for your application.
4 ki
1. Make initial determination as to failure of the
stalled machine to crank. Refer to special 7. On the stalled machine connect the
instruction SEHS7768 on use of 6V2150 appropriate jump start cable to the auxiliary start
Starting/Charging Analyzer Group. Procedure receptacle.
applies even if machine does not have diagnostic
connector. 8. Connect the other end of this cable to the
auxiliary start receptacle of the boost source.
2. Place the transmission control lever in
NEUTRAL on the stalled machine. Engage the 9. Start the engine on the boost machine. Or,
parking brake. Lower all equipment to the ground energize the charging system on the auxiliary
power source.
I Move all controls to HOLD.
3. Turn the start switch to OFF on the stalled
machine. Turn off all accessories.
10. Wait a minimum of two minutes for the
batteries in the stalled machine to partially charge.
4. Turn on (close) the disconnect switch (if 11. Attempt to start the stalled engine. Refer to
equipped) on the stalled machine. the beginning of "Starting the Engine" in this
section.
5. Move the boost start machine near enough to
the stalled machine for cables to reach, but DO 12. Immediately after starting the stalled engine,
NOT ALLOW MACHINES TO TOUCH. disconnect the jump start cable from the BOOST
SOURCE.
6. Stop the engine on the boost machine, or if
using an auxiliary power source, turn off the 13. Disconnect the other end of this cable from
charging system. the stalled machine.
14. Conclude failure analysis on starting/charging
system of the stalled machine as required, now
that engine is running and charging system in
operation.
Use of Jumper Cables
When auxiliary start receptacles are not available,
use the following procedure.
1. Make initial determination as to failure of
machine to crank. Refer to special instruction
SEHS7768 on use of 6V2150 Starting/Charging
I Analyzer Group. Procedure applies even if

machine does not have diagnostic connector.
43
2. Place the transmission control lever in 9. Connect the other end of this positive jumper
NEUTRAL on the stalled machine. Engage the cable (red) to positive (+) terminal of boost
parking brake. Lower all equipment to the ground battery. Use procedure of Step 8 to determine
Move all controls to HOLD. correct terminal.
3. On stalled machine, turn the start switch to 10. Connect one end of the negative (-) jumper
OFF. Turn off all accessories. cable to the negative (-) boost battery terminal
(connected to the disconnect switch) in the same
4. On stalled machine, turn on (close) the battery set as used in Step 9.
disconnect switch (if equipped).
11. Make final connection of negative (--) cable to
5. Move boost start machine near enough to frame (not battery negative post) away from
stalled machine for cables to reach, but DO NOT battery, fuel or hydraulic lines, or moving parts.
ALLOW MACHINES TO TOUCH.
12. Start the engine on the boost machine. Or,
6. Stop the engine on the boost machine. Or, if energize the charging system on the auxiliary
using an auxiliary power source, turn off the power source.
charging system.
13. Wait a minimum of two minutes for the
7. Make sure battery caps are all in place and batteries in the stalled machine to partially charge.
tight on both machines.
14. Attempt to start the stalled engine. Refer to
section on "Starting the Engine".
15. Immediately after starting the stalled engine,
disconnect the jumper cables in reverse order.
I
16. Conclude failure analysis on starting/charging
system of stalled machine as required now that
k
engine is running and charging system in
I. sa.*
a. a a a a
ma. am a
S 55
operation.
NOTICE
, •5 5
AM&W ONSEN
8. Connect positive (+) jumper cable (red) to When jump starting machine, follow the instruc-
positive (+) cable terminal of discharged battery, tions to properly start the machine.
or battery set on stalled machine.
Attach the jumper cable to the external starting
NOTE: Batteries in series may be located in source first.
separate compartments. Use terminal that is
connected to starter solenoid. This battery, or This machine has a 24 volt starting system. Use
battery set, is normally on the same side of the only equal voltage for jump starting. Use of welder
machine as the starter. or higher voltage will damage electrical system.
Do not allow positive cable clamps to touch any
metal other than battery terminals.
I
NOTE: On machines with two sets (two in each
fender) of two batteries (4 total), connect to either
set as per above procedure.
44

After Starting the Engine Moving and Stopping the
Machine
ii Keep the machine under control at all times.

Do not shift the transmission to NEUTRAL to allow
the machine to coast.
Select the gear range necessary before starting
downgrade. Do not change gears while going
downhill.
A good practice is to use the same gear range
going downgrade that would be used to go up the
grade.
1. Allow the engine to warm up at LOW IDLE for Do not allow the engine to overspeed downhill.
five minutes. Engage and disengage all implement Use the brake pedal to reduce engine overspeed
controls to help speed warm-up of hydraulic going downhill.
components. When the load will be pushing the machine, put
the transmission selector lever in FIRST speed
2. Move the EMS test switch up. The fault alarm before starting downhill.
should sound. The fault lights should come on.
The master fault light should flash. 1. Raise all lowered implements enough to clear
3.Release the EMS test switch. All fault lights and any obstructions.
the fault alarm, should go off. If the lights do not
go off, stop the engine. Have any necessary
repairs made before starting again.
2. Push down on the brake pedal to keep the

machine from moving.
4. LooK at the lau,i lights and gauges (if

equipped) frequently during operation.
5. Look at the hydraulic oil tank and power train
oil levels. Maintain the oil levels to the FULL marks.
45
Changing Speed and Direction
• tJU
T.
L
3. Pull tue lock lever up to disengage the parking Speed and directional changes at full engine
brake and to unlock the transmission control lever. speed are possible for power shift. However, for
operator comfort and maximum service life of
power train components, decelerating and or
braking, when changing directions is
recommended.
1. Decrease the engine speed by pushing the
governor control in, or by pushing the decelerator
TI3 pedal down.
I
4. Move the transmission oontro ever 10 the
desired direction and speed.
5. Release the brake pedal.
6. Move the governor control lever to the desired
engine speed.
2. Pusn me brake peoc anwn

to stop the
machine.
I
46
0
Normal Steering
3. Move the transmission control lever to To make a gradual right turn, pull the right steering
NEUTRAL. clutch/brake lever back toward the detent, until a
slight pressure is felt. This will release the right
4. Move the transmission control lever to the steering clutch.
desired direction and speed.
Pull the lever back against the stop to make a
5. Release the brake pedal. sharp right turn. This will apply the right brake.
6. Increase the engine speed by releasing the
decelerator pedal, or pulling back on the governor
control lever.
To make a gradual left turn, pull the left steering

clutch/brake lever back toward the detent, until a
slight pressure is felt. This will release the left
steering clutch.
Pull the lever back against the stop to make a
sharp left turn. This will apply the left brake.
S
47
Parking the Machine
Steering on a Steep Downgrade

I
Cross steering is the term used to describe turning 1. Stop the machine on level ground. Push the
gradually on a steep downgrade by declutching, governor control forward slightly to reduce the
without braking. engine speed.
To make a gradual right turn, pull the left steering
clutch/brake lever (1) back toward the detent, until
a slight pressure is felt. This will release the left NOTICE
steering clutch (cross steering).
To make a sharp right turn, pull the right steering Stopping the engine immediately after it has been
clutch/brake lever (2) back against the stop. This working under load, can result in overheating and
will apply the right brake (normal steering). accelerated wear of the engine components. Fol-
low the stopping procedure, outlined below, to
To make a gradual left turn, pull the right steering allow the engine to cool, and to prevent excessive
clutch/brake lever (2) back toward the detent, until temperatures in the turbocharger centerhousing
a slight pressure is felt. This will release the right which will cause oil coking problems.
steering clutch (cross steering).
To make a sharp left turn, pull the left steering
clutch/brake lever (1) back against the stop. This
will apply the left brake (normal steering). 2. Move the transmission control lever to
NEUTRAL.
3. Engage the parking brake.
4. Lower all raised implements to the ground.
Apply a slight down pressure.
I
48
Operating Adjustments
S
Dozer Blade Tilt - Standard
5. Before stopping the engine, operate at LOW
IDLE for five minutes. This allows hot areas in the
engine to cool gradually, extending engine life.
6. Push the governor control lever past detent (all
the way forward), to stop the engine.
7. Turn the start switch key to OFF. Remove the I...'
key.
8. Install the vandalism guards (if equipped) when
leaving the machine for an extended period.
Electrical Disconnect Switch 1. Pull the tilt lever toward you to lower the left
side of the blade.
2. Push the tilt lever away from you to lower the
right side of the blade.
3. If additional tilt is required, the left brace may
be adjusted. Shorten the brace to make left side
S i7t- of blade lower. Lengthen the brace to make the

left side of blade higher.
To Adjust Length of Brace:
rl
The switch is located on the left side of the
machine behind the access cover.
Turn the key off and remove the key, if parking for
an extended period of time, to prevent battery
drain, or vandalism, or when servicing the
machine.
This will also prevent the engine from being
started or lights being turned on by unauthorized
I
people.
1. Put blade on ground and move tilt cylinder to
remove brace tension.
2. Remove the retainer and lock pin.
3. Extend or retract tilt cylinder as desired.
4. Install lock pin and retainer.
911
49
I
vs"" I NOTICE

1
If tracks are too tight or loose, wear of compo-

nents is accelerated. If they appear too tight or too
loose, adjust the track. Follow the procedures in
_ the "Maintenance Section" for adjustment.
Cutting Edges and End Bits

Lengthen the left brace and extend the right
cylinder to tilt the blade forward. 1T .,.. !
I
Repioe UI IH urij :ges or end bits,
before wear occurs on the blade base. Follow the

procedures in the "Maintenance Section" for
replacement.
Shorten the left brace and retract the right cylinder Ripper Tip and Shank Protector
to tilt the blade rearward.
Tracks
Replace ripper tips or shank protectors before

wear occurs on the shank. Follow the procedures
The tracks should sag slightly for proper operation. in the "Maintenance Section" for replacement.
50
Winching
The winch has an adjustable sequence valve, To Adjust:
which permits the selection of either 'no inch" or
"inching" characteristics, during reel out
operations.
NOTICE
Inching is the controlled movement of the cable
during a reel out operation. The "inching" setting is
generally used when the machine and winch are Use valve in inching position only when needed for
used for construction and pipeline work. This inching out. Otherwise, possible winch damage
setting gives the operator the control necessary to could result.
put an object in an exact position.
Where precise control is not necessary, as when
logs are moved, the "no inch" setting may be
used.
When using the inching setting, move the winch
control lever to the reel out channel. Move the
lever into the channel to start drum rotation. Use
the engine speed to control the inching rate.
Always use a slower engine speed for better I
control when inching.
I The adjustable sequence valve, is set on the 'nc

inch" setting at the factory.
1. Remove the winch valve access cover on right

side of winch.
p.
2. Rernoc We two bolts and reverse the cover.

