‘SEBU6504-01 CATERPILLAR’ Operation Maintenance Manual D6D, DG6E, and DGE SR Track-Type Tractors 2MJ1158-UP 8FJ1-UP 7YK1-UP 9FK1-UPTable of Contents Information Section Foreword Safety Section Important Safety Information Safety Warning Signs and Labels General Hazard information (Crushing or Cutting Prevention Burn Prevention Fire or Explosion Prevention Mounting and Dismounting Before Starting the Engine Engine Starting Before Operating the Machine Machine Operation Machine Parking General Section Specifications and Model Views Product Identification and Serial Number Locations Operation Section Operator's Compartment Machine Controls Attachment Controls Botore Starting the Engine Stating the Engine After Stating the Engine Machine Operation Operating Techniques Operating Adustments Machine Parking Transportation Information Towing Information 1 Information Section Table of Contents nance Section Torque Specifications Cooling System Specifications Fuel Specitications Scheduied Oil Sampling (S+O+S) Lubricant Specifications Lubricant Viscosties and Refill Capacities Maintenance Intervals ‘When Required Every 10 Senvice Hours or Daly Every 50 Service Hours or Weokly Every 100 Service Hours or 2 Weeks Every 250 Service Hours or Monthly Every 500 Service Hours or 3 Months Every 1000 Service Hours or 6 Months Every 2000 Service Hours or 1 Year Every 3000 Service Hours or 2 Years Literature Reference Section Literature Reference Materials Index Section Index. 62 cy 70 n 74 75 76 87 100 101 112 7 121 128 131 1322 Information Section Foreword Foreword Literature Information This manual should be stored in the operator's compartment in the literature holder or seat back literature storage area ‘This manual contains safety, operation, transportation, lubrication and maintenance information ‘Some photographs or illustrations in this publication ‘show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes, Continuing improvement and advancement of product design might have caused changes to your machine ‘which are not included in this publication. Read, study land keep this manual with the machine. Whenever a question arises regarding your machine, or this publication, please contact your Caterpillar dealer for the latest available information. Safety ‘The Safety Section lists basic safety precautions, In addition, this section identifies the text and locations of warning signs and labels used on the machine. Read and understand the basic precautions listed in the Safety Section before operating or performing lubrication, maintenance and repair on this machine Operation ‘The Operation Section is a reference for the new operator and a refresher for the experienced one. This section includes a discussion of gauges, switches, ‘machine controls, attachment controls, transportation | ‘and towing information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities Maintenance ‘The Maintenance Section isa guide to equipment care. The ilusrated, step-by-step instructions are grouped by servicing intervals. Items without specific intervals are listed under When Required topics. tems in the Maintenance intervals chart are referenced to detaied instructions that folow. Maintenance intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the Maintenance Intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at Every $00 Service Hours ‘or 3 Months, also service those items listed under Every 250 Service Hours or Monthly and Every 10 Service Hours or Dally Machine Desc: These machines are equipped with a direct injection ‘3306 turbocharged diesel engine. The machine is primarily used for bulldozing, stockpiling, special applications in agricultural and industrial environments, etc. Machine Storage For complete machine storage information refer to ‘Special Instructions: SEHS9031, Storage Procedure for Caterpilar Products and SEHS7392, Storage of Diesel Engines,3 Safety Section Important Safety Information Important Safety Information Most accidents involving product operation, maintenance and repair are caused by fallure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident ocours. A person must be alert to potential hazards. This person should also have the necessary training, skils and tools to perform these functions properly, Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard ‘wamings are not heeded, bodily injury or death could occur to you or other persons, ‘The hazards are identified by the "Safety Alert Symbol’ and folowed by a “Signal Word!” such as WARNING’ as shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication, Caterpilar cannot anticipate every possible circumstance that might involve a potential hazard. The ‘warnings in this publication and on the product are therefore not all inclusive, Ifa tool, procedure, work ‘method or operating technique not specifically recommended by Caterpilar is used, you must satisfy yourself that itis safe for you and others. You should also ensure that the product will not be damaged. (or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and ilustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, istrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Caterpilar dealers have the most current information available, For a list of the mast current publication fom numbers available, see the Service Manual Contents Microfiche, REG1139F.4 Safety Section Safety Safety Warning Signs and Labels There are several specific safety signs on your machine. Their exact location and description of the hazard are reviewed in this section. Please take the time to familiarize yourself with these safety signs. Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, gasoline, etc. You must replace a label if itis damaged, missing or cannot be read. I a label is on a part that is replaced make sure a new label is installed on the replaced part Contact your Caterpillar dealer for new labels, Do not operate or work on this machine unless you have read and understand the instructions and ‘warnings in the Operation and Maintenance Man- ual, Failure to follow the instructions or heed the ‘warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility -_— = x = . Located in the operator's compartment. ‘Structural damage, an overturn, modification, alter- ation, or improper repair can impair this structure’s protection capability thereby voiding this certifica- tion. Do not weld on or drill holes in the structure. Contact a Caterpillar dealer to determine this struc ture’s limitations without voiding its certification. Located on the ROPS or FOPS. 7 MUU} Improper jumper cable connections can cause an explosion resulting in personal injury. Batteries can be located in separate compartments. When using jumper cables always connect positive (+) cable to positive (+) terminal of battery connected to starter solenoid and negative (-) cable from extern source to starter negative (-) terminal. (If not equipped with starter negative terminal, connect to engine block.) vi Located in the battery compartment.High Pressure Cylinder. Do not remove any parts until all pressure has been relieved to avoid possi- ble injury. Relieve pressure by opening relief valve one turn maximum. See the Operation and Mainte- nance Manual for correct procedure. Located on both track roller frames, General Hazard Information n iet to Attach a DO NOT OPERATE, SEHS7332, or similar warning tag to start switch or controls before servicing or repairing the machine. This tag is available from your Caterpillar dealer. Know the width of your attachments so proper clearance can be maintained when operating near fences, boundary obstacles, etc. Wear a hard hat, protective glasses and other protective equipment as required by job conditions. Do not wear loose clothing or jewelry that can catch on controls or other parts of the machine. 