SEBU7763-02
May 2007

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

Differential Steering
 

i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

Attention!! Be
Attention come Alert! Your Safety is Involved.
Become
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
that may cause product damage are identi fied by “NOTICE” labels on the product and in
Operations that
Operations
this publication.
Caterpillar cannot anticipate every possible
Caterpillar possible circumstance that might involve a potent
potential
ial hazar
hazard.
d.
The warning
warningss  in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar 
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
will not be damaged or be made unsafe by the operation, lubrication, maintenance or 
the product will
repair procedures that you choose.
information, specifications, and illustrations in this publication are on the basis of information that
The information,
availablle at the time that the publication was written. The speci fication
was availab cations,
s, torque
torques,
s, press
pressures,
ures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
job. Caterpillar dealers have the most current information available.
start any job.

When replacemen
replacementt parts
parts are req
requir
uired
ed for this
product Caterpillar recommends using Caterpil-
lar replacementt parts
replacemen parts or parts
parts with equ
equival
ivalent
ent
specification
cations
s including, but not limited to, phys-
ical dimensions, type, strength and material.
material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or 
death.
 

SEBU7763-02 3
Table of Contents

Table of Contents Operating Techniques

Techniques ...................
...............................
........................
............ 88

 Adjustments .............
.........................
.........................
..........................
....................
....... 94
Foreword
Foreword ........................
.....................................
.........................
........................
................
.... 4
Parking ...........
.......................
......................
......................
........................
.....................
......... 97
Safety Section
Section
Transportation Informat
Transportation Information
ion ...............................
..................................
... 101
Safety Messages
Messages (D8T Track-T
Track-Type
ype Tractor
Tractor ) .......... 6
Towing Information .............................................. 103
 Additional Messages ......
...................
.........................
.........................
............... 16
Engine Starting
Starting (Alternate Meth
Methods)
ods) ...........
...................
........ 108
Generall Hazard Information ............
Genera ........................
.....................
......... 17
Maintenance Section
Crushing
Crushing Prevention and Cutting Prevention ........
........ 19
Cooling Syste
Systemm Specifications .............
.........................
...............
... 111
111
Burn Prevention ............
........................
........................
........................
................
.... 20
Lubricant Viscosities and Re fill Capacities
Capacities .......... 112
Fire Prevention and Explosion Prevention ............
............ 20
Maintenance
Maintenance Support ..........
......................
.......................
.....................
.......... 117
Fire Extinguisher
Extinguisher Location ..........
.....................
.......................
...............
... 22
Maintenance Interval
Interval Sch
Schedule
edule ............
........................
...............
... 118
Track
Track Informa
Information
tion ...........
.......................
........................
........................
...............
... 22
Reference Inf ormation
ormation Section
Electrical Storm Injury Prevention
Electrical Prevention ..............
.........................
........... 23 Reference
Reference Materials .............
.........................
........................
...................
....... 182
Before Starting Engine ................................
..........................................
.......... 23
Index Section
Engine Starting ......................
..................................
........................
...................
....... 23
Index ...........
.......................
........................
........................
.......................
....................
......... 183
Before Operation
Operation ...........
.......................
........................
........................
...............
... 23

Visibility
Visibility Informat
Information
ion .........
.....................
........................
.......................
.............
.. 23

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

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

Engine Stopping ...........

.......................
........................
.......................
................
..... 25

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

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

Operatorr Station .......................

Operato ...................................
.......................
................
..... 28

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

Productt Information
Produc Information Section
Generall Information
Genera Information ............
........................
........................
......................
.......... 30

Identification Information ..........................

......................................
.............. 32

Operation Section

Before Operation
Operation ...........
.......................
........................
........................
...............
... 37
Machine
Machine Operation ............
........................
........................
.......................
........... 38

Engine Starting ......................

..................................
........................
...................
....... 85
 

4 SEBU7763-02
Foreword

Foreword Maintenance
maintenance section is a guide to equipment
The maintenance
Literature Information care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a speci fic service
should be stored in the operator’s
This manual should interval.
interval. Items without specific intervals are listed
Items
compartment in the literature holder or seat back under the "When Required" service interval. The
literature
literature storag
storage
e area. Maintenance Interval Schedule lists the page
This manual contain
contains
s safety information, operation number for the
the step-by
step-by-step
-step instructions required to
accomplish the scheduled maintenance. Use the
instructions, transportation information, lubrication Maintenance Interval Schedule as an index or "one
information   and maintenance information.
information source"  for all maintenance procedur
safe source" for procedures.
es.
Some photographs
photographs or illustrations in this publication
details  or attachments that can be different
show details or Maintenance Intervals
from your machine. Guards and covers might have
been removed for illustrative
illustrative purposes. Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
Continuing improvement and advancement of  etc.) can be used instead of service hour 
monthly, etc.)
product design might have caused changes to your  meter intervals if they provide more convenient
machine
machin e which are not included in this publication.
which servicing
servicing schedu
schedules
les and approximate the indica
indicated
ted
Read, study and keep this manual with the machine. service
service hour
hour meter reading. Recommended service
should always be performed at the interval that
question arises regarding your machine,
Whenever a question occurs   first.

or this publication,
dealer for the latestplease consult
available your Caterpillar 
information. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
Safety be necessary.

The safety section lists basic safety precautions. In service on items at multiples of the original
Perform service
addition, this section identifies the text and locations
addition, requirement. For example, at every 500 service
warning  signs and labels used on the machine.
of warning signs hours or 3 months, also service those items listed
every 250 service hours or monthly and every
under every
Read and understand the basic precautions listed 10 service hours or daily.
in the safety
safety section before operating or performing
lubrication,
lubrication, maintenanc
maintenancee and repair on this machine.
California Proposition 65 Warning
Operation engine exhaust and some of its constituents
Diesel engine
are known to the State of California to cause cancer,
The operat
operation
operator ionasection
and is afor
refresher reference for the new
the experienced birth defects, and other reproductive harm.
operator. This section includes a discussion of  Battery posts, terminals and related accessories
switches,, machine controls, attachm
gauges, switches attachment
ent contain lead and lead compounds. Wash
compounds.  Wash hands
controls, transportation and towing information. handling.
after handling.

Photographs and illustrations guide the operator 

Photographs
through correct procedures of checking, starting, Certified Engine Maintenance
operating
operating and stopping the machine.
machine.
Proper maintenance and repair is essential to keep
Operating techniques
Operating techniques outlined in this publication are engine and machine systems operating correctly.
the engine
basic. Skill and techniques develop as the operator   As the heavy duty off-road diesel engine owner, you
knowledge of the machine and its capabilities.
gains knowledge are responsible for the performance of the required
nance listed in the Owner Manual, Operation
maintenance
mainte
and Maintenance
Maintenance Manual, and Service Manual.
 

SEBU7763-02 5
Foreword

It is prohibited
prohibited for any person engaged in the 3. Check Character
Character (character 9)
business
busine ss of repairing,
repairing, servicing,
servicing, selling, leasing,
leasing, or 
trading engines or machines to remove, alter, or  4. Machine Indicator Section (MIS) or Product
render inoper ative
ative any emission related device or  Number (characters 10-17). These were
Sequence Number
element of design installed on or in an engine or  previously referred to as the Serial Number.
machine that is in compliance with the regulations
89). Certain elements of the machine
(40 CFR Part 89). generator sets produced before First
Machines and generator
and engine such as the exhaust system, fuel system, Quarter 2001 will maintain their 8 character PIN
electrical system, intake air system and cooling format.
system may be b e emission related and should not be
altered unless approved by Caterpillar
Caterpillar.. Components such as engine
Components engines,s, transmi
transmissions,
ssions, axles,
etc. and work tools will continue
continue to use an 8 charac
character 
ter 
Number (S/N).
Serial Number
Machine
Machine Capacit
Capacity
y
 Additional  attachments or modifications may exceed
 Additional attachments
machine
machin e design capacity which can adversely
adversely affec
affectt
performance
perform ance characteristic
characteristics.
s. Inclu
Included
ded would be
and system certifications such as brakes,
stability and
steering,
steerin g, and rollover protective structures (ROPS).
Contact your Caterpillar dealer for further information.

Caterpillar Product Identification

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

g00751314
Illustration 1

Where:

1. Caterpillar’s World Manufacturing Code

(characters 1-3)

2. Machine Descriptor
Descriptor (characters
(characters 4-8)
 

6 SEBU7763-02
Safety Section
Safety Messages

Safety Section
i02696213

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

g01074770
Illustration
Illustration 2
 

SEBU7763-02 7
Safety Section
Safety Messages

g01352591
Illustration
Illustration 3

There are several specific safety messages on this

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

Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
the illustrations if the illustrations are not visible.
When you clean the safety messages, use a cloth,
water, and soap. Do not use solvent, gasoline, or 
other harsh chemicals to clean the safety messages.
Solvents,
Solvent s, gasoli
gasoline,
ne, or harsh chemicals could loosen
g01352573
g01352573
the adhesive that secures the safety message
message.. Loose
Illustration 4 adhesive will allow the safety message to fall.
 

8 SEBU7763-02
Safety Section
Safety Messages

Replace any saf ety

ety message that is damaged or  Hot Fluid Under Pressure (2)
missing. If a safety message is attached to a part of 
the machine that is replaced, install a safety message Safety Message (2) is located under the access door 
replacement part. Any Caterpillar dealer can
on the replacement to the radiator cap.
provide
provide new safety messages.
messages.

Do Not Operate (1)

Message (1) is positioned in the cab beneath
Safety Message
the left window.

g01067344

Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. To open the cooling
g00930652 system   filler cap, stop the engine and wait until
the cooling system components
components are cool. Loosen
th
the
e cooli
cooling
ng syst
system
em pr
pres
essu
sure
re cap
cap slowl
slowly
y in orde
orderr to
relie
relieve
ve the pres
pressu
sure
re.. Rea
Read
d and
and und
under
ersta
stand
nd the
the Op
Op--
eration and Maintenance Manual before perform-
Do not operate or work on this equipment unless
ing any cooling system maintenance.
you hav
havee rea
read
d and unde
underst
rstand
and the instruc
instructio
tions
ns
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
Seat Belt (3)
tact any Caterpillar dealer for replacement manu-
Safety Message (3) is positioned on the cab post
als. Proper care is your responsibility.
above the differe
differential
ntial steering control..

g01067563

A seat belt should be worn at all times during ma-

operation to prevent serious injury or death
chine operation
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
may result in serious injury or death.
tion may
 

SEBU7763-02 9
Safety Section
Safety Messages

Electrical Shock Hazard (4) High Pressure Cylinder (5)

Safety Message (4) is located on the inside face of  Safety message (5) is on top right side of the valve
the fuse panel. cover plate in the middle of the fuel tank. Safety
message (5) can also be found behind the cab seat
on the back cover plate.

g01108645

g01058237

WARNING!
WARNING! Shock/
Shock/Electro
Electrocution
cution Hazard! Read and
understand the instructions and warnings in the
Operation and Maintenance Manual. Failure to fol- Personal injury or death can result from grease
low the instructions or heed the warnings could under pressure.
cause serious injury or death.
Grease coming out of the relief valve under pres-
sure
sure can penet
penetrate
rate the bod
body y caus
causing
ing inju
injury
ry or 
Refer to Operation
Operation and Maintenanc
Maintenance
e Manual, “Fuses
death.
and Circuit Breakers
Breakers - Replace/Rese
Replace/Reset”.
t”.
Do not watch the relief valve to see if grease is es-
caping. Watc
caping. Watch h the track or track adjustm
adjustment
ent cylin-
der to see if the track is being loosened.

Loosen the relief valve one turn only.

If track does not loosen, close the relief valve and

contact your Caterpillar dealer.
 

10 SEBU7763-02
Safety Section
Safety Messages

Accumulator (6) Improper Connections for Jump

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

g01067366
g01024378

High pressure cylinder.

cylinder. Rapid dischargin
discharging
g from Explosi
Exp losion
tions oncause
can Haz
Hazard
ard!! Impr
an Imprope
operr jump
explosionjumper
er cabl
cable
resulting e con
in connec
nec--
serious
disconnecting or disassembly can result in per-
injury or death. Batteries may be located in sep-
sonal injury or death. See your Caterpillar dealer 
arate compartments. Refer to the Operation and
for tools and instructions for relieving pressure
pressure or 
Maintenance Manual for the correct jump starting
charging.
charg ing. Precharge only with nitrogen gas.
procedure.

Refer to Operation and Maintenance Manual, “Engine

Staring with Jump Start Cables”.
 

SEBU7763-02 11
Safety Section
Safety Messages

Compressed Recoil Spring (8) Compressed Recoil Spring (9)

Safety Message (8) is located inside the track roller  Safety message (9) is located inside the covers for 
frames. the guides for the track roller frames.

g01108669 g01078108

Personal injury or death can result from a com- Personal injury or death can result from a com-
pressed recoil spring being released
pressed released suddenly
suddenly us- pressed
presse d rec
recoil
oil spring
spring bein
being
g releas
released
ed sud
sudden
denly
ly us-
ing incorrect disassembly procedures. ing incorrect disassembly procedures.

A recoil spring that is still held in compression A recoil spring that is still held in compression
can result in the recoil spring being released un- can result in the recoil spring being released un-
expectedly
expectedly with extrem
extreme e force which could cause expectedly with extreme force which could cause
serious injury or death. serious injury or death.

Make sur
Make sure e that the correc
correctt disass
disassemb
embly
ly proced
procedure
ure Make sur
Make sure e tha
thatt the cor
correc
rectt disass
disassembl
embly
y pro
proced
cedure
ure
is us
used
ed,, if a fron
frontt trac
track
k roll
roller
er fr
fram
ame
e th
that
at ha
has
s a cr
crac
ackk is used
used,, if a fr
fron
ontt tr
trac
ackk roll
roller
er fr
fram
ame
e th
that
at has
has a cr
crac
ackk
in the parent metal or weld connection (or a tubu- in the parent metal or weld connection (or a tubu-
lar section that has separated from the front of  lar section that has separated from the front of 
the frame assembly) when the recoil spring is still the frame assembly) when the recoil spring is still
held in compression.
compression. held in compression.

Refer to Spe
Refer Special
cial Instru
Instructio
ction,
n, SMH
SMHS82
S8273
73 which
which Refer to Spe
Refer Specia
ciall Ins
Instruc
truction
tion,, SMHS
SMHS827 82733 whic
which
h
contains
contains the disasse
disassembly
mbly procedure that must be contains
contains the disassembly proced
procedureure that must be
used
used to dec
decrea
rease
se the pos
possibi
sibility
lity of inju
injury
ry whil
while
e used
used to dec
decrea
rease
se the pos
possibi
sibility
lity of inju
injury
ry whil
while
e
performing service on the track roller frame. performing service on the track roller frame.
 