Install the bolts.
I
51
Operating Techniques
I
Dozing
11 r e 0
3. Remove the nut from the end of the valve. Straight Dozing: If the blade digs in and the rear
Reverse the position of the valve. Install the nut. of the machine rises, raise the blade to continue
even cut. When moving a heavy load causes
4. Install the access cover. travel speed to drop, shift to a lower speed and/or
raise the blade slightly.
When doing finishing or leveling work, a full blade
handles easier than a partially loaded blade.
Slot Dozing: This allows larger loads to be carried

in front of the blade. It is used in stockpiling and
high production dozing.
I
52
I
LL
Side-by-Side Dozing: Use when moving large
quantities of loose material. Keep the blades close
Straight Dozer Ditching: Tilt the blade to cut
shallow "V' ditches. For larger ditches, doze at
together and the machines parallel. right angles to the center line of the ditch. When
the desired depth is reached, doze the length of
ditch to smooth the sides and bottom.
Tilt Dozer Ditching: Tilt the blade and work with

the low side in the ditch center. Level the blade
when the required depth and slope are reached. Straight Dozer Backfilling: Push at a 900 angle to
ditch.
I
53
I
Land Clearing
Typical Artwork
Brush Clearing: Lower the blade slightly into the

ground and move forward. Lift the blade when the
1. Remove all dead limbs. Cut roots on side brush is out, to loosen the earth from the roots.
opposite direction of fall.
2. Cut roots on sides parallel to direction of fall.
3. Ease into the tree. Push in direction of fall with
blade high. Build a earth ramp if higher contact is
needed.
4. Do not drive onto stump while tree is falling. I
Back away immediately when tree starts to fall,
to prevent possible injury.
Stump Removal: Lift the blade while pushing.
Large Brush and Medium Size Trees: Contact

the tree 300 to 400 mm (12 to 16 inches) above
the ground. Move forward while lifting the blade.
I
54
Ripping
Ripper Operating Hints
Use FIRST speed for most ripping operations. It is

better to use additional shanks, where practical,
rather than to increase speed. In most cases it is desirable to rip as deep as
possible. Sometimes it is better to rip at partial
Always use center shank when ripping with one depth and remove the material in its natural layers.
shank. If material breaks up satisfactorily, more
shanks may be used. Keep material on top of the unripped formation to
cushion the machine and provide traction.
I
Cross rip only when necessary.
When final material size must be relatively small,
When ripping for scraper loading, rip in same close spacing of passes is recommended.
direction that scrapers will load.
Packed Soil, Hard Pan, Clay, Shale or
Rip downhill whenever possible. Cemented Gravel
NOTICE
Do not turn or back the machine while shanks are

in the ground. Twisting strain on the shanks and
tips may cause failure.
Inspect the ripper tips frequently for excessive
wear.
Three shanks work well in these materials. Use as

many shanks as possible to break material to
desired size, without stalling or hanging up the
machine.
I
55
Rock with Fractures, Faults and Planes of Asphalt Road Surfaces
Weakness
Raise the ripper shanks to lift out and break

Use two shanks where rocks break out in small material.
pieces, and the machine can handle the job easily.
When the machine begins to stall or tracks spin, Concrete Road Surfaces
use only the center shank.
Solid Rock, Granite or Hard-to-Rip Material
Use a single ripper shank. Ripper is especially

effective in severing reinforcing rods or mesh.
Use one shank in tough-to-rip material or material
that tends to break out in large slabs or pieces.
Always use the center shank when one-shank
ripping.
56
Adjustable Ripper
The shank on the ripper has angle and length
adjustment features.
To achieve the maximum performance throughout
each ripping pass, the angle of the shank must be
varied, as described below.
Move the ripper shank forward ("shank in" position)

when prying out lodged material.
To insert the ripper into the material to be ripped,

' adjust the angle of the shank back vertical
position. This will give the correct tip angle for
easy entry into the material. The angle will differ
depending upon the material being ripped.
Move the ripper to the rear ("shank out' position),

but only as much as necessary, for additional
clearance between ripper and track.
Lower the ripper into the material while moving

forward. When desired ripping depth is reached,
move the shank forward to obtain the correct
angle for best performance. This is usually
between vertical and forward positions of shank.
I
57
I
Winch
Make certain personnel are clear of cable

when there is a load on it. Cable can break and
cause personal injury.
NOTICE
Shallow ripping is recommended when material is Always winch with cable in as straight a line be-
to be removed by a scraper or loader. hind machine as possible.
Deep ripping is recommended when material is to For safety and maximum service life of winch
be removed by an excavator or dozer. components, engine decelerating is recommend-
ed before moving the winch control lever.
Control cable line speed after shifting, by varying
the engine speed.
Do not leave in the BRAKE OFF position for ex-
tended periods. I
Whem moving away from a load, operate the
machine in low gear speeds to prevent over-
speeding of winch components.
Inch loads with engine speed low and machine
stationary. Do not operate winch for extended
periods of time while winching.
Adjust the length of the shank according to
clearance required between the ground and the
beam.
Engine or torque converter may stall if line load
and/or engine load is too high when winch is
engaged.
To reel in or out slowly, engage and disengage
control lever and/or decelerate and accelerate
engine as necessary.
58
Transportation Hints
1. Free Spool (If Equipped) - Use this position Attach the retaining bolt to each lift cylinder to
to allow cable to be pulled out manually by hand. prevent lift cylinders from moving.
2. Brake Off Detent - Use the detent position, Secure the lift cylinders to the machine when
when needed to have hand free from control. blade is not attached.
3. Brake Off - Used to move the machine away Check the travel route for overpass clearances.
from loads, or to lower load by its own weight. In Make sure there will be adequate clearance, if the
most applications, sufficient cable tension will be machine being transported is equipped with
maintained with the lever fully engaged. However, ROPS, cab or canopy.
I holding a load on a slope, with the machine
moving forward, may require some braking action.
Brake only as much as necessary to maintain the
Basic standard machine shipping specifications
are listed below.
minimum cable tension required. Weight (approximate) 44411 kg (97,910 Ib)
Length (maximum) 5595 mm (18.4 ft)
4. Brake On - For towing, holding loads or
when winch is not in use. Width (across track) 3160 mm (11.5 ft)
Height (with flOPS) 4242 mm (13.11 ft)
5. Reel In - At low engine rpm, pull the lever
slowly into the reel in position, until load starts to
move. Increase engine speed, if necessary, to
control the cable line speed. NOTICE
6. Reel Out - At low engine rpm, pull the lever
slowly into reel out position until the load starts to Remove ice, snow or other slippery material from
move. Increase the engine rpm speed if shipping machine and loading dock, before load-
necessary, to control the cable line speed. ing the machine.
NOTE: The reel out position can be used for
inching operations.
59
Maintenance Section
General Torque
Specifications
For additional torque specifications, not included in

this section, refer to "Torque Specifications," Form
SENR3130, available from your Caterpillar dealer.
Bolt Torques for Ground Engaging Tools
Bolt Size Recommended Torque
Inch N.m Ibft
5/8 265±35 195±25
3/4 475 ± 70 350 ± 50
7/8 765 ± 115 565 ± 85
1 1220 ± 150 900 ± 110
11/4 2000 ± 200 1480 ± 150
Always block the trailer or rail car wheels before
loading the machine. These values are applicable only to Caterpillar cutting edge bolts.
Move the transmission control lever to NEUTRAL. General Torque for Standard Bolts, Nuts
and Taperlock Studs
Stop the engine.
NOTICE
The following charts give general torques for

bolts, nuts and taperlock studs of SAE Grade 5 or
better quality.
Torques for Bolts and Nuts With Standard

Threads
Thread Size Standard Torque
Inch N.m Ibtt
1/4 12±4 9±3
Turn the start switch and the disconnect switch 5/16 25±7 18±5
key to OFF and remove the keys. 45±7 33±5
3/8
Install tie-downs at several locations, and block 7/16 70±15 50±11
tracks, front and rear. 1/2 100±15 75±11
9/16 150±20 110±15
Cover the engine exhaust opening to prevent 5/8 200±25 150±18
turbochargers windmilling in transit. 3/4 360 ± 50 270 ± 37
7/8 570 ± 80 420 ± 60
Check state and local laws governing weight,
width and length of load. 1 875±100 640±75
11/8 1100±150 820±110
Contact your Caterpillar dealer for shipping 11/4 1350± 175 1000±130
instructions for your machine. 13/8 1600± 200 1180± 150
11/2 2000± 275 1480±200
• 1 Newton meter (N . m) is approximately the same as 0.1 mkg.
I
60
I
Torques for Taperlock Studs Metric 1S0 Thread
Thread Size Standard Torque
Thread Size Standard Torque lb ft
Inch N.m' lb It
M6 12±4 9±3
114 8±3 6±2 M8 25±7 18±5
5/16 17±5 13±4 M10 55±10 41±7
3/8 35±5 26±4 M12 95±15 70±11
7/16 45±10 33±7 M14 150±20 110±15
1/2 65±10 48±7 M16 220±30 160±22
9/16 90±15 65±11 M20 450 ± 70 330 ± 50
5/8 110±15 80±11 M24 775 ± 100 570 ± 75
3/4 170±20 125±15 M30 1600±200 1180±150
7/8 260±30 190±22 M36 2700 ± 400 2000 ± 300
1 400±40 300±30 'ISO-International Standard Organization.
1 1/8 500 ± 40 370 ± 30 "1 Newton meter (Nm) is approximately the same as 0.1 mkg.
11/4 650±50 480±37
1 3/8 750 ± 50 550 ± 37 Standard Torque for Hose Clamps - Worm
11/2 870±50 640±37 Drive Band Type
1 Newton meter (N . m) is approximately the same as 0.1 mkg.
NOTICE
General Torque for Metric Fasteners
The following chart gives the torques for initial
NOTICE installation of hose clamps on new hose and for
reassembly or retightening of hose clamps on
Be very careful never to mix metric with U.S. existing hose.
customary (standard) fasteners. Mismatched or
incorrect fasteners will cause machine damage or
malfunction and may even result in personal
injury. Initial Installation
Torque on New Hose
Original fasteners removed from the machine N'm' lb in.
should be saved for reassembly whenever possi- Clamp Width
16 mm
ble. (.625
If new fasteners are needed, they must be of inch) 7.5 ± 0.5 65 ± 5
the same size and grade as the ones that are 13.5 mm (.531 inch) 4.5 ± 0.5 40 ± 5
being replaced. Bmm(.3l2inch) 0.9±0.2 8±2
Reassembly or
The material strength identification is usually Retightening Torque
shown on the bolt head by numbers (8.8, 10.9, Clamp Width N.m' lb in,
16 etc.).
mm The following chart gives standard torques
(.625 inch) 4.5 ± 0.5 40 ± 5
for bolts and nuts with Grade 8.8. 13.5 mm (.531 inch) 3.0 ± 05 25 ± 5
8 mm (.312 inch) 0.7 ± 0.2 6±2
'1 Newton meter (Nm) is approximately the same as 0.1 mkg.
I
61
Recommendations and
Specifications
General Air Intake System
I
Check the precleaner screen or bowl daily for
NOTICE accumulation of dust and debris.
Accumulated grease and oil on a machine is a fire Remove any dust and debris as needed.
hazard. Remove this debris with steam cleaning If the indicator light comes on shortly after
or high pressure water, at least every 1000 hours installing a cleaned primary element, install another
or each time any significant quantity of oil is spilled clean element, or a new element.
on a machine.
The primary element can be cleaned up to six
times before replacement. The element, when
cleaned, should be thoroughly checked for rips or
Wipe all fittings, caps and plugs before servicing tears in the filter material. Replace the primary
element every year, even though it has not been
Keep a close watch for leaks. If leaking is cleaned six times.
observed, find the source and correct the leak. The secondary filter element should be replaced at
Check the fluid levels more frequently than the the time the primary filter element is serviced for
recommended periods if leaking is suspected or the third time.
observed. If the indicator light comes on after installation of a
clean primary element, or if the exhaust smoke is
d
Electrical System
black, install a new secondary element.
NOTICE
When jump starting a machine, follow the instruc- NOTICE