5 Safety Section Safety Make certain all protective guards and covers are secured in place on the machine. a 7 Keep the machine, especially the deck, walkways and steps, free of foreign material, such as debris, oll, tools land other items which are not part of the machine. Secure all loose items such as lunch boxes, tools and ‘other objects which are not part of the machine Know the appropriate work-site hand signals and who ives them. Accept signals from one person only. Inhaling freon gas through a lt cigarette or other ‘smoking method or inhaling {ures released from a flame contacting freon can cause bodily harm or death, Do not smoke when servicing air conditioners or wherever freon gas may be present. Never put maintenance fuids into glass containers Use all cleaning solutions with care. Report all needed repairs Do not allow unauthorized personnel on the machine,6 Safety Section Safety Perform all maintenance items with the machine as follows, unless otherwise specified: ‘* The machine parked on level ground. ‘©All attachments are lowered to the ground. ‘* The attachment controls in HOLD. ‘* The transmission control in NEUTRAL. ‘* The parking brake engaged. ‘* The engine stopped. ‘* The battery disconnect switch key off and the key removed. Pressure Air Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes, The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes. Fluid Penetration Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injury, and possible death, If fuidis injected into your skin, it must be treated by a doctor familiar with this type of injury immediately Asbestos Information Caution should be used to avoid breathing dust that might be generated when handling components Containing asbestos fibers. If this dust is inhaled, it can bbe hazardous to your health. Components in Caterpillar products that might contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates land some gaskets. The asbestos used in these ‘components is usually bound in a resin or sealed in ‘some way. Normal handing is not hazardous as long ‘as airborne dust which contains asbestos is not generated If dust which can contain asbestos is present, there are ‘several common sense guidelines that should be followed. ‘Never use compressed air for cleaning, * Avoid brushing or grinding of asbestos containing materials, '*For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. ‘* Use exhaust ventilation on permanent machining jobs. ‘* Wear an approved respirator if there is no other way to control the dust. ‘© Comply with applicable rules and regulations for the ‘work place (for example in the U.S.A., OSHA requirements as set forth in 29 CFR 1910.1001). ‘* Follow environmental rules and regulations for disposal of asbestos. ‘* Avoid areas where asbestos particles might be in the air. Cru 1g or Cutting Prevention ‘Support equipment and attachments properly when working beneath them. Do not depend on hydraulic oylinders to hold itup. Any attachment can fallif a control is moved, oi a hydraulic line breaks. Never attempt adjustments while the machine is ‘moving or the engine is running unless otherwise specified, Where there are attachment linkages, the clearance in the linkage area increases or decreases with movement Of the attachment, Stay clear ofall rotating and moving parts, Keep objects away from moving fan blades. They may ‘throw or cut any object or tool that fas or is pushed into them.Do not use a kinked or frayed wire rope cable. Wear gloves when handling the wire rope cable. Retainer pins, when struck with force, can fly out and: injure nearby persons, Make sure the area is clear of people when driving retainer pins. Wear protective glasses when striking a retainer pin to avoid injury to your eyes, Chips or other debris can fly off objects when struck, Make sure no one can be injured by flying debris, before striking any object. Rollover Protective Structure (ROPS) or Falling Objects Protective Structure (FOPS) This is an attached guard located above the operator's compartment and secured to the machine To avoid possible weakening of the Rollover Protective Structure (ROPS) or Falling Objects Protective Structure (FOPS), contact a Caterpillar dealer before altering, by ‘adding weight to, welding on, or cutting or driling holes into the structure, Any altering done that is not specifically authorized by Caterpillar invalidates Caterpilar's ROPS and FOPS certification. The protection offered by this ROPS/FOPS is impaired if it has been subjected to structural damage. Structural damage can be caused by an overturn accident, by falling objects, etc. Do not mount any item such as fire extinguishers, frst aid kits or lights by welding brackets to or driling holes in any ROPS/FOPS structure, Contact your Caterpillar dealer for mounting guidelines. 7 Safety Section Safety Burn Prevention Coolant ‘At operating temperature, the engine coolant is hot and Under pressure. The radiator and all ines to heaters or the engine contain hot water or steam. Any contact can cause severe burns, Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fil cap is cool enough to remove with your bare hand. Remove the cooling system fil cap slowly to relieve pressure. Cooling system additive contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before raining,8 Safety Section Safety Hot oil and components can cause personal injury. Do rot allow hot oil or components to contact the skin ‘At operating temperature, the hydraulic tank is hot and can be under pressure. Remove the hydraulic tank fil cap only after the engine has been stopped and the fil cap is cool enough 10 remove with your bare hand, Remove the hydraulic tank fil cap slowly to relieve pressure. Relieve all pressure in air ol, fuel or cooling systems before any lines, fitings or related items are disconnected or removed, Batteries Batteries give off flammable fumes which can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes, Always wear protective glasses when working with batteries, Fire or Explosion Prevention All fuels, most lubricants and some coolant mixtures, are flammable. Fuel leaked or spiled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling area, Do not smoke in areas where batteries are charged, or where flammable materials are stored, Batteries in series can be located in separate ‘compartments. When using jumper cables always Connect positive (+) cable to positive (+) terminal of battery connected to starter solenoid and negative (~) cable from external source to starter negative (—) terminal. (if not equipped with starter negative (—) terminal, connect to engine block.) See the Operation Section of this manuel for specific instructions.Clean and tighten all electrical connections. Check daily for loose or frayed electrical wires. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the machine, Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons. Store all oly rags or other flammatle material in a protective container. Store container in a safe place. Do not wold or flame cut on pipes or tubes that contain flammable fluids. Clean pipes or tubes thoroughly with nonfiammable solvent before welding or flame cutting ‘on them, Remove all flammable materials such as fuel, oil and ‘other debris before they accumulate on the machine. If at all possible, do not expose the machine to flames, burning brush, etc. Shields, which protect hot exhaust components from oil or fuel spray in the event of a line, tube or seal falure, must be installed correctly. Fire Extinguisher Have a fire extinguisher avaliable and know how to use it Inspect and have it serviced as recommended on its instruction plate. Ether Ether is poisonous and flammable, Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Use ether only in well-ventilated areas. Do net smoke while changing ether cylinders, Use ether with care to avoid fires Do not store replacement ether cylinders in ving areas or in the operator's compartment, Do not store ether oylinders in direct sunlight or at temperatures above 39°C (102°F). Discard cylinders in a safe place. Do not puncture or bburn cylinders. Keep ether cylinders out of the reach of unauthorized personnel 9 erat Sect Safety Lines, Tubes and Hoses Do not bend or strike high pressure lines. Do not install bbent or damaged lines, tubes or hoses, Repair any loose or damaged fuel and oil ines, tubes ‘and hoses. Leaks can cause fires. Contact your Caterpilar dealer for repair or replacement. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or Cardboard to check for leaks. See Fluid Penetration in the Safety Section for more details. Tighten all Connections to the recommended torque. Replace if any of the following conditions are found. End fittings damaged or leaking. 2. Outer covering chafed or cut and wite reinforcing exposed, 3. Outer covering ballooning locally 4, Evidence of kinking or crushing of the flexible part of hose. 5. Armoring embedded inthe outer cover. 6. End fitings displaced. Make sure that al clamps, guards and heat shields are installed correctly to prevent vibration, rubbing against ‘other parts, and excessive heat during operation. Mounting and Dismounting ‘* Mount and dismount the machine only where steps and/or handholds are provided. ‘s Inspect, and when necessary, clean and have repairs made to steps and handholds before mounting and dismounting10 Safety Section Safety ‘* Face the machine when mounting and dismounting, ‘* Maintain a three-point contact (two feet and one hand Or one foot and two hands) with the steps and handholds. ‘Never get on or off a moving machine. ‘© Never jump off the machine Do not try to climb on or off the machine when. cartying tools or supplies. Use a hand line to pull equipment up onto the platform. '*Do not use any controls as handholds when entering cr leaving the operator's compartment. ‘Secondary Exit Machines with cabs are equipped with secondary onits. Before Starting the Engine Start the engine only from the operator's compartment, Never short across the starter terminals or across the batteries, as this could bypass the engine neutral-start system as well as damage the electrical system, Inspect the condition of the seat belt and mounting hardware. Replace any damaged or worn parts, Replace the seat belt regardless of appearance, after three years of use. Adjust the seat so that full pedal travel can be obtained with the operator's back against the seat back. Make sure the machine is equipped with a lighting system as required by conditions, Make sure all lights are working properly. Make sure no one is working on, underneath or close to the machine before starting the engine or beginning to move the machine. Make sure the area is free of personnelEngine Starting Do not start the engine or move any of the controls if there is aDO NOT OPERATE or similar warning tag attached to the start switch or controls. Move all hydraulic controls to the HOLD position before starting the engine. Move the transmission control lever to NEUTRAL. Engage the parking brake, Diesel engine exhaust contains products of combustion which can be harmful to your health. Always start and operate the engine in a well-ventilated area and, if in an enclosed area, vent the exhaust to the outside 1 Safety Section Safety Before Operating the Machine Clear all personne! from the machine and the area. Clear all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc. Be sure all windows are clean, if the machine is equipped with a cab. Secure the doors and windows in either the open or shut position. ‘Adjust the rear view mirrors (if equipped) for best Vision, especially close to the machine. Make sure the machine horn, the back-up alarm (it equipped) and all other warning devices are working properly. Fasten the seat belt securely Check for proper operation of all controls and protective devices while moving slowly in an open area Machine Operation Operate the machine only while seated Operate the controls only with the engine running, ‘The operator must be satisfied that no one is ‘endangered before moving the machine, Do not allow riders on the machine unless additional seat, seat belt and Rollover Protective Structure (ROPS) or Falling Objects Protective Structure (FOPS) are provided. Report any needed repairs noted during operation. Carry attachments close to the ground, approximately -40 om (15 in) above ground level Stay a safe distance from the edge of clffs, overhangs and slide areas, If the machine begins to sideslip on a grade, immediately dispose of the load and turn the machine downhill Be careful to avoid the condition which could lead to tipping when working on hill, banks or slopes, and when crossing ditches, ridges or other obstructions,12 Safety Section Safety Work up and down siopes, rather than sideways, whenever possible. Keep the machine under control and do not work it over its capacity, Be sure hitch points and the towing device are adequate, Connect trailing equipment to a drawbar or hitch only. Never straddle a wire rope cable or similar device, nor allow others to do so. 'No personnel should be between the machine and tralling equipment when maneuvering to connect them. Block the tongue or hitch of trailing equipment to align it with the drawbar or hitch, Know the maximum height and reach of your machine. Always keep the Rollover Protective Structure (ROPS) or Falling Objects Protective Structure (FOPS) (if equipped) installed when operating the machine. Machine Parking Park on a level surface. If necessary to park on a ‘grade, block the tracks. ‘Apply the service brake to stop the machine, Move the transmission control lever to NEUTRAL and the speed control to LOW IDLE.13 Safety Section Safety Engage the parking brake. Lower all attachments to the ground. Stop the engine. Turn the disconnect switch key to OFF and remove.14 General Section Specifications and Model Views Specifications and Model Views D6D PS and DD, D6E and D6E SR Basic machine shipping specifications are listed below. Engine (1), fue! tank (2), buildozer (3), and cab or canopy (4) 'D60 00 Track-Type Tractor ‘Weight (approximate) 11 650 ko (26,660 ) ‘Length wybuldozer 5050 mm (16.6 f) ‘Length witipper (6120 mm (20.1 ‘Wiath across track shoes | 2990 mm (7.6) Height 2870 mm (5 1) DAD PS Track Type Tractor ‘Weight (epproximate) 11 960 kg (26,370) Length w/buldozer 5050 mm (16.6 ft) Length wirpper 6120 mm (20.1 ft) ‘Width across tack shoes | 2990 mm (7.8) Height 2870 mm (85 1) Operator's compartment (6), hydraulic tank (6), radiator (7), and battery compartment (8), key disconnect switch (9), DBE Track Type Tractor Weight (@pproximate) 12.590 kg (27,700 6) [Length w/bulldozer 5060 mm (16.6) Length wiripper {6120 mm (20.1 ft) ‘Wath across track shoes | 2890 mm (7-8 f) Height 2870 mm (95 1) DBE SA Track Type Tractor | ‘Weight (approximate) 12.280 kg (27,016 B) Length wjbulldozer 15050 mm (16.6 ft) ‘Wath across track shoes | 2890 mm (78 1) Height 2870 mm (85 1)15 General Section Product Identification and Serial Number Locations Product Identification and Serial Number Locations The Product Identification Number (PIN) is used to identify a powered machine that is designed for an ‘operator to ride. Caterpillar products such as earthmoving equipment not designed for an operator to ride (engines, transmissions, etc.) are identified by ySerial Numbers. Also, most major Caterpillar attachments are identified by Serial Numbers. For quick reference, record the identification numbers in the spaces provided below the illustration photographs. Service Information Number