12 SEBU7763-02
Safety Section
Safety Messages

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

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

g01058237 g01108685

Personal injury or death can result from grease This

This ma
machchin
ine
e is equi
equipp
pped
ed wi
with
th a Cate
Caterprpil
illa
lar 
r 
under pressure. Product Link radio communication device which
must be deactivated within 6.0 m (20 ft) of a blast
Grease coming out of the relief valve under pres- zone.
zone. Fa
Failu
ilure
re to do so could
could resu
result
lt in seri
seriou
ous s
sure
sure can penetrate
penetrate the body
body causing
causing injury
injury or  injury or death.
death.
Refer to Specia
Speciall Instruction,
Instruction, REHS1642, “Operation
Do not watch the relief valve to see if grease
grease is es-
of the Product Link System” for additional information.
caping. Watch the track or track adjustme
adjustment
nt cylin-
der to see if the track is being loosened.

Loosen the relief valve one turn only.

If track does not loosen, close the relief valve and

contact your Caterpillar dealer.

Refer
ckto
“Track
“Tra the Operation
- Check/A
Check/Adjust” andadditional
djust” for Maintenance
additio Manual,
nal information.
 

SEBU7763-02 13
Safety Section
Safety Messages

Do Not Weld On The FOPS (12) Rotating Shaft (13)

Safety message (12) is positioned on the outside
right of the cab.
This safety message (13)is located on top of 
the guard which is covering the coupling for the
implementt pump. The  fi lm is visible by removing the
implemen
floorplate of the cab.

g01077753

g01113701

Structural damage, an overturn, modi fication, al-

teration, or improper repair can impair this struc-
ture’s
ture’s protec
protection
tion capability
capability thereb
therebyy voiding this Rotatins shaft pinch hazard. The shaft under this
certification. Do not weld on or drill holes in the cover is rotating anytime the engine is running.
structu
structure.
re. Consult
Consult a Cate
Caterpil
rpillar
lar dealer
dealer to deter-
deter- Contact with a rotating shaft could cause injury or 
mine this structure’s limitations without voiding death. Keep hands away
away..
its certification.

This machine has been certified to the standards that

Falling Hazard (14) (If Equipped)
are listed on the certification plate.
Safety message (14) is located on the rear of the
 Accugrade mast at eye level.

g01108716

prevent possible personal injury during instal-

To prevent
la
latio
tion
n and
and remov
removal
al of the las
laser
er rece
receive
ivers
rs,, low
lower
er the
mast to the minimum height and use an approved
 system to reach the mounting locations of 
access system
access
the laser receivers at the top of the mast. Do not
climb on the blade.
 

14 SEBU7763-02
Safety Section
Safety Messages

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

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

g01108701

g01352487

Structural damage, an overturn, modi fication, al-

Activating the machine’s steering and work tools teration,
teration, or imprope
improperr repair
repair,, can impair this struc
struc--
ture’s
ture’s protec
protective
tive capabi
capability
lity thereb
thereby y voiding this
can be haz
hazard
ardous
ous whe
whenn person
personnel
nel are workin
workingg
certification. Do not weld on or drill holes in the
around the machine.
str
struct
ucture
ure.. Con
Consul
sultt a Cat
Caterp
erpilla
illarr dea
dealer
ler to dete
deter-
r-
mine this structure’s limitations without voiding
Before moving the machine, make sure the ma-
its certification.
chine is on  fi rm level ground. Engage the parking
brake.
brake. Mak
Makee su
sure
re the area
area is clear
clear of per
person
sonnel
nel b
be-
e-
fore activating any work tool. This machine has been certified to the standards that
are listed on the certification plate. The maximum
Failure to follow
Failure follow thi
this
s inst
instruc
ruction
tion could result
result in mass of the machine, which includes the operator 
injury or death. and the attachments without a payload, should not
exceed the mass on the certification plate.

Do
younot
havoperate
havee rea d or
read work
and onrstand
unde
understthis
andequipment
the instrucunless
instructio
tions
ns
and warnings in the Operation and Maintenance
Manu
Ma nuals
als.. Fa
Failu
ilure
re to follo
follow
w the instr
instruct
uctio
ions
ns or 
heed the warnings could result in serious injury
or death.

The engine must be shut off before any maintenance

is performed. Use a wand in order to clean debris
from the fan and baf fle assembly.
 

SEBU7763-02 15
Safety Section
Safety Messages

Do Not Operate (17)

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

g01055734

Do not operate or work on this equipment unless

you hav
havee rea
read
d and unde
underst
rstand
and the instruc
instructio
tions
ns
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
 

16 SEBU7763-02
Safety Section
 Additional Messages

i01944134

Additional
Additional Messages
SMCS Code: 7405
Code:  7405

g01023544
Illustration
Illustration 5

There are several specific messages on this machine.

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

Make sure that all of the messages are legible.

Clean the messages or replace the messages if 
you cannot read the words. Replace the illustrations
if the illustrations are not legible. When you clean
the messages, use a cloth, water and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall. g01024657
Illustration
Illustration 6
Replace any message that is damaged, or missing.
If a message is attached to a part that is replaced, NOTICE
install a message on the replacement part. Any When the steering lever is moved with the transmis-
Caterpillar
Caterp illar dealer can provide new messag
messages.
es. sion
sion in NE
NEUT
UTRALor
RALor in gear
gear,, and
and th
the
e engin
engine
e is runni
runningng,,
the machine
machine will turn. Engage the
the steering con
control
trol lock
Steering Control (1) by engaging the parking brake in order to prevent ma-
chine movement.
This message is located on the cab post above the
differential steering control. Air Conditioner (2)
 

SEBU7763-02 17
Safety Section
Generall Hazard Information
Genera

This message is located

is  located on the left side of the front i02443908
instrument panel.
instrument
General Hazard Information
SMCS Code: 7000
Code:  7000

g00927763
Illustration 7

This message for the air conditioner has the g00104545

Illustration
Illustration 9
appropriate
approp riate information for the following services: the
conditiioner lubricant, the refrigerant charge, and
air condit
 Attach a “Do Not Operate” warning tag or a similar 
the refrigerant capacity.
warning tag to the start switch or to the controls
Follow instruction
instruction in order to avoid engine damage. before youequipment.
repair the service theThese
equipment or before
warning you
tags (Special
Instruction, SEHS7332) are available from your 
Reference: See Operation and Maintenance Manual,
Reference: See
Caterpillar dealer.
nce Interval Schedule” for all maintenance
“Maintenance
“Maintena
recommendations.
Know the width of your equipment in order to maintain
proper clearance when you operate the equipment
(3) (if equipped)
Prelube (3)
near fences or near boundary obstacles.
This message is located next to the engine start
Be aware of high voltage power lines and power 
switch.
cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocutio
electrocution.n.

g01114731
Illustration 8

NOTICE g00702020
Illustration 10
To operate, turn machine start switch to START po-
HOLD to activat
sition, HOLD activate
e pre-lubricatio
pre-lubricationn system and
hard hat, protective glasses, and other 
Wear a hard
start engine. When adequate oil pressure is available,
protective
protective equipment,
equipment, as required
required..
pre-lubrication system will disengage, then will AU-
TOMATIC ALLY
TOMATIC  ALLY crank engine to start.
s tart. RELEASE KEY Do not wear
wear loose clothing or jewelry that can snag
WHEN ENGINE STARTS.
on controls or on other parts of the equipment.

Make sur e that all protective guards and all covers

are secured in place on the equipment.
 

18 SEBU7763-02
Safety Section
Generall Hazard Information
Genera

Keep the equipment

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.
signals. Accept hand signals from one person only.
Accept
Trapped Pressure
Pressure can be  trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
you  disconnect hydraulic lines or  fi ttings.
caution if you disconnect
High pressure oil that is released can cause a hose to
whip. High pressure oil that is released can cause oil
to spray. Fluid
Fluid penetration can cause serious injury
and possible death.

Do not smoke when you service an air conditioner.

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

Do not allow  unauthorized personnel on the

equipment.

you  are instructed otherwise, perform

Unless you are
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance Manual
for the procedure
pro cedure for placing the equipment in the
servicing position.

Pressurized Air and Water 

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

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

Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
Dealer Service Tool Catalog” for the following items:
 

SEBU7763-02 19
Safety Section
Crushing
Crushing Prevent
Prevention
ion and Cutting Prevent
Prevention
ion

•  Tools that are suitable

s uitable for collecting   fluids and •  Use exhaust ventilation
ventilation on permane
permanent
nt machini
machining
ng
equipment that is suitable for collecting  fl uids  jobs.

•   Tools that are suitable

are  suitable for containing   fluids and •   Wear an approved
approved respirator if there is no other 
equipment
equipm containing  fl uids
ent that is suitable for containing way to control the dust.

local  regulations for the disposal of liquids.

Obey all local regulations •   Comply with applicable
applicable rules and regulations
for the work place. In the United States, use
Information
Asbestos Information Occupational
Occupa tional Safety and Health Administratio
Administration
n
requirements.. These OSHA require
(OSHA) requirements requirements
ments
can be found in “29 CFR 1910.1001”.

•   Obey environmental
environmental regulations for the disposal
of asbest
asbestos.
os.

•   Stay away from

from areas that might have asbestos
particles in the air.

Dispose of Waste Properly

g00702022
Illustration 12

Caterpillar
Caterpillar equipment and replacement
replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar 
recommends the use of only genuine Caterpillar 
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be

generated
genera ted when you handle compon
components
ents that contai
contain
n Illustration 13
g00706404
asbestos  fi bers. Inhaling this dust can be hazardous
to your health. The components that may contain Improperly disposing of waste can threaten the
asbestos   fibers are brake pads, brake bands, lining environment.
environ Potentially harmful   fluids should be
ment. Potentially
material, clutch plates, and some gaskets. The disposed
disposed of according to local regulation
regulations.
s.
asbestos
bound in athat is used
resin in these
or sealed components
in some is usually
way. Normal  Always use leakproof containers when you drain
handling is not hazardous unless airborne dust that fluids. Do not pour waste onto the ground, down a
contains asbestos is generated. drain, or into any source of water.

If dust that may contain asbestos is present, there

are several guidelines that should be followed: i01359664

•   Never use compressed

compressed air for cleaning.
cleaning. Crushing Prevention and
Cutting Prevention
Prevention
•   Avoid brushing materials that contain asbestos.
SMCS Code: 7000
Code:  7000
•   Avoid
Avoid grinding materials that contain asbestos.
Support  the equipment properly before you perform
Support the
•   Use a wet method in order to clean up asbestos any work or maintenance beneath that equipment.
materials. Do not depend on the hydraulic cylinders to hold

•  A vacuum cleaner that is equipped with a high up the equipment.

moved, eq
oruipment. Equipment
if a hydraulic can fall if a control is
line breaks.
ef ficiency particulate air   filter (HEPA) can also be
used. Do not work
work beneath the cab of the machine unless
the cab is properly supported.
 

20 SEBU7763-02
Safety Section
Burn Prevention
Prevention

Unless you are instruc

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

Whenever there are equipment

Whenever equipment control linkages the Cooling system conditioner
conditioner contai
contains
ns alkali. Alkali can
clearance
cleara in  the linkage area will change with the
nce in the personal injury. Do not allow alkali to contact
cause personal
movement of the equipment or the machine. Stay the skin, the eyes, or the mouth.
clear of areas that may have a sudden change in
clearance
clearance wi
withth machine movement or equipment
movement.
Oils
hot components can cause personal
Hot oil and hot
Stay clear of  all
  all rotating and moving parts.
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
maintenance,
Remove the hydraulic tank  fi ller cap only after the
maintenance
mainten ance is performe
performed.
d.
engine has been stopped. The   filler cap must be
enough  to touch with a bare hand. Follow the
cool enough to
objects away from moving fan blades. The fan
Keep objects
standard procedure in this manual in order to remove
blade will throw objects or cut objects.
the hydraulic tank   filler cap.
Do not use a kinked
k inked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable. Batteries
When you str ikeike a retainer pin with force, the retainer  Electrolyte is an acid. Electrol
Electrolyte Electrolyte
yte can cause personal
pin can   fly out. The loose retainer pin can injure injury. Do not allow electrolyte to contact the skin or 
personnel. Make sure that the area is clear of people the eye s. Always wear protective
eyes. protective glasses for servici
servicing
ng
strike a retainer pin. To avoid injury to
when you strike batteries. Wash hands after touching the batteries
your eyes, wear protective glasses when you strike and connectors. Use of gloves is recommended.
a retainer pin.
i01359795
Chips or other debris can  fl y off an object when you
strike the object. Make sure that no one can be Fire Prevention and Explosion
by  fl ying debris before striking any object.
injured by
Prevention
i01329099 SMCS Code: 7000
Code:  7000
Burn Prevention
SMCS Code: 7000
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,
system, in the lubrication
lubrication system,
in the fuel system, or in the cooling system before
any lines,  fi ttings or related items are disco
disconnecte
nnected.
d.

Coolant
When the engine is at operating temperature, the g00704000
g00704000
engine coolant is hot. The coolant is also under  Illustration 14

pressure. The radiator and all lines to the heaters or 

to the engine contain hot coolant.  All fuels, most lubricants, and some coolant mixtures
are   flammable.
 Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
 

SEBU7763-02 21
Safety Section
Fire Prevention and Explos
Explosion
ion Preven
Prevention
tion

Flammable  fl uid
uids
s that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a   fire. Fire may cause personal injury and property
damage.

Remove all  fl ammable materials

materials such as fuel, oil, and
the machine. Do not allow any  fl ammable
debris from the
materials to accumulate on the machine.

and lubricants in properly marked

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

operate the machine near any  fl ame.

Do not operate

Exhaust shields (if equipped) protect hot exhaust

 from oil spray or fuel spray in case of 
components from
components
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.
g00704059
Illustration 15
Do not weld on lines or on tanks that contain
flammable   fluids. Do not   flame cut lines or tanks
contain  fl ammable  fl uid. Clean any such lines or 
that contain Usesmoke
not cautionwhile
when youare
you arerefueling
refuelinga amachine.
machine.Do
Do
tanks thoroughly with a nonflammable solvent prior  not refuel a machine near open   flames or sparks.
to welding or   flame cutting.  Always stop the engine before refueling. Fill the fuel
tank outdoors.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
machine.
machin e. Clean all electric
electrical
al connections and tighten
all electrical connections.

