Professional Documents
Culture Documents
February 2012
Operation and
Maintenance
Manual
525C, 535C and 545C Wheel Skidders
5251-Up (525C)
5351-Up (535C)
5451-Up (545C)
SAFETY.CAT.COM
i03991620
When replacement parts are required for this product Caterpillar recom-
mends using Cat replacement parts or parts with equivalent specica-
tions including, but not limited to, physical dimensions, type, strength
and material.
Failure to heed this warning can lead to premature failures, product
damage, personal injury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7892-09 3
Table of Contents
Table of Contents
Foreword .................................................................................................. 5
Safety Section
Safety Messages ..................................................................................... 9
Operation ............................................................................................... 51
Parking ................................................................................................... 52
Operation Section
Before Operation ................................................................................... 84
Maintenance Section
Tire Ination Information ...................................................................... 175
Index Section
Index .................................................................................................... 344
SEBU7892-09 5
Foreword
Foreword
Literature Information
This manual should be stored in the operator's compartment in the
literature holder or seat back literature storage area.
Safety
The safety section lists basic safety precautions. In addition, this section
identies the text and locations of warning signs and labels used on the
machine.
Read and understand the basic precautions listed in the safety section
before operating or performing lubrication, maintenance and repair on
this machine.
Operation
The operation section is a reference for the new operator and a refresher
for the experienced operator. This section includes a discussion of
gauges, switches, machine controls, attachment controls, transportation
and towing information.
Maintenance
The maintenance section is a guide to equipment care. The Maintenance
Interval Schedule (MIS) lists the items to be maintained at a specic
service interval. Items without specic intervals are listed under the "When
Required" service interval. The Maintenance Interval Schedule lists the
page number for the step-by-step instructions required to accomplish the
scheduled maintenance. Use the Maintenance Interval Schedule as an
index or "one safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing intervals. Calendar
intervals shown (daily, weekly, monthly, etc.) can be used instead of
service hour meter intervals if they provide more convenient servicing
schedules and approximate the indicated service hour meter reading.
Recommended service should always be performed at the interval that
occurs rst.
Battery posts, terminals and related accessories contain lead and lead
compounds. Wash hands after handling.
SEBU7892-09 7
Foreword
Machine Capacity
Additional attachments or modications may exceed machine design
capacity which can adversely affect performance characteristics. Included
would be stability and system certications such as brakes, steering, and
rollover protective structures (ROPS). Contact your Caterpillar dealer for
further information.
g00751314
Illustration 1
Where:
Machines and generator sets produced before First Quarter 2001 will
maintain their 8 character PIN format.
Safety Section
i03239202
Safety Messages
SMCS Code: 7000
There are several specic safety messages on this machine. The exact
location of the hazards and the description of the hazards are reviewed in
this section. Please become familiarized with all safety messages.
Make sure that all of the safety messages are legible. Clean the safety
messages or replace the safety messages if you cannot read the words.
Replace the illustrations if the illustrations are not legible. When you
clean the safety messages, use a cloth, water and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen the adhesive that
secures the safety message. Loose adhesive will allow the safety
message to fall.
g01379082
Illustration 2
g01379087
Illustration 3
SEBU7892-09 11
Safety Section
Safety Messages
g01370904
No Ether (2)
This warning is located near the rain cap for the engine air intake. This
warning is located near the engine air precleaner (if equipped).
g01372254
g01379094
g01371636
g01211895
This machine has been certied to the standards that are listed on the
certication plate. The maximum mass of the machine, which includes
the operator and the attachments without a payload, should not exceed
the mass on the certication plate.
16 SEBU7892-09
Safety Section
Safety Messages
g01379131
No Clearance (7)
This warning is located on both sides of the machine near the articulation
joint.
g01371644
g01371640
g01371640
g01371647
g01372252
To relieve pressure:
Battery (12)
This warning is located on the right side of the radiator guard.
g01370909
g01370917
i03991610
Additional Messages
SMCS Code: 7000
g02170833
Illustration 4
Make sure that all of the additional messages are legible. Clean the
messages or replace the messages if you cannot read the words. Replace
the illustrations if the illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the messages. Solvents, gasoline, or
harsh chemicals could loosen the adhesive that secures the message.
Loose adhesive will allow the message to fall.
Winch (1)
SEBU7892-09 25
Safety Section
Additional Messages
g01102562
Illustration 5
This additional message is located next to the controls for the winch on
the RH console.
g01102567
Illustration 6
This additional message is located on the bottom left corner of all cab
windows.
Clean the windows with a wet cloth or a wet sponge. A dry cloth or a dry
sponge may scratch the windows.
26 SEBU7892-09
Safety Section
Additional Messages
g01418953
Illustration 7
If your machine is equipped with the Product Link System, this additional
message is located in the cab.
g02095974
Illustration 8
This message describes the re points that are available on the engine
compartments. Use the apertures in order to suppress re hazards in
the engine compartment.
i04010649
g00104545
Illustration 9
Attach a “Do Not Operate” warning tag or a similar warning tag to the
start switch or to the controls. Attach the warning tag before you service
the equipment or before you repair the equipment. These warning tags
(Special Instruction, SEHS7332) are available from your Cat dealer.
Be aware of high voltage power lines and power cables that are buried.
If the machine comes in contact with these hazards, serious injury or
death may occur from electrocution.
SEBU7892-09 29
Safety Section
General Hazard Information
g00702020
Illustration 10
Make sure that all protective guards and all covers are secured in place
on the equipment.
Keep the equipment free from foreign material. Remove debris, oil, tools,
and other items from the deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools, and other items that
are not a part of the equipment.
Know the appropriate work site hand signals and the personnel that
are authorized to give the hand signals. Accept hand signals from one
person only.
Do not smoke when you service an air conditioner. Also, do not smoke if
refrigerant gas may be present. Inhaling the fumes that are released from
a ame that contacts air conditioner refrigerant can cause bodily harm
or death. Inhaling gas from air conditioner refrigerant through a lighted
cigarette can cause bodily harm or death.
Never put maintenance uids into glass containers. Drain all liquids into
a suitable container.
Use all cleaning solutions with care. Report all necessary repairs.
When pressurized air and/or pressurized water is used for cleaning, wear
protective clothing, protective shoes, and eye protection. Eye protection
includes goggles or a protective face shield.
Trapped Pressure
Pressure can be trapped in a hydraulic system. Releasing trapped
pressure can cause sudden machine movement or attachment movement.
Use caution if you disconnect hydraulic lines or ttings. High-pressure
oil that is released can cause a hose to whip. High-pressure oil that
is released can cause oil to spray. Fluid penetration can cause serious
injury and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has
been stopped. The pressure can cause hydraulic uid or items such as
pipe plugs to escape rapidly if the pressure is not relieved correctly.
SEBU7892-09 31
Safety Section
General Hazard Information
Do not remove any hydraulic components or parts until pressure has been
relieved or personal injury may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved or personal injury
may occur. Refer to the Service Manual for any procedures that are
required to relieve the hydraulic pressure.
g00687600
Illustration 11
Always use a board or cardboard when you check for a leak. Leaking uid
that is under pressure can penetrate body tissue. Fluid penetration can
cause serious injury and possible death. A pin hole leak can cause severe
injury. If uid is injected into your skin, you must get treatment immediately.
Seek treatment from a doctor that is familiar with this type of injury.
• Tools that are suitable for collecting uids and equipment that is suitable
for collecting uids
• Tools that are suitable for containing uids and equipment that is
suitable for containing uids
32 SEBU7892-09
Safety Section
General Hazard Information
Inhalation
g02159053
Illustration 12
Exhaust
Use caution. Exhaust fumes can be hazardous to your health. If you
operate the machine in an enclosed area, adequate ventilation is
necessary.
Asbestos Information
Cat equipment and replacement parts that are shipped from Caterpillar
are asbestos free. Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when you handle any
replacement parts that contain asbestos or when you handle asbestos
debris.
Use caution. Avoid inhaling dust that might be generated when you
handle components that contain asbestos bers. Inhaling this dust can
be hazardous to your health. The components that may contain asbestos
bers are brake pads, brake bands, lining material, clutch plates, and
some gaskets. The asbestos that is used in these components is bound in
a resin or sealed in some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there are several guidelines
that should be followed:
SEBU7892-09 33
Safety Section
General Hazard Information
g00706404
Illustration 13
Always use leakproof containers when you drain uids. Do not pour waste
onto the ground, down a drain, or into any source of water.
i01359664
Do not work beneath the cab of the machine unless the cab is properly
supported.
Unless you are instructed otherwise, never attempt adjustments while the
machine is moving or while the engine is running.
Never jump across the starter solenoid terminals in order to start the
engine. Unexpected machine movement could result.
Keep objects away from moving fan blades. The fan blade will throw
objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable. Wear gloves when
you handle wire cable.
When you strike a retainer pin with force, the retainer pin can y out. The
loose retainer pin can injure personnel. Make sure that the area is clear of
people when you strike a retainer pin. To avoid injury to your eyes, wear
protective glasses when you strike a retainer pin.
SEBU7892-09 35
Safety Section
Burn Prevention
Chips or other debris can y off an object when you strike the object. Make
sure that no one can be injured by ying debris before striking any object.
i04760300
Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine. Allow the engine to cool
before any maintenance is performed on the engine. Relieve all pressure
in the air system, in the oil system, in the lubrication system, in the fuel
system, or in the cooling system before any lines, ttings, or related items
are disconnected.
Coolant
When the engine is at operating temperature, the engine coolant is hot.
The coolant is also under pressure. The radiator and all lines to the
heaters or to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause severe burns. Allow
cooling system components to cool before the cooling system is drained.
Check the coolant level only after the engine has been stopped.
Ensure that the ller cap is cool before removing the ller cap. The ller
cap must be cool enough to touch with a bare hand. Remove the ller cap
slowly in order to relieve pressure.
Oils
Hot oil and hot components can cause personal injury. Do not allow hot oil
to contact the skin. Also, do not allow hot components to contact the skin.
Remove the hydraulic tank ller cap only after the engine has been
stopped. The ller cap must be cool enough to touch with a bare hand.
Follow the standard procedure in this manual in order to remove the
hydraulic tank ller cap.
36 SEBU7892-09
Safety Section
Fire Prevention and Explosion Prevention
Batteries
The liquid in a battery is an electrolyte. Electrolyte is an acid that can
cause personal injury. Do not allow electrolyte to contact the skin or the
eyes.
Do not smoke while checking the battery electrolyte levels. Batteries give
off ammable fumes which can explode.
Always wear protective glasses when you work with batteries. Wash
hands after touching batteries. The use of gloves is recommended.
i03863998
g00704000
Illustration 14
SEBU7892-09 37
Safety Section
Fire Prevention and Explosion Prevention
General
Much of the material that is found in forestry applications is highly
ammable. This includes the following pieces: limbs, bark, leaves,
sawdust, small wood chips, and pine tree's needles. When this debris
from forestry applications is soaked with fuel or lubricants, the risk of
re is greatly increased. Perform a daily inspection before every shift or
more often when the amount of work output and buildup of debris is the
best way to prevent a machine re. Frequent inspections and thorough
cleanings of the machine are critical when the machine is engaged in
forestry applications. Even minor leaks or electrical malfunctions should
be repaired as soon as possible.
All fuels, most lubricants, and some coolant mixtures are ammable.
Understand the use of the primary exit and alternative exit on the
machine. Refer to Operation and Maintenance Manual, “Alternative Exit”.
Do not operate a machine with a uid leak. Repair leaks and clean up
uids before resuming machine operation. Fluids that are leaking or
spilled onto hot surfaces or onto electrical components can cause a re. A
re may cause personal injury or death.
Keep shields in place. Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of a break in a line, in a
hose, or in a seal. Exhaust shields must be installed correctly.
Do not weld or ame cut on tanks or lines that contain ammable uids
or ammable material. Empty and purge the lines and tanks. Then clean
the lines and tanks with a nonammable solvent prior to welding or ame
cutting. Ensure that the components are properly grounded in order to
avoid unwanted arcs.
Inspect all lines and hoses for wear or deterioration. Replace damaged
lines and hoses. The lines and the hoses should have adequate support
and secure clamps. Tighten all connections to the recommended torque.
Damage to the protective cover or insulation may provide fuel for res.
g00704059
Illustration 15
Use caution when you are fueling a machine. Do not smoke while you
are fueling a machine. Do not fuel a machine near open ames or sparks.
Always stop the engine before fueling. Fill the fuel tank outdoors. Properly
clean areas of spillage.
Follow practices for safe fueling that are described in the “Operation”
section of the Operation and Maintenance Manual section and follow local
regulations. Never store ammable uids in the operator compartment
of the machine.
40 SEBU7892-09
Safety Section
Fire Prevention and Explosion Prevention
g00704135
Illustration 16
Follow safe procedures for engine starting with jump start cables.
Improper jumper cable connections can cause an explosion that may
result in injury. Refer to Operation and Maintenance Manual, “Engine
Starting with Jump Start Cables” for specic instructions.
Gases from a battery can explode. Keep any open ames or sparks away
from the top of a battery. Do not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the
terminal posts. Use a voltmeter in order to check the battery charge.
SEBU7892-09 41
Safety Section
Fire Prevention and Explosion Prevention
Daily inspect battery cables that are in areas that are visible. Inspect
cables, clips, straps, and other restraints for damage. Replace any
damaged parts. Check for signs of the following, which can occur over
time due to use and environmental factors:
• Fraying
• Abrasion
• Cracking
• Discoloration
• Cuts on the insulation of the cable
• Fouling
• Corroded terminals, damaged terminals, and loose terminals
Replace damaged battery cable(s) and replace any related parts.
Eliminate any fouling, which may have caused insulation failure or related
component damage or wear. Ensure that all components are reinstalled
correctly.
An exposed wire on the battery cable may cause a short to ground if the
exposed area comes into contact with a grounded surface. A battery cable
short produces heat from the battery current, which may be a re hazard.
An exposed wire on the ground cable between the battery and the
disconnect switch may cause the disconnect switch to be bypassed if
the exposed area comes into contact with a grounded surface. This
may result in an unsafe condition for servicing the machine. Repair
components or replace components before servicing the machine.
Wiring
Check electrical wires daily. If any of the following conditions exist, replace
parts before you operate the machine.
• Fraying
• Signs of abrasion or wear
• Cracking
• Discoloration
• Cuts on insulation
• Other damage
Make sure that all clamps, guards, clips, and straps are reinstalled
correctly. This will help to prevent vibration, rubbing against other parts,
and excessive heat during machine operation.
g00687600
Illustration 17
Replace the affected parts if any of the following conditions are present:
Do not operate a machine when a re hazard exists. Repair any lines
that are corroded, loose or damaged. Leaks may provide fuel for res.
Consult your Caterpillar dealer for repair or for replacement parts. Use
genuine Caterpillar parts or the equivalent, for capabilities of both the
pressure limit and temperature limit.
Ether
Ether (if equipped) is commonly used in cold weather applications. Ether
is ammable and poisonous.
Follow the correct cold engine starting procedures. Refer to the section in
the Operation and Maintenance Manual with the label “Engine Starting”.
Use ether in well ventilated areas. Do not smoke while you are replacing
an ether cylinder or while you are using an ether spray.
Fire Extinguisher
As an additional safety measure, keep a re extinguisher on the machine.
Be familiar with the operation of the re extinguisher. Inspect the re
extinguisher and service the re extinguisher regularly. Follow the
recommendations on the instruction plate.
i02399496
Make sure that a re extinguisher is on the machine. Make sure that you
are familiar with the operation of the re extinguisher. Inspect the re
extinguisher and service the re extinguisher. Obey the recommendations
on the instruction plate.
g01198463
Illustration 18
The recommended location for mounting the re extinguisher is the inside
of the left cab door.
Strap the mounting plate to a leg of the ROPS in order to mount the re
extinguisher. If the weight of the re extinguisher is more than 4.5 kg
(10 lb), mount the re extinguisher as low as possible on one leg. Do not
mount the re extinguisher on the upper one-third area of the leg.
46 SEBU7892-09
Safety Section
Tire Information
i04160129
Tire Information
SMCS Code: 7000
A tire explosion is much more violent than a blowout. The explosion can
propel the tire, the rim components, and the axle components from the
machine. Stay out of the trajectory path. Both the force of the explosion
and the ying debris can cause property damage, personal injury, or
death.
g02166933
Illustration 19
Typical example of tire is shown
Dry nitrogen gas is recommended for ination of tires. If the tires were
originally inated with air, nitrogen is still preferred for adjusting the
pressure. Nitrogen mixes properly with air.
When you inate a tire, stand behind the tread and use a self-attaching
chuck.
Servicing tires and rims can be dangerous. Only trained personnel that
use proper tools and proper procedures should perform this maintenance.