Plate (SIN) Bulldozer Serial Number Ripper Serial Number16 Operation Section Operator's Compartment Operator’s Compartment Gauges ‘operating hours of the engine. It should be ® Service Hour Meter (1) Indicates the total Used to determine service intervals, Powe Taio Tenpraue 2 © SESE AE ane ‘Stop operation of the machine Slow the engine speed to % of HIGH IDLE to reduce the excessive temperature. Ifthe pointer remains in the red area alter a few minutes of reduced engine speed, stop the engine. Have all necessary repairs made, before starting the ‘engine again, Possible cause could be low oil level, defective oll pump, working in too high a gear, ete. Engine Oil Pressure ~ When the pointer in the (gauge is in the red area at HIGH IDLE, the engine ail pressure is t00 low. ‘Stop operation of the machine and stop the engine. Possible cause could be oil pump failure, low oil level due to ail leakage or loss, or clogged engine oll filter element, et. Replace the engine oil fiter element. ‘See the Maintenance Section of this manual for oil filter element replacement instructions, NOTICE Operate the engine at LOW IDLE until normal oil pres- sure registers. Engine Coolant Temperature ~ When the pointer in the gauge is in the red area, the lengine coolant temperature is too high ‘Stop operation of the machine. Slow the engine speed to % of HIGH IDLE to reduce the excessive temperature Ifthe pointer remains in the red area after a few minutes of reduced engine speed, stop the engine. Have all necessary repairs made before starting the engine again. Possible cause could be water pump failure, a defective relieve valve cap, hose or radiator, low engine coolant level, a plugged radiator core, etc.ad Aerator (1) ~ When the pointer nth gauge GD) kinins Cheat fe gta higher engine speed, the alleratr not working corey. ‘The machine can be operated until repairs can be made. However, if any electrical accessories are used, the battery discharges rapidly. Possible cause could be a loose alternator belt or bad electrical connection, low battery electrolyte level, detective battery, gauge, etc. (On machines equipped with variable horsepower, an amber (yellow) light on dash (2) lights up to indicate, ‘when the higher horsepower is engaged. ‘Analog Tachometer and Shift Speed Inaiator(F equipped) ~The ptr in the ‘gauge indicates the engine speed in rpm (in hundreds) by the numbers around the edge of the gauge. The Scale on the upper half ofthe tachometer face shows upshift and downshift segments. Use it to determine when to Upshift and downshift for maximum machine efficiency 7 Operation Section Operator's Compartment Digital Tachometer (if equipped) - The cigital readout in the tachometer indicates the engine speed in rpm. Use it to determine when to Upshift and downshift for maximum machine efficiency. Battery Disconnect Switch The battery disconnect switch is located at the left side Of the machine in the operator's compartment, ©) Disconnect Switch ON - Insert the key, and ® turn tothe ight, to turn ON the eectcal system, The sich must be on Before starting the engine Disconnect Switch OFF - Turn the key to the left to tun OFF the electrical system Remove the key when leaving the machine. Also, remove the key when servicing the electrical system. NOTICE Never turn the disconnect key OFF with the engine running. Engine damage could result.18 Operation Section Operator's Compartment Engine Start Switch —— - . The disconnect switch must be ON to start the engine. ‘Always start the engine with the transmission in NEUTRAL (N) and the parking brake engaged. OFF (1) - Turn the switch knob to OFF only when the engine is stopped. ON (2) ~ The switch knob returns to ON after the engine is started, returns to ON (2). NOTICE Do not turn the switch knob to OFF (1) when the engine is running, to prevent damage to the electrical system. NOTE: If the engine does not start the on the first attempt, return the switch knob to OFF to reset the switch before attempting to start the engine again. Starting Aid - Ether (If Equipped) ® ‘Starting Aid (if equipped) - Depress the ® knob, while cranking ony, when starting aids required during cold weather This releases @ premeasured amount of ether ino the ai ita Light Switch OFF (1) - Turn the switch knob to OFF to turn ‘out all the lights. switch knob to this position to turn on all dash Dash and Instrument Lights (2) - Turn the @ and instrument light. position to turn on all work lights. ll dash and instrument lights stay on, when the switch knab is in this position, @® Work Lights (3) - Turn the switch knob to thisFuses Fuse - Replace any fuse, ifthe element is broken and/or the circuit is in does not function, So Horn Fuse (1) ~ 158 Light Fuse (2) - 154 Starting Aid (8) - 54 19 Operation Section Operator's Compartment Windshield Washer/Wiper (If Equipped) ae... Front Left Side (4) - 158 Front Right Side (5) - 154 Rear (6) ~ 154 NOTICE ‘Always replace fuses with ones of the correct ampere rating to prevent damage to the electrical system.20 Operation Section Operator's Compartment Circuit Breaker Windshield Wiper/Washer (If Equipped) Left Front Windshield Wiper/Washer (1) ~ in to reset the circuit breaker. The button Turn the knob to the right (clockwise) to turn should stay depressed. If it does not stay in or ‘on the windshield wiper. First click is low comes out again shortly after being reset, have the ‘speed; second click is high speed. electrical system checked, a Main System - Push the circuit breaker button Push the knob in to spray windshield washer solvent ‘onto the windshield. Right Front Windshield Wiper/Washer (2) ~ Operates the same as item (1) Rear Windshield Wiper/Washer (3) — Operates the same as iter (1) Heating and Air Conditioning Reset (if equipped) - Push the button in to reset the cicutt breaker. The button should stay depressed. If it does not stay in or comes out again shortly after being reset, have the electrical circuit for the heating and air conditioning system checked.Heating and Air Conditioning Operation (It Equipped) 8 ' a] Louvers are located in various areas of the operator's compartment. The louvers can be adjusted to regulate the direction of the air flow. ‘When a reduction of air flow oceurs, the cab air filter elements need cleaning. See the topic Cab Air Filters in the Maintenance Section of this manual. The heating and air conditioning system can perform four functions: sing Ton a rr oh ia QD Serene ee either LOW, MEDIUM, or HIGH. Adjust heating control switch knob (3) for the desired temperature. ‘Cooling - Turn heating control switch knob (3) to OFF Tun fan spoed suten kno (1) 10 either LOW, MEDIUM, of HIGH. Adjust air conditioning control switch knob (2) for the desired temperature 24 Operation Section Operator's Compartment Pressurizing ~ Turn heating (3) and air ‘coneitioning (2) switch knobs to OFF. Turn fan speed switch knob (1) to either LOW, 1, or HIGH to adjust airflow to the required volume to keep out dust. Pressure inside the operator's cab helps to keep out dust when heating or air conditioning is not required. Defogging - Turn fan speed switch knob (1) to HIGH. Adjust both heating (2) and air conditioning (2) switch knobs until the moisture level inside the operator's compartment is. lowered, the temperature is comfortable, and the windshield and all other windows are free of condensation, Fan Fan Speed (1) ~ This switch knob controls the blower fan speed for the desired amount of air flow. Ct 2) ~ Tur he switch knob to OFF t stop © Low (3) = Tur the svitch knob to LOW for © lowest fan speed Medium (4) ~ Turn the switch knob to eS MEDUM for med fan speed ® High (6) - Turn the switch knob to HIGH for highest fan speed.22 Operation Section Operator's Compartment Air Conditioning Heating ‘Air Conditioning (1) - This switch knob Off (2) - Turn the switch knob to OFF to shut off the air conditioner. Maximum Cooling (8) - Turn the switch knob to COOL for maximum cooling Variable Temperature (4) - Turn the switch knob to any position between OFF and COOL for the desired temperature. Cf) Sea eons Off (2) - Turn the switch knob to OFF to turn off the heating system. Maximum Heating (9) ~ Tun the sth knob Ore knob to any position between OFF and WARM. a Variable Temperature (4) - Turn the switch for the desired temperature, Horn (If Equipped) b Horn — Push the knob in to sound the horn. Use the horn to alert or to signal personnelBack-up Alarm (If Equipped) Backup Alam ~The alarm sounds when he tranomision levers inthe REVERSE postion iis used fo warn people behing the machine that is backing up A three position switch at the ear ofthe back-up alarm regulates its volume. (1) is High, (2)is Low, and (3) is Medium. The alarm is set at the highest sound level when shipped from the factory. The setting should remain on high, unless the job site requires a lower level. 