Dust that is
is generated from repairing nonmetallic
hoods or nonmetallic fenders can be   flammable
and/or explosive. Repair such components in a well
ed area away from open  fl ames or sparks.
ventilated
ventilat

Inspect all lines and hoses for wear or for 

deterior ation.
ation. The hoses must be properly routed.
The lines and the hoses must have adequat
adequate e support
and secure clamps. Tighten all connections to the
recommended
recomme nded torque. Leaks can cause  fi res.

g00704135
Illustration 16

Gases from a battery can explode. Keep any open

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

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or 
a hydrometer.
 

22 SEBU7763-02
Safety Section
Fire Extinguisher
Extinguisher Location
Location

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

Extinguisher 
Fire Extinguisher  •   End  fi ttings are displa
displaced.
ced.

Make sure that all clamps, guards, and heat shields

Make sure that a   fire extinguisher is available. Be
are installed correctly. During machine operation, this
with the operation of the   fire extinguisher.
familiar with
will help to pr event
event vibration, rubbing against other 
Inspect the   fire extinguisher and service the   fire
parts, and exces
excessive
sive heat.
extinguisher regularly. Obey the recommendations
instru ction plate.
on the instruction
i01834364

Ether  Extinguisher Location

Fire Extinguisher
Ether is   flammable and poisonous.
SMCS Code: 7419
Code:  7419
Use ether in well ventilated areas. Do not smoke
Make sure that a  fi re extinguisher is available. Be
while you are replacing an ether cylinder or while you
familiar with the operation of the   fire extinguisher.
an  ether spray.
are using an ether
 fi  fi
Inspect the re
extinguisher. extinguisher
Obey and service the
the recommendations re
on the
Do not store ether cylinders in living areas or in the
instruction
instruction plate.
compartment of a machine. Do not store
operator compartment
ether cylinders in direct sunlight or in temperatures
Mount the  fi re extinguisher in the accepted location
above 49 °C (120 °F). Keep ether cylinders away
per local regulations.
regulations.
from open   flames or sparks.
Do not weld the ROPS structure in order to install the
Dispose of used ether cylinders properly. Do not
fire extinguisher. Also, do not drill holes in the ROPS
an ether cylinder. Keep ether cylinders
puncture an
in order to mount the   fire exting
structure in extinguisher
uisher on
away from unauthorized
unauthorized personnel.
the ROPS.
spray ether into an engine if the machine is
Do not spray
Strap the moun
Strap ountin
tingg pla
plate
te to a leg of the ROPS in
equipped with a thermal starting aid for cold weather 
order to mount the   fire extinguisher, as needed. If 
starting.
the weight of the   fire extinguisher exceeds 4.5 kg
mount the  fi re extinguisher near the bottom of 
(10 lb), mount

Lines, Tubes and Hoses the ROPS.

upper Do not
one-third mount
area the
of the  fi re extinguisher at the
ROPS.
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent Consult your Caterpillar dealer for the proper 
damaged.
or damaged. procedure for mounting the  fi re extinguisher.

Repair any lines that are loose or damaged. Leaks

i01329108
can cause  fi res. Consult your Caterpillar dealer for 
repair or for replacement parts. Track Information
lines, tubes and hoses carefully. Do not use
Check lines, SMCS Code: 7000
Code:  7000
your bare hand to check for leaks. Use a board or 
cardboard
cardbo ard to check for leaks. Tighten
Tighten all connec
connections
tions Track adjusting systems use either grease or oil
recommended torque.
to the recommended under high pressure to keep the track under tension.
Replace the parts if any of the following conditions Grease or oil under high pressure coming out of the
are present:
present: relief valve can penetrate the body causing injury or 
death. Do not watch the relief valve to see if grease
•   End   fittings are damaged or leaking. or oil is escaping. Wat
Watchch the track or track adjustm
adjustment
ent
cylinder to see if the track is being loosened.
•  Outer coverings are chafed or cut.
 

SEBU7763-02 23
Safety Section
Electrical Storm Injury Preve
Electrical Prevention
ntion

The pins and bushings

bus hings in a dry track pin joint i01492207
can become very hot. It is possible to burn the
fingers if there is more than brief contact with these Engine Starting
components.
SMCS Code: 1000;
Code:  1000; 7000

i01122596 If a warn
warning tag  is attached to the start switch or 
ing tag is
attached
attache d to the controls, do not start the engine. Also,

Electrical
PreventionStorm Injury
do not move any controls.
Move all hydraulic controls to the HOLD position
SMCS Code: 7000
Code:  7000 before starting the engine. Move the transmission
NEUTRAL positio
control to NEUTRAL position.
n.
When lightning is striking in the vicinity of the
machine, the operator should never attempt the Engage the parking brake switch.
procedures:
following procedures:
Diesel engine exhaust contains products of 
•  Mount the machine. combustion. These products can be harmful to your 
health. Always
Always start the engine and always operate
•  Dismount the machine. the engine in a well ventilated area. If you are in an
enclosed area, vent the exhaust to the outside.
in  the operator’s
If you are in the operator’s station during an electrical
storm, stay in the operator’s station. If you are on the
i01944266
ground during an electrical storm, stay away from
the vicinity
vicinity of the machine. Before Operation
SMCS Code: 7000
Code:  7000
i01896223

Before Starting Engine personnel from the machine and from the
Clear all personnel
area.
SMCS Code: 1000;
Code:  1000; 7000
obstacles from the path of the machine.
Remove all obstacles
Start the engine only from the operator’s Beware of hazards such as wires, ditches, etc.
compartment. Do not short across the battery
terminals and do not short across the batteries. that  all windows are clean. Secure the doors
Be sure that all
Bypassing the engine neutral start system can and the windows in either the open position or the
damage the electrical system. shut positio
position.
n.

Inspect the condition of the seat belt and mounting  Adjust the rearview mirrors (if equipped) for best
vision close to the machine. Make sure that the
hardware.
hardwar
Regardl e. Replace
Regardless
ess any damage
damaged
of appearance,
appea rance, d parts
replace the or worn
seat beltparts.
after  machine
machin horn, the backup alarm (if equipped) and all
e horn,
three years of use. Do not use an extension for a other warning devices are working properly.
seat belt on a retractable seat belt.
Reference:  Refer to Operation and Maintenance
Reference:
 Adjust the seat so that full pedal travel can be Manual, “Daily Inspection” in this manual.
achieved. Make sure that the operator’s back is
against the back of the seat. the  seat belt securely.
Fasten the seat

Make sure that the machine is equipped with a

i02773460
lighting system that is adequate for the job conditions.
Make sure that all lights are working properly. Before Visibility Information
you start the engine or before you move the machine,
make sure that no one is working on the machine, SMCS Code: 7000
Code:  7000
working underneath the machine or working close
to the machine. Make sure that the area is free of  Before you start the machine, the operator shall
personnel. perform a walk-around inspection in order to ensure
that there are no hazards around the machine.
 

24 SEBU7763-02
Safety Section
Operation

While the machine

machine is in operation
operation,, the operator should Machine
Machine Operati
Operation
on
constantly survey the area around the machine. The
operator needs to identify potential hazards as a Only operate the machine while you are in a seat.
becomes visible around the machine.
hazard becomes The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
Your machine may be equipped with mirrors or other  is running.
aids.  An example of a visual aid is Closed
visual aids. An
Circuit Television (CCTV). The operator should While you operate the machine slowly in an open
ensure that the visual aids are in proper working area, check for proper operation of all controls and all
condition
conditi and that the visual aids are clean. Adjust
on and protective devices.
the visual aids for the best visibility of all areas
around the machine. Before you move the machine, you must make sure
that no one will be endangered.
It may not be possible to provide direct visibility on
large machines to all areas around the machine. Do not allow riders on the machine unless the
 Appropriate
 Appropriat e job site organization is required in order  machine has the following equipment:
to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules •   additional seat
procedures that coordinates machines and
and procedures
people that
that work together
together in the same ar
area.
ea. Examples
Examples •  additional seat belt
of job site organization include the following:
•   Rollover
Rollover Protective Structure (ROPS)
•   Safety instructions
Note any needed repairs during machine operation.
•   Controlled
Controlled patterns of machine movement Report any needed repairs.

•   Controlled
Controlled patterns of vehicle movement Carry work tools approximately 40 cm (15 inches)
above ground level. Do not go close to the edge of a
•  Restricted areas cliff, an excavation, or an overhang.

•   Operator training
training If the machine begins to sideslip downward on a
grade, immediately remove the load and turn the
•   Warning
Warning symbols or warning signs on machines machine downhill.
or on vehic les
vehicles
 Avoid any conditions that can lead to tipping the
•  A system of communication machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine
•   Communication
Communication between worke
workers
rs and operators
operators can tip when you cross ditches, ridges or other 
prior to approaching the machine unexpected obstructions.

Modifications of the machine con figuratioguration

n that result  Avoid operating the machine across the slope. When
in a restriction of visibility shall be verified according
according possible, operate the machine up the slopes and
50 06”.
to “ISO 5006”. down the slopes.

Maintain control of the machine. Do not overload the

i01930605
machine beyond the machine capacity.
Operation
Operatio n Be sure that the hitches and the towing devices are
SMCS Code: 7000
Code:  7000 adequate.

Only connect the trailing equipment to a drawbar or 

Machine Operating Temperature to a hitc
hitch.
h.
Range
Never straddle a wire cable. Never allow other 
standard machine con figuration is intended
The standard personnel to straddle a wire cable.

for −
of  −use within
40 °C (−40an°F)
ambient temperature
to 50 °C range
(122 °F). Special
configur ations
ations for different ambient temperatures
may be available. Consult your Caterpillar dealer for 
additio nal information on special configuration
additional gurations
s of 
machine.
your machine.
 

SEBU7763-02 25
Safety Section
Parking

Before you maneuver

maneuver the machine, make sure that  After the machi
machine
ne is parked and the parking brake
no personnel are between the machine and the is engaged, allow the engine to run for   five minutes
trailing equipment. Block up the hitch of the trailing before shutdown. This allows hot areas of the engine
equipment
equipme nt in order to align the hitch with the drawbar. gradually.
to cool gradually.
Maneuver the machine. Connect the machine to the
trailing equipment. For more information, refer to the following topics
Operation Section of the Operation and
in the Operation
Know the maximum dimensions of your machine. Maintenance Manual:

 Always keep the Rollover Protective Structure •   “Stopping the

the Engine”
(ROPS) installed during machin
machine
e operation.
operation.
•   “Stopping
“Stopping the Engine if an Electrical Malfun
Malfunction
ction
Occurs”
i01492258

Parking i01329161

SMCS Code: 7000
Code:  7000 Equipment Lowering with
Park on a level surface. If you must park on a grade,
Engine Stopped
use blocks to prevent the machine from rolling.
SMCS Code: 7 000
Code:  7000
 Apply the service brake in order to stop the machine.
Before lowering any equipment with the engine
Move the transmission control to NEUTRAL position
stopped,
stoppe d, clear the area around the equipment of 
clear
and the speed
the parking control
brake to LOW IDLE position. Engage
switch. all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind
systems use a high pressure   fluid or air to
most systems
Lower all attachments to the ground.
raise or lower equipment. The procedure will cause
high pressure air, hydraulic, or some other media
Stop the engine.
released in order to lower the equipment.
to be released
Wear appropriate personal protective equipment and
Turn the engine start switch key to OFF position and
follow the established procedure in the Operation
remove the key.
Maintenance Manual, “Equipment Lowering with
and Maintenance
Engine Stopped” in the Operation Section of the
Turn the key for the battery disconnect switch to the
manual.
OFF position. Remove the key when you exit the
machine for an extended period of time.
i02659468
i02659468
Turning the battery disconnect switch to the OFF
position will provide the following bene fits: Sound Information and
•  Prevent battery discharge that is caused by a Vibration
Vibration Information
battery short circuit.
SMCS Code: 7000
Code:  7000
•   Prevent
Prevent battery discharge that is caused by some
of the components. Sound Level Information
•   Prevent battery discharge that is caused by The operator Equivalent Sound Pressure Level
vandalism. (Leq) is 81 dB(A) when “ANSI/SAE J1166 OCT 98”
to measure the value for an enclosed cab.
is used to
This is a work cycle sound exposure level. The cab
i01889291 was properly installed and maintained. The test was
conducted
conduct ed with the cab doors and the cab windows
Engine Stopping closed.
SMCS Code: 1000;
Code:  1000; 7000
Hearing   protection may be needed when the
Do not stop the engine immediately after the machine isperiods
extended operated with
or in an open
a noisy operator
operator station
environment. Hearingfor 
machine has been operated under load. This can
tion may be needed when the machine is
protection
protec
cause overheating and accelerated wear of engine
operated with a cab that is not properly maintained or 
components.
when the doors and windows are open for extended
periods
period s or in a noisy environment.
 

26 SEBU7763-02
Safety Section
Sound Information and Vibration
Vibration Information
Information

The average exterior

exterior sound pressure level is 85 Estimate the vibration
vibration levels for the three vibration
dB(A) when the “SAE J88 Jun86 - Constant Speed directions. For typical operating conditions, use the
Moving Test” procedure is used to measure the value average vibration levels as the estimated level. With
standard machine. The measurement was
for the standard experienced operat
an experienced operator
or and smooth terrain, subtract
conducted
condu cted under the following conditions: distance of  the Scenario Factors from the average vibration level
15 m (49.2 ft) and “the machine moving forward in an in order to obtain the estimated vibration level. For 
intermediate
intermediat e gear ratio”. operations and severe terrain, add the
aggressive operations
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
Information for 
Sound Level Information
Machines in European Union Note:  All vibration levels are in meter per second
Note: All
Countries and in Countries that squared.

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

European Union Physical

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

When the machine is operated according to the

 use, the hand/arm vibration of this machine
intended use,
intended
is below 2.5 meter per second squared.

Information Concerning
Information Concerning Whole Body Vibration
Level

section provides vibration data and a method for 

This section
estimating
estimating the vibrat
vibration
ion level for track-type tractors.
Vibration levels are influenced by many
Note:   Vibration
Note: 
different parameters. Many items are listed below.

•   Operator
Operator training,
training, behavior,
behavior, mode, and stress

•   Job site organiz

organization,
ation, preparation,
preparation, environment,
weather , and material

•  Machine type, quality of the seat, quality of the

suspension system, attachments,
suspension attachments, and condition
condition of 
the equipment
equipment

not  possible to get precise vibration levels for 

It is not possible
this machine. The expected vibration levels can be
estimated with the information in Table 1 in order 
calculate the daily vibration exposure. A simple
to calculate
evaluation of the machine application can be used.
 