tions in "Starting the Engine" in the" Operation
Section" to properly start the engine. Do not try to reuse the secondary element by
This machine has a 24 volt starting system. Use cleaning it. Always use a new element. Engine
only equal voltage for jump starting. The use of a damage can result.
welder or higher voltage will damage the electrical
system.
I
62
I
Cooling System
Coolant should be drained, the system cleaned and
NOTICE new coolant added every 3000 service hours or two
years. When not using Caterpillar Antifreeze and
To prevent damage to your engine, never add supplemental coolant additive as recommended, the
coolant to an overheated engine. Allow the engine drain period must be shortened to 1500 service
to cool first. hours or one year.
All water is corrosive at engine operating tem- Filling at over 20 liters (5 U.S. gallons) per minute
perature. The cooling system should be protected can cause air pockets in the cooling system.
with a 3% to 6% concentration of cooling system After draining and refilling the cooling system,
conditioner at all times, regardless of the concen- operate the engine with the radiator cap removed
tration of antifreeze. until the coolant reaches normal operating
Excessive coolant conditioner (greater than the temperature and the coolant level stabilizes. Add
recommended 6% initial fill) together with concen- coolant as necessary to fill the system to the
trations of antifreeze greater than 65% cause proper level.
deposits to form and may result in radiator tube Operate with a thermostat in the cooling system all
blockage and overheating, and/or water pump year-round. Cooling system problems can arise
seal damage. without a thermostat.
Do not use Caterpillar liquid cooling system condi-
tioner or coolant conditioner elements with
I Dowtherm 209 Full-Fill coolant. Follow the in-

structions provided with the Dowtherm 209 Full-
Fill coolant.
NOTICE
Dowtherm 209 Full-Fill coolant is not compatible If the machine is to be stored in, or shipped to, an
with other antifreezes and coolant mixtures. area with freezing temperatures the cooling
system must be protected to the lowest expected
Dowtherm 209 Full-Fill coolant cannot be substi- outside (ambient) temperature.
tuted for ethylene glycol, due to its inability to
raise the water pump cavitation temperature. The engine cooling system is protected to -.28°C
Dowtherm 209 Full-Fill coolant lowers the coo- (-20°F) with a permanent-type antifreeze, when
lant's boiling point. shipped from the factory.
Caterpillar recommends that the coolant mix con- Check the specific gravity of the coolant solution
tain a minimum of 30% Caterpillar Antifreeze, or frequently in cold weather to ensure adequate
equivalent- Also use acceptable water to maintain protection.
an adequate water pump cavitation temperature
for efficient water pump performance.
If you choose to use Dowtherm 209 Full-Fill cool- Refer to "Know Your Cooling System," Form
ant, then contact your Dowtherm supplier for the SEBDO518, for more detailed specifications.
proper inhibitor package.
Water
Hard water, or water with high levels of calcium
and magnesium ions, encourages the formation of
Clean the cooling system if it is contaminated, if insoluble chemical compounds by combining with
the engine overheats or if foaming is observed in cooling system additives such as silicates and
I the radiator. phosphates.
63
I
The tendency of silicates and phosphates to Use Caterpillar Antifreeze or equivalent. Caterpillar
precipitate out-of-solution increases with increasing Antifreeze [Part No. 8C3686 - 208 liter (55 U.S.
water hardness. Hard water, or water with high gallon) drum or Part No. 8C3684 - 3.79 liter (1 U.S.
levels of calcium and magnesium ions encourages gallon) container] is available through your
the formation of insoluble chemicals, especially Caterpillar dealer.
after a number of heating and cooling cycles.
Caterpillar prefers the use of distilled water or Most commercial antifreezes are formulated for
deionized water to reduce the potential and gasoline engine applications and will, therefore,
severity of chemical insolubility. have high silicate content. Caterpillar Antifreeze is
formulated with a low silicate content and the
Acceptable Water proper coolant additives for heavy duty diesel
Water Content Without Antifreeze engines.
Chlorides 50 ppm or less
Sulfates 50 ppm or less The major advantages of Caterpillar antifreeze are:
Hardness as CaCO3 100 ppm or less
Dissolved Solids 250 ppm or less
Significantly reduces water pump seal leakage
problems caused by over concentration of
pH 6.5 or higher chemical additives.
ppm = parts per million
There is no need to add coolant inhibitor
Using water that meets this requirement may not on initial fill which must be done with
prevent drop out of these chemical compounds current commercially available antifreezes.
totally but should minimize the rate to acceptable
levels. High silicate antifreezes used with a
supplemental coolant conditioner can cause
Antifreeze a buildup of solids over a period of time
which can cause plugging, loss of heat
NOTICE transfer, and water pump seal damage.
Make proper antifreeze additions.
Caterpillar recommends that the coolant mix Con-
tain a minimum of 30% Caterpillar Antifreeze, or Adding pure antifreeze as a makeup solution for
equivalent, and acceptable water to maintain an cooling system top-up is an unacceptable
adequate water pump cavitation temperature for practice. It increases the concentration of
efficient water pump performance. antifreeze in the cooling system which increases
the concentration of dissolved solids and
Premix coolant solution to provide protection to undissolved chemical inhibitors in the cooling
the lowest expected outside (ambient) tempera- system. Add antifreeze mixed with water to the
ture. Pure undiluted antifreeze will freeze at same freeze protection as your cooling system.
—23°C (-10°F).
Use the chart below to assist in determining the
Only use a greater concentration (above 30%) of concentration of Caterpillar Antifreeze to use.
Caterpillar Antifreeze as needed for anticipated
Antifreeze Concentrations
outside (ambient) temperatures. Do not exceed a
coolant mixture of 60% antifreeze to water since Protection Temperature Concentration
a concentration above 60% antifreeze will reduce Protection to -15°C (5°F) 30% antifreeze and 70% water
the engine's freeze protection and increase the Protection to -23°C (-10°F) 40% antifreeze and 60% water
possibility of deposit formation in the cooling Protection to -37°C (-34°F) 50% antifreeze and 50% water
system. Protection to -51°C (-60°F) 60% antifreeze and 40% water
64
S
Conditioner Conditioner can be purchased from your
Caterpillar dealer.
Cooling system coolant conditioner is necessary
to prevent pitting and/or corrosion of engine parts Use Caterpillar Cooling System Conditioner or
that coolant comes in contact with. Most equivalent. Follow the instructions on the
antifreeze solutions DO NOT contain sufficient container.
coolant conditioner. See the following topic
Conditioner" and the "Cooling System" section of
this publication for precharge and maintenance
recommendations and procedures. NOTICE
DO NOT add coolant conditioner at initial fill when

NOTICE using Caterpillar Antifreeze or equivalent.
Caterpillar Antifreeze contains the necessary
coolant conditioner precharge. Addition of cool-
Always add Caterpillar Cooling System Condi- ant conditioner could result in an
tioner or equivalent to the coolant, or install a overconcentration.
Caterpillar Coolant Conditioner Element (if
equipped). Never use coolant only, except if
Caterpillar Antifreeze is being used. In this case,
no supplemental coolant conditioner is needed on
p initial fill, but is necessary to be used on a mainte-