23 Operation Section Operator's Compartment Seat Adjustment NOTE: Adjust the seat at the beginning of each shift or when changing operators ‘Adjust the seat to allow full travel of the pedals when the operator is seated against the seat back Static Seat et Push the lever to the operator's left, to allow moving, the seat forward or backward, Suspension Seat (If Equipped) Pull backrest (1) UP and move to the desired position Lower the backrest to lock in position.24 Operation Section Operator's Compartment ull UP fore-ft lever (2). Hold the lever UP, slide the seat forward or back to the desired position. Release the lever to lock the seat in place Turn handle (3) clockwise to increase or counterclockwise to decrease the stiffness of the suspension. Always check the condition of the seat belt and mounting hardware before operating the machine. Replace the seat belt at least once every three years, regardless of appearance. A date label, to determine the age of the belt, is sewn onto each belt. Inspect for worn or frayed webbing (1). Check for worn cor damaged buckle or anticreep slide on each hal of the belt, Replace the belt, buckle or slides if they are worn or damaged, Ingpact the belt mounting hardware. Replace any damaged or worn hardware. Keep the mounting bolts tight If bolt and nut (2) that holds the two parts of the seat belt mounting hooks together are no! correctly installed, the hooks can separate. This allows the seat belt to separate from its mounting, Inspect the hooks of each half of the belt to make certain the bolt and nut are correctly installed. If the bolt and nut are not correctly installed, remove them. Install a new bolt and nut Seat Belt Adjustment Adjust both ends of the belt, The belt should be snug but comfortable, To Lengthen the Belt 4. With the belt unfastened, move the anticreep slide toward the buckle25 Operation Section Operator's Compartment 2. To remove the slack in outer loop (1), rotate buckle 2. Move the antcreep slide toward the anchor end of (2) to tree the lock bar. This permits the belt to move the belt to take up the slack in the outer loop. through the buckle, 3. Adjust the other half of the belt in the same 3. Pullon the buckle until the slack is removed from manner. the outer belt loop. 4, readjust the belt iit does not fit snugly with the 4. Loosen the other half ofthe belt in the same buckle in the center ‘manner. Readjust the bet if it does not fit snugly with the buckle in the center. Rear View Mirrors (If Equipped) To Shorten the Belt 33 Ifthe machine is equipped with rear view mirrors, adjust all micrors for viewing close to the rear of the machine, with the seat in the operator's operating position, 41. With the belt fastened, pull on the outer loop to tighten the belt26 Operation Section Machine Controls Machine Controls Service Brake Pedals eh, Bako Pedals - Push brake pedal (1) and 2) (©) Bane he reteset sono sop the machine Use the brakes ona downgrade to Keep the engine from overspeed Disengage the flywheel clutch on direct drive machines just before machine comes to a complete stop to prevent stalling of the engine. Brake Pedals - Release the brake pedals to @) release the machine's bres and to alow the ‘machine to move or increase ground speed. Use the brake pedals and the steering clutch when ‘making tight turns, Left brake pedal (1) is used with the left steering ‘clutch. Right brake pedal (2) is used with the right steering clutch, ‘Transmission Neutral Lock - Power Shift we i ‘Transmission Neutral Lock - This lever locks the transmission lever in NEUTRAL (N). Unlocked ~ Pull the lever UP to allow the transmission lever to move, Locked - Push the lever DOWN to lock the transmission lever in NEUTRAL.Parking Brake 27 Operation Section Machine Controls Steering Clutch and Brake pedals (1) DOWN to engage the service Drakes. Push parking brake lock lever (2) DOWN to engage and lock. @ Parking Brake Locked - Push both brake Release brake pedals (1). The left pedal stays down, Parking Brake Unlocked ~ Push both brake ppedals (1) DOWN. Pull parking brake lock lever, (2) UP. left lever (1) BACK to steer the machine to the left. The rate of steering is controlled by how far the lever is pulled back. When a slight lever pressure is felt while pulling it back, the lever is entering the braking position, ® Left Steering Clutch/Brake Lever (1) ~ Pull ul the lever all the way BACK to stop the left track for a pivot tur. Pulling the left lover all the way back does not stop the machine. Right Steering Clutch/Brake Lever (2) - Pull right lever (2) BACK to steer the machine to the right. The rate of steering is controlled by @ how far the lever is pulled back. When a slight lever pressure is felt while puling it back, the lever is entering the braking position ul the lever all the way BACK to stop the right track for @ pivot turn, Pulling the right lever all the way back does not stop the machine.28 Operation Section Machine Controls Governor and Decelerator Transmission - Power Shift Governor Lever — Pull the lever BACK to Inreace engine pm. Push the lever FORWARD fo desrese the engine rm, Push the lever FORWARD to the detent poston for LOW IDLE. Push the lever lhe way FORWARD tough the Galen to stop the engine ‘Transmission Direction and Speed Selector = This lever controls transmission NEUTRAL (N) and three speeds FORWARD (F) or REVERSE (R). Move the lever to the desired direction and speed, e The transmission neutral lock must be unlocked fo move the lever Decelerator Pedal (i Equipped) ~ Push the pedal DOWN to override the governor contol find reduce the engine speed Use the pedal to reduce engine rpm for directional shifts Decelerating on directional shifts can extend power train wear life.Transmission - Direct Drive Forward ~ Neutral ~ Reverse Direction Lever ~ Push lever FORWARD (1) to travel back. Pull the lever BACK through NEUTRAL (2)0 position (8) to travel forward. Transmission Speed Lever ~ Move lever to the desired travel speed, Move transmission speed lever as per shift pattern on the machine to the desired speed. 