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

Table 1

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

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

Note:  Refer to “ISO/TR 25398 Mechanical

Note: Refer Mechanical Vibration
Vibration - b.  Fill any ditches and holes.
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving c.  Provide machines and schedule time in order 
machines” for more information about vibration. to maintain the conditions of the terrain.
This publication uses data that is measured
by international institutes, organizations and 4.  Use a seat that meets “ISO 7096”. Keep the seat
manufacturers. This document provides information maintained
maintained and adjust
adjusted.
ed.
about the whole body exposure of operators of 
earthmoving equipment. Refer to Operation and a.  Adjust the seat and suspension for the weight
Maintenance
Mainten ance Manual, SEBU82
SEBU8257,57, “The European
European and the size of the operator.
Union Physical Agents (Vibration) Directive
2002/44/EC” for more information about machine b.   Inspec
Inspectt and maintai
maintain
n the seat suspens
suspension
ion and
vibration levels. adjustment mechanisms.
The Caterpillar suspension seat meets the criteria of  5.   Perform the following operations smoothly.
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. This seat is tested a.   Steer 
with the input “spectral class EM6”. The seat has a
transmissibility factor of “SEAT<0.7”. b.   Brake

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

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

b.  Brake and steering systems c.  If no ride control system is available, reduce
speed in order to prevent bounce.
c.   Controls,
Controls, hydraulic system and linkag
linkages
es
d.   Haul the machine
machines
s betwee
between
n workplaces.
3.  Keep the terrain in good condition.

a.  Remove any large rocks or obstacles.

 

28 SEBU7763-02
Safety Section
Operatorr Station
Operato

9.  Less operator comfort

comfort may be caused by other risk i01649970
factors. The following guidelines can be effective
in order to provide better operator comfort: Operator Station
a.  Adjust the seat and adjust the controls in order  SMCS Code: 7000
Code:  7000
to achieve good posture.
 Any modificatio ns to the inside of the operator 
cations
b.  Adjust the mirrors in order to minimize twisted station should not project into the operator space.
posture. The addition of a radio,   fire exting
extinguisher
uisher,, and other 
mustt be installed so that the de fined
equipment mus
equipment
c.  Provide breaks in order to reduce long periods operator space is maintained. Any item that is brought
of sitting. into the cab should not project into the defined
operatorr spa
operato ce. A lunch box or other loose items
space.
d.  Avoid jumping from the cab. must be secured. Objects must not pose an impact
hazard in rough terrain or in the event of a rollover.
repeated handling of loads and lifting
e.  Minimize repeated
of loads. i01992325

f.   Minimize any shocks and impacts during sports

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

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

Operation and Maintenance Manual,

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

Consult your local Caterpillar dealer for more

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

Use the following web site in order to  fi nd your local

dealer:
Caterpillar, Inc.
www.cat.com
 

SEBU7763-02 29
Safety Section
Guards

Rollover Protective Structure •   Demolition applications

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

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

Do not mount items (fire extinguishers,   first aid

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

The Tip Over Protection Structure (TOPS) is

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

Other Guards (If Equipped)

Protection from  fl ying objects and/or falling objects is
required
required for special applicat
applications.
ions. Logging applications
applications
and demolition applications are two examples that
require special protect
protection.
ion.

 A front guard needs to be installed when a work

tool that creates   flying objects is used. Mesh
front guards that are approved by Caterpillar or 
polycarbonate front guards that are approved by
Caterpillar are available for machines with a cab or 
an open canopy. On machines that are equipped with
cabs, the windshield should also be closed. Safety
glasses are recommended when  fl ying hazards exist
for machines with cabs and machines with open
canopies.

If the work material extends above the cab, top

guards and front guards should be used. Typical
examples of this type of application are listed below:
 

30 SEBU7763-02
Product Information Section
Generall Information
Genera Information

Product Information Table 2

Section D8T Track-Type Tractor 

Engine Power 310 hp

General Information and Model)

Engine (Make and   Caterpillar C-15 Acert
Engine Displacement   15.2 L ()

i02769197 Engine Rated Speed   1850 RPM

Specifications Engine (No. of Cylinders)   6

  349
3493.4
3.4 mm
SMCS Code: 1000;
Code:  1000; 7000 Height (Top of Cab) (A)
(137.5 inch)
the  Machine(1)
Length of the Machine
  4632 mm (182 inch)
(B)
Height
Height to Top
Top of Rai
Rain
n Cap (C) 350
3505.4
5.4 mm ((138
138 inc
inch)
h)
Grou
Ground
nd Cle
lear
aran
ance
ce (D
(D)) 52
527.
7.9
9 mm (2
(20.
0.8
8 in
inch
ch))
Track Gauge (E) 2083 mm (82 inch)
Wi
Widt
dth
h Over
Over Tru
runn
nnio
ions
ns (F
(F)) 3050
3050 mm (1
(120
20 in
inch
ch))
He
Heig
ight
ht of the Dr
Dra
awb
wbar
ar 52
528
8 mm (2
(20.
0.8
8 inch)
nch)
Width of Standard
Standard Track
Track Shoe
Shoe 560 mm (22 inch)
Lengt
Length
h of Tra
rack
ck on Grou
Ground
nd 3200
3200 mm (1
(126
26 in
inch
ch))
Weight(2)
Operating Weight (84851 lb)
38488 kg (84851
Illustration 17
g01119768 (The single shank ripper and
the SU-blade are included in
weight.)
the weight.)
Drawbar (Length) 325 mm (12.8 inch)
Single Shank Ripper (Length)(3)(3) 1829 mm (72 inch)
(Length is measured from the
grouser tip with the ripper 
shank in a vertical position and
the ripper tip at the ground.)
ground.)
Multiple Shank Ripper  1623 mm (64 inch)
(Length)(3)
8SU Bull
Bulldo zer Blade
dozer Blade (Length
(Length))(3)
(3) (57  inch)
1438 mm (57 inch)
8SU Bulldozer Blade (Width) 3937 mm (155 inch)
8SU Bulldozer Blade 8.7 m3 (11.4 yd3)
(Capacity))
(Capacity
g00678145
Illustration 18
8U Bulldozer Blade (Length)(3) 1835 mm (73 inch)
8U Bulldozer Blade (Width) 4262 mm (168 inch)
Basic machine specifications are listed in Table
Table 2. 8U Bulldozer Blade (Capacity) 11.7 m3 (15.3 yd3)
8A Bulldozer Blade (Length)(3) 1621 mm (64 inch)
8A Bulldozer Blade (Width) 4978 mm (196 inch)
8A Bulldozer Blade (Capacity) 4.7 m3 (6.1 yd3)
(1) The length of the machine is measured from the trunnion of 
the tag link to the end of the track (standard).
(2) The weight includes the machine
machine and the following items:
full tank of fuel, all lubricants, coolant, SU Bulldozer Blade
with tilt cylind
cylinders,
ers, single shank ripper
ripper,, hydra
hydraulic
ulic controls, air 

conditioner,
and operator.560 mm (22 inch) track (MS), cab with EROPS,
(3)  Add to length of the machine.
 

SEBU7763-02 31
Product Information Section
Generall Informat
Genera Information
ion

Intended Use
is  a Track-Type Tractor that is classi fied
This machine is a
as a “Tractor-dozer”. The machine is earthmoving
equipment that is described in ISO 6165:2001. The
propels the track forward. Also, the machine
machine propels
propels the track rearward. This allows the machine
to move independently. The machine uses equipment
either a dozing attachment which cuts, moves,
that is either
and grades material through forward motion of the
machine or a mounted attachment that is used to
exert a push or or a pull force such as a ripper or 
towing winch. Additional applications include pushing
scrapers
scrape rs during loading and pulling towed equipment
by using a dr awbar.
awbar.

Application and Configuration

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

Maximum drawbar pull (67191 kg (148130 lb))

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

maximum slope that has the proper lubrication is

The maximum
100 percent or 45 degrees.

machine only in environments that are not

Use the machine
explosive with gases.
explosive

attachments
Special attachme nts and operating instructions are
required for waste handling applications and other 
custom configurations.
 

32 SEBU7763-02
Product Information Section
Identification Information
Information

Identification Informat
Information
ion
i02696536

Plate Locations and Film

Locations
SMCS Code: 1000;
Code:  1000; 7000

Productt Identification Plates

Produc
The Product Identification Number (PIN) will be used
to identify a powered machine that is designed for 
g01057083
an operator to ride. Illustration 20

Serial Numbers identifyCaterpil

identifyCaterpillar
lar products
products such as Machine
Machine PIN   ______
__ ___ ________________________________________ 
engines,
engine s, transmis
transmissions
sions and major attachments that
are not designed for an operator to ride. Service Information Number plate (2) is located on
the left hand side of the front dash in the cab.
For quick reference, record the identification numbers
in the spaces that are provided below the illustration.

g01087470
g01087470
Illustration 21
Enclosed ROPS arrangement

g01016776
Illustration 19

The plate for Machine PIN (1) is located to the left of 
the transmission cover on the rear of the machine.

g01014397
Illustration 22
 

SEBU7763-02 33
Product Information Section
Identification Information
Information

Service Information
Information Number plate  _
 ___
____
____
____
__________
____________ 

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

block, as shown.
of the engine block,

g01057104
Illustration 26

Ripper Serial Number (7)   __

____
____
____
___
_____________
________
___________ 

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

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

on the back of the blade.

g01334816
Illustration
Illustrat ion 27

Illustration 24 g00939077

g01323812
Illustration 28

Serial Number   ___

Winch Serial __ ___
_______
__ _____________________________ 

Illustration 25 g01057098
g01057098

Bulldozer
Bulldozer Serial Number (4)   _____________________________ 

serial number plate (7) for the ripper is located

The serial
on the side of the ripper frame.
 

34 SEBU7763-02
Product Information Section
Identification Information
Information

Certifications FOPS Plate (6)

ROPS Plate (5)

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

g01077753
Illustration
Illustratio n 30
Certification plate (FOPS)

Message (6) is positio

positioned
ned on the outside left canopy
canopy..

Structural damage, an overturn, modi fication, al-

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

This machine has been certified to the standards that

Structural damage, an overturn, modi fication, al- are listed on the certification plate.
teration,
teration, or improper
improper repair, can impair this struc-
ture’s
ture’s protec
protective
tive capabil
capability
ity thereb
therebyy voiding this Sound Certification
certification. Do not weld on or drill holes in the
structu
structure.
re. Consult
Consult a Cate
Caterpil
rpillar
lar dealer
dealer to deter-
deter-
mine this structure’s limitations without voiding
its certification.

This machine has been certified to the standards that

are listed on the certification plate. The maximum
mass of the machine, which includes the operator 
and the attachments without payload, should not
exceed the mass on the certification plate.

 A typical example of the certification  fi lm is shown

above.

Refer to Operation and Maintenance Manual, Illustration 31

g00933634
“Guards (Operator Protection)”
Protection)” for more information.
 A typical example of this   film is shown. Your machine may have a
different value.
 

SEBU7763-02 35
Product Information Section
Identification Information
Information

the certification  fi lm is used to verify the

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

European
European Union

g01062968
ion 32
Illustration
Illustrat

This plate is positioned on the bottom left side of the

PIN (1).
Machine PIN

Note:  The CE plate is on machines that are certi fied

Note: The
valid European Union requirements at that
to the valid
time.

•   Power (kW)
(kW) _______________________________________________ 

•   Weight (kg) ________________________________________________ 
•   Year of Compliance _____________________________________ 

i01915747

Emissions
Emission s Certification Film
SMCS Code: 1000;
Code:  1000; 7000; 7405

Certification Label for Emissions

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

This label is located on the engine oil cooler.

 

36 SEBU7763-02
Product Information Section
Identification Information
Information

g00638668
Illustration 33
Typical Example (English)

g00638373
Illustration 34
Typical Example (French)
 

SEBU7763-02 37
Operation Section
Before Operation
Operation

Operation Section i02243194

Daily Inspection
Before Operation SMCS Code: 1000;
Code:  1000; 7000

 A walk-around inspection must be done daily before

i02415882 operating
operating the machine
machine..

Mounting and Dismounting fer to Operation and Maintenance

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

g00037860
ion 35
Illustration
Illustrat

Use steps and handholds whenever you mount

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

Face the machine whenever you mount the machine

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

 Thr ee-point
Note: Thr 
Note: ee-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.

Do not mount a moving machine. Do not dismount a

moving machine. Never jump off the machine. Do
to mount the machine when you carry tools
not try to
or supplies. Do not try to dismount the machine
when you are carrying tools or supplies. Use a hand
pull equipment onto the platform. Do not
line to pull
use any controls as handholds when you enter the
operator compartment or when you exit the operator 
compar ttment.
ment.
 

38 SEBU7763-02
Operation Section
Machine Operation

Machine Operation Fore and

and Aft Adjust
Adjustment
ment (1) – Pull up fore
and aft lever (1). This will allow movement
i01930019 of the seat for ward
ward or this will allow
movement of the seat back to the desired position.
Alternate Exit Release lever (1) in order to lock the seat in place.

SMCS Code: 7254;
Code:  7254; 7308; 7310
Adjusting the
Adjusting the Angle of the Back of the
Machines with cabs are equipped with alternate exits. Seat
If a door becomes disabled, the other door can be
used as an alternate
alternate exit. Release
Release the latch and open
the door.

i02247402

Seat
SMCS Code: 7312-025;
Code:  7312-025; 7324

Adjusting the Seat

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

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

Note: Adjust
beginning of each shift.

The operator should be seated against the seat

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

Adjusting the Height of the Seat

Seats with Mechan
Mechanical
ical Suspension

g00999315 g01131998
Illustration 36 Illustration 38
 

SEBU7763-02 39
Operation Section
Machine Operation

Adjustment of the Seat Hei
Adjustment Height
ght (4) –  Pull
up on height adjustment lever (4) and pull
in order to raise the height of 
up on the seat in
the seat. Pull up on height adjustment lever (4) and
push down on the seat in order to lower the height
of the seat.
Seats with Air Suspension
Adjustmentt (7
Weight Adjustmen (7)) –  Rotate knob (7) and
observe gauge (8) in order to obtain the proper 
adjustment for the weight of the operator. Turn
counterclockwise in order to reduce the
the knob counterclockwise
stiffness of the suspension for an operator of lighter 
weight. Turn the knob clockwise in order to increase
stiffness of the suspension for an operator of a
the stiffness
heavier weight.
Air Suspens
Seats With Air Suspension
ion

The weight adjust

adjustment
ment is automat
automatically
ically controlled by
the height of the seat.
adjusting the
adjusting

Adjusting
Adjusting the Lumbar Support

g00999499
Illustration 39

Adjustment of the Seat Hei

Adjustment Height
ght (6) –  Push
in on the air valve knob (6) in order to raise
the height of the seat. Pull out on the air 
valve knob (6) in order to lower the height of the seat.
g01001077
Illustration 41

Note: The
Note:  The key switch must be on in order to raise
Adjustment for the Lumbar Support
the seat. –  Rotate the knob (9) counte
(9) – Rotate counterclockw
rclockwise
ise
in order to increase support for the lower 
Weight Adjustment back. Rotate the knob (9) counterclockwise in order 
to decrease support for the lower back.
Seats with Mechanical
Mechanical Suspension

g01001175
Illustration 40
 

40 SEBU7763-02
Operation Section
Machine Operation

the Back of the Seat (if 

Extension for the Storage for the   Operation and
equipped) Maintenance Manual

Illustration 43 g01001129

The Operation and Maintenance Manual should be

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

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

SAE J386 standards.

all replacement parts. See your Caterpillar dealer for 

 Always check the condition of the seat belt and

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

Seat Belt Adjustment for 

Non-Retractable
Non-Retractable Seat Belts
 Adjust both ends of the seat belt. The seat belt should
be snug but comfortable.
 