nance basis.
Use Caterpillar liquid cooling system conditioner
or a coolant conditioner element (if equipped).
On initial fill of a new or reconditioned engine if
Caterpillar Antifreeze is not used, add 1 liter (1
quart) of Caterpillar Cooling System Conditioner, or
equivalent, for each 30 liters (8 U.S. gallons) so
that the cooling system will have a 3% to 6%
This will provide a 3% to 6% concentration of concentration of conditioner.
conditioner in the cooling system to help prevent
corrosion. To maintain a 3% to 6% concentration of
conditioner, add liquid cooling system conditioner
To prevent overinhibiting the engine's cooling or install a maintenance coolant conditioner
system, never use both the liquid cooling system element every 250 service hours or oil change,
conditioner and the coolant conditioner element (if whichever occurs first. Use the 815296 Coolant
equipped) at the same time. The use of these Conditioner Test Kit to check for concentration.
inhibitors together could result in a conditioner
concentration that would exceed the Caterpillar If the engine is not equipped with spin-on Coolant
recommended maximum of 6%. Conditioner Elements, add 1.0 liter (1 quart) of
Caterpillar Cooling System Conditioner for each
The over concentration of a conditioner will de- 152 liters (40 U.S gallons) of coolant capacity to
posit on the higher temperature surfaces of the maintain the 3% to 6% concentration of
cooling system and create a barrier that reduces conditioner.
the engine's heat transfer characteristics. Re- -
duced heat transfer could cause cracking of the Available Quantities of Cooling System
cylinder head and other high temperature compo- Conditioner
nents. Excessive concentrations of conditioner Available Quantities of cooling System
could also accelerate water pump seal wear. Conditioner
Part No. Size
6V3542 0.25 Liter (0.53 Pint)
3P2044 1.00 Liter (1.05 Quart)
S 5P2907 208 Liter (55 Gall)ns)
65
Cooling System Conditioner Needed When Not Fuel Heaters
Using Caterpillar Antifreeze For Premixed
Coolant Solution Use of a fuel heater can help eliminate some cold
weather problems. A fuel heater should be
Cooling System Amount at Amount at installed so that the fuel is heated before it goes
Capacity Initial 250 Hour
liter (gal) Fill Maintenance into the first or primary fuel filter. Select a fuel
22-32(6-8) 3P2044 (I Bottle) 6V3542 (1 Bottle) heater that is mechanically simple, yet adequate
33-47 (9-12) 3P2044 (2 Bottles) 6V3542 (1 Bottle) for the application. The fuel heater should also
48-62 (13-16) 3P2044 (2 Bottles) 6V3542 (2 Bottles)
prevent overheating of the fuel. Disconnect or
deactivate the fuel heater in warm weather. A loss
63-85 (17-22) 3P2044 (3 Bottles) 6V3542 (2 Bottles) of engine power will occur if the fuel supply
86-115 (23-30) 3P2044 (4 Bottles) 6V3542 (3 Bottles) temperature exceeds 30°C (85°F).
116-165(31-43) 3P2044(5 Bottles) 3P2044(1 Bottle)
166-244 (44-64) 3P2044 (8 Bottles) 3P2044 (2 Bottles) NOTE: Use only thermostatically controlled or self-
regulating fuel heaters as recommended. Do not
Fuel System use fuel heaters in warm temperatures.
For further information on fuel heaters, contact
NOTICE your Caterpillar dealer.
Types of Fuel
Fill the fuel tank at the end of each day of opera-
tion to drive out moist air and to prevent Caterpillar diesel engines have the ability to burn a
condensation.
Do not fill the tank to the top. Fuel expands as it
gets warm and may overflow.
wide variety of fuels. These fuels are divided into
two general groups, preferred and permissible.
The preferred fuels provide maximum engine
4
service life and performance. They are distillate
Do not fill the fuel filters with fuel before installing fuels. They are commonly called diesel fuel,
them. Contaminated fuel will cause accelerated furnace oil, gas oil or kerosene.
wear to the fuel system parts.
The permissible fuels are crude oils or blended
fuels. Use of these fuels can result in higher
maintenance costs and reduced engine service
Drain the water and sediment from the fuel tank at life.
the start of a shift or after the fuel tank has been Refer to Fuels for Caterpillar Diesel Engines,"
filled and allowed to stand for 5 to 10 minutes. Form SEHS7067, for a detailed summary of
After changing the fuel filter, always prime the fuel preferred and permissible fuels and their
system to remove air bubbles from the system. specifications.
Drain water and sediment from any fuel storage Refer to S.A.E. J313 Diesel Fuel Specifications for
tank weekly, and before the tank is refilled. This information about fuel properties, such as ignition
will help prevent water or sediment being pumped quality, gravity/density, viscosity, cloud point,
from the storage tank into the machine fuel tank. sulfur content, etc.
Use only fuel as recommended in this section.
I
66
Hydraulic System
Fuel Cetane Requirement
NOTICE
The minimum fuel cetane number recommended
for the direct injection engine is 40.
Make-up oil added to the hydraulic tanks must
Fuel Cloud Point mix with the oil already in the systems. Use only
petroleum products unless the systems are
Fuel waxing can plug the fuel filters in cold equipped for use with special products.
weather. The fuel cloud point must be below the
temperature of the surrounding air to prevent filter If the hydraulic oil becomes cloudy, water or air is
waxing and power loss. Fuel heating attachments entering the system. Water or air in the system will
are available from your Caterpillar dealer to cause pump failure. Drain the fluid, retighten all
minimize fuel filter waxing. hydraulic suction line clamps, purge and refill the
system. Consult your Caterpillar dealer for purg-
Fuel Sulfur Content ing instructions.
The percentage of sulfur in the fuel will affect the
engine oil recommendations. Fuel sulfur is
chemically changed during combustion to form
both sulfurous and sulfuric acid. These acids See "Hydraulic System" at "Every 2000 Service
chemically attack metal surfaces and cause Hours or 1 Year" for hydraulic tank drain and refill
corrosive wear. Certain additives used in instructions.
p
lubricating oils contain alkaline compounds that
are formulated to neutralize these acids. The Scheduled Oil Sampling (S•O•S)
measure of this reserve alkalinity in a lubricating oil Use Scheduled Oil Sampling (SO-S) to monitor
is known as its Total Base Number (TBN). Higher the condition and maintenance requirements of
engine oil TBN values are essential to neutralize your equipment. Each oil sample should be taken
the acids from combustion gases and to minimize when the oil is warm and well mixed, to ensure
corrosive wear. that the sample is representative of the oil in the
Any API performance oil should have sufficient compartment.
TBN for fuels with less than 0.5% sulfur. NOTE: When using the drain stream to obtain the
If the fuel has over 0.5% sulfur content, the engine oil sample, do not collect the sample from the first
oil must have a TBN of 20 times the percentage of or final draining.
fuel sulfur as measured by the ASTM (American S .O . S Interval Chart
Society of Testing Materials) D-2896 method. Compartment Interval
(ASTM D-289€ can normally be found at your local Engine Oil 250 Hours
technological society, library or college.) Transmission Oil 500 Hours
If the sulfur content in the fuel is greater than 1.5% Hydraulic Oil 500 Hours
by weight, use an oil with a TBN of 30 and reduce Final Drive Oil 500 Hours
the oil change interval by one half.
Consult your Caterpillar dealer for complete
Periodically request fuel sulfur content information information and assistance in establishing a
from your fuel supplier. Fuel sulfur content can Scheduled Oil Sampling program for your
change with each bulk delivery. equipment.
For more information on oil, fuel sulfur content,
etc., refer to "Oil and Your Engine," Form
SEBDO640 or contact your Caterpillar dealer.
I
67
I
Lubricant Specifications
Certain abbreviations listed below follow S.A.E. NOTE: The percentage of sulfur in the fuel will
J754 nomenclature. Some classifications follow affect the engine oil recommendations. See "Fuel
S.A.E. J183 abbreviations. The MIL specifications Sulfur Content" in the "Recommendations and
are U.S.A. Military Specifications. The definitions Specifications" section of this publication.
other than Caterpillar's will be of assistance in
purchasing lubricants. The recommended oil Higher TBN values are essential to neutralize the
viscosities can be found in the "Lubricant Viscosity corrosive acids formed during combustion. These
Recommendations" chart in this publication. corrosive acids could damage internal engine
parts. Consult your Caterpillar dealer for correct
Diesel Engine Oils (DEO) engine oil recommendations.
Caterpillar has two engine oils. To achieve the For more information on oil, fuel sulfur content,
maximum engine life and performance in your etc., refer to "Oil and Your Engines," Form
diesel engines, Caterpillar's first recommendation SEBDO64O.
is:
• CAT Diesel Engine Oil (DEO)
CAT Diesel Engine Oil is specially formulated for NOTICE
Caterpillar diesel engines to reduce piston and ring
deposits and thus provide longer engine life and Failure to follow these recommendations can
stable oil control. cause shortened engine life due to carbon depo-
Engine Oil (EO)
CAT Engine Oil is Caterpillar's second
recommendation for an engine oil specifically
sits or excessive wear.
I
intended for use in mixed fleets. This oil is only for Always consult with your Caterpillar dealer for the
the convenience of having the same oil for latest lubrication recommendations.
gasoline and diesel engines.
Transmission Oil (TDTO)
For mixed fleet convenience, use Caterpillar's:
CAT Engine Oil (EO) NOTICE
If circumstances require the use of an oil other
than the CAT Diesel Engine Oil or CAT Engine Oil, This oil is formulated for transmissions and drive
the following oil specifications can be used: trains only and should not be used in engines.
European Oil Specification CCMC D3, API Shortened engine life will result.
Specification CD, CE, or Military Specifications
MIL-L-2104D or MIL-L-2104E.
Oil with these specifications may require shortened
oil change periods as determined by close Maximum transmission life and performance can
monitoring of oil condition with Scheduled Oil be achieved by using Caterpillar's:
Sampling (S . O • S) and infrared analysis.
CAT Transmission/Drive Train Oil (TDTO)
68
I
If different viscosities are required because of
NOTICE extreme ambient temperatures, use the following
Caterpillar oils:
Failure to follow this recommendation can cause • CAT Engine Oil (EO)
shortened transmission/drive train life due to ma- • CAT Diesel Engine Oil (DEO)
terial incapability and inadequate frictional
requirements for disk material. If CAT Hydraulic Oil, Engine Oil, or Diesel Engine
Oil is not available, use an engine oil that meets
one of these API service classifications: CC,
CC/SF, CD, or CE. Any Military Specification MIL-
If circumstances require the use of an oil other L-2104 oils can also be used.
than CAT Transmission/Drive Train Oil, use an oil Industrial type hydraulic oils that are certified by
that meets API CD/TO-2 or Military Specification the oil supplier to have antiwear, antifoam, antirust,
MIL-L-2 1 04D and antioxidation additives for heavy duty use are
also acceptable, if CAT oils are not available.
Final Drive Oil (TDTO)
NOTICE
NOTICE
This oil is formulated for transmissions and drive
I trains only and should not be used in engines.