29 Operation Section Machine Controls to engage the clutch with the transmission and to move the machine, ® Flywheel Clutch Lever ~ Pull lover BACK (1) Push lever FORWARD (2) to disengage the clutch, Push lever all the way FORWARD (3) to engage the flywhee! clutch brake, Use when shifting the transmission gear lever to stop the clutch, Do not engage the clutch unless the machine is ready to be moved, The machine can move, even though the transmission directional lever or speed lever isin NEUTRAL (N). Itis important that the machine is. stopped before a transmission shift of any kind is made. ‘When the machine is stopped with the engine iding land the transmission in NEUTRAL, engage the flywheel clutch brake. The flywheel clutch brake stops the rotation of the transmission gears. With the gears stopped, a speed and direction shift can be selected ‘without grinding the gears.30 Operation Section Attachment Controls. Attachment Controls Bulldozer Blade (If Equipped) Bulldozer Blade Tilt (If Equipped) Float (1) ~ Push the lever all the way FORWARD into detent for blade float. In this position, the blade bears against the ground ‘and move up and down following the ground contour. ‘The lever remains in the FLOAT (detent) until manually pulled out of detent position. The lever then returns to HOLD. Lower (2) ~ Push the lever FORWARD to lower the blade. Release the lever and it returns to HOLD, ‘or LOWER, and it returns to HOLD. The blade ® Hold (8) - Release the lever from either RAISE movement stops, Raise (4) - Pul the lever BACK to raise the a) blade, Release the lever andi eturs to HOLD Tilt Left (1) - Pull the lever to the LEFT to lower the blade to the left. Release the lever and it returns to HOLD. Tilt Hold (2) ~ Move the lever to HOLD to stop the blade movement. Tilt Right (3) - Push the lever to the RIGHT to lower the blade to the right. Release the lever and it returns to HOLD.31 Operation Section Attachment Controls Ripper (If Equipped) No. 3 Rear Attachment Valve 7 | fad Raise (1) - Pull the lever to the LEFT (towards: Lower (1) - Push the lever forward to LOWER to lower returns fo HOLD when released Hold (2) ~ Move the lever to HOLD to stop the Hold 2) ~ The lever returns to HOLD when attachment movement ‘eased. Ripper movement Stops Raise (8) ~ Pll the lever to RAISE to raise the attachment from the operator) to lower the ripper. The Raise Detent (4) ~ Pul the lever to RAISE DETENT to lever returns to HOLD when released. raise the attachment, Release the lever and when the attachment reaches its maximum height, the lever returns to HOLD. @ Lower (3) ~ Push the lever to the RIGHT (away32 Operation Section Before Starting the Engine Before Starting the Engine Diesel engine exhaust contains products of com- bbustion which may be harmful to your health. Al- ways start and operate the engine in a well-ventilat- edarea and, ifin an enclosed area, vent the exhaust to the outsid Machine Walk-Around Inspection a Lt iL For maximum service life of the machine, make a thorough walk-around inspection before mounting the machine to start the engine. Look around and under the machine for such items as loose bolts, trash build up, oll or coolant leaks, broken or worn parts. Inspect the condition of the blade and the hydraulic components, ‘See the topic Walk-Around Inspection under Every 10, Service Hours or Daily in the Maintenance Section of this manual for detailed walk-around inspection information, NOTE: When operating on severe slopes, see the information in the footnote of the Refill Capacities chart and in Every 10 Service Hours or Dally in the Maintenance Section of this manual, Pre-Start Checks Check all of the oil, coolant and fuel levels. See Every 10 Service Hours or Daily in the Maintenance Section of this manual for more detailed information, ‘See Walk-Around Inspection in the Maintenance Section of this manual for detailed walk-around. inspection information. Seat and Seat Belt Checks NOTE: Adjust the seat at the beginning of each shift or when changing operators ‘Adjust the seat to allow full travel of the pedals when the operator is seated against the seat back. Ingpact the belt mounting hardware. Replace any damaged or worn hardware. Keep the mounting bolts tight. Fasten the seat belt before starting the engine.33 Operation Section Starting the Engine Starting the Engine Power Shift Push the transmission neutral lock lever DOWN. 5. Move the altachment control levers to HOLD position, 2. Push the parking brake lock lever DOWN. Release the brake pedals, 6. Pull the governor control lever BACK through the shutoff detent. Then return it to the LOW IDLE position 3. Push the transmission speed control lever into NEUTRAL,34 Operation Section Starting the Engine 7. Insert the key into the battery disconnect switch and turn the key to ON. Direct Drive 2. Push the parking brake lock lever DOWN. Release the brake pedals. 3. Move the forward-neutral-everse directional lever (1) to NEUTRAL, 4, Move the transmission speed lever (2) to NEUTRAL. 5. Push the flywheel clutch lever (3) FORWARD to disengage clutch, pap = 6. Move the attachment control levers to HOLD.7. Pull the governor control lever BACK through the shutoff detent, Then return it to the LOW IDLE position. ai 8. insert the key into the battery disconnect switch and turn the key to ON. 35 Operation Section Starting the Engine Engine Starting Above 0°C (32°F) 1. Folow the steps on preceding pages under the topic Power Shift or Direct Drive, depending on which transmission the machine has, before going to Step 2 below. 2. Turn the start switch knob to START. 3. Release the knob after the engine starts. NOTICE Do not turn the start switch or the disconnect switch key to OFF while the engine is running to avoid electri- cal damage. After every 30 seconds of engine cranking, allow 2 minutes for the starting motor to cool before cranking again36 Operation Section Starting the Engine Engine Starting Below 0°C (32°F) - (If Equipped with Ether Starting 41. Follow the steps on preceding pages under the topic Power Shift or Direct Drive, depending on which transmission the machine has, before going to Step 2 AP td 2. Turn the start ewitch knob to START. 3. Push the starting aid (ether) butlon IN and release. 4, Use additional starting fluid every two seconds until the engine starts. NOTICE Inject starting aid (ether), only while cranking the engine. Use sparingly, excessive ether without cranking can ‘cause piston and ring damage. Wait approximately two seconds before injecting again. Use ether for cold starting purposes only. After every 30 seconds of engine cranking, allow 2 minutes for the starting motor to cool before cranking again. 5. Release the start switch knob when the engine stars. For starting below —18°C (0°F), use of additional cold weather starting aids is recommended. A coolant, fuel or ol heater or extra battery capacity may be required, At temperatures below -23°C (-10°F), contact your Caterpilar dealer, or refer to the Cold Weather Recommendations Operation & Maintenance Guide, SEBUS898, available from your Caterpillar dealer. Starting with Jumper Cables Batteries give off flammable fumes that can explode. Prevent sparks near the batteries. They could cause vapors to explode. Do not allow jump cable ‘ends to contact each other or the machine. Do not smoke when checking battery electrolyte levels. Electrolyte is an acid and can cause personal injury it it contacts skin or eyes. Always wear eye protection when starting a ma- chine with jump cables, Improper jump procedures can cause an explosion resulting in personal injury. Always connect battery positive (+) to battery posi- /e (+) and battery negative (--) to battery negative ©. Jump only with a battery source and with the same voltage as the stalled machine. ‘Turn off all lights and accessories on the stalled machine. Otherwise, the lights and accessories ‘operate when the jump source is connected. NOTICE ‘When starting from another machine, make sure the machines do not touch. This could prevent damage to engine bearings and electrical circuits. Turn on (close) the disconnect switch prior to the boost connection to prevent damage to electrical com- ponents on the stalled machine.Machines with Auxiliary Start Receptacles ‘Some Caterpillar products may be equipped with auxliary start receptacles as standard. All other machines can be equipped with a parts service receptacle. A permanent receptacle is then always avaliable for jump starting, Two mating cable assemblies are also available to jump the stalled machine from another machine also ‘equipped with this receptacle or an auxiliary power ppack. Your Caterpilar dealer can provide the correct cables in lengths for your application. 