SEBU7763-02 41
Operation Section
Machine Operation

Lengthening
Lengthe the Seat Belt
ning the Shortening
Shorten the  Seat Belt
ing the Seat

g00100709 g00100713
Illustration
Illustratio n 44 Illustration
Illustratio n 46

1.  Unfasten the seat belt. 1.   Fasten the seat belt

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

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

manner.

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

Fastening The Seat Belt

g00932817
Illustration 45

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

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

3.  Remove the slack from the outer belt loop by

pulling on the buckle.

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

42 SEBU7763-02
Operation Section
Machine Operation

Seat Belt
Releasing The Seat Seat Belt
Releasing The Seat

g00100717 g00039113
Illustration
Illustratio n 48 Illustration
Illustratio n 50

Pull up on the release lever. This will release the seat Push the release button on the buckle in order to
belt. release the seat
seat belt. The seat belt will automatically
retract into the retract
retractor.
or.
Seat Belt Ad justment for 
Ad justment
Extension of the Seat Belt
Retractable Seat Belts
Fastening The Seat Belt
When using r etractable
etractable seat belts, do not use seat
belt extensions, or personal injury or death can
result.

The retractor system may or may not lock up de-

pending on the length of the extension and the
size of the   person. If the retractor does not lock
up, the seat belt will not retain the person.

non-retractable
Longer, non-retractable seat belts and extensions for 
the non-retractable
non-retractable seat belts are available.

Caterpillar requires only non-retractable seat belts to

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

seat belt catch (3) into buckle (2). Make sure

Fasten seat i02742390
that the seat belt is placed low across the lap of the
operator. Operator Controls
Controls
The retractor will adjust the belt length and the SMCS Code: 7300;
Code:  7300; 7301; 7451
retractor will lock in place. The comfort ride sleeve
allow the operator to have limited movement.
will allow
 

SEBU7763-02 43
Operation Section
Machine Operation

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

44 SEBU7763-02
Operation Section
Machine Operation

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

Note:  Your machine may not have all the controls

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

Th
Thee us
use
e of th
the
e pa
park
rkin
ing
g br
brak
ake
e as a se
serv
rvic
ice
e br
brak
ake
e in re
reg-
g-
ular operation causes severe damage to the parking
brake system.

g01015542
Illustration 54

Parking Bra
Parking Brake
ke –  This switch engages the
parking brake. This switch also locks the
transmission
transm ission in NEUTRAL
NEUTRAL.. The machine
should not move when the parking brake switch is
engaged.
engag ed. When the parking brake switch is engag
engaged,ed,
g01107108
the parking brake indicator on the dashboard will
Illustration 53 light. Do not use the parking brake for stopping the
Left armrest machine.
machin e. The transmissio
transmission n directio
direction
n selector will still
rotate but the transmission will stay locked in neutral.
Use the following procedure in order to adjust the left
armrest and right armrest(1), if necess
necessary
ary..

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

armrest.
 

SEBU7763-02 45
Operation Section
Machine Operation

Gear Selection
Transmission Gear
Engaged –   Raise knob (2) in order 
Engaged
to engage the parking brake. This will Gear Selector (5) –  Press the transmission
 lock the steering
mechanically lock
mechanically steering control. Also, switch (5A) in order to upshift the
upshift switch
upshift
this will electri
electrically
cally disable the transm
transmission
ission controls. transmission to the next higher gear. Press
The transmission will be locked in NEUTRAL. the transmission downshift switch (5B) in order to
downshift
downsh the transmission to the next lower gear.
ift the

Disengaged
Disenga ged –  Depress
 D epress switch (2) in order  The gauge and indicators
the transmission will show
that has been the direction
selected. of 
Also, the
to disengage the parking brake.
gear is displayed on “Advisor” panel (12).
selected gear

Differential Steering Control and Steering Lever 

Transmission Control (3) (4) (5) can be steered with the transmission in
The machine can
the NEUTRAL positi
position.
on.

NOTICE
When the steering lever is moved with the transmis-
sion
sion in NE
NEUT
UTRALor
RALor in gear
gear,, and
and th
the
e engin
engine
e is runni
runningng,,
the machine
machine will turn. Engage the
the steering con
control
trol lock
by engaging the parking brake in order to prevent ma-
chine movement.

g01015497
Illustration 55

Steering control lever (3) allows the steering system

and the transmission system to be simultaneously
controlled. Push down on the parking brake
knob in order to release the parking brake and
allow movement of the steering. Also, this will
enable transmission controls. The steering lever 
is mechanically locked by the parking brake. The g01103286
transmission controls are electronically disabled. Illustration 56

When the machine is moving forward, push the

Transmission Direction Selection steering control lever forward for a left turn. When
the machine is moving backward, push the steering
Rotate control (4) (transmission direction selector)
control lever forward for a right turn. When you move
clockwise
clockw ise or counte
counterclockw
rclockwise
ise in order to change
change tthe
he
the steering control lever farther in a forward motion,
direction of the machine.
the machine will turn faster.
Forwar
For wardd –  Rotate the twist handle on the
In order to pivot the machine in the clockwise
lever forward to the FORWARD position
direction, place the transmission in NEUTRAL and
in order to move the transmission to
pull the steering lever backward toward the operato
operator.
r.
FORWARD.
In order to pivot the machine in the counterclockwise
Reverse
Revers e –  Rotate the twist handle on the direction, place the transmission in NEUTRAL and
lever backward to the REVERSE position push the steering lever forward.
in order to move the transmission to
REVERSE.

Neutrall –  Rotate the twist handle on the

Neutra
lever to the NEUTRAL position in order to
move the transmission to NEUTRAL.
 

46 SEBU7763-02
Operation Section
Machine Operation

Table 3 Decelerator (8)

Mac
ach
hin
ine
e tr
trav
ave
el Leve
ever mo
mov
vemen
ementt Machi
achine
ne
direction
(turn)
FORWARD PUSH LEFT
FORWARD PULL RIGHT
REVERSE PULL LEFT
REVERSE PUSH RIGHT
NEUTRAL   PUSH   LEFT
NEUTRAL PULL   RIGHT

Gauges and Indicators (6)

g01021776
Illustration 58
Refer to Operation and Maintenance Manual,
“Monitoring
“Monito ring System” for more information. Decelerator Pe
Decelerator Pedal
dal –  Use the decelerator pedal in
order to control the desired engine speed. Push
pedal in order to reduce the engine
down on the pedal
Service Brake Control (7) speed. Release the pedal in order to increase engine
speed. Use the pedal in order to reduce the engine
speed whenpedal
when you
decelerator  you make a directional
in order shift.inUse
to maneuver tightthe
locations.

Adjustme
Adju stment
nt –  The height of the decelerato
deceleratorr pedal is
adjustable. The minimum setting for the decelerator 
ad justable. Consult your Caterpillar dealer 
pedal is ad justable.
for the adjustment procedure.

Bulldozer Joystick Control (9)

Bulldozer Blade Lift
Bulldozer
g01107061
Illustration 57

Applying the Brake Pedal

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

Releasing the Brake

Releasing Brake Ped
Pedal
al –  Release the brake
pedal in order to allow the machine to move.

g01073385
Illustr ation
ation 59

Float (9A
Float (9A)) –  Push the lever forward
ely past the detent force in order to
completely
complet
activate the blade   float function. The   float
function is not deactivated when the lever is released
the NEUTRAL position. When the  fl oat functio
into the functionn
is activated the blade moves up and down with the
ground contour. The top of the “Advisor” display will
change from
change  from MANUAL to FLOAT when FLOAT is
activated.
 

SEBU7763-02 47
Operation Section
Machine Operation

The  fl oat will deactivate

deactivate if the lever is moved through
the NEUTRAL position to the RAISE position or the Tilt
Tilt Righ
Rightt (9G) –  Push the blade control
LOWER position.
position. lever toward the right in order to lower the
the bulldozer blade. When
right side of the
Note: The
Note:  The default setting for the operator
operator is ENABLE. you release the lever, the lever returns to the HOLD
The  fl oat function is enabled in “Advisor”or disabled position.
“Advisor”. Refer to Operation and Maintenance
in “Advisor”.

Manual,
the “Monitoring
“Advisor”
“Adviso System” for the explanation of 
r” functions.
functions. Bulldozer
Bulldozer Blade
Blade Tilt (Dual Tilt)

(9B)) –  Push the lever forward in

Lower (9B
Lower Dual Tilt (If Equipped)
order to lower the blade. Release the lever.
will return to the HOLD position.
The lever will

Hold (9C
(9C)) –  The lever will return to the
HOLD position, when you release the
the RAISE position and from the
lever from the
LOWER position. The movement of the bulldozer 
blade stops. If the lever is released from the   float
position
positio the  fl oat function remains active.
n the active.

Raise (9
Raise (9D)
D) –  Pull back on the lever in order 
to raise the blade. Release the lever. The
lever will r eturn
eturn to the HOLD position.
g01130936
“Advisor” allows the blade response to be Illustration 61
automatically set. Refer to Operation and
Maintenance
Maintenanc e Manual, “Monitoring Systems” for  Tr
Trigger
igger switch
switch ((Not Shown)) –  The trigger switch
proper adjustment of this setting. is located on the underside of the joystick. Hold the
trigger switch inward in order to operate the bulldozer 
blade in single tilt mode. Release the trigger switch in
Blade Tilt (Single
Bulldozer Blade (Single Tilt)
Tilt) order to return the bulldozer blade to dual tilt mode.

Tilt
Tilt Lef
Leftt (9E) –  Pull the blade control lever 
toward the left in order to lower the left side
of the bulldozer blade. When you release
the lever, the lever returns to the HOLD position.

Tilt
Tilt Hold (9
(9F)
F) –  When you release the
lever, the lever returns to the HOLD
position. The movement of the bulldozer 
blade stops.

Tilt
Tilt Righ
Rightt (9G) –  Push the blade control
lever toward the right in order to lower the
right side of the bulldozer blade. When
g01073394
tion 60
Illustration
Illustra you release the lever, the lever returns to the HOLD
Single Tilt Control position.

Tilt
Tilt Left (9
(9E)
E) –  Pull the blade control lever  Pitch Control (Dual Tilt)
toward the left in order to lower the left side
of the bulldozer
bulldozer blade. When you release Thumb switch (9H) is used to pitch the blade forward
the lever, the lever returns to the HOLD position. and backward. This blade movement changes the

Tilt Hold (9F) – When

–  When you release the performance of the blade.
lever, the
th e lever returns to the HOLD
position. The movement of the bulldozer 
blade stops.
 

48 SEBU7763-02
Operation Section
Machine Operation

Auto Blade Assist (if 

Definitions of Auto
Pitch Bac
Pitch Backk –  Move the thumb lever(9H) equipped)
on the bulldozer blade control lever to the
to pitch the blade backward.
left in order to
When you pitch the bulldozer blade to the rear you
will improve the ability of the bulldozer blade to carry
the load.

Pitch Forwar
Forward d –  Move the thumb lever 
(9H) on the bulldozer blade control lever to
order to pitch the blade forward.
the right in order
When you pitch the bulldozer blade forward you will
improve the penetration of the bulldozer blade. This
help to dump the load. This will also help to
will also help
minimize the carryback of the material.

Bulldozer Blade (Automatic Modes) Illustration 63

g01130936

The Auto blade assist has three sequences of 

operation:“Carry
operation:“Carry”,
”, “Spread
“Spread”,
”, and Load.

Carry –  Press the left button on the joystick (9J) one

Carry
time in order to activate the sequence. The blade will
adjust the pitch that was set in Advisor for this portion
of the application.

Spread –  Press the left button on the joystick (9J)

Spread
again in order to activate the sequence. The blade
will adjust the pitch that was set in Advisor for this
portion of the application.

g01385602 Note: If
Note:  If the machine is equipped with the position
Illustration 62
sensor on the lift cylinder the blade will also rise, in
addition to the change in pitch.
Dual tilt mode must be selected in the Advisor 
system. Activate the auto blade assist by pressing
Load
Load –  Press the left button on the joystick (9J)
(10). Buttons (9J) and (9K) can be used to
switch (10).
again in order to activate this sequence. The blade
assist with changing the blade pitch. Push button (9J)
will adjust the pitch that was set in Advisor for this
to toggle
that sbetween the 3 positions of the blade pitch
et in Advisor.
are set portion of the application. The activation of the load
sequence will recalibrate the blade. In order to
recalibrate the pitch, the blade will pitch all the way
Auto Blade
Blade Assist (10) (if equipped) to the back. Then, the blade will pitch forward to the
appropriate angle.
The auto blade assist moves the blade to preset
positions.
pitch positions. Note:  You can override the auto blade assist at any
Note: You
time by moving the dozer controls. The auto blade
Auto Blade
Blade Assist
Assist –  Push the switch in assist will be suspended by the selection of the right
to  set the system to the ON position.
order to set button on the joystick (9K). The auto blade assist
The indicator light will illuminate when the will resume at any time by the selection of the right
system is active. Push the switch again in order to button on the joystick (9K).
the  system OFF.
turn the system
Procedures for the Auto Blade Assist
Note:   Be aware that this procedure will move
Note: 
the dozer blade automatically. Make sure that the
hydraulic oil is warmed up before performing this
procedure.

1.  Press the throttle switch in order to activate high

 idle.