Shortened engine life will result.
Make-up oil added to the hydraulic tanks must
mix with the oil already in the systems. Use only
petroleum products unless the systems are
equipped for use with special products.
If the hydraulic oil becomes cloudy, water or air is
NOTE: DO NOT use CAT Gear Oil in the above entering the system. Water or air in the system will
compartments. Gear Oil can cause seal material to cause pump failure. Drain the fluid, retighten all
fail and result in oil leaks. hydraulic suction line clamps, purge and refill the
For maximum life and performance of the final system. Consult your Caterpillar dealer for purg-
drives, select the correct viscosity of Caterpillar's: ing instructions.
CAT Transmission/Drive Train Oil (TDTO)

If circumstances require the use of an oil other
than CAT, use an API classification CC or CD Lubricating Grease (MPGM)
engine oil (MIL-L-2104B or MIL-L-2104C). Use Multipurpose-type Grease (MPGM) which
Hydraulic Oil (HYDO) contains 3% to 5% molybdenum disulfide. NLGI
No. 2 Grade is suitable for most temperatures.
CAT Hydraulic Oil should be used to achieve Use NLGI No. 1 or No. 0 Grade for extremely low
maximum life and performance from hydraulic temperatures.
system components and hydrostatic transmissions
Use of CAT Hydraulic Oil is recommended for use
in most hydraulic hydrostatic systems. Use
Caterpillar's:
• CAT Hydraulic Oil (HYDO)
I
69
Lubricant Viscosity Refill Capacities -
Recommendations (Approximate)
LUBRICANT VISCOSITIES' REFILL CAPACITIES - (APPROXIMATE)

FOR TEMPERATURE RANGES °C AND °F Compartment U.S. Imperial
Compartment Oil or System Liters Gal. Gal.
or System Viscosities Mm Max Min Max Engine Crankcase w/Filter 60 15.75 13.25
Diesel Engine SAE lOW -20 +10 -4 +50 Power Train Oil System' 189 50 39.25
Oil SAE1OW30 -20 +40 04 Final Drives (each) 23 6 5
DEO
SAE 15W40 -15 +50 +5 +122 Recoil Spring 64 17 14
SAE 30 0 +40 +32 +104 Compartments (each)
SAE 40 +5 +50 +41 +122 Implement Hydraulic Tank 108 28.5 23.75
Engine Oil SAE lOW -20 +10 -4 +50 Cooling System 1
114 30 25
EO Fuel Tank 1 1032 270 225
SAE 10W30 -20 +10 -4 +50
SAE 15W40 -15 +50 +5 +122 Winch Sump 1 68 18 - 15
SAE 30 0 +40 +32 +104 1 Quanity in the transmission can be increased up to 10% when
operating on severe slopes. When the machine is returned to
Transmission SAE 1 O -20 0 -4 +32 normal slope operation, remove the excessive oil.
and Torque SAE 30 : +14 +104
Convert er -
TOTO SAE 50 0 +50 +32 +122
Hydraulic HYDO SAE lOW -20 +40 -4 +104
Implement ED SAE 30 :;-5- +122
System - -
HYDO, DEO DEO SAE 30 +10 +50 +50 +122
OREO
Final Drives SAE lOW
TDTO SAE 30
SAE 50
Sealed and SAE 80W90
Lubricated
-30 0 -22 +32
-20 +25 -4 +77
0 +50 +32 +122
-30 +50 -22 +122
I
Track Pins
MPL
Recoil Spring, SAE 30 -30 +50 -22 +122
Track Idlers,
Track Rollers,
Track Roller
Frame Pivot
Bearings
L
TDTO
When operating below -30°C (-22°F) refer to the Operation
and Maintenance Manual, for Cold Weather Recommendations,
Form SEBU5898, available from your Caterpillar dealer.
I
70
Lubrication and Maintenance
S Interval Chart
When Required
Engine Air Intake - Service filters ..................72 Alternator and Air Conditioner Belts - Inspect,
Air Conditioner - Check indicator ..................74 adjust or replace ...............................................89
Fuel Filters - Wash primary, change secondary Fan Drive Pulley - Lubricate fittings ..............89
....96 Brakes - Test ..................................................89
Ether Starting Aid Cylinder - Replace ..........75 Tracks - Check track adjustment ...................90
Batteries - Inspect, clean top and terminals .. 75 Coolant Conditioner - Change element ........91
Cutting Edges and End Bits - Inspect, replace if Equalizer Bar End Pins - Lubricate fittings ... 91
worn or damaged .............................................76 Final Drive Oil - Check oil level ......................92
Ripper Tip and Shank Protector - Inspect,
replace if worn or damaged .............................77 Every 500 Service Hours or 3 Months
Power Train Oil System - Clean screens when
transmission/torque converter/steering clutches Power Train Oil Filters - Change filter element
are disassembled/repaired ...............................77 92
Winch - Inspect, replace frayed or worn cable 78 Hydraulic System Filter - Change filters .......93
Equalizer Bar Center Pin - Check ................79 Engine Crankcase Oil Breather - Clean .......94
Equalizer Bar Pads - Inspect .........................95
Every 10 Service Hours or Daily Fuel Tank Cap and Screen - Clean cap and filler
screen...............................................................95
Engine Crankcase Oil - Measire oil level ......79 Fuel Filters -Wash primary, change final filter 96
Power Train Oil System - Measure oil level .. 80 Winch Filter and Magnetic Strainer - Change
Engine Cooling System - Check coolant level filter element, wash strainer .............................98
80
Every 1000 Service Hours or 6 Months
p Hydraulic System Oil - Check oil level .......... 81
Tracks - Inspect .............................................. 82
Pivot Shaft - Check oil level ........................... 82
Fuel Tank - Drain water and sediment .......... 83
Rollover Protective Structure (ROPS/FOPS) -
Inspect, retighten mounting bolts ....................99
Lift Cylinder Yoke Bearings - Lubricate fittings
Walk-Around Inspection - Inspect machine 83
Electronic Monitoring System and Gauges - 99
Check............................................................... 84 Power Train Oil System - Change oil, wash
Fire Suppression (If Equipped) - Check ....... 84 breather..........................................................100
Winch - Change oil, wash breather ..............101
Seat Belt - Inspect webbing and hardware 84
Winch - Check oil level ................................... 85 Every 2000 Service Hours or 1 Year
Every 50 Service Hours or Weekly Final Drive Oil - Change oil ..........................102
Recoil Spring Oil Compartment - Check oil level Engine Valve Lash - Adjust .........................102
..................................85 Engine Valve Rotators - Check rotation .....103
Ripper Linkage and Cylinder Bearings - Hydraulic System Oil - Change oil ..............103
Lubricate fittings ..............................................86 Track Roller Frame Guides - Measure wear 104
Tracks - Check tension, inspect for wear or Every 3000 Service Hours or 2 Years
damage............................................................86
Cab Air Filter Elements - Clean ....................87 Cooling System Coolant - Change coolant, clean
system............................................................106
Every 250 Service Hours or Monthly
Engine Crankcase Oil and Filters - Change oil First Perform Previous Service Hour Items
and filter. It sulfur content of fuel is more than
1.5% by weight, use an oil with a TBN of 30 and
reduce oil change interval by one half .............88
Engine Valve Lash - Adjust at first oil change on
S new and reconditioned engines only .............102
71
When Required
Engine Air Intake System

I
Clean the Air Intake Change the Primary Element
Pressure air can cause personal injury.

When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.
1. Remove the covers and clean the primary filter

elements on both sides of the engine. Change
element if damaged.
2. Clean the inside of the air cleaner housing.
3. Install the cover. Tighten the retainers finger
tight only.
F--
Check the air inlet screen for accumulation of

trash and dirt.
1. Remove the screens and clean.
2. Inspect the precleaner tubes for accumulation
of dust and dirt.
3. Clean with air pressure if dirty.
4. Reset the filter indicators by pushing in the
4. Install the screens. reset buttons.
5. If the yellow piston in the filter element indicator
moves into the red zone after starting the engine,
or the exhaust smoke is still black after installation
of a primary filter element, change to another
clean filter element.
Normally a filter can be cleaned up to 6 times.
Replace after 6 cleanings maximum.
I
72
Change the Secondary Element Cleaning Primary Elements
NOTICE NOTICE
The secondary filter element should be replaced Do not clean the filter elements by bumping or
at the time the primary element is serviced, for the tapping them.
third time.
The secondary filter element should also be re-
placed if the yellow piston in the filter element
indicator enters the red zone after installation of a Filter elements can be cleaned with pressure air,
clean primary element, or if the exhaust smoke is pressure water, or detergent washing.
still black.
Remove the covers on both sides of the engine

and the primary filter elements.
p
Direct air or water along pleats inside and outside
of filter element.
1. Remove the nuts that hold the secondary filter

element to the housing. Do not remove the two
nuts that hold the housing to the inlet manifold.
2. Inspect the gasket between the housing and
the filter. Replace it if damaged.
3. Install the new secondary filter elements.
Tighten the nuts to 27 ± 7 N • m (20 ± 5 lb. ft.).
4. Install the primary filter element and the cover.
Tighten the retainers finger tight only. Inspect the filter elements after cleaning. Do not
use a filter element with damaged pleats, gaskets
S. Reset the filter indicators. or seals.
p
73
Air Conditioner - If Equipped
Check the Charge Indicator

I
Refrigerant in the air conditioner system can
cause personal injury. Avoid any contact with
refrigerant.
Before warm weather begins or when the system

does not work properly, check the refrigerant.
Indicator sight glass window is located on the left

side of the engine.
Operate the air conditioning system five to ten
minutes when the outside temperature is above
21°C (70°F).
If the sight glass has few or no bubbles (1),
system is working properly. Bubbles (2) in the
sight glass, system needs refrigerant. Foam (3) in
the sight glass, system very low and needs
refrigerant. Oil streaks (4) in the sight glass,
system out of refrigerant.
I
Remove the engine access cover on the left side The moisture indicator in the sight gauge should
of machine. normally be blue. The receiver dryer must be
replaced if it is red. This indicates moisture in the
system. Check after one hour of operation.
See your Caterpillar dealer for proper installation
when system needs refrigerant.
Operate the air conditioner at least once a month
to lubricate the compressor seals. Set the controls
on maximum for 15 minutes.
I
74
Ether Starting Aid Cylinder Batteries

Installing the Cylinder Check Electrolyte Level
Ether is poisonous and flammable. Batteries give off flammable fumes that can
explode.
Breathing ether vapors or repeated contact of
ether with skin can cause personal injury. Do not smoke when observing the battery elec-
trolyte levels.
Use ether only in well ventilated areas.
Electrolyte is an acid and can cause personal
Use ether with care to avoid fires. injury if it contacts skin or eyes.
Do not smoke while changing ether cylinders. Always wear protective glasses when working
with batteries.
Do not store ether cylinders in the operator's
compartment or living areas.
Do not store ether cylinders indirect sunlight or
at temperatures above 39°C (1020F). Battery Electrolyte Chart
Battery Interval
Discard ether cylinders properly. Do not punc- 100 Hours
Conventional
ture or burn ether cylinders.
Low Maintenance 250 Hours
p Keep ether cylinders out of the reach of unau- Maintenance Free None Required
thorized personnel.
Tighten the battery retainers every 1000 hours on
all batteries.
Check the following at least every 1000 hours, and
more often as conditions require:
Clean the top of the batteries with a clean cloth.
Keep the terminals clean and coated with
petroleum jelly.
At the proper charging rate, in a moderate climate,
a battery should not require more than 30 cc (1
ounce) of water per cell per week. Check the cells
weekly in extreme temperatures, cell water usage
could be higher.
1. Loosen the cylinder retaining clamp.
2. Unscrew and remove the empty ether cylinder.
3. Remove the used gasket. Install the new
gasket provided with each new cylinder.
4. Install the new cylinder. Tighten the cylinder
hand tight. Refasten the cylinder clamp securely.
75
Cutting Edges and End Bits
I
Change the Edges and End Bits
Lma ^ CAT
_, ,*