1. Make initial determination as to failure of the stalled machine to crank. Refer to Special instruction, ‘SEHS7768, on use of 6V2150 Starting/Charaing ‘Analyzer Group. Procedure applies even if machine does not have diagnostic connector. 2. Place the transmission control in NEUTRAL on the stalled machine. Engage the parking brake. Lower all attachments to the ground, Move all controls to HOLD. 3. Turn the start switch to OFF on the stalled machine. Turn off all accessories 4. Turn on (close) the disconnect switch (if equipped) (on the stalled machine. 5. Move the boost start machine near enough to the stalled machine for cables to reach, but DO NOT ‘ALLOW MACHINES TO TOUCH 6. Stop the engine on the boost machine, or if using an auxilary power source, tum off the charging system, 7. On the stalled machine connect the appropriate jump start cable to the auxilary start receptacle, 8. Connect the other end of this cable to the auxiliary start receptacle of the boost source, 9. Start the engine on the boost machine. Or, energize the charging system on the auxiliary power source, 10. Wait a minimum of two minutes for the batteries in the stalled machine to partially charge. 11. Attempt to start the stalled engine. See the beginning of Engine Starting in this section. 37 Operation Section Starting the Engine 12. Immediately after starting the stalled engine, disconnect the jump start cable from the BOOST SOURCE, 43. Disconnect the other end of this cable from the stalled machine, 14, Conclude failure analysis on starting/charging system of the stalled machine as required, now that engine is running and charging system in operation, Starting with Jumper Cables When auxiliary start receptacies are not available, use the following procedure. 1. Make initial determination as to failure of machine to crank. Refer to Special Instruction, SEHS7768, on se of 6V2150 Starting/Charging Analyzer Group. Procedure applies even if machine does not have diagnostic connector. 2. Place the transmission control in NEUTRAL on the stalled machine. Engage the parking brake. Lower all atfachments to the ground. Move all controls to HOLD. 3. On stalled machine, turn the start switch to OFF. Tur off all accessories. 4. On stalled machine, turn on (close) the disconnect switch (if equipped), '5. Move boost start machine near enough to stalled machine for cables to reach, but 00 NOT ALLOW MACHINES TO TOUCH. 6. Stop the engine on the boost machine. Or, if using {an auniary power source, turnoff the charging system 7. Make sure batlery caps are all in place and tight ‘on both machines.38 Operation Section Starting the Engine 8. Connect positive (+) jumper cable (red) to positive (#) cable terminal of discharged battery, or battery set (on stalled machine, Do not allow positive cable clamps to touch any metal other than battery terminals, 9. Connect the other end of this positive jumper cable (red) to positive (+) terminal of boost battery. Use procedure of Step 8 to determine correct terminal 10. Connect one end of the negative (~) jumper ‘cable to the other terminal (negative) of the boost battery. 11. Make final connection of negative (-) cable to frame (not battery negative post) away from battery, fuel or hydraulic lines, or moving parts 12. Start the engine on the boost machine. Or, energize the charging system on the auxiliary power source. 13. Wait a minimum of two minutes for the batteries, in the stalled machine to partially charge. 14, Attempt to start the stalled engine. See Starting the Engine in the Operation Section of this manual 15. Immediately after starting the stalled engine, disconnect the jumper cables in reverse order 16. Conclude failure analysis on starting/charging system of stalled machine as required now that engine is running and charging system in operation.After Starting the Engine NOTICE Keep engine speed low until the engine oil pressure: registers on the gauge. If it does not register within 10 seconds, stop the engine and investigate the cause before starting again. Failure to do so, can cause engine damage. 41. Allow a cold engine to warm up at LOW IDLE for at least five minutes. Engage and disengage all attachment controls to help speed warm-up of hydraulic, ‘components. 2. Look at the gauges frequently during operation, ‘Also, to speed hydraulic oll warm-up, hold the blade control in the LOWER position for short periods, not more than 10 seconds. This allows the oil to reach relief pressure, which causes it to warm more rapidly. Cycle all controls to allow warm ol to circulate through all cyinders and lines, When idling the engine for warm-up, observe the following recommendations: ‘In temperatures above 0°C (32°F), warm-up requires: approximately 15 minutes, ‘In temperatures below 0°C (32°F), warm-up requires approximately 30 minutes or more. ‘In temperatures below ~18°C (0°F) or if hydraulic, functions are sluggish, more time may be required. 39 Operation Section After Starting the Engine40 Operation Section Machine Operation Machine Operation Be sure no one is working on or near the machine to prevent injury. Keep the machine under control at all times to prevent injury. Reduce engine speed when maneuvering in tight quarters or when breaking over a rise. Select the gear speed necessary before starting downgrade. Do not change gears while going downhill ‘A good practice is to use the same gear speed going downgrade that would be used to go up the grade. Do not allow the engine to overspeed downhill. Use the service brake pedal to reduce engine overspeed going downhill When the load is pushing the machine, put the transmission selector lever in FIRST speed before starting downhill, ‘Adjust the operator's seat. Fasten the seat belt, Raise all attachments enough to clear any obstructions. Power Shift 1. Push both brake pedals down before moving or to stop the machine, 2. Pull the parking brake lever UP to disengage and unlock. 3. Pull the transmission neutral lock lever UP to unlock. 4. Move the transmission direction and speed selector lever to the desired direction and speed.41 Operation Section Machine Operation 5. Move the governor control lever to the desired 2. Pul the parking brake lever UP to disengage and engine speed. Unlock. 6. Release the brake pedals to allow the machine to move, Push the brake pedals down to slow or stop. clutch brake. Direct 4, Move the transmission speed selector lever to the desired speed. 1. Push down on the service brake pedals to keep the machine from moving. 5. Move the forward:neutralreverse lever to the desired direction.42 Operation Section Machine Operation ‘Transmission Speed and Direction Changes - Power Shift Do not use brake pedals as foot rests to avoid early brake wear or damage. ‘Speed and directional changes at full engine speed are possible on machines with power shift transmission. However, for operator comfort and maximum service lite of transmission components, decelerating and/or braking when changing directions is recommended. 