SEBU7763-02 49
Operation Section
Machine Operation

2.  Turn on ABA switch.

swit ch. The ABA switch is located Engine Reverse Fan (11) (if 
under the Advisor display monitor in front of the
bulldozer control lever.
equipped)

3.  Raise the blade about 2 feet off the ground.

butt on on the left side of the bulldozer 

4.  Press the button

control lever
will move in order
to zero toThe
pitch. reset the ABA.
blade The blade
will remain there
seconds. Then, the blade will move to
for several seconds.
the default setting (load position).

the settings on the “Home” screen. Press

5.  Highlight the
the OK button.

ee “Home Button” in “Monitoring

Reference:  See
Reference: S
System” story for more information
information..
g01131670
the setup for the implement controls.
6.  Highlight the Illustration 64
Press the OK button. Fan control switch (if equipped)

Reference:  See “Settings Menu” in “Monitoring

Reference: See If the machine is equipped with the reverse fan
System” story for more information
information.. function (attachment), the fan can reverse the
direction of air   flow from forward to the rearward
he auto blade pitch. Press the OK
7.   Highlight tthe direction. This enables the fan to purge debris from
button. the radiator, aftercooler cores, and engine access
doors. The purge cycle will begin automatically when
Reference:  See the same section in “Monitoring
Reference: See the purge interval expires or the purge cycle can
System” story for more information
information.. begin manually with a switch(11) on the right dash.

the segment of the dozing cycle in order 

8.  Highlight the Reversing Fan Contro
Reversing Controll –  In order to
to adjust the change in the pitch. The dozing cycle initiate the fan purge cycle, press fan
consists of a load segment, the carry segment, control switch (11) while the machine is
and the spr ead
ead segmen
segment.t. in NEUTRAL and the parking brake is released or 
when the machine is in REVERSE. In order to initiate
9.  Move the thumb lever on the bulldozer control the continuous fan purge cycle, press fan control
until the blade pitch is in the desired position.
lever until position. switch (11) while the machine is in NEUTRAL and
Press the OK button. the parking brake is ON and hold for three seconds.
The fan will remain in a continuous purge cycle until

10.blade
Repeat steps
steps
pitch 8 and
in the 9 in
other order to change
segments the
of the dozing the switch is pressed again or the parking brake is
released.
cycle. The new settings
settings are active until the ignition
ignition
key is tur ned
ned off. The setting range for fan purge duration is 5 - 60
seconds. The setting range for fan purge interval is 5
Note:  In order to save the desired settings, make
Note: In - 120 minutes. See “Procedures for the Reverse Fan
that  you have selected an operator profile.
sure that you Function (If Equipped)” for more information.

11. In order to save the settings of the dozer blade
to the operator profile, follow the steps 10
pitches to
& 11 in the Operation and Maintenance Manual,
“Creating Operator Profile”.
If the purge interval expires, a purge cycle will begin
when the track-type tractor is in a REVERSE gear or 
in NEUTRAL and the parking brake is released. If the
purge interval
interval expires and the track-ty
track-type
pe tractor is in a
FORWARD
FORW ARD gear, starting a purge cycle is preven
prevented.
ted.
If the purge interval expires and the track-type tractor 
is in NEUTRAL with the parking brake engaged,
starting a purge cycle is prevented. A purge cycle is
prohibited until there is a shift into REVERSE gear or 
the parking brake is released in NEUTRAL.
 

50 SEBU7763-02
Operation Section
Machine Operation

If the purge button

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

engaged.

g01107176
g01386038 Illustration 66
Illustration 65  All buttons on the left side of the Advisor monitor display are
Top banner in Advisor Monitor Display
inactive.

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

Procedures for the Reverse Fan Function

(If equipped)
equipped)
Reference:  See the “Monitoring System” story in this
Reference: See
manual for “Procedures for the Reverse Fan Function
 (If equipped)
equipped) .

SEBU7763-02 51
Operation Section
Machine Operation

Auxiliary Power Switch (13) (If  Note:  If the engine

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

Note:  The auxiliary circuit also serves as the switch

Note: The
for the rotating beacon.

Engine Start Switch (14)

g01073346
Illustration 68

High Idle
High Idle –  For high idle, press the top of 
the throttle switch that is right of the engine
start switch. The engine throttle is set at
the low idle speed position. Starting an engine that is
cold will cause the engine to start at a higher engine
speed. Improved combustion and reduce reduced d smoke
will occur.

g01073300 Low Idle –  For low idle, press the bottom of 
tion 67
Illustration
Illustra
the throttle switch to the right of the engine
OFF –  Insert the engine start switch key start switch. The engine speed immediatel
immediatelyy
from  the OFF position and remove
only from the moves to low idle.
the engine start switch key only from the
OFF position. Turn the engine start switch key to
position in order to stop the engine. In the
the OFF position
Set Engine Throttle
OFF position, there is no power to most electrical
Set the engine throttle between low idle and high idle
circuits onworking
lights,
tail lights, the machine. The
lights (if cab lights,
equipped) andpanel
fuel lights,
gauge in the following manner:
light are operational even when the engine start
1.   Set the engine throttle to high idle. Push on
switch is in the OFF position.
the decelerator pedal until the desired speed is
reached.
ON –  Turn  the engine start switch key
 Turn the
clockwise to the ON position in order to 2.   When the desired speed is reached, push the high
activate all of the cab circuits. idle side of the throttle switch and hold the switch
for three seconds. This will electronically lock in
STAR
START T –  T
 Turn
urn the engine start switch key the engine speed.
clockwise to the START position in order to
crank the engine. Release the key after the 3.  In order to return to low idle or high idle, push
 starts. The key will return to the ON position.
engine starts.
engine the Throttle switch on the appropriate side of the
Throttle switch and release the switch.
Note: The
Note:  The engine start switch will start differently
if the engine is equipped with the prelube system.
Refer to
to Operation and Maintenance Manual, “Engine
Starting ” for more instruction.
 

52 SEBU7763-02
Operation Section
Machine Operation

Implement Lockout Switch (16) Bidirectional Shift (17) (Direction

Shift)

g01016340
Illustration 69
g01016340
Illustration 70
This switch will make all hydraulic attachment
nonfunctional.
bidirectional shift function can be selected with
The bidirectional
the switch (17). The switch is located on the right
Implement Lockout Switch
Implement Switch –  Press the
console. The default setting for the bidirectional shift
top of the switch (16) in order to deactivate
is OFF. Ref er
er to theOperation and Maintenance
the implemin
implement
the switch ent controls.
order Pressthe
to activate theimplement
bottom of  Manual, “Monitoring System” for more details about
the directional shift indicator. The bidirectional
bidirectional shift
controls.
displayed on the top banner of the “Advisor”.
mode is displayed
The autoshift function includes the following modes:

Note:  The hydraulic shutoff control is designed to

Note: The Bidirectionall shift mode –  The electronic
Bidirectiona
deactivate the control levers. Depress the top of  transmission
transmi ssion system is equipp
equipped
ed with a bidirec
bidirectional
tional
the switch in order to deactivate the control levers. shift function for directi
directional
onal changes.
The indicator for the implement control on the dash
panel will illuminate when the hydraulic controls are First gear forward to second reverse
deactivated.
deactiv ated. Deactivate the contro
controll levers before you directional
directional shif
shiftt mode –  Push button (5)
exit the seat or before you service the machine. The once for  the
 the autos
autoshift
hift function. A directional
directional
control levers should always be deactivated when the shift to the FORWARD position will always shift to
machine is left unattended. first gear. A directi
directional
onal shift to the REVERSE position
always shift to second gear. This mode allows
will always
Note:  You may lower the implements for only a
Note: You a direct shift from the FIRST GEAR FORWARD
short time after you stop the engine. The engine position to the SECOND GEAR REVERSE position.
start switch key must be ON in order to lower the the default setting for this machine.
This is the
implements. Refer to the Article “Equipment Lowering
with Engine Stopped” in this manual.
Note:  Advisor will recall the previous gear selection.
Note: Advisor
Press “OK” at the recall operator settings screen in
to  load the previous settings.
order to load

The top line of the “Advisor” panel displays the

specific bidirectional shift mode (“1F-2R, 2F-2R,
2F-1R”). For the best results, change the options with
the transmission in NEUTRAL
NEUTRAL..
 

SEBU7763-02 53
Operation Section
Machine Operation

Automatic Downshift (18) Automatic Downshi

Downshiftft (LOW)
(LOW) –  Push switch (18)
and release the switch until the indicator for the
(Downshift) automatic downshift is ON. This setting allows the
engine lug setpoint and the most reduction in
highest engine
travel speed before an automa
automatic
tic downshift occurs.
The selection can be Changed in Advisor.

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

Downshift (HIGH) –  Push switch (18)

Automatic Downshift
and release the switch again until the indicator for the
g01016340 automatic downshift is ON. This setting allows the
Illustration 71
engine lug setpoint and the least reduction in
lowest engine
travel speed before an automa
automatic
tic downshift occurs.
Downshif
Automatic Down shiftt –  The electronic
The selection can be changed in the Advisor menu.
transmission system is equipped with
a mode for the automatic downshift.
When the machine is powered down, the active mode
If a significant decrease in machine speed is
detected,
detect ed, this function automa
automatically
tically downshifts the for
Whenthe the
automatic downshift
machine
machine is kept
is powered up, in ECM
the memory.
automatic
transmission. This function works in forward and
downshift is activated in the same mode.
gears. The default setting for this machine is
reverse gears.
OFF. When the automatic downshift is activated the
default setting is medium. Light Switches (21) (22) (23) (24)
(31)
automatic downshift switch (18) is located on
The automatic
the right console of the cab. The current mode
of operation is shown by the indicator for the
automatic
automati c downshift. When the machine is started,
the transmission will be in the mode of automatic
downshift that was selected prior to shutting down
the machine.
machine. When the machine is started and the
automatic downshift is not active, push switch (18)
and release the switch. If the mode for the automatic

downshi
downshift
downshiftft is active,
will the indicator
illuminate for the automatic
and the display monitor will
display “LO or HI”. Select the mode for the automatic
ift with the transmission in NEUTRAL. If the
downshift
downsh
operation for the automatic downshift is not desired,
the machine can be operated in the manual mode.
Changes
Change s in performance for the automatic downshift Illustration 72
g01127109
can be made in “Advisor”.
Interior Dome Ligh
Interior Lightt (31) –  This is a three-position
operation for the automatic downshift can be
The operation switch. The dome light is OFF in the center position.
used in the following modes. Push the right side of the rocker switch in order to
enable the light to turn on when either one of the cab
Manual Shif
Manual Shiftt in Automa
Automatic Downshift –   The
tic Downshift doors are open. Push the left side of the switch in
automatic downshift allows the transmission to order to turn on the dome light. See illustration 52.
downshift automatically. After a manual upshift, the
kickdown is prevented for two seconds. The
auto kickdown Panel Backlights and Front Lights on
operator can make manual shifts at any time. Cylinders (21
Cylinders (21)) –  Press the rocker switch
to the top position in order to turn on the
Automatic Downshift
Automatic Downshift (OFF) –  Push switch (18) and dash panel lights and the front halogen   floodlights.
release the switch in order to turn off the automatic Move the rocker switch to the middle position in order 
downshift.
downsh ift. The indica
indicator
tor on the front instrument panel to turn on the dash lights. Press the bottom of the
will  no longer be illuminated. The manual shift mode
will no switch in order to turn off the lights.
 is then active if no autoshift indicators are on.

54 SEBU7763-02
Operation Section
Machine Operation

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

Note:   The switch can be in the top position or 

Note:  Ripper Auto Stow switch (28)
the middle position during shutdown. The fender 
Push ripper auto stow switch (28) on the ripper 
floodlig hts will remain on for a short period of time
oodlights
control in order to raise the ripper to maximum height.
when the switch is left in one of these two positions.
If the machine is con figured move the ripper to a full
SHANK IN position. The positions of the ripper can be
Lights  on ROPS
Front Lights on ROPS (23)
(23) –  Press the
configured with Advisor. Refer to System Operation
Operations,
s,
top of the switch to the  fi rst position in order 
RENR8170
RENR817 0 for more information about Advisor.
Advisor.
to turn on the lights on the ROPS that face
forward.. If  equipped,
forward   equipped, with HID lights, the lights on the
SHANK
SHANK IN –  Position “In”
ROPS, that face forward will use HID lights. Depress
the switch to the second position in order to light the
SHANK
SHANK OU
OUT
T –  Position “Out”
HID lights on on the cylinders.
NK –   Unchanged position
SHANK
SHA
Rear lights on ROPS (24) (if equipped)
 –  Press the top of the switch in order to turn
 – Press
light on the ROPS that faces the rear.
on the light While
ripper,the ripper
press the auto stow
ripper autofunction is moving
stow switch againthe
in
order to stop ripper movement.

Action Light (25)

Ripper Raise/Lower (29)
Action Light
Action Light –  The action light illuminates
when a Warning Level 2 is active. The
light illuminates when a Warning
action light
Level 3 is active. The action light is on the gauge
and indicators. A second action light is on the right
console.
hand console.

Refer to the Operation and Maintenance Manual,

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

Shank In/Out Lever (26)

Ripper Shank
Shank
Sha nk In –  Pull the front of the ripper 
in/out lever (26) toward the operator 
shank in/out g01129001
Illustration 73
in order to move the shank in closer to the
machine. Release the lever. The lever will return to RAISE – Push
–  Push the top of the ripper lift
position.
HOLD position. controll lever (29) in order to raise the ripper.
contro
Release the lever. The lever will return to
Hold –  The ripper shank in/out lever 
Hold the HOLD position.
(26) returns to the HOLD position. Ripper 
movement   will stop when the lever is
movement HOLD –  The ripper lift control lever (29)
HOLD
released. automatically returns to HOLD position.
Ripper movement will stop when the lever 
Shank Out – Pull
–  Pull the rear of the ripper  is release
released.
d.
shank in/out
in/out lever (26) toward the operator 
in order to move the shank out away from LOWER –  Push the bottom of the ripper 
LOWER
the machine. Release the lever. The lever will return lift control lever (29) in order to lower the
to HOLD position.
position. ripper. Release the lever. The lever will
return to the HOLD position.
 

SEBU7763-02 55
Operation Section
Machine Operation

Winch Control (30) (If Equipped)

Reel-In (3
Reel-In (30B)
0B) –  Push the lever forward
in order to reel in the wire rope. The wire
move toward the winch under 
rope should move
power. Release the lever. The lever will return to the
BRAKE ON (neutral) position.

Freespool (30
Freespool (30C)
C) –  Push the control
away from the operator in order to release
the winch. The control will stay in the
DETENTED
DETENT ED pos ition. The wire rope will unreel by the
position.
weight of the load. The wire rope will unreel as the
machine moves away from the load. Pull the control
DETENTED position. The lever will return to
from the DETENTED
the BRAKE ON (neutral) position.
g01129007
Illustration 74
(30) Winch control lever 

(Lock) –  Press the switch (20) on

Winch (Lock) Do no
nott use dr
drum
um clu
clutc
tch
h rele
releas
ase
e for
for con
contro
trolle
lled
d
the console to the winch control circuit to reeloutt of suspe
reelou suspended
nded loads.
the stop position. This switch deactivates
control lever. A light on the gauge display
the winch control Su
Sudd
dden
en relea
release
se of load
load ma
may
y resul
resultt in injur
injury
y or 
will illuminate when this mode is active. death and proper
property
ty damage
damage..