If correct procedures are not used for servicing tires and rims, the
assemblies could burst with explosive force. This explosive force can
cause serious personal injury or death. Carefully obey the specic
instructions from your tire dealer.
i01122596
i00934890
The steering frame lock must be in the unlocked position in order to steer
the machine.
Start the engine only from the operator compartment. Never short across
the starter terminals or across the batteries. Shorting could bypass the
engine neutral start system. Shorting could also damage the electrical
system.
Inspect the condition of the seat belt and the condition of mounting
hardware. Replace any parts that are worn or damaged. Regardless of
the appearance, replace the seat belt after three years of use. Do not use
a seat belt extension on a retractable seat belt.
Adjust the seat so that there is full pedal travel while the operator's back
is against the back of the seat.
Make sure that the machine is equipped with a lighting system that is
adequate for the job conditions. Make sure that all lights are working
properly.
Before you start the engine or before you move the machine, make sure
that no one is on the machine, underneath the machine, or around the
machine. Make sure that there are no personnel in the area.
i03162317
Visibility Information
SMCS Code: 7000
While the machine is in operation, constantly survey the area around the
machine in order to identify potential hazards as hazards become visible
around the machine.
SEBU7892-09 49
Safety Section
Engine Starting
Your machine may be equipped with visual aids. Some examples of visual
aids are Closed Circuit Television (CCTV) and mirrors. Before operating
the machine, ensure that the visual aids are in proper working condition
and that the visual aids are clean. Adjust the visual aids using the
procedures that are located in this Operation and Maintenance Manual.
If equipped, the Work Area Vision System shall be adjusted according
to Operation and Maintenance Manual, SEBU8157, “Work Area Vision
System”.
• Safety instructions
• Controlled patterns of machine movement and vehicle movement
• Workers that direct trafc to move when it is safe
• Restricted areas
• Operator training
• Warning symbols or warning signs on machines or on vehicles
• A system of communication
• Communication between workers and operators prior to approaching
the machine
i03690423
Engine Starting
SMCS Code: 1000; 7000
Move all hydraulic controls to the HOLD position before you start the
engine.
Check for the presence of personnel. Ensure that all personnel are clear
of the machine.
i01360271
Before Operation
SMCS Code: 7000
Make sure that there are no personnel on the machine or in the area
around the machine.
Perform a walk-around inspection. Check all of the uid levels. Look for
loose bolts, leaks, and parts that are worn or broken. Inspect the condition
of the attachments and the condition of the hydraulic components.
Clear all obstacles from the path of the machine. Beware of hazards such
as wires, ditches, etc.
Make sure that all windows are clean. Secure the doors and the windows
in the shut position.
Adjust the rear view mirrors (if equipped) for the best vision of the
areanear the machine.
Make sure that the horn, the backup alarm (if equipped), and all other
warning devices are working properly.
i04329851
Operation
SMCS Code: 7000
Operation
Only operate the machine while you are sitting in a seat. The seat belt
must be fastened while you operate the machine. Only operate the
controls while the engine is running.
While you operate the machine slowly in an open area, check for proper
operation of all controls and all protective devices.
Before you move the machine, make sure that no one will be endangered.
Do not allow riders on the machine unless the machine has the following
equipment:
• additional seat
• additional seat belt
• Rollover Protective Structure (ROPS)
Never use the work tool for a work platform.
Note any needed repairs during machine operation. Report any needed
repairs.
Avoid any conditions that can lead to tipping the machine. The machine
can tip when you work on hills, on banks and on slopes. Also, the machine
can tip when you cross ditches, ridges, or other unexpected obstructions.
i02624835
Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine immediately after the machine has been operated
under load. This can cause overheating and accelerated wear of engine
components.
After the machine is parked and the parking brake is engaged, allow the
engine to run for two minutes before shutdown. This allows hot areas of
the engine to cool gradually.
i03907830
Parking
SMCS Code: 7000
Park the machine on a level surface. If you must park the machine on a
downgrade, block the tires.
Apply the service brake in order to stop the machine. Move the
transmission control to the NEUTRAL position.
SEBU7892-09 53
Safety Section
Slope Operation
Lower all work tools to the ground. Activate any control locks.
Turn the engine start switch to the OFF position and remove the key.
Always turn the battery disconnect switch to the OFF position before
leaving the machine.
If the machine will not be operated for a month or more, remove the
battery disconnect switch key.
i03745198
Slope Operation
SMCS Code: 7000
When you work on side hills and when you work on slopes, consider the
following important points:
Nature of surface – Ground that has been newly lled with earth may
collapse from the weight of the machine.
Height of the working load of the machine – When the working loads
are in higher positions, the stability of the machine is reduced.
i04159629
Work Tools
SMCS Code: 6700
Only use work tools that are recommended by Caterpillar for use on
Cat machines.
Work tools and work tool control systems, that are compatible with your
Cat machine, are required for safe machine operation and/or reliable
machine operation. If you are in doubt about the compatibility of a
particular work tool with your machine, consult your Cat dealer.
Make sure that all necessary guarding is in place on the host machine
and on the work tool.
Keep all windows and doors closed on the host machine. A polycarbonate
shield must be used when the host machine is not equipped with windows
and when a work tool could throw debris.
Do not exceed the maximum operating weight that is listed on the ROPS
certication.
To prevent personnel from being struck by ying objects, ensure that all
personnel are out of the work area.
56 SEBU7892-09
Safety Section
Equipment Lowering with Engine Stopped
i01329161
Before lowering any equipment with the engine stopped, clear the area
around the equipment of all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind most systems use a
high pressure uid or air to raise or lower equipment. The procedure will
cause high pressure air, hydraulic, or some other media to be released
in order to lower the equipment. Wear appropriate personal protective
equipment and follow the established procedure in the Operation and
Maintenance Manual, “Equipment Lowering with Engine Stopped” in the
Operation Section of the manual.
i00457455
The exterior sound pressure level for the standard machine measured at
a distance of 15 m (49.2 ft) according to the test procedures specied in
“SAE J88Jun86”, with the machine in middle gear range and moving,
is 88 dB(A).
Vibration Level
The hands and arms are exposed to a weighted root mean square
acceleration that is less than 2.5 m/sec2.
• “ISO 2631/1”
• “ISO 5349”
• “SAE J1166”
58 SEBU7892-09
Safety Section
Operator Station
i03634321
Operator Station
SMCS Code: 7000
Any modications to the inside of the operator station should not project
into the operator space or into the space for the companion seat (if
equipped). The addition of a radio, re extinguisher, and other equipment
must be installed so that the dened operator space and the space for
the companion seat (if equipped) is maintained. Any item that is brought
into the cab should not project into the dened operator space or the
space for the companion seat (if equipped). A lunch box or other loose
items must be secured. Objects must not pose an impact hazard in rough
terrain or in the event of a rollover.
SEBU7892-09 59
Product Information Section
General Information
General Information
i02207491
Specications
SMCS Code: 7000
g01228876
Illustration 20
Bunching and Thinning Grapple
The bunching head is primarily used when the diameters of the logs are
consistent or when the diameters of the logs are under 305 mm (12 inch).
The bunching head is suited for operations that use a feller buncher.
60 SEBU7892-09
Product Information Section
General Information
g01228970
Illustration 21
Sorting Grapple
Table 1
525C Grapple Continuous Rotation
Sorting Bunching Thinning
2 2
Grapple 0.83 m 1.16 m 1.34 m2
A
Capacity (9 ft2) (12.5 ft2) (14.4 ft2)
2045 mm 1920 mm
Tip to Tip 1981 mm
B (80.5 (75.6
Height (78 inch)
inch) inch)
Tong 2540 mm 3050 mm 3124 mm
C
Opening (100 inch) (120 inch) (123 inch)
1590 mm
Full Open 1677 mm 1832 mm
D (62.6
Height (66 inch) (72.1 inch)
inch)
Minimum
76 mm 155 mm 190 mm
E Stem
(3 inch) (6 inch) (7.5 inch)
Diameter
Fully 1285 mm
1829 mm 1371 mm
F Closed (50.6
(72 inch) (54 inch)
Height inch)
SEBU7892-09 61
Product Information Section
General Information
g01228892
Illustration 22
Dual Function
62 SEBU7892-09
Product Information Section
General Information
g01229060
Illustration 23
Single Function
SEBU7892-09 63
Product Information Section
General Information
Table 2
525C Function Arch
Single
Dual Funtion
Function
Lift Highest, 2212 mm 2623 mm
A
Retracted (87.1 inch) (103.3 inch)
Lift Highest, 1944 mm
B
Farthest (76.5 inch)
Lift Maximum 1336 mm
C
Reach (52.6 inch)
Lift Lowest, 752 mm
D
Retracted (29.6 inch)
Lift Lowest, 600 mm 259 mm
E
Farthest (23.6 inch) (10.2 inch)
Loaded Tire 843 mm 843 mm
F
Radius(1) (33 inch) (33.2 inch)
Reach
1630 mm 1513 mm
G Highest,
(64.2 inch) (59.6 inch)
Retracted
Reach Lowest, 1469 mm
H
Retracted (57.8 inch)
Reach Lowest, 2521 mm 2488 mm
I
Farthest (99.3 inch) (98 inch)
Reach
2765 mm
J Highest,
(108.9 inch)
Farthest
Reach 2880 mm
K
Maximum (113.4 inch)
(1) With 30.5 x 32 tires
64 SEBU7892-09
Product Information Section
General Information
g01228906
Illustration 24
SEBU7892-09 65
Product Information Section
General Information
Table 3
525C Machine Dimensions
Ground Level to Top Boom
(Grapple)
Dual Function 4103 mm (161.5 inch)
Single Function 3760 mm (148 inch)
Ground Level to Top Roller
2794 mm (110 inch)
(Cable)
Ground Level to Axle
843 mm (33.2 inch)
Center Line(1)
Rear Axle Center Line to Pin 1798 mm (70.8 inch)
Wheel Base 3534 mm (139.2 inch)
Overall Length (Grapple)
7626 mm (300.2 inch)
Dual Function
8369 mm (329.4 inch)
Single Function
Overall Length (Cable) 6945 mm (273.4 inch)
Ground Clearance 581 mm (22.9 inch)
Decking Blade Lift Height 1381 mm (54.4 inch)
Decking Blade Dig Depth 456 mm (17.9 inch)
Height to Top of Cab(2) 3184.4 mm (125.4 inch)
Decking Blade Width 3138 mm (123.5 inch)
Tread Width 2622 mm (103.2 inch)
Overall Width 3398mm (133.8 inch)
Turning Radius Over Tires(1) 6000mm (226.2 inch)
Approximate Maximum Weight
18416 kg (40600 lb)
with Attachments
(1) With 30.5 x 32 tires
(2) Add 188 mm (7.4 inch) if equipped with optional lights or water
tank.
g01228876
Illustration 25
The bunching head is primarily used when the diameters of the logs are
consistent or when the diameters of the logs are under 305 mm (12 inch).
The bunching head is suited for operations that use a feller buncher.
SEBU7892-09 67
Product Information Section
General Information
Table 4
535C Grapple Continuous Rotation
Bunching Thinning
2
Grapple 1.34 m 1.54 m2
A
Capacity (14.4 ft2) (16.6 ft2)
Tip to Tip 1981 mm 2108 mm
B
Height (78 inch) (83 inch)
3124 mm 3226 mm
C Tong Opening
(123 inch) (127 inch)
Full Open 1832 mm 1905 mm
D
Height (72.1 inch) (75 inch)
Minimum
190 mm 183 mm
E Stem
(7.5 inch) (7.2 inch)
Diameter
Fully Closed 1371 mm 1371 mm
F
Height (54 inch) (54 inch)
g01228892
Illustration 26
68 SEBU7892-09
Product Information Section
General Information
Table 5
Standard Extended
Boom Boom
g01228906
Illustration 27
70 SEBU7892-09
Product Information Section
General Information
Table 6
535C Machine Dimensions
Ground Level to Top Boom
(Grapple)
Standard 4103 mm (161.5 inch)
Extended 4304 mm (169.4 inch)
Ground Level to Top Roller
2794 mm (110 inch)
(Cable)
Ground Level to Axle
843 mm (33.2 inch)
Center Line(1)
Rear Axle Center Line to Pin 1798 mm (70.8 inch)
Wheel Base 3534 mm (139.2 inch)
Overall Length (Grapple)
7626 mm (300.2 inch)
Standard Boom
7514 mm (295.8 inch)
Extended Boom
Overall Length (Cable) 6945 mm (273.4 inch)
Ground Clearance 533 mm (21 inch)
Decking Blade Lift Height 1381 mm (54.4 inch)
Decking Blade Dig Depth 456 mm (17.9 inch)
Height to Top of Cab(2) 3184.4 mm (125.4 inch)
Decking Blade Width 3138 mm (123.5 inch)
Tread Width 2622 mm (103.2 inch)
Overall Width 3398mm (133.8 inch)
Turning Radius Over Tires(1) 6000mm (226.2 inch)
Approximate Maximum Weight
18689 kg (41200 lb)
with Attachments
(1) With 30.5 x 32 tires
(2) Add 188 mm (7.4 inch) if equipped with optional lights or water
tank.
g01228876
Illustration 28
The bunching head is primarily used when the diameters of the logs are
consistent or when the diameters of the logs are under 305 mm (12 inch).
The bunching head is suited for operations that use a feller buncher.
72 SEBU7892-09
Product Information Section
General Information
Table 7
545C Grapple Continuous Rotation
Bunching Thinning
2
Grapple 1.54 m 1.78 m2
A
Capacity (16.6 ft2) (19.0 ft2)
Tip to Tip 2108 mm 2159 mm
B
Height (83 inch) (85 inch)
3226 mm 3429 mm
C Tong Opening
(127 inch) (135 inch)
Full Open 1905 mm 1880 mm
D
Height (75 inch) (74 inch)
Minimum
183 mm 241 mm
E Stem
(7.2 inch) (9.5 inch)
Diameter
Fully Closed 1371 mm 1473 mm
F
Height (54 inch) (58 inch)
g01228892
Illustration 29
SEBU7892-09 73
Product Information Section
General Information
Table 8
545C Dual Function Arch
Continuous Rotation
A Lift Highest, Retracted 2817 mm (111 inch)
B Lift Highest, Farthest 2163 mm (85 inch)
C Lift Maximum Reach 1443 mm (57 inch)
D Lift Lowest, Retracted 1014 mm (40 inch)
E Lift Lowest, Farthest 335 mm (13 inch)
F Loaded Tire Radius(1) 843 mm (33 inch)
Reach Highest,
G 1653 mm (65 inch)
Retracted
Reach Lowest,
H 1775 mm (70 inch)
Retracted
Reach Lowest,
I 2762 mm (109 inch)
Farthest
Reach Highest,
J 2978 mm (117 inch)
Farthest
K Reach Maximum 3121 mm (123 inch)
(1) With 30.5 x 32 tires
74 SEBU7892-09
Product Information Section
General Information
g01228906
Illustration 30
SEBU7892-09 75
Product Information Section
General Information
Table 9
545C Machine Dimensions
Ground Level to Top Boom
4302 mm (169.4 inch)
(Grapple)
Ground Level to Top
2771 mm (109 inch)
Roller (Cable)
Ground Level to Axle
843 mm (33.2 inch)
Center Line(1)
Rear Axle Center Line to Pin 2203 mm (86.7 inch)
Wheel Base 3939 mm (155.1 inch)
Overall Length (Grapple) 8028 mm (316 inch)
Overall Length (Cable) 7514 mm (295.8 inch)
Ground Clearance 533 mm (21 inch)
Decking Blade Lift Height 1381 mm (54.4 inch)
Decking Blade Dig Depth 456 mm (17.9 inch)
Height to Top of Cab(2) 3184.4 mm (125.4 inch)
Decking Blade Width 3138 mm (123.5 inch)
Tread Width 2622 mm (103.2 inch)
Overall Width 3398mm (133.8 inch)
Turning Radius Over Tires(1) 6400mm (252 inch)
Approximate Maximum
19913 kg (43900 lb)
Weight with Attachments
(1) With 30.5 x 32 tires
(2) Add 188 mm (7.4 inch) if equipped with optional lights or water
tank.
76 SEBU7892-09
Product Information Section
Identication Information
Identication Information
i03698294
For quick reference, record the identication numbers in the spaces that
are provided below the illustration.
g00740332
Illustration 31
SEBU7892-09 77
Product Information Section
Identication Information
g02033102
Illustration 32
CE Plate(2)_____________________________________________________________________________
Year of Manufacture(3)______________________________________________________________
Country of Origin(4)__________________________________________________________________
Year of Manufacture(5)______________________________________________________________
g01228540
Illustration 33
g00495347
Illustration 34
g01133431
Illustration 35
535C and 545C
g01209622
Illustration 36
g01209629
Illustration 37
The serial number plate for the winch is located on the right side of the
winch case.