6. Move the governor control lever to the desired engine speed. Br ¥ a > 1. Decrease the engine speed by pushing the \ governor canto in, of by pushing he decelerator — Boda equipped) down er is 7. Rolease the brake pedals to allow the machine to soe A move oN f 2. Push both brake pedals down to stop the machine 8. Pull the fywhee! clutch lever back to engage clutch ‘and to alow the machine to move. Ifthe machine is inoperable, and must be moved, see the topic Towing Information in the Operation Section of this manual.3. Move the transmission control lever to NEUTRAL. Then move the lever to the desired direction 4, Move the transmission control lever to the desired speed Release both brake pedals. = >e 6. increase the engine speed by releasing the | SAE 10W30 =a0 [+40] 4 [oso Fuel Tank -D6E SA ws_|_vs | 96 SAE 15W40 <5] +60] 95 [122 Quantity inthe transmission can Be increased up to 10 poroont SAE 30 +10 [450 +50 [+122 Toure tonsa spe operate, remove exces Fil Drives [SPGSAE5W20 | -a0| -10]-22| +14 2 BMJTISB-UP, 7YKT-UP.SFKI-UP Toro [sae OW =a0] =10|[-28 [+14 9 BFUT-UP SAE 90 =20| 5] «| +59 SAE 40 =10] +90 [+14] +08 SAE 50 0] +50) +52 +122 SAE 8OW90 a0] +50] -28| +122 | "When operating below ~80°C (22°F) refer 10 the Operation land Maintenanee Manual, for Cold Weather Recommendations, ‘SEBUSE98, avaiable from your Caterpillar dale.Maintenance Intervals When Required Engine Air Intake System ~ Service fters 76 Ether Starting Aid (If Equipped) - Replace 79 Fuses ~ Replace 79 Cutting Edges and End Bits Replace 80 Ripper Tips (if Equipped)- Replace 81 Radiator - Clean/replace 81 Bulldozer Tilt Brace - Adjust... nnn 82 Fuel System Filters ~ Change 82 Flywheel Clutch and Brake Adjust on Windshield Wiper/Washer (If Equipped) ~ Inspect/Fill 86 Fuel Filter Element ~ Bosch Fuel System (if Equipped) - Service when loss of power occurs ... 129 Every 10 Service Hours or Daily Walk-Around Inspection - Inspect machine 87 Seat Belt - inspect 89 Window Cleaning 89 Engine Crankcase Oil ~ Check 89 Power Train Oil System — Check 20 Hydraulic Tank Oil - Check 9 Radiator ~ Check coolant level 8 Fuel Tank ~ Drain moisture and sediment 92 Indicators and Gauges - Test 92 Back-up Alarm (If Equipped) ~ Test 8 Every 50 Service Hours or Weekly” Batteries ~ Check 4 Ripper Linkage and Cylinder Bearings ~ Lubricate 95 Cab Air System (if Equipped) ~ Clean fiters elements 95 Bulldozer Cylinder Support Bearings ~ Lubricate . 97 Track Roller Frame Bearings ~ Lubricate 98 Power Train Oil System ~ Change filter element/clean strainer 98 Track Pins ~ inspect 99 Every 100 Service Hours or 2 Weeks* Hydraulic Control Linkage ~ Lubricate 100 Sprocket Hub Bearings ~ Inspect 100 Every 250 Service Hours or Monthly* Engine Oil and Filter — Change. If the sutur Content inthe fuel is greater thann 1.5 percent by weight, use an oll with @ TEN of 30 and reduce the «il change interval by one half 101 75 Maintenance Section Maintenance Intervals Cooling System ~ Add supplemental coolant additiveyreplace element 102 Fan Pulley Bearing — Lubricate 108 Air Conditioning, Fan, and Alternator Beits ~ Inspect/Adjust 103 Final Drives ~ Check oil level 105 Power Train Oil System- Change filter element/clean screen and magnets) 105 Brakes ~ Check brake podalsjparking brake... 107 Tracks ~ Adjust 108 Air Conditioner (if Equipped) ~ Test 110 Bulldozer Tilt Brace — Lubricate 111 Engine Valve Clearance Setting ~ Adjust on new or reconditioned engines at first oll change only .... 126 Every 500 Service Hours or 3 Months* Hydraulic System — Change filter element 112 Fuel System - Change primary and secondary filter 113 Fuel Tank - Clean cap and fil screen 114 Engine Crankcase Breather ~ Clean 415 Equalizer Bar Pads — Inspect 116 Sprocket Hub Bearings - Inspect 116 Every 1000 Service Hours or 6 Months Power Train Oil System (Power Shift) ~ Drain ol, ‘change filter, clean soreen and magnets, Fill ol... 117 Universal Joints ~ Lubricate 119 Rollover or Falling Objects Protective ‘Structure/Falling Object Protective Structure (ROPS/FOPS) (If Equipped) - Inspect 120 Every 2000 Service Hours or 1 Year" Hydraulic System ~ Change oil 11 Power Train Oil System (Direct Drive) ~ Drain ol, change filter, clean screen and magnets, Fill ol... 122 Final Drives = Change oi! 185 Engine Valve Clearance Setting ~ Adjust 126 Engine Valve Rotators ~ Check 128 ‘Sprocket Hub Bearings ~ Adjust 187 Every 3000 Service Hours or 2 Years" Cooling System ~ Change coolant, clean system . 128 Fuel Filter Element - Bosch Fuel System (If Equipped) - Change 129 “First Perform Previous Service Hours Items76 Maintenance Section ‘When Required When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation ‘or maintenance procedures. Engine Air Intake System Precieaner ome ‘N as 1. Inspect the cup visually. Cup should be emptied whenever dirt reaches the indicator mark. 2. Loosen the wing nut on top and remove the cover and cup. Empty and clean the cup, wipe the cover clean. 3. instal the cup and cover. Tighten the wing nut finger tight ony. Do not use too Service Filter Elements NOTICE ‘Service the air cleaner only with the engine stopped. Engine damage could result —¥< Service the air cleaner if the yellow piston inthe filter ‘element indicator moves into the red zone with the {engine running at HIGH IDLE. Stop the engine. Service Primary Element 1. Open the access cover (if equipped) 2. Remove the air cleaner cover. 3. Remove the primary filter element from the air leaner housing4. Clean the inside of the air cleaner housing 5. Clean and inspect the primary element. See the topic Cleaning Primary Elements under When Required in the Maintenance Section of this manual 6. Install a clean primary element 7. Clean and install the cover. Tighten the cover bolts finger tight. Do not use a tool to tighten the bolts. 8. Close the access door (if equipped). Ifthe yellow piston in the iter element indicator moves into the red zone after starting the engine, or the exhaust smoke is stil black after installation of a clean primary fiter element, install a new primary fter element The primary element should be replaced after being cleaned a maximum of six times. Replace the element once a year even though it has not been cleaned six times. 7 Maintenance Section ‘When Required Replace Secondary Element NOTICE Always replace the secondary filter element. Never attempt to reuse it by cleaning. ‘The secondary filter element should be replaced at the time the primary element s serviced for the third time. The secondary filter element should also be replaced if the yellow piston in the filter element indicator enters, the red zone after instalation of a clean primary ele- iment, or if the exhaust smoke is stil black. 41. Open the access cover (if equipped). a wi 2. Remove the housing cover and the pximary siement78 Maintenance Section When Required 3. Remove the bolts that hold the secondary filter element to the housing. Remove the secondary element. 4. Cover the air inlet opening. Clean the inside of the air cleaner housing, 5. Inspect the gasket between the air inlet pipe and the housing. Replace iti it is damaged. 6. Uncover the air inlet opening, Install a new secondary element. 7. Install the nuts and washers on the studs. Tighten the nuts to a torque of 27 + 7 Nem (20 + 5 Ib ft). 8. Install the primary element. Install the cover. Tighten the cover bolls finger tight only. Do not use a to0| to tighten the cover bolts. 9. Close the access cover (if equipped), Cleaning Primary Elements NOTICE Donot clean the filter elements by bumping or tapping them. Do not use filter elements with damaged pleats, gaskets or seals. Engine damage can result Make sure the cleaned filter elements are completely dry before installing into the filter housing. Water re- ‘maining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results. Filter elements can be cleaned with pressure air - 205 kPa (30 psi) maximum, pressure water - 280 kPa (40 psi) maximum, or detergent washing, 1. Direct air or water along the pleats inside and outside of filter element. The element can be washed in warm water and rnonsudsing household detergent. Rinse inside and outside the pleats and air dry fully. 2. Inspect the fiter elements after cleaning. Do not Use a filter element with damaged pleats, gaskets or seals 3. Wrap and store the clean filter elements in a clean, dry place,