Note:  Deactivate the winch control lever before you

Note: Deactivate
seat or before you service the machine. The
exit the seat
winch control lever should always be deactivated
when the machine is left unattended.
Use only reelout to lower loads.
Reel-Out (30D) –  Pull the lever rearward
Reel-Out
in order to reel out the wire rope. The wire
rope will reel out under power. Release the
lever. The lever will return to the BRAKE ON (neutral)
position.

Window Wiper and Window Washer 

(32)

g01127181
Illustration 75

The electronic control provides variable speed

control for the winch. Slight movement in the REEL
IN position or slight movement in the REEL OUT
position results in a winch drum speed that is very
slow and controlled. As the control is moved further 
from the center BRAKE ON (neutral) position, the g01129013
g01129013
Illustration 76
winch drum speed is increased
increased proportionally
proportionally.. When
the control is released from the REEL IN position or 
from the REEL OUT position, the control will return to Front Windshield Wiper and Front
the BRAKE ON (neutral) position. Windshse
Windshield
ield Was
Washer
her (32A
(32A)) –  Turn the knob
clockwise in order to turn on the windshield
clockwi
Brake On (Neutral)
(Neutral) (3
(30A)
0A) –  The wire rope wiper. Continue to turn the knob clockwise in order to
should not move. Use this position when move the windshield wipers faster. Push the knob in
you are holding a load and when the winch to  activate the windsh
order to activate windshield
ield washer.
washer. Spring force
returns the knob when you release the knob.
 is not active.

56 SEBU7763-02
Operation Section
Machine Operation

Variable Control (33B)

Temperature Variable
The Windsh
Windshield
ield Wiper/Wash
Wiper/Washer er for the
left door
door (32B)
(32B) –  All of the Windshield Temper
emperature
ature Var
Variable
iable Control (33B) –
Wiper/Washer s operate in the same Turn the contr ol
ol knob anywhere between
manner as Windshield Wiper/Washer (32A). the blue area (left) and the red area (right).
This will control the amount of heating and the
the Windshield Wiper/Washer for the cooling.
amount of cooling.
right door (32C)
(32C) –  All of the Windshield
Wiper/Washers operate in the same Move temperature variable control (33B) clockwise
manner as Windshield Wiper/Washer (32A). in order to operate the heating system. Turn the
the red area in order to increase cab
knob toward the
Windshield Wiper/Washer for the
The Windshield temperature. Turn the knob toward the blue area in
rear window
window (32D)
(32D) –  All of the Windshield order to decrease the temperature.
Wiper/Washers operate in the same
Windshield Wiper/Washer (32A).
manner as Windshield Heating and Air Conditioning System
Operation
Heating and Air Conditioning The Fan Control for the Heating and for 
Controls (33) the Air Conditionin
Conditioning g –  The fan control
assists the functioning of the heating
knob assists
(33A)
Fan Control (33A) and air conditioning system.

The Fan Speed Switch (33C) for the The heating and air conditioning system can perform
and  for the Air Conditionin
Heating and for Conditioning
g – functions:
four functions:
The fan speed switch controls the
four-speed
four-speed blower fan motor.
motor. Heating –  Turn the fan speed switch to LOW, HIGH
Heating
speed. Adjust temperat
or MAXIMUM speed. temperature
ure variable
variable
OFF – Move fan speed switch (33C) to the
–  Move fan control (33B) for the desired temperature.
left position in order to stop the blower fan.
Air Conditioni
Conditioning ng –  Activate the A/C switch. Turn
the fan speed switch to LOW, MEDIUM, HIGH or 
MAXIMUM speed. Adjust the temperature variable
Low – Move
–  Move the switch to this symbol. This for the desired temperature.
control for
is the lowest fan speed.
Pressurizing –  When heating or cooling is not
Pressurizing
pressurize the cab in order to prevent dust
desired, pressurize
Medium –  Move the switch to this symbol.
Medium from enterin
entering.
g.
This is the medium fan speed.
Turn the temperature
temperature variable controls to a
comfortable stage. Turn the blower fan switch to
High –  Move the switch to this symbol for 
High LOW, MEDIUM, HIGH, or MAXIMUM speed. Use the
the high fan speed. speed  that is needed to keep out the dust.
fan speed that

Defogging –  Activate the air conditioning system.

Defogging
Maximum
Maxi mum –  Move the switch to this symbol Select a f an
an speed for the air conditioner. Use the
for the maximum fan speed. fan speed that is needed to remove moisture from
the air in the cab. This prevents moisture from
 on the windshield and the windows. Adjust
forming on
forming
the temperature control until the moisture level is
Air Conditio ning Switch
Conditioning lowered. Adjust the temperature control until the
ture of the cab is comfortable.
temperature
tempera
Air Conditioning
Conditioning (33(33A)
A) –  Depress A/C
(33A)  in order to activate the air 
switch (33A) in
conditioning system. Turn fan speed switch
(33C) to LOW, MEDIUM, HIGH or MAXIMUM speed.
 Adjust temp erature variable control (33B) for the
temperature
desired temperature.
 

SEBU7763-02 57
Operation Section
Machine Operation

Cab Door (34) (35) (36) Window (39)

g01127191 g01129016
Illustration 77 Illustration 79
Front view
Open latch (39A). Then squeeze latch (39B) in order 
(34) in order to open the cab door (35).
Pull lever (34) to release the window from the CLOSED position.
latch (39A) in order to secure an open window.
Close latch
Fully open the door until the door latches.
i02703644

Monitoring
Monitoring System
SMCS Code: 7490
Code:  7490

Functional Test
The monitoring system informs the operator of the
status of the machine systems. The monitoring
system informs the operator of problems or of an
impending problem.

g01127201
Illustration 78
Typical machine cab (Track-Type Tractor)
Some components are removed for clarity.
Pull inside top lever (36) in order to release the cab
door from the fully open position. Pull the lever that is
outside of the cab in order to close the cab door.
Alternate
Alternate Exits
Machines with cabs are equipped with alternate exits.
If a door becomes disabled, the other door can be
used as an alternate
alternate exit. Release
Release the latch and open
the door.
Mirror (37)
The operator will adjust the rear view mirror in order  properly operating.
to get the best visibility. Adjust the mirror before you
operate the machine and after operators change.
If the action alarm does not sound during this test
or machine monitoring displays are not function-
ing, do not operate the machine until the cause
has been corrected. Machine operation with faulty
action alarms or displays could result in injury or 
death as any Warning Category 3 noti fications will
not be relayed to the operator.
When the engine start switch key is turned to the
ON position, the monitoring system runs a test. The
operatorr must observe the monitor
operato monitoring
ing system during
the test to determine proper operation.
The self testing feature verifies that the modules of 
the monitoring system are properly operating. The
self testing feature verifies that the display module is
The operator must observe the outputs in order to
determine
determin e if the module
moduless are operating properly
properly.. This
self testing feature is three seconds long.
 

58 SEBU7763-02
Operation Section
Machine Operation

During the self  test,

  test, all status indicators on the Electrical
Electri Fault
cal Fault
instrument
instrument module light.
Electrical System
Electrical System (2) –  This indicator 
display window on the instrument module
The digital display ma lfunction in the electrical
indicates a malfunction
shows the following readouts: system. If this alert indicator lights, the
system voltage is too high or too low for machine
•   Initial part number
number of the instrument module operation.

•   All indicators
indicators of units (Deg C, kPa, rpm, and liters) Increase the engine speed to high idle, if the electrical
loads are high. The electric loads consist of the air 
•   “X10” conditioning
conditionin g and/or the lighting. An alternator will
generate more output when the engine is at high idle.
•   Symbol for the  hour meter  If the alert indicator for the electrical system stops
minute, the electrical system is operating
within one minute,
•   “8.8.8.X8.8” readout normally. During the periods of low engine speeds,
the alternator is overlo
overloaded.
aded.
The pointers in the quad gauge point upward. Then,
the pointers point to the left. Then, the pointers point Modify the operating cycle. This will prevent the
Then, the pointers point to the   final
to the right. Then, electrical system from overloading. This will also
position. the  electrical system from discharging the
prevent the electrical
batteries. You can also reduce the loads on the
•   The readout of
of the gear shows “**”. electrical system. Use the medium fan speed in the
instead of the high fan speed.
cab instead
•   The speed readout shows “888”, “MPH”, and
“km/h”. Run the engine speed at normal rpm. Run the
electricall system at a light load. If the light remains on,
electrica
•   The rear action light
light “ON then OFF” drive the machine to a convenient stop. Investigate
the cause of the problem. The cause may be a loose
•   The forward action light stays illuminated.
illuminated. alternatorr belt, a broken alternator belt, a faulty
alternato
battery, a faulty alternator, etc.
•   The action alarm
alarm sounds once.

The monitoring panel is then in the normal operating

mode.

Light
Action Light

g01108870
Illustration 80
Instrument module

Action
Acti on Lamp
Lamp (1) –  There are two action
lamps. One action lamp (1) is on the
instrument module. The other action lamp
is located on the right console. The rearward action
lamp is viewed when the operator is facing rearward.
 

SEBU7763-02 59
Operation Section
Machine Operation

Status Indic
Indicators
ators

g01356411
g01356411
Illustration 81

Parking
Parkin g Brake (3) –  This status indicator  This function (10) is not used.
indicates that the parking brake is engage
indicates engaged.d.
indicator lights, disengage the parking
If this indicator
brake.
Implement Lockout (1
Implement (11)
1) –  This indicator 
Float (4) –   This status indicator is
Float is illuminated when the implement lockout
ated when the  fl oat mode is selected.
illuminated
illumin selected. is activated.

This function (12) is not used.

Tilt (5) – This
Single Tilt –  This status indicator is
illuminated when the single tilt system is
activated.
Winch
Win ch Loc
Lockk (13) –  This status indicator is
Tilt (6) – This
Dual Tilt –  This status indicator is illuminated when the winch control lever is
illuminated when the dual tilt system is disabled.
activated.
Winch LowLow Speed (1(14)
4) –  This indicator 
function
This function (7) is not us
used.
ed. – is illuminated when the winch is locked at
low speed.

Winch Freespool
Freespool (1
(15)
5) –  This indicator is
This function (8) is not used. illuminated when the winch is released .

Automatic Downshift(16)
Automatic Downshift(16) –  This indicat
indicator 
or 
Auto Blade
Blade Assist
Assist (9) –  This indicator is is illuminated when the auto kickdown
illuminated when the auto blade assist is operation
operat ion is active
active..
enabled.
 

60 SEBU7763-02
Operation Section
Machine Operation

Table 4
Bidirectional Shift Function(17)
Bidirectional Function(17) –  This D8T High Inlet Manifold Air Temperature
indicator
indicator is illumina
illuminated
ted when the autoshift
functioning.
mode is functioning. Trip Point   80 °C 84 °C
(176 °F) (183 °F)
Warning 1 2
Gauges Level

Torque Converter Oil Temperature

Torque Temperature (18) –
This gauge indicates excessive torque Table 5
converter
conver oil temperature. If the gauge
ter oil High Engine Coolant Temperature D8T
needle reaches the red zone, the Advisor display
monitor will display a warning. If necessary, reduce Trip Point   10
107
7 °C (2
(225
25 °F
°F)) 115 °C (2
(239
39 °F
°F))
that  is on the machine until the torque
the load that is Warning Level   2 3
converter
conver ter oil tempera
temperature
ture decreases.
decreases.
Table 6
Fuel Leve
Levell (19) –  The fuel level gauge
High Hydraulic Oil Temperature D8T
indicates
indicat the amount of fuel that remains
es the
in the fuel tank. A gauge needle in the red Trip Point   10
102
2 °C (2
(216
16 °F
°F)) 117 °C (2
(243
43 °F
°F))
zone indicates a low fuel level. Re fill the fuel tank
Warning Level   2 3
before the machine
machine is empty of fuel.

Table 7

Running out of fuel canNOTICE

cause engine damage. Do not High Torque Converter Oil Temperature D8T (1)
continue
continue to operate
operate the mac
machine
hine w
when
hen critically
critically low on Trip Point   12
129
9 °C (2
(264
64 °F
°F)) 135
135 °C (2
(275
75 °F
°F))
fuel.
Warning Level   2 3
(1) This excessive oil temperature does not initiate the full forward
Hydraulic Oil Temper
Hydraulic Temperature
ature (20) –  The speed of the fan.
gauge indicates the temperature of the
hydraulic oil in the hydraulic oil sump for the Table 8
steering
steerin g and implement circuits. This gauge indicates
High Transmission Oil Temperature D8T (1)
excessive hydraulic oil temperature. If the gauge
needle reaches the red zone, the Advisor display Trip Point   119 °C (246 °F)
monitor will display a warning. If necessary, reduce
Warning Level   2
the load that is on the machine until the hydraulic
oil temperature decreases. Move the implement
cylinders without a load, or clean the hydraulic oil Thermostat Control
cooler.
The following table shows the thermostat opening
Engine Coolant
Coolant Temperatur
Temperaturee (21) –  The temperatures.
water temperature regulator regulates the
Table 9
coolant temperatures. This gauge indicates
excessive engine coolant temperature. If the gauge D8T Thermostatic Control
needle reaches the red zone, the Advisor display Opening Te
Temperature
mperature   81 °C (178
(178 °F)
monitor will display a warning. Continued operation to
of the machine during the sounding of the warning 84 °C (183 °F)
alarm or the gauge needle in the red zone may
damage the engine. Fully Open Temperature   92 °C (198
(198 °F)

Warnings For Overheating Fan Speed

The following tables show the temperatures for   All D8T tractors have a hydraulic fan drive.
the warning trip points for the following systems:
inlet manifold air temperature, engine coolant
temperature, hydraulic oil temperature, and torque
converter
conver ter oil tempera
temperature.
ture.
 