VC..
rr:1
-a
r' aS-fl
Cs.. -
aaam,aaa.._
a-
1. Open the battery access covers on both sides 1. Raise the blade and place blocking under it.
of cab.
2. Lower the blade to the blocking.
2. Clean the battery surface with a clean cloth.
Keep the terminals clean and coated with Do not block the blade any higher than necessary
petroleum jelly. Install the post cover after coating. to remove cutting edge or end bits.
3. Remove the bolts and remove cutting edge
and end bits.
4. Clean the contact surfaces.
5. Use the opposite cutting edge if it is not worn.
6. Install a new section if both edges are worn.
7. Install the new end bits.
8. Install the bolts and tighten to the specified
torque. See (Ground Engaging Tool Bolt Torques"
chart.)
a u ..
3. Inspect the electrolyte level in each battery cell, 9. Raise the blade and remove the blocks.
except maintenance free. Maintain the level to the 10. Lower the blade to the ground.
bottom of the fill openings with distilled water. If
distilled water is not available, use clean drinking 11. After a few hours of operation, check the
water. bolts for proper torque.
4. Close and secure the access covers.
I
76
Ripper Tip and Shank Power Train Oil System
Protector

Change the Tip and Protector Clean the Screens
Retainer pins, when struck with force, can fly Hot oil and components can cause personal
out and cause injury to nearby people. injury. Do not allow hot oil or components to
contact skin.
Make sure the area is clear of people when
driving retainer pins.
To avoid injury to your eyes, wear protective
glasses when striking a retainer pin. The power train oil screens should be removed
and cleaned if the power train oil pump fails, or if
the transmission or torque converter are
disassembled for any reason. Drain the oil before
removing any screens.
1. The bottom guard must be removed to gain
access to two screens.
Replace the ripper tip or shank protector when

worn close to shank. Too blunt of a tip will not
penetrate properly.
1. Raise and support the ripper.
2. If the ripper tip is worn, drive the pin out. 2. Remove the cover and screen located below
Remove the pin retainer and the tip. the pump.
3. Clean the shank pin retainer and pin.
4. Install the new tip pin retainer and spring.
5. Install the pin from the same side as the pin
retainer is installed.
6. Raise the ripper and remove the support.
7. Lower the ripper to the ground.
p
77
Winch
Installing the Wire Rope Cable

I
I-
Check the cable. If cable is worn or frayed

install a new cable. Worn or frayed cable could
cause personal injury or death.
Cable is attached to the drum on the winch with a

standard cable ferrule. The ferrule is fitted into a
socket on the drum and secured with a bolt-down
3. Remove the cover and screen on bottom of clamp.
torque converter.
Ferrules are made in various diameters and
lengths. When ordering the cable, use the
following guide to specify the correct ferrule.
PDiameter
Cable Cable Ferrules mm (in.)
Outside
mm (in.) Number Diameter Length
25 (1.0)
28 (1.12)
J-8
J-9
60.5 (2.38) 66.5 (2.62)
60.5(2.38) 66.5(2.62)
1. Put the cable in a straight line behind the

I
machine.
4. Remove the dome screen from bottom of

transmission.
5. Wash the screens in clean nonflammable
solvent.
6. Install the screens, covers, and bottom guard.
2. Remove the clamp (1) and install the ferrule

end into the socket (2).
3 Install the clamp (1).
4. Reel in the cable.
I
78
Every 10 Service Hours or Daily
Equalizer Bar Center Pin

Engine Crankcase Oil
I
Look for Wear or Looseness Measure the Oil Level
Hot oil and components can cause personal

injury. Do not allow hot oil or components to
contact skin.
I -."--
The crankcase oil level dipstick is located on the
left side of the engine.
Observe the equalizer bar center pin for looseness

or unusual wear.
If unusual wear is evident or suspected, consult
your service manual or Caterpillar dealer for N.
inspection and, if necessary, repair instructions.
..
Maintain the oil between the marks on cips:iok.

Add oil if necessary.
I
79

Power Train Oil System Engine Cooling System

Measure the Oil Level Look at the Coolant Level
Hot oil and components can cause personal At operating temperature, the engine coolant is
injury. Do not allow hot oil or components to hot and under pressure.
contact skin.
Steam can cause personal injury.
has been stopped and the fill cap is cool en-
ough to touch with your bare hand.
Remove the till cap slowly to relieve pressure.
Cooling system conditioner contains alkali.
Avoid contact with the skin and eyes to prevent
personal injury.
I
The power train oil dipstick is located on the left
side of the machine behirid the access cover.
/ I
LI
1. Remove the coolant fill cap slowly to relieve
any pressure.
2. Inspect the condition of the cap gasket.
Replace the cap gasket if necessary.
3. Maintain the coolant above the low level plate.
Maintain the oil between the marks on dipstick (1)
at LOW IDLE. Add oil if necessary through oil fill 4. Install the radiator cap.
tube (2). Remove oil fill cap for access.
I
80
Hydraulic System Oil
I
Clean Outside of Folded Core Radiator Look at the Oil Level
Pressure air can cause personal injury. At operating temperature, the hydraulic tank is
hot and under pressure.
protective face shield, protective clothing and Hot oil can cause burns.
protective shoes.
Remove the fill cap only when the engine is
The maximum air pressure must be below 205 stopped, and the cap is cool enough to touch
kPa (30 psi) for cleaning purposes. with your bare hand. Remove the fill cap slowly
to relieve pressure.
NOTICE
Never remove the cap from the implement hy-

draulic tank if oil is hot. Air can enter system and
cause pump damage.
I
I
:
,J.
Compressed air, high pressure water or steam can
be used to remove dust, leaves and general
debris from a folded core radiator. Clean as
required by condition of radiator.
The use of compressed air is preferred.
fleter to Know Your Cooling System," Form
SEBDO518, for the complete procedure and
instructions.
The hydraulic oil tank is located on the right rear
side of the machine.
I
81
Pivot Shaft
Look at the Oil Level

I
I L.JIIIIIIPIIIIIIIIII
auir' Hot oil and components can cause personal
contact skin.
A
Add oil to maintain the oil level to the FULL mark
in the sight gauge.
-,
Tracks
Am
Inspect for Proper Adjustment
Maintain the oil within the limits of the sight gauge.
Overfilling can cause hot oil to overflow the
reservoir.
IW
Visually inspect the tracks. Check for wear and
excessive dirt buildup on track components.
If track appears to be too tight or too loose, see
"Tracks" under Every 250 Service Hours or
Monthly.' Remove the oil 1111 cap to add oil to the oil
reservoir.
I
82
Fuel Tank

Walk-Around Inspection
I
Drain the Moisture and Sediment Inspect Machine
Fuel leaked or spilled onto hot surfaces or

electrical components can cause a fire.
See Walk-Around Inspection in the Before

Starting the Engine" section.
Cleaning Windows
Drain valve is located under the fuel tank.

p
Use commercially available window cleaning
solutions to clean the windows.
The rear window can be cleaned from the inside
of the cab. To do this the section of the window
that slides must be removed. Use the procedure
that follows to remove that section of the rear
window.
1. Open the drain valve and allow the moisture
and sediment to drain into a suitable container. 1. Move the handle stop to the UP position by
lifting at handle (1) and rotating counterclockwise
2. Close the drain valve. until it is vertical.
2. Move the section of the window that slides, to
the opening in the upper window channel (2).
3. Tilt the top of the window toward the inside of
the cab and remove it.
I
83
Electronic Monitoring System Seat Belt
and Gauges a

Test and Inspect for Broken Indicators Inspect for Wear or Damage
Always check condition of seat belt and mount-

ing hardware before operating machine.
Replace any damaged or worn parts.
Replace the seat belt after three years of us-
age, regardless of appearance.
1. Allow the engine to warm up at LOW IDLE !or

five minutes. To help speed the warmup of
hydraulic components, engage and disengage all
hydraulic implement controls.
2. Push the EMS Fault Light test switch. The fault
alarm should sound. The fault light and the EMS
panel should FLASH, until the EMS test switch is
released. If the lights or alarm did not come on,
have necessary repairs made.
Fire Suppression System Seat belt and mounting hardware must be

I
inspected for wear or damage. Replace the belt or
(If Equipped) mounting hardware if worn or damaged.
Check
See Fire Suppression System II Equipped) in

front of this guide, for testing the engine shutdown
system.
I
84
Every 50 Service Hours or Weekly

Winch (If Equipped) Recoil Spring Oil
Compartment

Look at the Oil Level Measure the Oil Level
Hot oil and components can cause personal Hot oil and components can cause personal
injury. Do not allow hot oil or components to injury. Do not allow hot oil or components to
contact skin. contact skin.
a.
•:t 1
I
With the engine at LOW IDLE, the oil must be 1. Remove the oil fill cover plate.
visible in the sight gauge.
Ole
2. Maintain the oil leve to the level mark on the

If necessary to add oil, remove the oil fill plug. dipstick.
Check and repair any oil leaks around covers or 3. Install the cover plate.
hoses.
4. Repeat the procedure on the other recoil
compartment.
85
Ripper Linkage and Cylinder
Bearings
Lubricate the Fittings
Tracks
Inspect Weekly
I
S
I 1•
The pins and bushings in a dry joint can be-
come very hot. It is possible to burn the fingers
if there is more than brief contact with these
components.
CAJ
Lubricate the twelve fittings.