Certication
ROPS/FOPS Structure
This message is positioned on the ROPS on the left side of the machine
above the door.
80 SEBU7892-09
Product Information Section
Identication Information
g01211894
Illustration 38
This machine has been certied to the standards that are listed on the
certication lm. The maximum mass of the machine, which includes
the operator and the attachments without a payload, should not exceed
the mass on the certication lm.
SEBU7892-09 81
Product Information Section
Identication Information
CE Mark
g01880193
Illustration 39
This plate is positioned on the bottom left side of the plate for the PIN.
g01120192
Illustration 40
This plate is positioned on the bottom left side of the plate for the PIN.
Sound
g00933634
Illustration 41
A typical example of this lm is shown. Your machine may have a
different value.
i04019095
Operation Section
Before Operation
i04021647
g00037860
Illustration 42
Typical example
Mount the machine and dismount the machine only at locations that have
steps and/or handholds. Before you mount the machine, clean the steps
and the handholds. Inspect the steps and handholds. Make all necessary
repairs.
Face the machine whenever you get on the machine and whenever you
get off the machine.
Maintain a three-point contact with the steps and with the handholds.
Note: Three-point contact can be two feet and one hand. Three-point
contact can also be one foot and two hands.
SEBU7892-09 85
Operation Section
Before Operation
Alternate Exit
Machines that are equipped with cabs have alternate exits. For additional
information, see Operation and Maintenance Manual, “Alternate Exit”.
86 SEBU7892-09
Operation Section
Before Operation
i01993565
Daily Inspection
SMCS Code: 1000; 7000
Inspect the area around the machine and under the machine. Look for
loose bolts, trash buildup, oil, coolant leakage, broken parts, or worn parts.
Make sure that all covers and guards are securely attached.
Adjust the mirrors for the correct rear view of the machine.
Note: Watch closely for leaks. If you observe a leak, nd the source of
the leak and correct the leak. If you suspect a leak or you observe a leak,
check the uid levels more frequently.
Note: Make all necessary repairs before you operate the machine.
SEBU7892-09 87
Operation Section
Before Operation
i02205646
The steering frame lock is located on the right side of the machine.
g01113809
Illustration 43
Stored Position
88 SEBU7892-09
Operation Section
Before Operation
The steering frame lock should be kept in the STORED position, while the
machine is running.
g01113800
Illustration 44
Locked Position
The steering frame lock should be placed in the LOCKED position, before
you perform service work near the articulation joint. Also, the steering
frame lock should be placed in the LOCKED position, when the machine
is being lifted and when the machine is being transported.
SEBU7892-09 89
Operation Section
Machine Operation
Machine Operation
i02127571
Alternate Exit
SMCS Code: 7308
g01095218
Illustration 45
The door on the left side of the machine serves as an alternate exit. Use
this door if the door on the right side is blocked.
The alternate exit can be opened from the inside of the cab and from the
outside of the cab. Both cab doors function in the same manner.
i02119886
Seat
SMCS Code: 7312
Note: This seat is an air suspension seat. Adjust the seat at the beginning
of each shift and for each new operator.
While the operator's back is against the back of the seat, the seat should
be adjusted so that there is full pedal travel.
90 SEBU7892-09
Operation Section
Machine Operation
g01079883
Illustration 46
Swivel Lever (1) – Pull up on the lever and hold the lever. Rotate the
seat to the desired position. Release the lever in order to lock the seat into
position. The seat will lock into position at zero degrees, fteen degrees,
and thirty degrees in either direction.
Fore/Aft Lever (2) – Pull up on the lever in order to slide the seat forward
or backward to the desired position. Release the lever in order to lock
the seat into position.
Seat Height Adjustment Switch (3) – Push down on the switch in order
to lower the height of the seat. Pull up on the switch in order to raise
the height of the seat.
Note: The engine start switch key must be turned to ON or the engine
must be running in order to adjust the height of the seat.
The height must be changed if the seat bottoms out excessively or if the
seat bounces to the maximum height too frequently.
SEBU7892-09 91
Operation Section
Machine Operation
i04200349
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt when the machine was
shipped from Caterpillar. At the time of installation, the seat belt and the
instructions for installation of the seat belt meet the SAE J386 and ISO
6683 standards. Consult your Cat dealer for all replacement parts.
Always check the condition of the seat belt and the condition of the
mounting hardware before you operate the machine.
g00100709
Illustration 47
g00932817
Illustration 48
2. To remove the slack in outer loop (1), rotate buckle (2). This will free
the lock bar. This permits the seat belt to move through the buckle.
3. Remove the slack from the outer belt loop by pulling on the buckle.
4. Loosen the other half of the seat belt in the same manner. If the seat
belt does not t snugly with the buckle in the center, readjust the seat
belt.
g00100713
Illustration 49
1. Fasten the seat belt. Pull out on the outer belt loop in order to tighten
the seat belt.
SEBU7892-09 93
Operation Section
Machine Operation
2. Adjust the other half of the seat belt in the same manner.
3. If the seat belt does not t snugly with the buckle in the center, readjust
the seat belt.
g00932818
Illustration 50
Fasten the seat belt catch (3) into the buckle (2). Make sure that the seat
belt is placed low across the lap of the operator.
g00100717
Illustration 51
Pull up on the release lever. This will release the seat belt.
94 SEBU7892-09
Operation Section
Machine Operation
g00867598
Illustration 52
Fasten seat belt catch (3) into buckle (2). Make sure that the seat belt is
placed low across the lap of the operator.
The retractor will adjust the belt length and the retractor will lock in place.
The comfort ride sleeve will allow the operator to have limited movement.
g00039113
Illustration 53
SEBU7892-09 95
Operation Section
Machine Operation
Push the release button on the buckle in order to release the seat belt.
The seat belt will automatically retract into the retractor.
Consult your Cat dealer for longer seat belts and for information on
extending the seat belts.
96 SEBU7892-09
Operation Section
Machine Operation
i03266808
Mirror
SMCS Code: 7319
g01665194
Illustration 54
Interior mirror
(A-A) Rear view
Make sure that the mirror is in proper working condition and that the
mirror is clean. Adjust the mirror at the beginning of each work period and
adjust the mirror when you change operators.
Mirror Adjustment
Interior Mirror
The interior mirrors can be adjusted to a position in order to allow
the operator to see preferred areas at the rear of the machine during
operations such as loading and unloading.
SEBU7892-09 97
Operation Section
Machine Operation
i04291971
Operator Controls
SMCS Code: 7300; 7301; 7451
g01100951
Illustration 55
OFF (1) – When you insert the engine start switch key and
when you remove the engine start switch key, the engine start
switch must be in the OFF position. To disconnect the power to
the electrical circuits in the cab, turn the engine start switch to the OFF
position. Also, turn the engine start switch to the OFF position in order to
stop the engine.
START (3) – To start the engine, turn the engine start switch
clockwise to the START position. When the engine start switch
key is released, the engine start switch will return to the ON
position.
Note: If the engine fails to start, return the engine start switch to the OFF
position. Do not attempt to start the engine again until the engine start
switch is in the OFF position.
98 SEBU7892-09
Operation Section
Machine Operation
g01100875
Illustration 56
The light switches are located above the right side window in the cab.
g00489242
Illustration 57
SEBU7892-09 99
Operation Section
Machine Operation
Press either side of the lens in order to turn on the dome light. Press the
other side of the lens in order to turn off the dome light.
g01100920
Illustration 58
The switches are located on the right side of the cab above the window.
Rear Window Wiper (3) – Press the top of the switch for high
speed. Move the switch to the center position for low speed.
Press the bottom of the switch in order to turn off the rear
window wiper.
100 SEBU7892-09
Operation Section
Machine Operation
g01097920
Illustration 59
Fan Speed Control(1) – This switch controls the fan speed for
the heater and for the air conditioner.
g01100931
Illustration 60
Blower Fan Switch (4) – The fan switch controls the air circulation
toward the windows and toward the operator. The top position is HIGH.
The middle position is LOW. The bottom position is OFF.
Note: In order to maximize the air circulation toward the operator, close
the defroster vents on the front windows.
g01099293
Illustration 61
102 SEBU7892-09
Operation Section
Machine Operation
Push the top of the switch in order to engage the parking brake. Push the
bottom of the switch in order to disengage the parking brake.
g01101986
Illustration 62
The indicator light on the dash panel will ash while the parking brake
(secondary brake) is engaged.
g01099254
Illustration 63
SEBU7892-09 103
Operation Section
Machine Operation
The service brake pedal is the left pedal on the cab oor.
Depress the service brake pedal in order to slow the machine ground
speed. Use the service brake pedal for normal braking.
g01231272
Illustration 64
When the torque converter lockup clutch is engaged, the torque converter
is in direct drive. The engine transfers power directly to the wheels. The
benets are listed below:
• More productive
104 SEBU7892-09
Operation Section
Machine Operation
g01231269
Illustration 65
This feature provides more efcient operation for high speeds and for
transporting loads.
Operation
When the operator enables the torque converter lockup control, the
operator should use lamp (8B) as an indicator to shift to the next gear.
The operator should select a low gear before applying full throttle.
While the machine is moving and lamp (8B) is illuminated, the operator
should shift to the next gear. The operator should maintain full throttle.
The operator should observe lamp (8B) during each gear change. The
green light should be on. Keep the machine in the safest highest speed
possible. This will increase efciency and speed.
If the green light goes off, then the lockup clutch is no longer engaged.
Downshift to the next lower gear. This will keep the lockup clutch engaged,
if the output speed of the transmission is in the correct speed range. The
machine is more efcient and faster in this mode. Staying in a higher gear
is less efcient and slower with the lockup clutch disengaged.
Turn off torque converter lockup control (1) only when the operating
conditions require the machine to stay in torque converter drive.
Service
If the following CID 0709 FMI 13 diagnostic code is recorded on the
Caterpillar Monitoring System, the modulating valve (torque converter
lockup clutch) needs to be calibrated.
Note: The CID 0709 FMI 13 diagnostic code is also recorded whenever
the power train ECM is replaced or whenever new software is ashed to
the power train ECM.
In order to clear the CID 0709 FMI 13 diagnostic code, the modulating
valve for the torque converter lockup clutch must be calibrated. Once the
calibration of the modulating valve for the torque converter lockup clutch
has been performed successfully, this diagnostic code will disappear.
g01099298
Illustration 66
Speed Selector
Note: This machine is equipped with a transmission that has ve forward
speeds and three reverse speeds.
SEBU7892-09 107
Operation Section
Machine Operation
g01099300
Illustration 67
The upshift gear speed switch and the downshift gear speed switch are
located on the steering wheel.
Upshift Gear Speed Switch (4) – Push the upshift gear speed switch in
order to shift the machine into the next highest gear.
Downshift Gear Speed Switch (5) – Push the downshift gear speed
switch in order to shift the machine into the next lowest gear.
g01099301
Illustration 68
The gear speed and the direction will be displayed on the digital display.
108 SEBU7892-09
Operation Section
Machine Operation
Action Indicator
g01366825
Illustration 69
Reference: For a complete list of diagnostic codes that may cause this
warning to be activated, refer to the Service Manual Troubleshooting,
RENR8952, “Troubleshooting Diagnostic Codes” for the machine that is
being serviced.
g01097963
Illustration 70
SEBU7892-09 109
Operation Section
Machine Operation
g00674468
Illustration 71
g01101993
Illustration 72
The alert indicator light on the dash panel will ash while the differential
lock is engaged.
110 SEBU7892-09
Operation Section
Machine Operation
When the differential lock is activated, both wheels on each axle will turn
at the same speed. This helps to prevent wheel slippage on soft ground.
If the wheels continue to slip, reduce the engine speed.
g01099304
Illustration 73
Turn the steering wheel clockwise in order to turn the machine to the right.
Turn the steering wheel counterclockwise in order to turn the machine to
the left. As the steering wheel is turned farther, the radius of the turn is
more acute.
SEBU7892-09 111
Operation Section
Machine Operation
g01099305
Illustration 74
To adjust the steering column, push the steering column tilt control inward
and move the steering column to the desired position. When you release
the steering column tilt control, the steering wheel will remain in the
desired position.
g01100177
Illustration 75
g01097216
Illustration 76
NOTICE
Do not activate the winch Freespool function with a
load on the cable. Use the Reel out to lower the load to
the ground before the freespool function is activated.
g01097218
Illustration 77
Reel In (1)
Reel In High – Push switch (1) to the bottom in order to reel
in the cable. The engine speed controls the speed of the winch
drum.
In order to turn the winch to the OFF position, press the Reel In switch
(1) to the center position.
Reel Out Slow – Place the switch (2) to the top in order to
slowly reel out the cable. The engine speed controls the speed
of the winch drum.
In order to turn the winch to the OFF position, press the Reel Out switch
(2) to the center position.
Freespool (3)
Freespool – Push the switch (3) to the bottom in order to
disengage the winch drum from the drive train. This allows the
cable to unwind freely. The FREESPOOL will not engage if the
machine is moving. The FREESPOOL position will disconnect the spool
drum from the winch drive. The FREESPOOL position should only be
used when the spool drum is not rotating. The FREESPOOL position
should only be used when the spool drum is not under a load.
Place the control for the winch into the FREESPOOL position. Adjust the
drag on the winch drum if the winch cable cannot be turned by hand.
NOTICE
Do not activate the winch Freespool function with a
load on the cable. Use the winch Brake Off function
to lower the load to the ground before the freespool
function is activated.
NOTICE
Freespool function will work only with the parking
brake applied.
g01242274
Illustration 78
(1) Winch control lever. (2) FREESPOOL position. (3) Winch
BRAKE OFF position. (4) Winch BRAKE ON position. (5) REEL
IN position.
When control lever (1) is in the BRAKE ON position (3), the spring-applied
brake that is splined to the clutch shaft rmly holds the entire gear train
and the load on the winch. The bevel pinion, the bevel gear, and the reel
in clutch friction discs are turning freely on the roller bearings.
Moving the control lever (1) to the REEL IN position (5) shifts the spool in
the control valve, sending oil pressure to both the winch brake and the
clutch. The brake is released and the clutch is applied. The bevel gear
now rotates the clutch shaft and the gear train. This will pull the cable to
the winch drum. When the control lever (1) is returned to the BRAKE ON
position (4), the clutch releases and the brake engages. This causes the
gear train to stop and the load is held in place.
116 SEBU7892-09
Operation Section
Machine Operation
Moving the control lever (1) to the BRAKE OFF position (3) activates the
brake solenoid valve on the winch control valve. This sends control oil
pressure to the winch brake in order to release the brake. The drum can
be rotated at this time, but considerable force is required since the gear
train is still engaged and the gear train must be backdriven by the drum.
Note: Apply the parking brake before activating the winch freespool
control.
To activate the winch freespool, control lever (1) must rst be placed
in the full BRAKE OFF position (3), then placed into the FREESPOOL
position (2). Be sure to pause in the BRAKE OFF position (3) until any
load on the drum is released and the drum has come to a complete stop.
Control oil pressure is sent to the freespool cylinder. When the piston
moves, the drum is mechanically disengaged from the gear train. This
allows the cable to be pulled off the drum by hand.
Note: When the parking brake is disengaged, the brake off function will
be immediately activated and the freespool mechanical clutch will be
engaged.
g01099311
Illustration 79
g01099314
Illustration 80
g01099315
Illustration 81
HOLD (3) – When the grapple control lever is in this position, movement
is stopped. The control lever will automatically return to the HOLD position
when the control lever is released.
i02127486
g01098016
Illustration 82
To access the battery disconnect switch (1), open the access door to the
engine compartment on the front left side of the machine.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
The battery disconnect switch and the engine start switch perform
different functions. The entire electrical system is disabled when you turn
off the battery disconnect switch. The battery remains connected to the
electrical system when you only turn off the engine start switch.
120 SEBU7892-09
Operation Section
Machine Operation
Turn the battery disconnect switch to the OFF position and remove the key
when you service the electrical system or any other machine components.
Turn the battery disconnect switch to the OFF position and remove the
key when the machine will not be used for an extended period of a month
or more. This will prevent drainage of the battery.
i02253482
Backup Alarm
SMCS Code: 7406
g01134891
Illustration 83
g00930005
Illustration 84
The alarm is set at the maximum sound level when the machine is
shipped from the factory. The setting should remain on HIGH unless the
job site requires a lower sound level.
122 SEBU7892-09
Operation Section
Machine Operation
i04054871
Monitoring System
SMCS Code: 7451; 7490
Gauges
g01101018
Illustration 85
Fuel Level (5) – This gauge indicates the amount of fuel that
is in the fuel tank. If the needle is in the red zone, the fuel tank
is almost empty.
SEBU7892-09 123
Operation Section
Machine Operation
Alert Indicators
g01101597
Illustration 86
g01101097
Illustration 87
Engine Oil Pressure (10) – When this alert indicator is on, the
engine oil pressure is low.
Brake Oil Pressure (13) – When this alert indicator is on, the
brake oil pressure is low.
Air Inlet Heater Starting Aid (16) – When this alert indicator
is on, the air inlet heater is activated.
Work Lights (20) – When this alert indicator is on, the work
lights are in the ON position.
Note: This indicator is for machines that are equipped with the secondary
steering attachment, only.
Note: This indicator is for machines that are equipped with the secondary
steering attachment, only.
g01101956
Illustration 88
126 SEBU7892-09
Operation Section
Machine Operation
Warning Categories
The Caterpillar Monitoring System provides three warning categories for
the operator. Each warning category is a different level of severity and
each warning category requires different actions by the operator.
Warning Category 1
For this warning category, only the alert indicator will ash. This warning
category only requires the operator to be aware of a condition.
If the electrical loads are too high and the engine speed is low, increase
the engine speed to high idle. This operation will generate more output
from the alternator. If the alert indicator goes off within one minute, the
electrical system is functioning normally. However, the electrical system
becomes overloaded, only during periods of low engine speed.
Low idle must be corrected. Adjust low idle to the high side of the
specication while the most commonly used electrical loads are turned on.
SEBU7892-09 127
Operation Section
Machine Operation
If the alert indicator does not go off, stop the machine and investigate
the cause of the problem. If the alert indicator still ashes near normal
operating speeds and with a light electrical load, stop the machine.
Investigate the cause of the problem. The alternator belt may be loose or
broken. The batteries or the alternator may be faulty.
Warning Category 2
For this warning category, action light (12) will ash. This warning
category requires a change in machine operation in order to lower the oil
temperature or the engine coolant temperature.
You may need to stop the machine in order to investigate the cause of the
problem. If the action light continues to ash, do not operate the machine
until the cause of the problem has been xed.
Warning Category 3
For this warning category, the alert indicator and action light (12) will ash
and an action alarm will sound. This warning category requires immediate
shutdown in order to prevent severe damage to a system and/or to the
machine.
Do not operate the machine until the cause of the problem has been xed.
Engine Oil Pressure (10) – When this alert indicator is on, the
engine oil pressure is low. Stop the machine immediately. Stop
the engine and investigate the cause of the problem.
Brake Oil Pressure (13) – When this alert indicator is on, the
brake oil pressure is low. Stop the machine immediately. Stop
the engine and investigate the cause of the problem.
SEBU7892-09 129
Operation Section
Machine Operation
Digital Display
g01101493
Illustration 89
130 SEBU7892-09
Operation Section
Machine Operation
g01099301
Illustration 90
Press the switch on the left side of the dash panel in order to change the
data that is being displayed on the digital display. The digital display is a
six-digit display area which shows the total service hours of the engine,
the currently selected gear, the rpm of the engine, or diagnostic codes
for troubleshooting. Hold the switch down for 5 seconds in order to get
the diagnostic codes. Once the diagnostic codes are displayed, press the
switch on the left side in order to step through the available displays.
Note: When the parking brake is engaged, the service hour meter is
shown. When the parking brake is not engaged, the gear readout is
shown.
Gear Readout – The digital display shows the selected gear speed and
the selected direction.
Diagnostic Code – The digital display shows the diagnostic code that is
currently active. Diagnostic information is available in the service mode.
i03992269
Product Link
(If Equipped)
SMCS Code: 7490; 7606
Data Broadcasts
Machine data about the machine condition and operation is being
transmitted by Product Link. This data is transmitted to Caterpillar and/or
Cat dealers in order to serve the customer better. Also, this machine
data will improve Caterpillar products and services. The information that
is transmitted may include the following data: machine serial number,
location of the machine, fault codes, emissions data, fuel usage, service
meter hours, version numbers for software and hardware, and installed
attachments.
Caterpillar and/or Caterpillar dealers may use this information for various
purposes: providing services to the customer and/or the machine,
checking or maintaining Product Link equipment, monitoring the machine
health or performance, helping to maintain the machine, improving the
machine efciency, evaluating or improving Caterpillar products and
services, complying with legal requirements and valid court orders,
performing market research, and offering the customer new products
and services.
132 SEBU7892-09
Operation Section
Machine Operation
This blast site warning does not supersede the published requirements or
regulations found in “Title 30 of the Code of Federal Regulations (CFR)”.
This warning does not allow deviation from the published requirements
or regulations found in “Title 30 of the Code of Federal Regulations
(CFR)”. A hazard assessment should be conducted by each customer.
Every customer should meet all of the requirements of “Title 30 of the
Code of Federal Regulations (CFR)” in order to ensure the safe storage,
transportation, loading, and blasting of any explosive.
• The transmit power rating for the Product Link PL121SR transmitter
is 5 to 10 w
• The operating frequency range for the Product Link PL121SR module
is 148 MHz to 150 MHz.
Regulatory Compliance
g01131982
Illustration 91
NOTICE
Transmission of information using Product Link is sub-
ject to legal requirements that may vary from location
to location, including, but not limited to, radio frequen-
cy use authorization. The use of Product Link must be
limited to those locations where all legal requirements
for the use of the Product Link communication network
have been satised.
Consult your Caterpillar dealer with any questions that concern the
operation of the Product Link in a specic country.
134 SEBU7892-09
Operation Section
Machine Operation
g02171578
Illustration 92
Table 10
DECLARATION OF CONFORMITY
CA 92124, Usa
(Previously 92123)
declare under our sole responsibility that the product
QHE2500, Q2000,Q1500, Q1400, Q1200S, Q1200SG, Q1200SH,
Q1200SM and Q1200SV
to which this declaration relates, is in conformity with the following standards
and / or other normative documents.
EN 301 721 V1.2.1 (June 2001)
EN 300 489-20V1.2.1
(November 2002)
EN 60950-1/A11:2004, 1st
Edition
We hereby declare that all essential radio test suites have been carried out and
that the above named product is in conformity to all the essential requirements
of Directive “1999/5/EC”.
The conformity assessment procedure referred to in Article 10 and detailed in
Annex [IV] of Directive “1999/5/EC” has been followed with the involvement of
the following Notied Body:
BABT, Claremont House, 34 Molesey Foad, Walton-on-
Thames, KT12 4RQ, UK
Polina Braunstein
President
(continued)
136 SEBU7892-09
Operation Section
Machine Operation
i02467298
Operation Information
SMCS Code: 7000
NOTICE
Do not operate the machine with the cab doors open.
Large tires can contact the doors when the front axle
is oscillated.
Note: To prevent injury, make sure that no one is working on the machine
or near the machine. Always maintain control of the machine.
Reduce the engine speed when you maneuver in tight quarters and when
you are going over a hill.
Select the necessary gear range before you begin to move downhill. Do
not change speeds while you travel downhill.
When you drive downhill, use the same gear range that is used for driving
uphill.
Do not allow the engine to overspeed while you travel downhill. Apply
the service brake in order to reduce engine overspeed while you travel
downhill.
Note: For operator comfort and maximum service life of power train
components, deceleration and/or braking is recommended before any
directional shifts are made.
4. Depress the service brake pedal in order to prevent the machine from
moving.
5. Push in the parking brake switch in order to release the parking brake.
9. Drive the machine forward for best visibility and for best control.
i02173654
Parking Brake
SMCS Code: 7000
g01101739
Illustration 93
138 SEBU7892-09
Operation Section
Machine Operation
If the brake loses oil pressure, the alert indicator (1) for the brakes will
ash and the action alarm will sound. The alert indicator for the brakes is
on the dash panel. Loss of oil pressure will cause the parking brake to
automatically engage. This will stop the machine.
Anticipate a sudden stop. Correct the cause of the loss of oil pressure. Do
not operate the machine without normal brake oil pressure.
The action light will also ash when the lights on the monitoring system
ash.
NOTICE
Moving the machine with the parking brake engaged
can cause excessive wear or damage to the brake.
i02262460
Secondary Steering
(If Equipped)
SMCS Code: 7000
NOTICE
The alarm system indicates that the primary steering
system has failed.
g01101919
Illustration 94
Alert indicator (2) indicates a failure of the primary steering. When alert
indicator (1) ashes, the secondary steering system is active. When
the alert indicators come on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the machine. Stop
the engine and investigate the cause of the failure. Do not operate the
machine until the cause of the failure has been corrected.
g01136250
Illustration 95
Test Switch (3)
When test switch (3) is pushed, the secondary steering motor will run.
Alert indicator (1) and the action light will come on and the action alarm
will sound. If alert indicator (1) does not come on or the action alarm does
not sound, do not operate the machine.
SEBU7892-09 141
Operation Section
Machine Operation
i02467154
NOTICE
Do not move the winch control lever out of the
FREESPOOL position while the drum is rotating. This
will cause serious damage to the winch gear train.
Note: The following procedure only applies to the mechanical winch C500.
A warm-up for the winch is recommended when the engine is started and
especially when the ambient temperature is below 4 °C (40 °F).
1. Start the engine and run the engine at low idle for ve minutes.
2. Cycle the winch control lever between the Winch Brake ON position
and the FREESPOOL position. Then, place the winch control lever in
the FREESPOOL position and pull out approximately 30 m (100 ft)
of wire rope.
3. Make sure that the area is clear of personnel. While the engine is
running at low idle, reel in the wire rope.
i02391191
Note: The water cleaning system is used to clean the cab oor. Do not
use the water cleaning system for re suppression.
The controls for the water cleaning system are located on the oor of the
cab next to the seat. The water tank is located on top of the cab.
g00868210
Illustration 96
(1) Water Tank
(2) Relief Valve
(3) Filler Plugs
(4) Air Valve
(5) Ball Valve
(6) Water Spray Nozzle
Ball valve (5) controls the ow of water to the water hose and water spray
nozzle (6). When the water cleaning system is not being used, ball valve
(5) should be shut off. After ball valve (5) is shut off, the pressure in the
water hose should be released through water spray nozzle (6).
SEBU7892-09 143
Operation Section
Machine Operation
Fill
1. In order to ll water tank (1), release pressure in the system through
water spray nozzle (6).
2. Unscrew ller plugs (3) for two turns counterclockwise. After the
pressure is completely relieved, remove the ller plugs.
The total volume of water tank (1) is 34 L (9 US gal). Water tank (1) will
hold 25.5 L (6.75 US gal) of water and 8.5 L (2.2 US gal) of air.
Engine Starting
i02391204
Engine Starting
SMCS Code: 1000; 7000
5. Make sure that the control levers are in the HOLD position.
6. Turn the engine start switch to the START position in order to start the
engine. Release the engine start switch key after the engine starts.
NOTICE
Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display veries
that the oil pressure is sufcient.
g01102202
Illustration 97
Turn the ignition switch into the ON position. The alert indicator (1) will
come on during the heating process prior to starting the engine. The
machine can be started after the alert indicator turns off.
i02173657
NOTICE
Keep engine speed low until the engine oil pressure
alert indicator goes out. If the alert indicator does not
go out within ten seconds, stop the engine and inves-
tigate the cause before starting again. Failure to do so
can cause engine damage.
146 SEBU7892-09
Operation Section
Engine Starting
g01101736
Illustration 98
Note: The monitoring system will perform a self test when the engine is
started. Always allow the monitoring system to complete the self test
before you begin operating the machine.
1. Allow a cold engine to warm up at low idle for at least ve minutes.
To help the hydraulic components to warm up faster, engage the
attachment controls and disengage the attachment controls.
Adjustments
i03009978
g01524123
Illustration 99
This is the location of the mechanical winch.
148 SEBU7892-09
Operation Section
Adjustments
g01524143
Illustration 100
This is the adjustment bolt for the mechanical winch (1).
Remove the protective cover from the right side of the winch.
Turn the screw inward in order to increase the drag. Turn the screw
outward in order to decrease the drag.
Adjust the drag so that the cable can be unreeled by hand. The winch
drum will stop when the cable is released.
g01524162
Illustration 101
This is the location of the hydraulic winch.
g01524163
Illustration 102
This is the adjustment bolt for the mechanical winch (2).
Remove the protective cover from the left side of the winch.
150 SEBU7892-09
Operation Section
Adjustments
Turn the screw inward in order to increase the drag. Turn the screw
outward in order to decrease the drag.
Adjust the drag so that the cable can be unreeled by hand. The winch
drum will stop when the cable is released.
Parking
i01358133
NOTICE
Do not engage the secondary brake while the machine
is moving unless the primary service brake fails.
5. Lower the work tool to the ground and apply slight downward pressure.
152 SEBU7892-09
Operation Section
Parking
i02173658
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
celerated wear of the engine components.
1. While the machine is stopped, operate the engine for ve minutes at
low idle. This allows hot areas in the engine to cool gradually. Also, this
will allow the turbocharger shaft to slow down.
g01100951
Illustration 103
(1) OFF position. (2) ON position. (3) START position.
2. Turn the engine start switch to the OFF position in order to stop the
engine.
SEBU7892-09 153
Operation Section
Parking
i02164117
Turn the engine start switch into the OFF position. If the engine does not
stop, an electrical malfunction exists.
g01097538
Illustration 104
g01097543
Illustration 105
154 SEBU7892-09
Operation Section
Parking
Open the access door (1). Move the switch (2) upward in order to stop
the engine.
i02157029
g01102146
Illustration 106
g00710946
Illustration 107
The pressurized oil enters the accumulator and the uid creates pressure
within the accumulator. Energy is stored as the bag that is within the
accumulator is compressed by the oil.
156 SEBU7892-09
Operation Section
Parking
The accumulator supplies pressurized oil to the pilot valve when the
engine is stopped.
Before you lower the attachments, make sure that no one is in the area
around the machine.
2. Push each control lever to the LOWER position in order to lower the
attachments to the ground. The control levers will return to the HOLD
position when the control levers are released.
After the attachments are lowered relieve the pressure in the accumulator
by moving the handle of the grapple control several times in different
directions.
i00936884
1. Make sure that the steps are free of debris. Use the steps and the
handholds when you dismount the machine.
2. Inspect the engine compartment for debris. Remove any debris from
the engine compartment in order to avoid a re hazard.
3. Remove all ammable debris from the bottom guard on the front of the
machine. Removing the debris will prevent a re hazard. Remove this
debris through the access doors and dispose of the debris properly.
4. Turn the battery disconnect switch to the OFF position and remove the
key when the machine will not be used for an extended period of time
(a month or more). This will prevent the battery from being drained.
Drainage of the battery can be caused by a short circuit, by a current
draw from certain components, or by vandalism.
Transportation Information
i02467779
Investigate the travel route for overpass clearances. Make sure that
there will be adequate clearance if the machine that is transported has a
ROPS, a cab, or a canopy.
Remove ice, snow, or other slippery material from the loading dock and
from the transport machine before you load the machine. This will help
to prevent slippage of the machine. This will also help to prevent a shift
while the machine is moving in transit.
Obey the appropriate laws that govern the parameters of the load (weight,
width, and length).
g01096801
Illustration 108
Properly chocked trailer wheels
1. Chock the trailer wheels or the rail car wheels before you load the
machine.
3. Lower the bucket or the work tool to the oor of the transport vehicle.
Move the transmission control to the NEUTRAL position.
SEBU7892-09 159
Operation Section
Transportation Information
5. Turn the engine start switch to the ON position. The engine does not
need to be on, but power must be available through the system.
6. Move all of the control levers in order to relieve any trapped pressure.
7. Turn the engine start switch to the OFF position. Remove the engine
start switch key.
8. Turn the battery disconnect switch to the OFF position. Remove the
battery disconnect switch key.
9. Lock the door and the access covers. Attach any vandalism protection.
10. Secure the machine, any equipment, and any tools with adequate
tie-downs in order to prevent movement during shipping.
11. Cover the exhaust opening. The turbocharger (if equipped) should not
rotate when the engine is not operating. Damage to the turbocharger
can result.
160 SEBU7892-09
Operation Section
Transportation Information
i01998604
Check with the proper ofcials in order to obtain the required licenses and
other similar items before roading the machine.
Carry the work tool as low to the ground as possible. Disable the controls
for the work tool when the machine is roaded.
When you road for long distances, schedule stops in order to allow the
tires and the components to cool. Stop for 30 minutes after every 40 km
(25 miles) or after every hour.
SEBU7892-09 161
Operation Section
Transportation Information
i02216077
NOTICE
Improper lifting or tie-downs can allow the load to shift
and cause injury or damage. Install the steering frame
lock link before lifting.
g01118386
Illustration 109
Tie Down Point – This lm identies a tie-down point that may
be used in order to tie down the machine.
Check all of the laws that govern the load characteristics (height, weight,
width, and length).
The machine shipping weight that is listed is the weight of the most
common conguration of the machine. If attachments have been installed
on your machine, the weight of your machine and the center of gravity
of your machine may vary.
Reference: For the dimensions and the weight of the machine, refer to
Operation and Maintenance Manual, “Specications”.