Follow these hints to extend the undercarriage life
and to avoid excessive downtime.
I
1. Listen for track squeak or squeal during
machine operation. This can indicate a dry joint.
2. Check for dry joints once a week, immediately
after machine operation. After machine operation,
lightly touch the end of each track pin or bushing,
with the back of your hand. Make a mark on any
joint that is very hot to the touch.
3. Do not hit the ends of the track with a sledge
hammer to loosen the track joints.
NOTICE
Striking the end of a track pin will introduce a

significant amount of end play into the track joint
and can result in early failures.
86
Consult your Caterpillar dealer's Custom Track
Service expert upon detection of dry joints or leaks
and/or for track inspection.
a
Cab Air Filter Elements
I
Clean the Filter Elements Cleaning the Filter Elements
Clean the filter elements daily when there is a
reduction of air circulation.
protective shoes.
Elements can be cleaned with pressure air or

pressure water.
1. Wash them in clean water and household
detergent.
- V
2. Rinse thoroughly with clear water, and blow dry

with pressure air.
p NOTICE
Do not clean the elements by bumping or tapping

iiI them.
1. Remove the covers. Inspect the elements after cleaning. Do not use an
2. Remove and clean the filter elements. See element with damaged pleats, gaskets or seals.
Cleaning the Filter Elements.' Replace with a new element.
3. Install the cleaned filter elements. When cleaning with pressure water, use 280 kPa
(40 psi) maximum pressure to prevent element
4. Replace the covers and tighten the retainers damage.
If the air conditioning does not cool after changing
filters, check the wet-dry indicator. The indicator is
on the left side of machine under the access cover
for disconnect switch. 3. Direct air or water along pleats inside and
outside of the element.
4. Air dry and inspect the element to see if any
debris remains visible.
p
87
Every 250 Service Hours or Monthly
Engine Crankcase Oil and

Filters
Change the Oil and Filters
I
contact skin.
ii
4. Remove and discard the crankcase oil filter
--I elements. Make sure all of the old filter seal is
removed from the filter base.
Apply a thin coat of oil to the seal on the new filter.
5. Install the filter by hand until the filter contacts
the base. Tighten 3/4 turn more. There are rotation
index marks on each new filter spaced 900 apart,
1. Crankcase drain access cover ioca:eo m He
bottom guard.
to be used as a guide for tightening.
,
4
ii 2
—
'r-- r-
6. Remove the oil fill cap (1) to add oil. See "Refill
Capacities."
2. Open the drain valve. Allow inc uu to drair nto
a suitable container. 7. Always measure the oil with the dipstick (2) to
make certain the quantity of oil added is correct.
A hose can be attached to the drain port for
draining also. 8. Maintain the oil between the marks on the
dipstick.
3. Close the drain valve after all of the oil has
drained.
88
I
Alternator and Air Brakes
p Conditioner Belts
Adjust Belts Test the Brakes
1. Start the engine.
2. Raise all lowered equipment.
Measure the deflection of the belts. Appi

approximately 110 N (25 lb) force midwa,
between the drive pulley and the alternaL
conditioning compressor pulley. Deflection shoui C:
be 14 to 20 mm (9/16 to 13/16 inch). If deflection
is not correct, loosen the mounting bolts and 3. Depress the braKe pecal.
adjust the belt.
4. Release the parking brake.
Look at the condition of the belt. Replace if
cracked or frayed. 5. With the brake pedal applied, move the
transmission control lever into 2nd speed forward.
Repeat the procedure on the air conditioner
compressor (if equipped). 6. Gradually increase the engine speed to full
load speed. The machine must not move.
Fan Drive Pulley
Lubricate Fitting If the machine moves during the test, reduce

the engine speed immediately, and apply the
parking brake.
If the machine moved while testing the brakes,
consult your Caterpillar dealer for brake in-
spection and repair. Damaged brakes must be
repaired before returning the machine to
operation.
7. Reduce the engine speed to LOW IDLE.

Engage the parking brake. Lower the implements
Luoricatu tci itting. to the ground. Apply a slight down pressure. Stop
the engine.

89
Tracks
Adjust the Tracks
NOTICE
Grease is under high pressure.
Do not attempt to tighten track when dimension
Grease coming out of the relief valve under (1) is 148 mm (5.8 inches) or more on machines
pressure can penetrate the body causing injury with S/N 2YD1-515 or 173 mm (6.8 inches) or
or death. more on machines with S/N 2YD51 6-UP. Contact
your Caterpillar dealer for track service or
Do not watch the relief valve to see if grease is instructions.
escaping. Watch the track or track adjustment
cylinder to see if the track is being loosened.
Loosen the relief valve one turn only.
If Track is Too Loose:
1. Remove adjusting valve cover plate.
Move the machine forward and allow it to stop
without applying the brake pedal. Tracks should
be adjusted under the same conditions in which
the machine will be used. If packing conditions
prevail on the job, the tracks should be adjusted
with packing present.
I
2. Add multipurpose grease (MPGM) through the
adjusting valve (3) until dimension (2) is correct.
3. Operate the machine back and forth to
equalize the pressure. Allow the machine to
coast to a stop. Do not use the brakes. Stop the
engine.
The sag in the track is measured between the
sprocket and the front idler. Correct adjustment 4. Remeasure dimension (2).
gives a dimension (2) of 155 ± 6 mm (6.0 ±.25 If Track Is Too Tight:
inches).
1. Loosen the relief valve (4) one turn only, and
allow the grease to escape.
2. Close the relief valve.
3. Add multipurpose grease (MPGM) through the
adjusting valve (3) until dimension (2) is correct.
4. Install the valve cover plate.
5. Repeat procedure on the other track.
Coolant Conditioner

Equalizer Bar End Pins
p
Replace Conditioner Element Lubricate the Fittings
At operating temperature, the engine coolant is

Steam can cause personal injury. I- -

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. A
/
NOTICE
p Excessive coolant conditioner (greater than the

recommended 6% initial fill) together with concen-
trations of antifreeze greater than 65%, cause a 1. Clean area around grease fitting plug.
mud-like deposit to form. This may result in radia-
tor tube blockage and overheating. 2. Remove the plug and install a zerk grease
fitting.
3. Lubricate fitting with 3 shots ONLY with a hand
operated grease gun.
4. Remove the grease fitting.
I
5. Clean and install the plug.
IW
6. Repeat steps 1 through 5 on the other side of
machine.
1. Remove the coolant conditioner element.

2. Install a new coolant conditioner maintenance
element.
See "Every 3000 Service Hours or 2 Years" for
additional information when changing coolant.
91

Final Drive Oil Power Train Oil Filters

Look at the Oil Level Change the Filter Elements
Hot oil and components can cause personal Hot oil and components can cause personal
injury. Do not allow hot oil or components to injury. Do not allow hot oil or components to
contact skin. contact skin.
1. Position one final drive so that the oil f ii plug 1. Open the access cover for the oil fill and
and the oil level mark are, horizontal. dipstick.
2. Remove the fill plug.
3. Oil should be to the bottom of the fill plug
opening. Add oil if necessary. I
4. Clean the magnet.
5. Install the fill plug.
6. Position the other final drive oil level mark and
repeat procedure.
2. Filters are located under the fuel tank on the

rear of the machine.
92
Hydraulic System Filter
Change the Filter Element
I
At operating temperature, the hydraulic tank is
Hot oil can cause burns.
stopped, and the cap is cool enough to touch
with your bare hand. Remove the fill cap slowly
to relieve pressure.
3. Remove the filter element housing.

4. Remove and discard the filter elements.
5. Clean the housings with a clean cloth.
6. Inspect the seal. Replace it if damaged.
7. Install the new elements and housing.
1. Remove the oil fill cap to relieve the tank

pressure.
2. Remove the cover mounting bolts.
3. Remove the cover, screen and filter assembly.
4. Remove the retaining nut and screen.
5. Remove and discard the filter elements.
9. Maintain the oil level to the FULL mark on the If stud was loosened during removal of the
dipstick. Add the oil through fill tube if necessary. retaining nut, it will be necessary to tighten stud to
55 ± 7 N • m (40 ± 5 lb ft).
10. Stop the engine.
11. Close the access cover.
93
Engine Crankcase Oil
Breather
Remove and Wash the Breather
I
6. Wash the cover and screen in clean,
nonflammable solvent.
7. Inspect the seal on the cover and top of tank. Hot oil and components can cause personal
Replace with new seals if used ones are injury. Do not allow hot oil or components to
damaged. contact skin.
8. Install a new filter element.
9. Install the clean screen and retaining nut.
1;
10. Install the cover and filter assembly. Tighten 4i
the cover mounting bolts to 45 ± 7 N • m (32 ± 5
lb ft). :
Li 1. Loosen the breather outlet hose clamp and

remove the hose from the breather cover.
2. Remove the breather.
I
kA r!v
11. Maintain the hydraulic oil to the FULL mark in
3. Check the condition of cover seal. Replace
with new seal if the used one is damaged.
the sight gauge. 4. Wash the element and cover assembly in
clean, nonflammable solvent.
12. Install the oil fill cap.
5. Shake, or use pressure air, to dry the element.
6. Install the clean breather element cover
assembly.
7. Install the hose and clamp.
94
Equalizer Bar Pads

Fuel Tank Cap and Screen
I
Inspect and Replace If Necessary Clean the Cap and Strainer
1. Remove the fuel tank fill cap and strainer.

2. Disassemble the fuel cap. Wash cap and
strainer in clean, nonflammable solvent.
3. Inspect the tank cap seal. Replace the seal if
damaged.
4. Put a light coat of oil on the cap components.
I 5. Assemble and install the cap.
Inspect the equalizer pads for cracked or large

missing portions of rubber. Contact your
Caterpillar dealer for replacement, or instructions,
when pads are cracked or missing rubber.
[!I1
Fuel Filters r
Wash Primary - Change Secondary Wash the Primary Filter
"I

protective shoes.
Use all cleaning solutions with care.
Fuel leaked or spilled onto hot surfaces or Shut of! tne fuel supply valve located on left front
electrical components can cause a fire. of tank in cover assembly.
Turn the disconnect switch OFF or disconnect

the battery when changing fuel filters.
AW

S
NOTICE pL1I1 I t! I
Do not fill fuel filters with fuel before installing
them. Contaminated fuel will cause accelerated
wear to fuel system parts.
1. Loosen the filter housing case retaining bolt.