1. Engage the parking brake before you sling the machine and before
you secure the machine with tie-downs.
3. There are two lifting points at the rear of the machine. Attach a lifting
cable to each lifting point. Each lifting point should be identied as a
lifting point.
Note: Use properly rated cables and properly rated slings to lift the
machine.
4. There are two lifting points at the front of the machine. Attach a lifting
cable to each lifting point. Each lifting point should be identied as a
lifting point.
5. Connect the four lifting cables to the spreader bars. The spreader bars
must be centered over the machine.
Note: The width of the spreader bar must be sufcient to prevent the
lifting cables or the lifting straps from contacting the machine.
7. Position the crane or the lifting device in order to lift the machine in
a level position.
10. Secure the machine at the tie-down points. Each tie-down point should
be identied as a tie-down point.
Towing Information
i02163070
This machine is equipped with spring applied parking brakes that are
released by oil pressure. If the engine is inoperable or if the brake oil
system is inoperable, the parking brakes are applied. The machine can
not be moved.
Use these towing instructions for moving a disabled machine over a short
distance. Do not move the machine faster than 2 km/h (1.2 mph). Move
the machine to a convenient location for repair. Use these instructions
for emergency situations only. Always haul the machine if long distance
moving is required.
Do not allow riders on the machine which is being towed unless the
operator can control the steering and/or the braking.
SEBU7892-09 165
Operation Section
Towing Information
Before you tow the machine, inspect the condition of the tow line or of
the tow bar. Make sure that the tow line or the tow bar is sturdy enough
to tow the disabled machine. The tow line or the tow bar must have a
strength that is equal to 1.5 times the gross weight of the machine that
is being towed. Use a tow bar with this strength or a tow line with this
strength to tow a disabled machine that is stuck in the mud. Also, use a
tow bar with this strength or a tow line with this strength to tow a disabled
machine up a grade.
Do not use a chain for pulling. A chain link may break. This can cause
personal injury. Use a wire cable with cable loops or end rings. Position
an observer at a safe location. The observer should stop the pulling
procedure if the cable starts to break or the cable starts to unravel. If
the towing machine moves without the pulled machine, stop the pulling
procedure.
Keep the tow line angle to a minimum. Do not exceed a 30° angle from
the straight ahead position.
Quick machine movement could overload the tow line or the tow bar.
This could cause the tow line or the tow bar to break. Gradual, smooth
machine movement works better.
Any towed machine with a load must be equipped with a brake system
that can be operated from the operator's compartment.
The operator on the towed machine must steer the machine in the
direction of the tow line.
Carefully obey all of the instructions that are outlined in this topic.
g01096802
Illustration 110
(A) Rod end. (B) Head end.
SEBU7892-09 167
Operation Section
Towing Information
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
NOTICE
Be sure the cylinder hoses are connected correctly be-
fore operating the machine. With the hoses reversed,
the steering system will not function.
NOTICE
Release the parking brake to prevent excessive wear
and damage to the parking brake system when towing
the machine.
Note: For information about the manual release of the parking brake, see
Operation and Maintenance Manual, “Parking Brake Manual Release”.
4. Remove the wheel blocks. Tow the machine slowly. Do not exceed
2 km/h (1.2 mph).
168 SEBU7892-09
Operation Section
Towing Information
i02719558
g00493183
Illustration 111
The parking brake drum is located on the lower back side of the
transmission.
Note: Place blocks in front of the tires and behind the tires in order to
prevent the machine from rolling.
Turn swivel nut (1) in order to move rod (2) downward. Brake lever (3) will
move downward and the parking brake will be released.
SEBU7892-09 169
Operation Section
Engine Starting (Alternate Methods)
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
2. On the stalled machine, turn the engine start switch to the OFF
position. Turn off the accessories.
4. Move the machine or the auxiliary power source close to the stalled
machine so that the cables can reach. DO NOT ALLOW THE
MACHINE OR THE AUXILIARY POWER SOURCE TO CONTACT
THE STALLED MACHINE.
5. Stop the engine on the machine that is the electrical source. (If you are
using an auxiliary power source, turn off the charging system.)
6. Check the battery caps for correct placement and for correct tightness.
Make these checks on both machines. Make sure that the batteries
in the stalled machine are not frozen. Check the batteries for low
electrolyte.
7. Connect the positive jump start cable to the positive cable terminal
of the discharged battery.
Do not allow positive cable clamps to contact any metal except for
battery terminals.
8. Connect the positive jump start cable to the positive terminal of the
electrical source. Use the procedure from Step 7 in order to determine
the correct terminal.
9. Connect one end of the negative jump start cable to the negative
terminal of the electrical source.
10. Make the nal connection. Connect the negative cable to the frame
of the stalled machine. Make this connection away from the battery,
away from the fuel, away from the hydraulic lines, and away from all
moving parts.
11. Start the engine of the machine that is the electrical source. (If you are
using an auxiliary power source, energize the charging system on the
auxiliary power source.)
12. Allow the electrical source to charge the batteries for two minutes.
14. Immediately after the stalled engine starts, disconnect the jump start
cables in reverse order.
i02180048
NOTICE
Ensure that the machine that is used as an electrical
source does not touch the stalled machine. This could
prevent damage to engine bearings and electrical cir-
cuits.
NOTICE
In order to jump start this machine, a jump start recep-
tacle must be used.
There are two cable assemblies that can be used to jump start the stalled
machine. You can jump start the stalled machine from another machine
that is equipped with an auxiliary start receptacle or with an auxiliary
power pack. Your Caterpillar dealer can provide the correct cable lengths
for your application.
2. On a stalled machine, turn the engine start switch key to OFF. Turn
off all accessories.
4. Open the engine access door on the right side of the machine in order
to access the auxiliary start receptacle.
5. Move the machine or the auxiliary power source close to the stalled
machine so that the cables can reach. DO NOT ALLOW THE
MACHINE OR THE AUXILIARY POWER SOURCE TO CONTACT
THE STALLED MACHINE.
6. Stop the engine on the machine that is the power source. If you are
using an auxiliary power source, turn off the charging system.
7. Check the battery caps for correct placement and for correct tightness.
Make these checks on both machines. Make sure that the batteries
in the stalled machine are not frozen. Check the batteries for low
electrolyte.
9. Connect the other end of the jump start cable to the auxiliary start
receptacle of the machine that is being used as a power source.
10. Start the engine on the machine that is being used as a power source
or energize the charging system on the auxiliary power source.
11. Allow the machine that is being used as the power source to charge
the batteries for two minutes.
174 SEBU7892-09
Operation Section
Engine Starting (Alternate Methods)
13. Immediately after the stalled engine starts, disconnect the jump start
cables from the power source.
SEBU7892-09 175
Maintenance Section
Tire Ination Information
Maintenance Section
The tire ination pressure for machines that are shipped from the factory is
suitable for shipping only. Always obtain the proper tire ination pressures
for your machine from the tire supplier before placing the machine into
operation. The recommended tire ination pressures for the front tires and
for the rear tires will vary for each application.
Proper tire ination pressure and maintenance of the tire ination pressure
is critical for optimum tire life. The tire ination pressure should always be
obtained from the tire supplier due to changes in the technology of tires,
equipment, and job applications.
i01909274
The tire pressure in a warm shop area (18° to 21°C (65° to 70°F) average
temperature) will signicantly change when you move the machine into
freezing temperatures. If you inate the tire to the correct pressure in a
warm shop, the tire will be underinated in freezing temperatures. Low
pressure shortens the life of a tire.
Lubricant Viscosities
SMCS Code: 7581
Machines that are operated continuously should use oils that have the
higher oil viscosity in the nal drives and in the differentials. The oils that
have the higher oil viscosity will maintain the highest possible oil lm
thickness. Consult your dealer if additional information is needed.
SAE 0W30
(2)
40 20 40 68
(continued)
178 SEBU7892-09
Maintenance Section
Lubricant Viscosities and Rell Capacities
SAE 0W20
(3)
40 0 40 32
SAE 0W30
(3)
40 10 40 50
Cat TDTO
Cat TDTO-TMS SAE 5W30
(3)
35 10 31 50
Cat Cold
Drive Axles
Weather TDTO
SAE 10W 25 15 13 59
Commercial
TO-4 SAE 30 20 43 4 110
SAE 50 10 50 50 122
TDTO-TMS
(6)
30 43 22 110
(1) API CI-4, API CI-4 PLUS, and API CH-4 oils are acceptable if the requirements of
Caterpillar's ECF-1-a or ECF-2 are met. API CI-4, API CI-4 PLUS, and API CH-4 oils
that have not met the requirements of Caterpillar's ECF-1 or ECF-2 specication may
cause reduced engine life. Refer to Special Publication, SEBU6250, “Caterpillar Machine
Fluid Recommendations” for more information to the CAT ECF specications and other
commercial oils.
(2) First Choice: Oils of full synthetic base stock without viscosity index improvers that
meet the performance requirements of the TO-4 specication for the SAE 30 viscosity
(continued)
SEBU7892-09 179
Maintenance Section
Lubricant Viscosities and Rell Capacities
i02211819
Capacities (Rell)
SMCS Code: 7560
Table 12
525CWheel Skidder
Approximate Rell Capacities
Component or System Liters US gal
Engine Crankcase 27 7.1
Transmission 54 14.3
Hydraulic Tank 54 14.3
Hydraulic Tank with Grapple 115 25.3
Cooling System 57 15
Fuel Tank 303 80
Front Differential and Final Drive 52 13.7
Rear Differential and Final Drive 52 13.7
Mechanical Winch 24.5 6.5
Hydraulic Winch 6.6 1.7
SEBU7892-09 181
Maintenance Section
Lubricant Viscosities and Rell Capacities
Table 13
535CWheel Skidder
Approximate Rell Capacities
Component or System Liters US gal
Engine Crankcase 27 7.1
Transmission 54 14.3
Hydraulic Tank 54 14.3
Hydraulic Tank with Grapple 115 25.3
Cooling System 57 15
Fuel Tank 303 80
Front Differential and Final Drive 52 13.7
Rear Differential and Final Drive 52 13.7
Mechanical Winch 24.5 6.5
Hydraulic Winch 6.6 1.7
182 SEBU7892-09
Maintenance Section
Lubricant Viscosities and Rell Capacities
Table 14
545CWheel Skidder
Approximate Rell Capacities
Component or System Liters US gal
Engine Crankcase 27 7.1
Transmission 54 14.3
Hydraulic Tank 54 14.3
Hydraulic Tank with Grapple 115 25.3
Cooling System 57 15
Fuel Tank 379 100
Front Differential and Final Drive 52 13.7
Rear Differential and Final Drive 74 16.3
Mechanical Winch 24.5 6.5
Hydraulic Winch 6.6 1.7
i04311449
S·O·S Information
SMCS Code: 1348; 3080; 4070; 4250; 4300; 5050; 7542
Maintenance Support
i03636245
1. Turn off the engine. Place the engine start switch in the OFF position.
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
3. Clamp the ground cable from the welder to the component that will be
welded. Place the clamp as close as possible to the weld. Make sure
that the electrical path from the ground cable to the component does
not go through any bearing. Use this procedure in order to reduce the
possibility of damage to the following components:
i04793508
Ensure that all safety information, warnings and instructions are read
and understood before any operation or any maintenance procedures
are performed.
When Required
Battery - Recycle ................................................................................. 194
Battery or Battery Cable - Inspect/Replace ......................................... 196
Circuit Breakers - Reset ....................................................................... 205
Engine Air Filter Primary Element - Clean/Replace ............................. 227
Engine Air Filter Secondary Element - Replace .................................. 231
Engine Air Precleaner - Clean ............................................................. 236
Ether Starting Aid Cylinder - Replace .................................................. 248
Fuel System - Prime ............................................................................ 250
Fuses - Replace ................................................................................... 260
Oil Filter - Inspect ................................................................................. 294
Radiator Core - Clean .......................................................................... 295
Water Cleaning System (Pressurized) - Purge .................................... 315
Winch Wire Rope - Install .................................................................... 333
Window Washer Reservoir - Fill ........................................................... 335
186 SEBU7892-09
Maintenance Section
Maintenance Interval Schedule
Every Year
Cooling System Coolant Sample (Level 2) - Obtain ............................ 216
i03239585
2. The air lter housing is located on the right side of the machine. The
air cleaner dust valve is located below the air lter housing.
g01645293
Illustration 112
3. Check the air cleaner dust valve after every ten service hours or at the
end of each day. Actuate the valve by squeezing the lips of the valve
in order to remove any accumulated debris.
i02354839
g01176013
Illustration 113
g01176016
Illustration 114
Place the steering frame lock into the LOCKED position before lubricating
the articulation bearings.
Apply lubricant through one tting on the upper hitch and through one
tting on the lower hitch.
SEBU7892-09 191
Maintenance Section
Axle Oscillation Bearings - Lubricate
i02155797
g01093280
Illustration 115
g01097093
Illustration 116
Open the engine access door on the right side of the machine.
Apply lubricant through two remote ttings (1) and (2) in order to grease
the bearings for the oscillating axle.
192 SEBU7892-09
Maintenance Section
Backup Alarm - Test
i02261741
1. Turn the engine start switch to the ON position. Do not start the engine.
g00930005
Illustration 117
The alarm is set at the maximum sound level when the machine is
shipped from the factory. The setting should remain on HIGH unless the
job site requires a lower sound level.
SEBU7892-09 193
Maintenance Section
Battery - Clean
i02146969
Battery - Clean
SMCS Code: 1401-070
g01089244
Illustration 118
Before you can clean the battery terminals, you must open the radiator
grill. The radiator grill is hinged in two places in the front of the machine.
Use the following procedure to open the radiator grill.
Remove bolts (1) and (2) from the left side of the radiator grill. This will
allow you to open the grill.
g01089245
Illustration 119
194 SEBU7892-09
Maintenance Section
Battery - Recycle
Clean the battery terminals and the surfaces of the batteries with a clean
cloth. Coat the battery terminals with petroleum jelly. Make sure that the
battery cables are installed securely.
i02039199
Battery - Recycle
SMCS Code: 1401-561
• A battery supplier
• An authorized battery collection facility
• A recycling facility
i02467359
g01089245
Illustration 120
Before you can tighten the hold-downs for the batteries, you must open
the radiator grill. The radiator grill is hinged in two places in the front of
the machine. Use the following procedure to open the radiator grill:
SEBU7892-09 195
Maintenance Section
Battery Hold-Down - Tighten
g01089244
Illustration 121
Remove bolts (1) and (2) from the left side of the radiator grill. This will
allow you to open the grill.
Over time, the vibration of an operating machine can cause the battery
retainers to loosen. To help to prevent loose batteries and the possibility
of loose cable connections, tighten the three locknuts to a torque of
8 ± 2 N·m (71 ± 18 lb in).
Note: Do not operate the blade while the radiator door is open.
196 SEBU7892-09
Maintenance Section
Battery or Battery Cable - Inspect/Replace
i03657099
1. Turn the engine start switch key OFF. Turn all of the switches OFF.
6. Inspect the battery terminals for corrosion. Inspect the battery cables
for wear or damage.
11. Install the key and turn the battery disconnect switch ON.
• A battery supplier
• An authorized battery collection facility
• Recycling facility
198 SEBU7892-09
Maintenance Section
Belt - Inspect/Adjust/Replace
i02216078
Belt - Inspect/Adjust/Replace
SMCS Code: 1397-025; 1397-040; 1397-510
g01090698
Illustration 122
(1) Air conditioner compressor
(2) Alternator
(3) Belt tensioner
Your engine is equipped with a serpentine belt that drives the alternator
(2) and the air conditioner compressor (1).
Insert a ratchet with a square drive into the square hole that is located
in the belt tensioner (3). Rotate the belt tensioner (3) in order to relieve
tension on the belt. Remove the belt.
Install the new belt correctly, as shown. The correct tension will
automatically be applied. Be sure that the belt is fully seated on the
pulleys.
SEBU7892-09 199
Maintenance Section
Brake Accumulator - Check
i02173659
g01101739
Illustration 123
Note: The brake oil pressure indicator light (1) should come on when the
engine is started. The indicator light should turn off when the braking
system reaches normal operating pressure.
2. Allow the engine to idle for at least 30 seconds in order to fully charge
the accumulators.
4. Turn the engine start switch to the ON position but do not start the
engine.
5. Depress the service brake pedal for at least eight applications until the
indicator light comes on.
6. If the indicator light comes on after less than eight applications, check
the nitrogen precharge pressure of the brake accumulator. Consult
your Caterpillar dealer for the proper tools.
i02127658
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Brake service life can vary greatly because of the different applications.
The following conditions can lead to premature brake failure:
Inspect wear on the brake discs in order to determine the remaining life of
the brake discs.
SEBU7892-09 201
Maintenance Section
Braking System - Test
Reference: For the procedure, refer to the Testing and Adjusting service
manual of the braking system or consult your Caterpillar dealer.
i02391229
• Make sure that the steering frame lock is in the unlocked position.
• Fasten the seat belt before you test the brakes.
The following tests are used to determine whether the braking system is
functional. These tests are not intended to measure the maximum brake
holding effort. The required brake holding effort for sustaining a machine
at a specic engine rpm varies from one machine to another machine.
The variations include differences in the engine setting, the power train
efciency, the brake holding ability, etc.
This test is performed when the service brakes are engaged. If the
machine begins to move, compare the engine rpm to the engine rpm of a
prior test. This will indicate the amount of system deterioration.
1. Start the engine. Raise the decking blade slightly. Apply the service
brakes. Release the parking brake.
202 SEBU7892-09
Maintenance Section
Braking System - Test
3. Gradually increase the engine speed to high idle. The machine should
not move.
4. Reduce the engine speed to low idle. Move the transmission direction
control to NEUTRAL. Engage the parking brake. Lower the decking
blade to the ground. Stop the engine.
If the machine moved during the test, consult your Caterpillar dealer for
a brake inspection. Make any necessary repairs before the machine is
returned to operation.
This test is performed when the parking brake is engaged. If the machine
begins to move, compare the engine rpm to the engine rpm of a prior test.
This will indicate the amount of system deterioration.
3. Start the engine. Apply the service brake. Disengage the parking
brake. Press the upshift switch until the display shows 4N.
4. Engage the parking brake. Raise the decking blade slightly. Raise the
grapple slightly. Release the service brake.
Note: This will cause a level 3 warning, which will activate the alarm.
6. Gradually increase the engine speed to high idle. The machine should
not move.
7. Reduce the engine speed to low idle. Move the transmission direction
control to NEUTRAL. Lower the decking blade. Lower the grapple
to the ground. Stop the engine.
If the machine moved during the test, consult your Caterpillar dealer for
a brake inspection. Make any necessary repairs before the machine is
returned to operation.
i02408600
Note: When you are operating the machine in dusty conditions, clean the
cab air lters more often.
g00584743
Illustration 124
g00584744
Illustration 125
5. Remove four bolts and the lter cover behind the seat inside the cab.
Remove the lter element.
6. Clean the lter element with pressure air or wash the lter elements
in warm water with a nonsudsing household detergent. Rinse the
lter element with clean water and allow the lter elements to air dry
thoroughly.
i02205736
g01097660
Illustration 126
The circuit breakers are located on the right side of the machine in the
engine compartment. Open the access panel on the right side of the
machine.
g01097663
Illustration 127
Press the reset button in order to reset circuit breaker (1). Circuit breaker
(1) is the breaker for the thermal starting aid. The thermal starting aid
is an air inlet heater.
206 SEBU7892-09
Maintenance Section
Cooling System Coolant (ELC) - Change
Press the reset button in order to reset circuit breaker (2). Circuit breaker
(2) is for the breaker for the alternator.
Press the reset button in order to reset circuit breaker (3). Circuit breaker
(3) is the main breaker for the electrical system.
Press the reset button in order to reset circuit breaker (4). Circuit breaker
(4) is for the unswitched circuits.
i02216952
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specications reduces
the effectiveness of the coolant and shortens coolant
service life.
If an Extended Life Coolant was previously used, ush the cooling system
with clean water. No other cleaning agents are required. Use the following
procedure to change the cooling system coolant (ELC):
SEBU7892-09 207
Maintenance Section
Cooling System Coolant (ELC) - Change
g01118819
Illustration 128
1. Remove bolts (1) and the access door (2) on the top front part of the
machine.
g01118820
Illustration 129
2. Slowly loosen the cooling system pressure cap (3) in order to relieve
system pressure.
208 SEBU7892-09
Maintenance Section
Cooling System Coolant (ELC) - Change
g01180997
Illustration 130
3. Remove the bottom guard at the front of the machine. Pull out the
drain hose through the opening.
4. Open the engine access door on the left side of the machine.
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
g01204097
Illustration 131
5. Open the drain valve at the bottom of the radiator. Allow the coolant
to drain into a suitable container.
6. Flush the cooling system with clean water until the draining water is
clean. Close the drain valve.
9. Start the engine. Run the engine without the cooling system pressure
cap until the water temperature regulator opens and the coolant level
stabilizes.
12. Install the access door (2) and the bolts (1).
i02216953
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specications reduces
the effectiveness of the coolant and shortens coolant
service life.
Use a coolant test kit in order to check the concentration of the coolant
solution.
SEBU7892-09 211
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
g01118819
Illustration 132
1. Remove bolts (1) and the access door (2) on the top front part of the
machine.
g01118820
Illustration 133
2. Slowly remove the cooling system pressure cap (3) in order to relieve
system pressure.
g00671272
Illustration 134
5. Install the cooling system pressure cap. Close the access door.
SEBU7892-09 213
Maintenance Section
Cooling System Coolant Level - Check
i02164357
g01097780
Illustration 135
g01097787
Illustration 136
2. Maintain the coolant level between the FULL and the LOW marks on
the coolant reservoir (3).
4. Open the cap on the top of the coolant reservoir (3) and add coolant
until the coolant level is between the FULL and LOW marks on the
coolant reservoir (3).
i02251419
• Commercial long life coolants that meet the Caterpillar Engine Coolant
Specication -1 (Caterpillar EC-1)
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
g01195489
Illustration 137
• Complete the information on the label for the sampling bottle before
you begin to take the samples.
• Keep the lids on empty sampling bottles until you are ready to
collect the sample.
• Place the sample in the mailing tube immediately after obtaining the
sample in order to avoid contamination.
i02471396
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
g01195489
Illustration 138
i04333314
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the uid with suitable containers before
opening any compartment or disassembling any com-
ponent containing uids.
A new thermostat should be installed after the cooling system has been
cleaned. Install the thermostat while the cooling system is drained
completely. Or install the thermostat while the cooling system coolant is
drained to a level that is below the thermostat housing.
NOTICE
Failure to replace the engine's thermostat on a regu-
larly scheduled basis could cause severe engine dam-
age.
218 SEBU7892-09
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Note: If you are only installing a new thermostat, drain the cooling system
coolant to a level that is below the thermostat housing.
g01097799
Illustration 139
g01097811
Illustration 140
The water temperature regulator housing is located on the front
right side of the engine.
Regulator housing (1). Water temperature regulator (2).
2. Remove the bolts from regulator housing (1). Remove the regulator
housing (1). Remove all of the used gasket from the regulator housing
(1).
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a thermostat.
NOTICE
If the thermostat is installed incorrectly, it will cause
the engine to overheat.
5. Install a new gasket and the two bolts on regulator housing (1). Install
the thermostat housing on the engine cylinder head.
7. Replace the coolant that was drained from the system. Refer to
Operation and Maintenance Manual, “Capacities (Rell)”.
220 SEBU7892-09
Maintenance Section
Differential and Final Drive Oil - Change
i02338399
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Note: The axles on this machine are equipped with ecology drain valves.
g01167201
Illustration 141
Front Axle
g01167202
Illustration 142
Front Axle
2. Remove the drain plug (3) near the bottom of the differential housing.
5. Remove the ecology drain valve. Inspect the magnet on the end for
metal particles.
6. Clean the metal particles from the magnet. Install the valve.
g01231823
Illustration 143
Rear Axle
222 SEBU7892-09
Maintenance Section
Differential and Final Drive Oil - Change
7. Remove the plate (5) from the rear bottom guard in order to access the
drain plug for the rear differential.
Note: The plate is slotted. Remove two bolts (4), and then loosen the
remaining two bolts. The plate will slide downward. Remove the plate
from the guard.
g01231828
Illustration 144
Rear Axle
8. Remove the drain plug (6) near the bottom of the differential housing.
Note: Remove the dipstick on the right side of the axle, in order to
improve the oil ow while the oil is draining.
11. Clean the drain plug and install the drain plug.
g01167247
Illustration 145
Front Axle (Right Side)
g01167248
Illustration 146
Rear Axle (Left Side)
13. Remove the dipstick/ll plugs on the right side of the axle. Add oil
through the opening.
i02338442
g01167247
Illustration 147
Front Axle (Right Side)
g01167248
Illustration 148
Rear Axle (Left Side)
SEBU7892-09 225
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
1. Remove the dipstick/ll plug on the axle and wipe off the dipstick with a
clean cloth. This will ensure a more accurate measurement. Reinsert
the dipstick/ll plug.
Note: Make sure that the dipstick/ll plug is installed tightly before you
check the oil level. Otherwise, the oil level reading may be incorrect.
2. Remove the dipstick/ll plug again and check the oil level on the
dipstick. The oil level should be between the “ADD” mark and the
“FULL” mark. Add oil through the opening, if necessary.
i02338440
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Operate the machine for a few minutes before you obtain the uid sample.
This will thoroughly mix the uid for a more accurate sample.
g01167247
Illustration 149
Front Axle (Right Side)
g01167248
Illustration 150
Rear Axle (Left Side)
The axles are not equipped with sampling valves. Obtaining a sample
of the differential and nal drive oil will require a vacuum pump or an
equivalent. Remove the dipstick/ll plug on the right side of each axle and
withdraw the oil through the ller opening.
i02468548
NOTICE
Service the air lter only with the engine stopped. En-
gine damage could result.
NOTICE
Always change the air lter based on the Air Filter Ser-
vice Indicator. Do not based service on the appear-
ance of the lter.
1. The air lter is located on the left side of the machine. Open the engine
access panel.
g01096335
Illustration 151
5. Install a clean primary air lter element. For more information, refer to
“Cleaning the Primary Air Filter Element”.
The element can be reused up to six times when the element is properly
cleaned and inspected after each use. When the primary air lter element
is cleaned, check for rips or tears in the lter material. The primary air lter
element should be replaced at least one time per year. This replacement
should be performed regardless of the number of cleanings.
SEBU7892-09 229
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
NOTICE
Do not clean the air lter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air lter element before cleaning. Inspect the
air lter element for damage to the seal, the gaskets, and the outer cover.
Discard any damaged air lter elements.
There are two common methods that are used to clean the primary air
lter element:
• Pressurized air
• Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean a primary air lter element that has
not been cleaned more than two times. Pressurized air will not remove
deposits of carbon and oil. Use ltered, dry air with a maximum pressure
of 207 kPa (30 psi).
g01096212
Illustration 152
Note: When the primary air lter element is cleaned, always begin with
the inside of the lter in order to force dirt particles toward the outside.
230 SEBU7892-09
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Aim the hose so that the air ows inside the element along the length of
the lter in order to help prevent damage to the paper pleats. Do not
aim the stream of air directly at the primary air lter element. Dirt could
be forced further into the pleats.
Vacuum Cleaning
Vacuum cleaning is another method for cleaning a primary air lter element
which requires daily cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior to vacuum cleaning.
Vacuum cleaning will not remove deposits of carbon and oil.
g01096213
Illustration 153
Inspect the clean, dry primary air lter element. Use a 60 watt blue light in
a dark room or in a similar facility. Place the blue light in the primary air
lter element. Rotate the primary air lter element. Inspect the primary air
lter element for tears and/or holes. Inspect the primary air lter element
for light that may show through the lter material. If it is necessary in
order to conrm the result, compare the primary air lter element to a new
primary air lter element that has the same part number.
Do not use a primary air lter element that has any tears and/or holes in
the lter material. Do not use a primary air lter element with damaged
pleats, gaskets or seals. Discard damaged primary air lter elements.
SEBU7892-09 231
Maintenance Section
Engine Air Filter Secondary Element - Replace
g01096217
Illustration 154
Place the primary air lter element into a box for storage. For identication,
mark the outside of the box and mark the primary air lter element.
Include the following information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
i02468628
1. The air lter is located on the left side of the machine. Open the engine
access panel.
232 SEBU7892-09
Maintenance Section
Engine Air Filter Secondary Element - Replace
g01096209
Illustration 155
Note: If necessary, unclamp the strap on the air lter housing so that the
air lter housing can be moved for better access.
g00882913
Illustration 156
4. Clean the inside of the air lter housing. Then, remove the secondary
element from the air lter housing.
SEBU7892-09 233
Maintenance Section
Engine Air Filter Service Indicator - Inspect
i02212237
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
g01095177
Illustration 157
1. Open the engine access door on the LH side of the machine. The air
lter service indicator (1) is located in the engine compartment on the
LH side of the machine.
234 SEBU7892-09
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace
g01116980
Illustration 158
2. If the yellow piston in the air lter service indicator (1) enters the red
zone, service the air cleaner.
3. Check the condition of the air lter service indicator. If the air lter
service indicator is damaged, then replace the air lter service indicator.
i02212375
g01116980
Illustration 159
The air lter service indicator (1) is located in the engine compartment on
the LH side of the machine.
In normal dust conditions, the air lter service indicator should be tested
for proper operation at 250 hours. Also, the indicator should be tested
when the air lter elements are serviced. In order to check the operation
of the air lter service indicator, do the following checks.
• Stop the engine. Check for ease of resetting the indicator. The indicator
should reset within a maximum of three pushes.
• Check for movement of the yellow core when the engine is accelerated
to high idle. When the engine is accelerated to high idle, the yellow core
should latch near the highest position.
If the indicator will not easily reset replace the indicator. When the engine
is accelerated to high idle and the indicator does not latch at the highest
position, replace the indicator.
236 SEBU7892-09
Maintenance Section
Engine Air Precleaner - Clean
i03238081
g01645019
Illustration 160
The engine air precleaner is located on the top of the engine enclosure.
Empty the precleaner bowl whenever the dirt reaches the “FULL” mark.
g01645093
Illustration 161
2. Empty precleaner bowl (3). Wash the precleaner bowl and the cover
with water.
SEBU7892-09 237
Maintenance Section
Engine Crankcase Breather - Clean
3. Install precleaner bowl (3) and cover (2). Tighten wing nut (1) nger
tight.
i02164487
g01095177
Illustration 162
g01097860
Illustration 163
2. Loosen breather outlet hose clamp (3) and remove the hose from
breather cover (1).
238 SEBU7892-09
Maintenance Section
Engine Crankcase Breather - Clean
3. Remove bolt (2) that holds the breather assembly onto breather cover
(1). Remove the breather.
4. Check the condition of the cover seal. Replace the seal if the seal
is damaged.
7. Install the breather assembly, breather cover (1) and bolt (2).
i02145934
NOTICE
Do not under ll or overll engine crankcase with oil.
Either condition can cause engine damage.
1. Open the engine access door on the left side of the machine.
g01089197
Illustration 164
2. Maintain the engine oil within the marks on the correct side of oil level
dipstick (1). Check the oil level while the engine is stopped.
g01089198
Illustration 165
i02127839
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
g01095579
Illustration 166
Operate the machine for a few minutes before you obtain the uid sample.
This will thoroughly mix the uid for a more accurate sample.
The sampling valve for the engine oil is located on the right side of the
engine on the engine oil lter base.
i02340757
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
g00698957
Illustration 167
535C and 545C
SEBU7892-09 243
Maintenance Section
Engine Oil and Filter - Change
g01096085
Illustration 168
535C and 545C
g01207506
Illustration 169
525C
g01230416
Illustration 170
525C
1. Remove the plug from the drain valve in order to drain the oil from
the engine.
2. Attach an elbow and hose to the drain valve. Open the drain valve and
allow the oil to drain into a suitable container.
3. Close the drain valve. Remove the elbow and the hose from the drain
valve.
4. Clean the plug and reinstall the plug in the drain valve.
g01096517
Illustration 171
SEBU7892-09 245
Maintenance Section
Engine Oil and Filter - Change
g01095949
Illustration 172
5. Open the front access door on the right side of the machine. Use a
strap type wrench to remove engine oil lter (1).
6. Clean the housing base. Make sure that the used gasket is completely
removed.
7. Apply a light coat of clean engine oil to the new gasket that is provided
with the new lter.
Note: There are rotation index marks on each engine oil lter that are
spaced 90 degrees or 1/4 of a turn from each other. When you tighten
engine oil lters, use the rotation marks as a guide.
8. Install the engine oil lter hand tight until the seal contacts the base.
Note: Note the position of the index marks on the lter in relation to a
xed point on the lter base.
9. Tighten the lter according to the instructions that are printed on the
lter. Use the index marks as a guide.
246 SEBU7892-09
Maintenance Section
Engine Oil and Filter - Change
g01095976
Illustration 173
g01095975
Illustration 174
10. Open the engine access door on the left side of the machine. Fill the
crankcase with oil through oil ller tube (3).
11. Start the engine and allow the oil to circulate. Check for leaks.
12. Check the engine oil level with oil dipstick (2).
13. If the oil level is correct, close the engine access doors.
SEBU7892-09 247
Maintenance Section
Engine Valve Lash - Check
i04538255
Note: A qualied mechanic should adjust the engine valve lash because
special tools and training are required.