2. Remove the case and remove the element
from the case.
3. Wash the element and case in clean,
nonflammable solvent and dry using pressure air.
4. Clean the filter housing base.
5. Inspect the seal, Replace it if it is damaged.
6. Insert the clean element into the case.
7. Install the element and case into housing.
8. Retighten the retaining bolt to a torque of 24 ±
7 N • m (18 ± 5 lb ft).
96
p
Change Secondary Fuel Filters Priming the Fuel Filter
I_I.. r __
1. Remove and discard the filter elements. 1. Turn the p iii ing punp plunger
counterclockwise and pull it out. Operate the
2. Clean the filter element mounting base. Be sure pump to fill the new filter elements with fuel.
all of the old seal is removed. Continue pumping until resistance is felt, indicating
the elements are full. Push the priming pump
3. Coat the seal of the new filter elements with plunger down and turn it clockwise to lock.
clean diesel fuel.
2. Start the engine and look for leaks around filter
4. Install the new filter elements by hand. When elements.
- the seal contacts the base, tighten 3/4 turn more.
There are rotation-index marks 900 apart on the
3. Close the cover assembly door.
filter. Use them as a guide for proper tightening. If the engine does not start, air is entrapped in the
fuel lines to the engine.
5. Open the fuel supply valve.
6. Prime the fuel system. (See next topic.)
'-I)f:e
:•
4. Loosen all fuel injection lines at the cylinder

head of the engine.
p
97
Winch Filter and Magnetic r
Strainer (If Equipped) L
Change Filter - Wash Strainer

contact skin.
5. Move the governor lever to the LOW-IDLE

position.
• _
---- •.
1. Remove the cover and gasket.
I
C
6. -f urn the key switch to START. Cranr

engine until fuel flows free of air bubbles, from all
the fuel lines.
7. Move the governor control lever all the way
forward to stop the engine.
8. Turn the key to OFF and remove.
9. Tighten the fuel line nuts to a torque of 40 ± 7 2. Remove the filter eiement housing witn a
Nm (30 ± 5 lb ft). wrench.
10. Remove any fuel that gets on the engine. 3. Remove the filter element from the housing.
I
98
Rollover Protective Structure

I (ROPS)
4. Clean the housing with a clean cloth, Retighten the Bolts

5. Replace the seal if damaged. Lubricate the
seals with clean winch oil.
6. Install a new filter element into the housing.
7. Tighten the housing to 27±4 N . m(20±3 lb ft).
8. Install the cover and gasket.
Wash the Magnet and Strainer
Look for any loose or damaged bolts. Replace

damaged bolts or missing bolts with original
equipment parts only. Retighten bolts to a torque
of 1350 ± 175 N • m (1000 ± 120 lb ft).
Do not straighten or repair by welding
reinforcement plates to the ROPS.
- Contact your Caterpillar dealer for repair of cracks
in welds, castings or any metal section on the
ROPS.
1. Remove the cover, magnet and strainer.
2. Wash them in clean, nonflammable solvent.
Lift Cylinder Yoke Bearings
3. Install the clean strainer and magnet.
4. Install the cover.
Lubricate the Fittings
Fittings are located on the left front and right front

sides of the machine. Lubricate the fitting on each
-
99
Power Train Oil System
Change Oil and Wash Breather

I
Hot oil and components can cause personal -
contact skin.
4. Remove the oil fill cap.

5. Add the oil. See "Refill Capacities.
6. Clean and install the oil fill cap.
7. Maintain the oil level to the FULL mark on the
dipstick.
1. Remove the power train oil drain plug under

the case. Drain the oil into a container.
2. Clean and install the drain plug.
pAS
_ 8. Unsctev anc rumoe me orealeer en the rear

of machine.
9. Wash the breather in clean, nonflammable
solvent.
3. Open the oil fill cap access door on the left 10. Install the breather.
I
100
Winch (If Equipped)
Change Oil and Wash Breather

contact skin.
A
5. Fill the oil compartment until oil is visible in the
sight gauge. See "Refill Capacities.
6. Clean and install the fill plug.
7. With the engine running at LOW IDLE, maintain
the oil level so that it is visible in the sight gauge.
8. Remove the breather on top of winch case.
Wash it in clean, nonflammable solvent and install.
p 1. Remove the oil fill plug.
2. Remove the drain plug. Allow the oil to drain

into a container.
3. Inspect the plug seal and replace if necessary.
4. Clean and install the drain plug.
101
Every 2000 Service Hours or 1 Year

Final Drive Oil Engine Valve Lash

I
Change the Oil Adjust Valve Lash
Hot oil and components can cause personal To prevent possible injury, do not use the start-
injury. Do not allow hot oil or components to er motor to turn the flywheel.
contact skin.
Hot engine components can cause burns. Al-
low additional time for the engine to cool
before measuring valve clearance.
I—
r
NOTICE
Measure the valve lash with the engine stopped.

To obtain an accurate measurement, allow at
least 20 minutes for the valves to cool to engine
cylinder head and block temperature.
1. Position one final drive with the oil drain plug at

the bottom.
2. Remove the drain plug (1). Allow the oil to
drain into a container.
H
3. Inspect the drain plug seal. Replace the seal if
damaged.
4. Clean and install the drain plug. i®@@®®__j
S. Remove the oil fill plug (2).
n
O o (toc
) (s o ^
(t S_c^-^)
6. Fill the final drive to bottom of fill plug opening
See "Refill Capacities."
Adjust the valve clearance to within ± 0.08 mm
7. Inspect the condition of oil fill plug seal. (.003 in) of the clearance as given in the chart.
Replace the seal if damaged.
Valve Clearance Setting
8. Repeat steps on the other side of machine. Intake ...................0.38 mm (.015 in)
Exhaust ...............0.76 mm (.030 in)
Refer to the Service Manual or your Caterpillar

dealer for the complete valve adjustment
procedure.
After adjusting the valve clearances and before
installing the valve cover, check valve rotators.
See next topic.
I
102

Engine Valve Rotators Hydraulic System Oil
Observe Rotation of Valves With Engine
Idling Change the Oil
When inspecting the valve rotators, protective At operating temperature, the hydraulic tank is
glasses or face shield and protective clothing hot and under pressure.
must be worn, to prevent being burned by hot
oil spray. Hot oil can cause burns.
stopped, and the cap is cool enough to touch
with your bare hand. Remove the fill cap slowly
With engine idling observe rotation of valves after to relieve pressure.
setting all valve clearances and before installing
the valve cover:
1. Remove the hydraulic system oil tank filler cap
2. Move the governor control lever to the LOW and strainer.
IDLE position.
2. Wash the filler strainer and filler cap in clean,
nonflammable solvent.
3. Watch the top surface on each valve rotator.

Each valve rotator should turn slightly each time
the valve closes. 3. Remove the oil drain plug, located under the
right side rear of machine.
If a valve fails to rotate, contact your Caterpillar
dealer. 4. Attach a hose to a 1 inch NPT pipe nipple, 10
cm (4 inch) long.
5. Install the pipe nipple and hose into the drain
plug opening.
6. Turn the pipe nipple clockwise to open the
internal drain valve. Allow the oil to drain into a
container.
p
103
Track Roller Frame Guides
Measure Wear
7. Remove the pipe nipple. This will close the Measure the rotational movement of the front roller
hydraulic oil tank drain valve. frame relative to the rear roller frame.
8. Clean and install the drain plug. Tighten the
plug to 68 ± 7 N . m (50 ± 5 lb ft).
9. Change the hydraulic system filter. See
"Hydraulic System Filter' in the Every 500 Service
Hours or 3 Months' section.
10. Install the filler strainer.
1. Raise the front of the machine with the dozer

hydraulics. Place a 100 mm (4 inch) block under
the outside end of a track grouser near the idler.
Lower the machine onto the block.
W ^ A 4T!1J
11. Fill the hydraulic system oil tank. See "Refill
Capacities."
12. Inspect the filler cap gasket. Replace the
gasket if damaged.
13. Install the oil fill cap.
14. Start and run the engine for a few minutes.
15. Maintain the oil level to the FULL mark in the
'. I
sight gauge. 2. Use a grease pencil to make a mark on the
tubular section of the front roller frame and a
16. Stop the engine. corresponding mark on the rear roller frame.
I
104

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18

Contour Series Seat

15. Installseat belt retractor (11). Install the bolt that

12. Install pin (19) and retainer clip (18) on each

16. Install two springs (7) in the plate. Pull up on

Illustration 43 g00275634 Illustration 46 g0027563

19.Install two bushings (2) on the seat assembly.

order to ; nstall the bushings

There is spring force against the seat lift plate.

6. Use a screwdriver to carefully pry the bottom seat

9. Remove pin (18) from seat back adjustment

7. Remove two springs (12) from seat pan assembly

10.Remove seven bolts (22) from the seat pan

11.Remove pin (25) from fore and aft adjustment

15.Remove bolt (42). Remove bolt (41) and the lock

13.Relieve the spring pressure of the spring on the

17.Remove rivet (44). Remove cable assembly (43)

14.Remove retainer clip (39) and cable (38) as a

Note: When the armrests are removed, the back

19. Turn upper slide plate (29) onto the opposite

Contour Seat With Lumbar

Assembly Procedure qO0275687

Illustration 64 g30275739 Illustration 67

Illustration 65 q00275 738

3. Install slide lever/lock shaft (46) and spring (47)

8. Install pin (36) and retainer clip (35) on each end

12.Install shaft (20). Slide spring (19) onto shaft

9. Install seat cushion tilt shaft (31) on the seat pan

13.Install seat belt retractor (14). Install the bolt that

Illustration 71 g002 75693 [I

2. Use the following procedure to release the air

a. Connect a 24 volt power supply to two-pin

b. Push down toggle (5). While you hold down

14. Put identification marks on two electrical OO€44'6

15. Remove tube (30) from fitting (33)

2. Install two rubber bumpers (34). Apply 5N-5561

Illustration 114 g00275786

4. Connect tube (30) to fitting (33). Make sure that

7. Install wiring harness connection (25) and

5. Position wiring harness (26). Connect two

6. Connect tube (30) to fitting (28). Make sure that

9. Install two bearings (17), damper (18), pin (20)

Illustration 120 g00275777 Illustration 123 g00275754

Illustration 122 900275755 g00291077

15.Install four slides (1). a. Connect a 24 volt power supply to two-pin

I SMCS Code: 7324-015-AJ

The air spring of the air suspension is filled with

2. Use the following procedure to release the air

4. Loosen the setscrew on knob (2). Remove nut

Illustration 129 g00275792 Illustration 132 g00275795

7. Disconnect two tether belts (11) from the scissor

11.Remove two tether belts (11), two rollers (2 1 )

g00275840 g002 7-5,843

Air Suspension With Air Valve

13. Put identification marks on two electrical

2. Install slider track (38) on upper housing (6).

S 14. Remove tube (32) from fitting (33). Remove

8. Apply 5N-5561 Lubrication Compound to the

Illustration 144 g00275830

Illustration 148 g00275792

14. Install upper housing (6) on scissor assembly

Illustration 146 900275795

10.Install scissor assembly (7) into lower housing