248 SEBU7892-09
Maintenance Section
Ether Starting Aid Cylinder - Replace
i02391361
NOTICE
Do not manually apply the ether into the intake. The
heating element will incur damage if ether is sprayed
directly into the intake.
SEBU7892-09 249
Maintenance Section
Ether Starting Aid Cylinder - Replace
g01095177
Illustration 175
1. Open the access panel on the left side of the engine enclosure.
g01225878
Illustration 176
2. Loosen cylinder retaining clamp (1). Unscrew ether starting aid cylinder
(2).
3. Remove the ether starting aid cylinder and the used gasket. Install the
new gasket that is provided with the new ether starting aid cylinder.
4. Install the new ether starting aid cylinder. Tighten the ether starting aid
cylinder and the cylinder retaining clamp by hand.
i02755946
g00586884
Illustration 177
On the cable skidder, apply lubricant through the tting on the end of each
fairlead roller. There is a total of four ttings.
i02456550
1. Turn the engine start switch to the ON position. Leave the engine start
switch in the ON position for two minutes.
2. Attempt to start the engine. If the engine starts and the engine runs
rough or the engine misres, operate at low idle until the engine is
running smoothly. If the engine cannot be started, or if the engine
continues to misre or smoke, repeat step 1.
Note: The electric fuel pump turns on when the key is turned on. There is
not a separate priming pump.
SEBU7892-09 251
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
i02217093
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
g01118968
Illustration 178
1. Open the engine access door on the left side of the machine. The
primary fuel lter and water separator (1) is located on the left side
of the machine.
2. Loosen drain valve (2) on the bottom of the water separator bowl.
Allow the water and the sediment to drain into a suitable container.
252 SEBU7892-09
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
4. If the engine fails to start or if there is a power loss, change the fuel
lter.
i02217164
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
NOTICE
Do not ll fuel lters with fuel before installing them.
The fuel will not be ltered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
g01119024
Illustration 179
1. Open the engine access door on the left side of the machine. The
primary fuel lter (1) is a spin-on type lter.
254 SEBU7892-09
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
2. Install a hose or a tube onto drain valve (3). Open drain valve (3) on
the bottom of water separator bowl (2). Allow the water and the fuel
to drain into a suitable container.
3. Close drain valve (3). Remove the tube or the hose from the drain
valve.
5. Remove water separator bowl (2) from primary fuel lter (1). Inspect
the fuel lter element for debris by cutting the lter open. Discard the
used fuel lter element properly. Clean water separator bowl (2).
6. Inspect the gasket on water separator bowl (2). Replace the gasket, if
necessary.
7. Lubricate the gasket with clean diesel fuel or with engine oil. Place the
gasket in water separator bowl (2).
8. Install water separator bowl (2) onto the new primary fuel lter (1) by
hand until water separator bowl (2) is snug. Do not use tools to tighten
water separator bowl (2).
Note: Remove the cap from the new primary fuel lter before you install
the water separator bowl. Discard the cap.
9. Clean the lter mounting base. Make sure that all of the used seal is
removed from the lter mounting base.
10. Apply a thin coat of diesel fuel or engine oil to the seal on new primary
fuel lter (1).
11. Install the new fuel lter by hand. When the seal contacts the lter
base, tighten primary fuel lter (1) by an additional 3/4 turn. This will
tighten primary fuel lter (1) sufciently. Do not use tools to tighten
primary fuel lter (1).
12. Prime the fuel system in order to ll the water separator element with
fuel.
i02252246
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
NOTICE
Do not ll fuel lters with fuel before installing them.
The fuel will not be ltered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
256 SEBU7892-09
Maintenance Section
Fuel System Secondary Filter - Replace
g01098027
Illustration 180
1. Open the left front engine access door. The secondary fuel lter is
located on the left side of the engine.
g01099064
Illustration 181
3. Clean the lter mounting base. Make sure that all of the used seal is
completely removed.
SEBU7892-09 257
Maintenance Section
Fuel System Secondary Filter - Replace
g01099018
Illustration 182
4. Install the new lter element by hand. After the gasket contacts the lter
mounting base, tighten the lter elements by an additional 3/4 turn.
i02145893
The fuel tank cap is located on the right side of the machine.
g00702968
Illustration 183
1. Lift lever (5) and turn the lever counterclockwise until the lever stops.
Lift the cap straight up in order to remove the cap.
3. Remove screws (1), lter assembly (2), valve (3) and the gaskets.
5. Install the new cap lter kit. Install the components in reverse order.
6. Remove the strainer from the tank ller opening. Wash the strainer in a
clean, nonammable solvent. Install the strainer.
i01408020
g00741044
Illustration 184
The fuel tank drain valve is located in the articulation joint near the drive
shaft.
Note: For better access, turn the machine all the way to the right.
g00587858
Illustration 185
1. Pull the attached hose out of the opening in the hitch. Remove the plug
from the end of the hose.
260 SEBU7892-09
Maintenance Section
Fuses - Replace
g00585242
Illustration 186
2. Open the drain valve. Allow the water and the sediment to drain into
a suitable container for disposal.
3. Close the drain valve. Install the plug in the end of the hose and place
the hose back into the rear frame.
i02206402
Fuses - Replace
SMCS Code: 1417-510
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
g01097733
Illustration 187
g01099172
Illustration 188
i02461972
g01228503
Illustration 189
Apply lubricant through six ttings on each side of the grapple arch. There
is a total of twelve ttings.
266 SEBU7892-09
Maintenance Section
Grapple Boom and Arch (Single Function) - Lubricate
i02462104
g01228518
Illustration 190
Apply lubricant through three ttings on each side of the grapple arch.
There is a total of six ttings.
SEBU7892-09 267
Maintenance Section
Grapple Head (Bunching) - Lubricate
i02462202
g00954439
Illustration 191
i01906178
g00954439
Illustration 192
g00956334
Illustration 193
Grapple Rotator
g00992708
Illustration 194
Grapple Snubber
i02462227
g00954439
Illustration 195
i01878169
g00955879
Illustration 196
Remove cover plate (1) in order to access tting (2). Fill the rotator with
lubricant through tting (2).
SEBU7892-09 273
Maintenance Section
Grapple Snubber - Inspect/Adjust
i01906192
In order to achieve the longest life of the components for the snubber, the
operation of the snubber should be monitored constantly. The adjustment
should be tight enough to avoid damaging contact with the arch or the
boom while the grapple arms (tongs) are empty.
g00956113
Illustration 197
274 SEBU7892-09
Maintenance Section
Grapple Snubber - Inspect/Adjust
g00956038
Illustration 198
View A-A
Upper Joint Assembly
(1) Bolt
(2) Cap
(3) Shims
(4) Reaction plate
(5) Friction plate
SEBU7892-09 275
Maintenance Section
Grapple Snubber - Inspect/Adjust
g00956037
Illustration 199
View B-B
Lower Joint Assembly
(1) Bolt
(2) Cap
(3) Shims
(4) Reaction plate
(5) Friction plate
The amount of drag of the snubber is set with shims (3). In order to
increase the drag of the snubber, remove shims. In order to decrease
drag of the snubber, add shims.
Note: Each shim goes halfway around cap (2). Therefore, the shims are
removed in pairs. The machine is shipped with 5 shim thicknesses.
2. Add or remove shims until the desired swing of the grapple is achieved.
3. Replace the reaction plates and the friction plates if the drag of the
snubber is not high enough.
Installation Procedure
Upper Joint Assembly
g00956218
Illustration 200
(6) 204-9606 Shim
(7) 204-9607 Shim
(8) Pin
SEBU7892-09 277
Maintenance Section
Grapple Snubber - Inspect/Adjust
g00956219
Illustration 201
View A-A
(1) Bolt
(2) Cap
(3) 203-3956 Shim
(4) Reaction plate
(5) Friction plate
(9) O-ring seal
(10) Bushing
(11) Lip seal
(12) Pin
(13) Spring
(14) Retaining ring
(15) Bushing
1. Install one reaction plate (4) and one friction plate (5).
Note: All friction plates should be dipped in 8T-9579 Oil for ve minutes
before assembly.
Note: A total of ve friction plates are required for proper operation.
2. Insert the pin (12) with retaining ring (14) until the retaining ring
touches the rst friction plate (5).
Note: Install cap (2) with the reversed grease zerk at the top.
4. Retract the pin (8) far enough in order to slide shims (6,7) between the
lug edge and the clevis end. Insert the shims and assemble pin (8).
6. Repeat Step 5 again after one hour of operation after the initial ll.
g00956278
Illustration 202
SEBU7892-09 279
Maintenance Section
Grapple Snubber - Inspect/Adjust
g00992715
Illustration 203
View B-B
(1) Bolt (6) 204-9606 Shim (11) Lip seal
(2) Cap (7) 204-9607 Shim (12) Pin
(3) 203-3956 Shim (8) Pin (13) Spring
(4) Reaction plate (9) O-ring seal (14) Retaining ring
(5) Friction plate (10) Bushing
2. Install one reaction plate (4) and one friction plate (5).
Note: All friction plates should be dipped in 8T-9579 Oil for ve minutes
before assembly.
Note: A total of ve friction plates are required for proper operation.
280 SEBU7892-09
Maintenance Section
Hydraulic System Oil - Change
3. Insert the pin (12) with retaining ring (14) to the back of the clutch
housing.
4. Insert shims (6,7) at the back of the clutch housing lug and pass pin
(12) through the shims until retaining ring (14) touches the rst friction
plate (5).
Note: Install cap (2) with the reversed grease zerk at the top.
7. Repeat Step 6 again after one hour of operation after the initial ll.
i02156191
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
When you change the hydraulic oil, be sure to clean the cover for the lter
and the hydraulic ller cap, before you remove these items. Be sure to
plug or cap any lines or hoses that are disconnected. This will prevent
foreign material from contaminating the hydraulic system.
Note: The hydraulic tank supplies oil to the decking blade, to the grapple,
to the differential lock, to the brakes and to the steering system.
1. Operate the machine in order to warm the oil. Then, park the machine
on a level surface.
3. Lower all attachments to the ground. Apply the parking brake and
stop the engine.
282 SEBU7892-09
Maintenance Section
Hydraulic System Oil - Change
g01093673
Illustration 204
g01093664
Illustration 205
5. Slowly loosen the hydraulic tank ller cap (1) in order to release the
pressure from the hydraulic tank (2).
SEBU7892-09 283
Maintenance Section
Hydraulic System Oil - Change
g01095177
Illustration 206
6. Open the access door on the left side of the engine enclosure.
g01093612
Illustration 207
7. Remove the bolt and the retainer (3) so that hose (5) can be moved.
284 SEBU7892-09
Maintenance Section
Hydraulic System Oil - Change
g01095187
Illustration 208
g01093617
Illustration 209
10. Open drain valve (7). Allow the oil to drain into a suitable container.
13. Return hose (5) to the original position and install the bolt and the
retainer (3).
SEBU7892-09 285
Maintenance Section
Hydraulic System Oil - Change
15. Remove the strainer from the hydraulic oil ller tube. Clean the
strainer and install the strainer.
17. Inspect the ller cap gasket. If the gasket is damaged, replace the
gasket.
19. Start the engine and check for leaks. Check the hydraulic oil level.
Note: The oil must be free of bubbles. If bubbles are present in the oil, air
is entering the hydraulic system. Inspect the suction line for leaks.
286 SEBU7892-09
Maintenance Section
Hydraulic System Oil Filter - Replace
i02156638
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
When you change the hydraulic lters, be sure to clean the cover for the
lter and the hydraulic ller cap, before you remove these items. Be sure
to plug or cap any lines or hoses that are disconnected. This will prevent
foreign material from contaminating the hydraulic system.
SEBU7892-09 287
Maintenance Section
Hydraulic System Oil Filter - Replace
g01094632
Illustration 210
2. Open the access door on the top of the engine enclosure and open the
access door on the right side of the engine enclosure.
g01095207
Illustration 211
3. Slowly loosen hydraulic tank ller cap (1) in order to release the
pressure from the tank.
288 SEBU7892-09
Maintenance Section
Hydraulic System Oil Level - Check
4. Use an oil lter strap wrench to remove the hydraulic oil lters (2) and
(3). Dispose of the used lters properly.
5. Clean both of the lter bases. Make sure that all of the used gaskets
are removed.
7. Install the new hydraulic oil lters (2) and (3). When the lter contacts
the lter base, tighten the lter by an additional 3/4 turn.
9. Start the engine and operate the brakes, the steering and the
attachments. Check the hydraulic oil level.
i02392258
g01196941
Illustration 212
SEBU7892-09 289
Maintenance Section
Hydraulic System Oil Level - Check
1. Lower the decking blade to the ground. Move the grapple tongs
together so the tips of the grapple touch each other. Lower the grapple
to the ground. This position is critical in order to obtain a proper reading
of the hydraulic oil level. Cable machines have only a decking blade
that is hydraulic. Therefore, the decking blade is the only component
that must be on the ground.
g01094632
Illustration 213
2. Open the access door on the top of the engine enclosure and open the
access door on the right side of the engine enclosure.
g01095207
Illustration 214
290 SEBU7892-09
Maintenance Section
Hydraulic System Oil Level - Check
3. Slowly loosen the hydraulic ller cap (1) in order to release the
pressure from the tank.
g01095177
Illustration 215
5. Check the oil level sight gauge. The oil level should be visible through
the sight gauge.
6. If the oil level is low, open the access door on the top of the engine
enclosure.
g01093664
Illustration 216
7. Slowly loosen the hydraulic cap (1) in order to release the pressure
from the tank (2).
SEBU7892-09 291
Maintenance Section
Hydraulic System Oil Sample - Obtain
8. Remove the hydraulic tank ller cap and add oil, if necessary.
9. Clean the ller cap and install the ller cap. Close the access door.
i02127840
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Operate the machine for a few minutes before you obtain the uid sample.
This will thoroughly mix the uid for a more accurate sample.
292 SEBU7892-09
Maintenance Section
Hydraulic System Oil Sample - Obtain
g01088315
Illustration 217
i02156875
g01094645
Illustration 218
g01093924
Illustration 219
2. Slowly loosen the hydraulic tank ller cap (1) in order to relieve the
pressure in the hydraulic tank (3). Tighten the hydraulic tank ller cap
(1). Remove the hydraulic tank breaker relief valve (2).
294 SEBU7892-09
Maintenance Section
Oil Filter - Inspect
i02161948
g01096266
Illustration 220
The element is shown with debris.
Use a lter cutter to cut the lter element open. Spread apart the pleats
and inspect the element for metal and for other debris. An excessive
amount of debris in the lter element can indicate a possible failure.
Ferrous metals can indicate wear on steel parts and on cast iron parts.
Nonferrous metals can indicate wear on the aluminum parts of the engine
such as main bearings, rod bearings, or turbocharger bearings.
SEBU7892-09 295
Maintenance Section
Radiator Core - Clean
Small amounts of debris may be found in the lter element. This could
be caused by friction and by normal wear. Consult your Caterpillar dealer
in order to arrange for further analysis if an excessive amount of debris
is found.
i02469270
Before you can clean the radiator, you must open the radiator grill. The
radiator grill is hinged in two places.
g01089244
Illustration 221
Radiator Grill
1. Remove bolts (1) and (2) from the left side of the radiator grill. This will
allow you to open the grill.
296 SEBU7892-09
Maintenance Section
Radiator Core - Clean
g01096285
Illustration 222
g01231388
Illustration 223
3. Remove the cover plates on the left side of the radiator and the right
side of the radiator in order to expose the access hole for the radiator.
The holes will allow easier access in order to clean the radiator.
i01701441
i02252267
g01133939
Illustration 224
Remove the access panels from both sides of the machine. Tighten the
four cab mounting bolts to a torque of 850 ± 100 N·m (625 ± 75 lb ft).
Replace the mounting supports if the ROPS rattles during machine
operation.
Inspect the ROPS for bolts that are loose, damaged or missing. Replace
any bolts that are damaged or missing with original equipment parts only.
Note: Apply oil to all bolt threads before installation. Failure to apply oil
may result in improper bolt torque.
i02429612
Always check the condition of the seat belt and the condition of the seat
belt mounting hardware before you operate the machine. Replace any
parts that are damaged or worn before you operate the machine.
g00932801
Illustration 225
Typical example
Check the seat belt mounting hardware (1) for wear or for damage.
Replace any mounting hardware that is worn or damaged. Make sure
that the mounting bolts are tight.
Check buckle (2) for wear or for damage. If the buckle is worn or
damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or frayed. Replace the
seat belt if the seat belt is worn or frayed.
Consult your authorized dealer for the replacement of the seat belt and
mounting hardware.
Note: Within three years of the date of installation or within ve years of
the date of manufacture, replace the seat belt. Replace the seat belt at
the date which occurs rst. A date label for determining the age of the
seat belt is attached to the seat belt, the seat belt buckle, and the seat
belt retractor.
300 SEBU7892-09
Maintenance Section
Seat Belt - Replace
If your machine is equipped with a seat belt extension, also perform this
inspection procedure for the seat belt extension.
i04421974
The seat belt should be replaced within 3 years of the date of installation.
A date of installation label is attached to the seat belt retractor and buckle.
If the date of installation label is missing, replace belt within 3 years
from the year of manufacture as indicated on belt webbing label, buckle
housing, or installation tags (non-retractable belts).
g01152685
Illustration 226
Typical Example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Year of manufacture (tag) (fully extended Web)
(4) Year of manufacture (underside) (buckle)
Consult your Cat dealer for the replacement of the seat belt and the
mounting hardware.
Date of installation labels should be marked and afxed to the seat belt
retractor and buckle.
If your machine is equipped with a seat belt extension, also perform this
replacement procedure for the seat belt extension.
i02468987
1. Park the machine on a hard level surface. Lower the implements and
shut off the engine. Leave the engine start switch in the ON position.
g01136250
Illustration 227
2. Press and hold the top of the test switch for the secondary steering.
This will activate the secondary steering motor.
3. Turn the steering wheel fully from left to right. If the machine responds
to the steering input the secondary steering is operating. If the machine
does not respond to the steering input the secondary steering is not
working.
302 SEBU7892-09
Maintenance Section
Steering Cylinder Bearings - Lubricate
4. Release the test switch for the secondary steering. Spring force will
return the test switch for the secondary steering to the OFF position.
This will deactivate the secondary steering motor. Do not run the
secondary steering motor longer than 12 seconds while you are testing
the secondary steering.
NOTICE
Do not operate the machine if the secondary steering
is not operating correctly.
i02252283
1. Wipe off the ttings before you apply lubricant. There is a total of four
ttings.
g00725258
Illustration 228
2. Apply lubricant through the tting at the rod end of each steering
cylinder.
SEBU7892-09 303
Maintenance Section
Steering Cylinder Bearings - Lubricate
g01093280
Illustration 229
g01133957
Illustration 230
4. Apply lubricant through the remote ttings (1) and (2) for the head end
of each steering cylinder.
i01110218
g00585803
Illustration 231
Remove the valve caps on each tire. Measure the tire pressure on each
tire. Inate the tires, if necessary.
i02786556
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
1. Operate the engine in order to warm the oil. Park the machine on a
level surface and lower the decking blade to the ground with slight
down pressure.
5. Clean the drain plug and install the drain plug. Install the access plate.
g00701384
Illustration 232
g00586353
Illustration 233
Note: The rst photo shows a machine that is equipped with a secondary
steering pump and electric motor. The second photo shows a machine
that is not equipped with a secondary steering pump and electric motor.
SEBU7892-09 307
Maintenance Section
Transmission Oil - Change
g00585943
Illustration 234
8. Remove suction screen (2) and tube (4) from the housing. Remove
three magnets (3) from the tube.
10. Use a cloth, a stiff bristle brush or pressurized air to clean the magnets.
NOTICE
Do not drop or rap the magnets against any hard ob-
jects. Replace any damaged magnets.
11. Clean the cover and inspect cover seal (1). Replace the seal, if
necessary.
12. Install three magnets (3) on the tube. Insert suction screen (2) and
tube (4) in the housing.
g01135465
Illustration 235
15. Open the access door on the right side of the machine.
g01135488
Illustration 236
16. Pull out the extendable oil ller tube for easier access and ll the
transmission with oil.
17. Remove the transmission breather from the top of the dipstick tube.
Wash the breather in a clean, nonammable solvent. Install the
breather.
SEBU7892-09 309
Maintenance Section
Transmission Oil - Change
g01115803
Illustration 237
18. Open the access panel on the left side of the machine.
g01119039
Illustration 238
19. Remove the transfer gear housing breather. Wash the breather in a
clean, nonammable solvent. Install the breather.
20. Start the engine and run the engine at low idle.
23. Move the transmission control to the NEUTRAL position and engage
the parking brake.
26. If transmission oil level is low, add oil. Recheck the transmission oil
level.
29. Close the access panel on the left side of the machine. Install the
transmission guards underneath the machine.
i02254243
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
g01101509
Illustration 239
g01135506
Illustration 240
3. Use an oil lter strap wrench to remove the transmission oil lter.
Dispose of the used lter properly.
4. Clean the lter base. Make sure that all of the used gasket is removed.
5. Apply a light coat of clean transmission oil on the new gasket. Install
the gasket on the new lter.
312 SEBU7892-09
Maintenance Section
Transmission Oil Level - Check
6. Install a new transmission oil lter. When the lter contacts the lter
base, tighten the lter by an additional 3/4 turn.
11. Inspect the lter for leaks. Check the transmission oil level.
i02254945
g01135465
Illustration 241
SEBU7892-09 313
Maintenance Section
Transmission Oil Sample - Obtain
g01135568
Illustration 242
2. Remove the dipstick and wipe off the dipstick with a clean cloth. This
will ensure a more accurate measurement of the oil level.
3. Reinsert the dipstick and remove the dipstick again. Check the oil
level. The oil level should be between the marks on the dipstick while
the engine is running at low idle and the transmission is in neutral.
4. If the oil level is low, remove the oil ller cap and add transmission oil
through the oil ller tube, as needed. Reinstall the oil ller cap.
i02255100
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Operate the machine for a few minutes before you obtain the uid sample.
This will thoroughly mix the uid for a more accurate sample.
g01135571
Illustration 243
i02393313
g00868210
Illustration 244
Water Cleaning System
(1) Water Tank
(2) Relief Valve
(3) Filler Plugs
(4) Air Valve
(5) Ball Valve
(6) Water Spray Nozzle
2. Use water spray nozzle (6) to expel all of the water from water tank (1).
Allow the compressed air to escape through the nozzle also.
316 SEBU7892-09
Maintenance Section
Water Cleaning System (Pressurized) - Purge
3. Unscrew ller plugs (3) for two complete turns in order to relieve
pressure.
5. Close ball valve (5). Fill the tank with 60 L (16 US gal) of water.
7. Connect an air hose to air valve (4). Pressurize water tank (1) to
345 kPa (50 psi).
9. Expel the water from water spray nozzle (6). If the discharge is not
strong, repeat the purging process. If there is still a problem, remove
the hose and the lines and check for an obstruction.
10. Once the purging process is complete, ll and pressurize the water
tank.
SEBU7892-09 317
Maintenance Section
Water Cleaning System (Pressurized) - Test
i02143406
g00868210
Illustration 245
Water Cleaning System
(1) Water Tank
(2) Relief Valve
(3) Filler Plugs
(4) Air Valve
(5) Ball Valve
(6) Water Spray Nozzle
1. Remove the water hose from behind the seat. Open ball valve (5).
2. Squeeze water spray nozzle (6) in order to expel the water. There
will be pressure as the water is expelled. If there is very little water
pressure, purge the water cleaning system.
3. After you test the water cleaning system, rell water tank (1). Water
tank (1) must also be pressurized.
318 SEBU7892-09
Maintenance Section
Winch Drive Shaft Spline - Lubricate
i02786672
Note: This procedure only pertains to machines that are equipped with
a mechanical winch.
i02786655
Note: This procedure only pertains to machines that are equipped with
a mechanical winch.
i02216955
Note: This procedure only pertains to machines that are equipped with
a mechanical winch.
g01118824
Illustration 246
Top View
Apply lubricant through ttings (1) and (2) on the rear drive shaft.
i01367960
Note: This procedure only pertains to machines that are equipped with
a Caterpillar C-500 Series winch.
g00721798
Illustration 247
Apply a small amount of lubricant through the tting on the right side of the
winch. Excess lubricant may escape from the vent hole in the cover plate.
SEBU7892-09 321
Maintenance Section
Winch Fairlead Rollers - Lubricate
i04794110
g02911616
Illustration 248
i02456564
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Mechanical Winch
Note: This procedure only pertains to machines that are equipped with
a Caterpillar C-500 Series winch.
SEBU7892-09 323
Maintenance Section
Winch Oil - Change
g00694842
Illustration 249
1. Remove drain plug (1) on the left side of the winch. Attach a hose to a
suitable drain adapter. Install the adapter in the drain valve and allow
the oil to drain into a suitable container.
g00672642
Illustration 250
2. Remove the protective cover from the right side of the winch.
g00690980
Illustration 251
g00699155
Illustration 252
4. Remove the four bolts and cover (2) on the lower right side of the
winch. Remove the strainer from the winch. Remove the strainer from
the suction tube. Remove the metal band and the magnets from the
strainer.
7. Install the magnets and the metal band on the strainer. Apply clean
winch oil to the O-ring seal and install the strainer on the suction tube.
SEBU7892-09 325
Maintenance Section
Winch Oil - Change
8. Inspect the cover seal for wear or for damage. Replace the cover seal,
if necessary. Install the cover and the four bolts.
g00694843
Illustration 253
11. Remove vent plug (3) on the left side of the winch. Clean the vent plug
in a clean, nonammable solvent. Install the vent plug.
Note: Do not replace the vent plug with a solid plug. Do not apply paint
over the vent plug. Either condition may cause oil leaks due to increased
internal pressure during operation of the winch.
326 SEBU7892-09
Maintenance Section
Winch Oil - Change
g00694839
Illustration 254
12. Remove ller plug (4) and ll the winch with oil through the opening.
13. Clean the ller plug and install the ller plug. Clean the vent plug and
install the vent plug.
Hydraulic Winch
Note: The line for the hydraulic winch must be extended in order to
expose the drain hole in the center of the winch.
SEBU7892-09 327
Maintenance Section
Winch Oil - Change
g01231645
Illustration 255
g01225969
Illustration 256
2. Remove drain plug (1) on the right side of the winch. Attach a hose
to a suitable drain adapter. Install the adapter in the drain valve and
allow the oil to drain into a suitable container.
328 SEBU7892-09
Maintenance Section
Winch Oil - Change
g01231535
Illustration 257
3. Remove drain plug (2) on the center of the winch. Attach a hose to a
suitable drain adapter. Install the adapter in the drain valve and allow
the oil to drain into a suitable container.
4. After you have drained the oil, remove the adapters from the drain
openings.
g01231657
Illustration 258
6. Remove vent plug (3) on the left side of the winch. Clean the vent plug
in a clean, nonammable solvent. Install the vent plug.
SEBU7892-09 329
Maintenance Section
Winch Oil - Change
Note: Do not replace the vent plug with a solid plug. Do not apply paint
over the vent plug. Either condition may cause oil leaks due to increased
internal pressure during operation of the winch.
g01231668
Illustration 259
7. Remove ller plug (4) and ll the winch with oil through the opening.
8. Clean the ller plug and install the ller plug. Clean the vent plug and
install the vent plug.
g01231645
Illustration 260
i02156039
g01096103
Illustration 261
g00698328
Illustration 262
1. Remove the access panels on the right side of the machine in order to
access the winch oil lter.
2. Use a strap type wrench to remove the oil lter. Clean the lter base
and dispose of the used lter properly.
SEBU7892-09 331
Maintenance Section
Winch Oil Level - Check
3. Apply a thin coat of oil to the seal of a new lter and install the lter by
hand. When the lter contacts the lter base, tighten the lter by an
additional 3/4 turn.
i01312912
Note: This procedure only pertains to machines that are equipped with
a Caterpillar C-500 Series winch.
g00694965
Illustration 263
Check the oil level of the winch, when the engine is stopped. Maintain the
oil level within the sight gauge. Add oil, if necessary.
332 SEBU7892-09
Maintenance Section
Winch Oil Sample - Obtain
i02127842
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Operate the machine for a few minutes before you obtain the uid sample.
This will thoroughly mix the uid for a more accurate sample.
SEBU7892-09 333
Maintenance Section
Winch Wire Rope - Install
g00697412
Illustration 264
i00947128
Note: Ferrules are made in various sizes. Make sure that you use the
correct ferrule for the size of the wire rope.
Table 15
g00483393
Illustration 265
2. Wrap the wire rope once around the drum and slide the ferrule into the
slot in the drum. Make sure that the wire rope is installed so that the
wire rope will be reeled in over the top of the drum.
3. Move the winch control lever to the REEL IN position in order to wind
the wire rope onto the winch drum.
Note: The wire rope will detach if the wire rope is unwound below one full
turn. Applying red paint to the last six coils of the wire rope will help to
serve as a visual warning.
SEBU7892-09 335
Maintenance Section
Window Washer Reservoir - Fill
i02176858
NOTICE
When operating in freezing temperatures, use
Caterpillar nonfreezing window washer solvent or
equivalent. System damage can result from freezing.
g01102225
Illustration 266
The window washer reservoir is located inside the top engine access
cover on the left side of the hood.
i02143121
Inspect
Inspect the front wiper blade and the rear wiper blade. Replace the wiper
blades if the wiper blades are worn or damaged or if streaking occurs.
The window wiper and/or the wiper motor should be replaced under the
following conditions:
Replace
Use the following procedure in order to install a new wiper and/or a new
wiper motor on the front window and the rear window:
4. Remove the cover in order to access the wiper arm and the wiper
motor.
6. Install the new wiper arm and/or the new wiper motor.
i01921569
Windows - Clean
SMCS Code: 7310-070
Note: Use a damp cloth to clean the windows. Using a dry cloth will
damage the surface of the window.
338 SEBU7892-09
Reference Information Section
Reference Materials
Reference Materials
i03984369
Reference Material
SMCS Code: 1000; 7000
Cooling System
Special Publication, PMEP5027, “Label - ELC Radiator Label”
Grease
Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease (NLGI grade 1 and
grade 2)”
Data Sheet, NEHP6011, “Cat Arctic Platinum Grease (NLGI grade 0)”
Data Sheet, NEHP6012, “Cat Desert Gold Grease (NLGI grade 2)”
Data Sheet, NEHP6015, “Cat High Speed Ball Bearing Grease (NLGI
grade 2)”
Data Sheet, PEHP0002, “Cat Advanced 3Moly Grease (NLGI grade 2)”
SEBU7892-09 339
Reference Information Section
Reference Materials
Hydraulic Oil
Special Publication, PEGP6028, “Caterpillar Hydraulic Systems
Management Guide”
Miscellaneous Publications
Special Publication, REHS2348, “Product Link PL121SR Operation &
Maintenance Manual”
Oil
Special Publication, PEHP3050, “Product Data Sheet for Caterpillar
Multipurpose Tractor Oil (MTO)”
Parts Manuals
Parts Manual, SEBP3855, “525C Wheel Skidder”
ROPS/FOPS Structure
Special Publication, SEBD1587, “What ROPS/FOPS Certication Means”
Safety Information
Operation and Maintenance Manual, SEBU8257, “The European Union
Physical Agents (Vibration) Directive 2002/44/EC”
S·O·S Information
Special Publication, PEDP7036, “S·O·S Services”
Specications Manuals
Specications Manual, SENR3130, “Torque Specications”
Tools
Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog”
342 SEBU7892-09
Reference Information Section
Reference Materials
SAE J313, “Diesel Fuels” This reference can be found in the SAE
handbook. Also, this publication can be obtained from your local
technological society, from your local library, or from your local college.
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
i03989612
When the product is removed from service, local regulations for the
product decommissioning will vary. Disposal of the product will vary with
local regulations. Consult the nearest Cat dealer for additional information.
344 SEBU7892-09
Index Section
Index
A
Specications ......................................................................................... 59
Specications for the 525C ................................................................. 59
Specications for the 535C ................................................................. 65
Specications for the 545C ................................................................. 70
Steering Cylinder Bearings - Lubricate................................................. 302
Steering Frame Lock .............................................................................. 87
Stopping the Engine ............................................................................. 152
Stopping the Engine if an Electrical Malfunction Occurs ...................... 153
Stopping the Machine........................................................................... 151
Table of Contents...................................................................................... 3
Tire Ination - Check ............................................................................ 304
Tire Ination Information....................................................................... 175
Tire Ination Pressure .......................................................................... 175
Tire Ination Pressure Adjustment ....................................................... 175
Tire Information ...................................................................................... 46
Towing Information ............................................................................... 164
Towing the Machine.............................................................................. 164
Towing with the Engine Running....................................................... 166
Towing with the Engine Stopped....................................................... 166
Transmission Oil - Change ................................................................... 305
Transmission Oil Filter - Replace ......................................................... 310
Transmission Oil Level - Check ............................................................ 312
Transmission Oil Sample - Obtain ........................................................ 313
Transportation Information ................................................................... 158
Visibility Information................................................................................ 48
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
©2012 Caterpillar Cat, Caterpillar, their respective logos,
All Rights “Caterpillar Yellow” and the Power edge trade
Reserved dress, as well as corporate and product identity
used herein, are trademarks of Caterpillar and
may not be used without permission.