SEBU7763-02 61
Operation Section
Machine Operation

Fan speed will vary.

v ary. The fan speed depends
on the following temperatures: inlet manifold air  NOTICE
temperature, engine coolant temperature, and 3150 rpm in any situatio
Do not exceed 3150 situation.
n. Overspeed-
oil  temperature. These temperatures
hydraulic oil temperature. temperatures rise ing when downshifting, going downhill, etc., can result
as the load and ambient temperatures increase. in serious damage to your engine.
Under the condition of very light loads and cooler 
temperatures, the fan operates at minimum
ambient temperatures,
forward speed
and ambient in order to conserve
temperatures increasefuel. As the
the fan load
speed Digital Display Window (23)
increases.  Under heavy load and high ambient
increases. Under The digital display
display window (23) provides readouts
temperatures, the fan reaches maximum forward that show the following items:
speed.
•   Operational hours
hours (service hours)
Maximum Forward Speed of Fan
•  Selected gear and direction
will  operate at full forward speed when any of 
The fan will operate
the temperatures that are listed in the following table •   Ground speed
are met or the temperature is exceeded.
Meter 
Service Hour Meter 
Table 10

Temperatures at Maximum Demand Fan Speed Service Hour Mete

Service Meterr –  This display indicates the
operating hours of the engine. Use the display
total operating
Engine Coolant 98 °C (208 °F) in order to determine the service hour maintenance
Temperature
intervals. Service hours are displayed even with the
Hydraulic Oil
Hydraulic 90 °C (194 °F) start  switch key in the OFF position.
engine start switch
Temperature
Inlet Manifold Air  48 °C (118 °F)(1)
(1) Warning Leve ls
Levels
re
Temperature
Temperatu
(1) temperature with the sound suppression arrangement
This temperature arrangement The operator will be warned of immediate problems
(129 °F).
is 54 °C (129 machine system or impending problems with a
with a machine
machine
machin e system by Adviso
Advisor.
r.
Engine Speed (22)
monitoring system provides three
The machine monitoring
warning levels. Warning level (1) requires no
Do not allow the engine speed to exceed 3150 rpm.
Severe engine damage may result. immediate action. The   first level requires only
awareness.
operator awarenes s. The system needs attention.
Warning level (2) requires a response to the
The following range marks are displayed on the
tachometer (22): White zone, Yellow zone, and Red warning. Change the machine operation or perform
ce to the system. In all events except
maintenance
maintenan
zone. engine overspeed, warning level (3) requires
Engine Speed
Speed (White zon
zone)
e) –  0 - 2700 immediate shutdown of the machine. Engine
 requires an immediate reduction in engine
overspeed requires
overspeed
RPM
speed.

The Advisor
Advisor system will display a text message for 
Speed (Yellow
Engine Speed (Yellow zone
zone)) –  2700 - the current highest level active event.
2850 RPM is only a visual caution. This
indicates
indicates that the machine is approaching
approaching
Level  2 Warning.
the Level 2

Engine Speed
Speed (Red zone)
zone) –  2850 - 3500
rpm is a visual warning that immediate
is  required to maintain the engine
action is required
speed below the maximum allowable engine speed of 
3150 rpm. A Level 2 Warning begins at 2850 rpm. A
Warning starts at 3150 rpm. Apply the service
Level 3 Warning
brake in order to reduce engine speed immediately.
immediately.

Note:  See the Topic “Engine Overspeed” in this

Note: See
manual f or
or more information.
 

62 SEBU7763-02
Operation Section
Machine Operation

Table 11

Warning Operation
Warning indications(1)
Warning Front Action Rear Action Action Advisor 
Category Lamp(3) Lamp(4) Alarm Monitor  “Operator Action “Possible
Sounds Display Required” Result ”(2
(2))

1 X Amber X(5)
(5) No immediate
immediate No machine
action is required. damage
The system needs occurs. Minor 
attention soon. reductions
in machine
performance
may occur.
2 X Red X   (4
(4)) X(5)
(5) Change machine Severe
operation or perform damage to
maintenance to the components
system. can occur.
3 X Red X   (4
(4)) X   (6) X(5) (7)Immediately Injury to the
perform
perform a saf
safe
e engine
engine operator 
shutdown. or severe
damage to
components
can occur.
(1) The active indicators are marked with an X.
(2) This is the possible result, if the operator takes no action.
(3) The lamp is color coded. The lamp   flashes at Level 2 and 3.
(4) Rear action lamp  fl ashes at Level 2 and 3.
(5)  Advisor indicates an active fault.
(6) The action alarm sounds.
(7) Engine overspeed
overspeed does not require engine shutdown. Engine overspeed require
requires
s applying
applying the brake in order to immedi
immediately
ately reduce
engine speed.

If an action alarm, alert indicator, or Warning The Advisor display monitor monitors the machine
occurs, the message will override the screen that operations,
operations, diagno
diagnostic
stic events
events,, service intervals,
was displayed on the CAT Advisor graphic display and modes of operation. Advisor is used to change
module. customerr prefere
custome preferences
nces and operat
operation
ion parame
parameters.
ters.
This allows additional means for the operator to
increase machine ef ficiency.
CAT Advisor Graphic Display
Module

g01361910
Illustration 83

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

SEBU7763-02 63
Operation Section
Machine Operation

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

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

g01372719
Illustration 85
Operator menu

The menu file” allows the user to

perform thefor the “Operator
following Proto
changes an operator pro file:

•   selection
g01356674
Illustration 84
Home menu •   editing
•   creating
•   deleting
•   saving
The user may reset a pro file back to the default
settings or the user may recall the previously used
settings.
 

64 SEBU7763-02
Operation Section
Machine Operation

 An Operator Profile is a private

private set of preferences
preferences that The “Operator Pro Profile” menu option is entered by
is identified by a name. Once the profile is created, selecting “Operator” from the “Home” menu. Press
the operator may associate various items to that the up arrow button or the down arrow button until
as   the following components: implement
profile such as  is  highlighted. Then press the “OK” button.
“Operator” is highlighted.
features and settings, display settings, and power  Refer to Illustration 87.
train settings. After all of the parameters have been
the operator’s preference, the operator 
adjusted to the Note: The
Note: “Home Menu” can be displayed from any
 The “Home
may then save the parameters for future usage. screen by pressing the Home button.
The following screen will now be displayed.
followin

g01115796
Illustration 86

g01104635
Upon the next restart, the user will be prompted to Illustration 88
recall the previous settings. Refer to Illustration 86.
Press the “OK” button within ten seconds in order to The “Operator Profile” menu options and contents
recall the previous settings. If ten seconds pass by contain the followin
following
g components:
components:
the start-up, the default settings will activate.
•   Select the profile.
  Edit the name.
•
•   Create the profile.
•   Delete the profile.
•  “View/save” to the current profile
•   Default Set
•   “Recall Previous”
Press the “UP” arrow button or the “DOWN” arrow
button until the desired category is highlighted in
order to access the “Operator Profile” menu options .
Then press the “OK” button. The following explains
the usage of each menu option.

g01104631
Illustration 87
 

SEBU7763-02 65
Operation Section
Machine Operation

le”
“Create Profile” •   Backlight intensity
intensity “night mode %”

•  Backlight intensity “day mode %”

•   Contrast “%”
Note: A
Note: maximum of 10 pro files may be used. The
 A maximum
typical display settings will allow 11 characters to the
name of profile information to be viewed.

“View/Save Current”
From the “Oper ator
a tor Profile” menu, use the
appropriate
approp riate arrow button to highligh
highlightt the “View/Save
Current” option. Then, press the “OK” button in
order to view the
view  the settings that are associated with
the current profile. This procedure will cause the
following components to be displayed on the screen:
ed profile and current settings. The displayed
selected
select
settings are the current settings. Also, the settings will
reflect any overrides that are not saved to the stored
settings
setting s in  memory. The operator may then exit this
in memory.
g01356469
Illustration 89 display
displa y without saving the override
overrides
s to memory or the
Engine Reverse Fan operator may save the overrides to memory. Then,
display by following the screen prompts. In
exit the display
From
From the “Oper
“Operat
ator
or Profile” menu,
Pro menu, us
use
e th
the
e appr
appropr
opria
iate
te either case, the machine operation will re flect these
arrow button to highlight the “Create Profile” option. settings. When the settings are not saved and this
Then press the “OK” button in order to display the profile is r ecalled
ecalled next, the overrides will not be active.
“Create Profile” screen. Follow the prompts that
are on the screen in order to create a new name. “Select” Profile
Save the new name to the existing list of pro files.
This procedure creates a profile. The “Settings” From
From th thee “Op
“Opera
erato
torr Profile” me
Pro menu
nu,, use
use the appr
approp
opria
riate
te
menu can then be used to adjust parameters. These arrow button to highlight the “Select Pro file” option.
parameters may then be associated to the new press the “OK” button in order to display a
Then press
profile by using the “View/Save Current” option. list of existing pro files. Again, use the appropriate
arrow button to highlight the desired pro file. Then
The user profile contains these options that are able the  “OK” button in order to select that pro file.
press the “OK”
to be modified. This procedure will cause the selected pro file and
the associated settings to be the active pro file. The
•   Blade response  operation will reflect these setting
machine operation
machine settings.
s.

•   Blade tilt mode  A maximum of 10 profiles may be used.

Note: A
Note:

•   Blade   float “Edit” Name

•   Auto downshift From
From ththee “Ope ratorr Profile” me
“Operato menu
nu,, use
use the appr
approp
opria
riate
te
arrow button to highlight the “Edit Name” option.
•  “Auto downshift setting” Then press the “OK” button in order to display a list
existing profiles. Again, use the appropriate arrow
of existing
•  “Bidirectional shift configuration” button to highlight the name of the desired pro file.
Then press the “OK” button in order to select that
•   “Bidirectional
“Bidirectional shift setting” le.. Follow the prompts that are on the screen in
profile
order to edit the selected name. Save the changes.
•  “Reverse fan manual switch” This procedure renames the selected profile. Also,

•  “Ripper auto stow function” this

name.keeps the settings associated with the original
keeps

•   Measurement Note:  The typical display settings will allow 11

Note: The
characters to the name of pro file information to be
•   Language
 viewed.

66 SEBU7763-02
Operation Section
Machine Operation

“Delete” Profile Display Module

From
From the “Oper
“Operat
ator
or Profile” menu,
Pro menu, us
usee th
the
e appr
appropr
opria
iate
te
to highlight the “Delete Pro file” option.
arrow button to
Then press the “OK” button in order to display a list
of existing profiles. Again, use the appropriate arrow
order to highlight the profile that will be
button in order
deleted.
deleted. Then press the “OK” button in order to delete
that profile. This procedure deletes the selected
the list of stored pro files. This procedure
profile from the procedure
also deletes the settings that are associated with
that profile.

Default Set
“Operator Profile” menu, use the
From the “Operator
appropriate
approp riate arrow button to highligh
highlightt the “Default Set”
option. Then press the “OK” button in order to make
default  settings active. This procedure recalls
the default settings
the default settings. The default settings are then
the active settings and the machine operation will
the  default settings. Once the default settings
reflect the default
have been activated, the settings may be viewed
withoutt saving using the “View/Save
withou “View/Save Current” option.
default settings are not permanently associated
The default
with the current pro file unless the operator saves the
default settings to the current pro file by using the
“View/Save
“View/Sa ve Current” option.

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

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

Tr
Transmiss
ansmissionion gear and directio
direction
n (1) –  This display
area shows the active transmission gear and the
current direction of the machine.

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

Doze
number of different messages such as the following
modes: the current dozer mode, the current segment
of ABA (Auto Blade Assist) or Auto Carry, the
implement status, and the status of the implement
 system .

SEBU7763-02 67
Operation Section
Machine Operation

“Active”
“Active ” (3) –  When
 W hen this message is shown, the Upon turning the
the engine start key to ON, the Advisor 
forward and reverse control to the engine fan is display module will perform a self test. The   first
password protected. The reverse fan function initiates preliminary screen asks the operator to accept the
the  “REVERSE” speed. The automatic
turning in the “REVERSE” customer preferences that are still active
use of the customer
mode stops the purge cycle when the machine shifts from the previous start-up. Press the OK button,
into FORWARD speed. Manual mode will complete in a timely manner in order to use the active set of 
the timed pur ge
ge cycle if the machine shifts into customer
custom er preferences. Without acceptance of the
preferences.
FORWARD speed. previous settings as “OK”, the default settings are
loaded into the memory 10 seconds after start-up.
Autoshift
Autosh Mode (4) – This
ift Mode –  This display area shows the
current auto
current autoshif
shiftt mod
mode
e that is selected.
selected. Use the swit
switch
ch  A second popup screen appears when active faults
on the right operator console in order to select one of  or events are reported to the Advisor display module
following autoshift modes: “1F-2R”, “2F-2R”, and
the following Warning information appears on the
by any ECM. Warning
“2F-1R”. If no autoshift mode is selected, “Inactive” screen and the operator must acknowledge the
status will show in the display area. warning message
message by pressin
pressing
g the OK button. Advisor 
scroll  through all the warning messages that are
will scroll through
Five buttons on the right of the Advisor Graphical generated by active faults or events. The warning
Display Module are the user interface. Use the messages are not cleared from system memory by
buttons for  the
  the following purposes: navigation pressing
pressi ng the OK button. The message may reoccur 
buttons, menu buttons, and data information after a period of time according to the severity of the
warning information.
Left Up (5)   –  This button is used for the following
purposes:
purposes: navigation button, data informat
information,
ion, and a  After all screens with warning messages are
decrease in a setting value. acknowledged, the   first performance
performance monitor screen
appear. This is the default screen.
will appear.
Ri
Righ
ghtt Down
Down (6)
(6) – Th
 This
is butto
button
n is used for the followin
following
g
purposes: navigation button, data information, and an
 in a setting value.
increase in
increase
nce Menu
Performance
Performa

Back
Bac k button
button (7) –  This button is used to return to
previous screen
the previous screen..

Return to  fi rst menu (8) – Home

–  Home button

OK (9)
(9) –  This button is used to make selections
on the screen . Also, use this button to con firm an
 entry or use the button to save an operator 
password entry
password
profile.

Display Menu
Menu (10) –  This display area shows the
numerous menus and submenus in order to navigate
from one screen to another screen. Also, this display
depends on the menu or the submenu that
area depends Illustration 91
g01107257
is selected in order to show the information in the
system,, system status, and operator
system operator warnings.
warnings. The “Performance” menu allows the operator or the
technician to view two pages of information. These
Options (11
(11)) –  Additional information
information is available
available pages of information monitor critical data from the
on the subject that is highlighted on the display machine systems during machine operation. This
screen. Use
screen.  Use the appropriate arrow button to view the information can only be viewed. The typical display
information. settings
settings will allow 11 characters to the name of profile
characters
information to be viewed. The “Performance” menu
the  arrow buttons to highlight the desired
Use the arrow uses two screens for the real time monitoring of the
selection in order to navigate through the menus and following information:
submenus. Then press the OK button. Also, use
the arr ow
ow buttons to highlight a mode or parameter 
setting. Then, press the OK button in order to select
that option.
 

68 SEBU7763-02
Operation Section
Machine Operation

Table 12

“Performance” Screen 1 of 2
Description Units
Engine Coola
Engine Coolant
nt °C or °F
Temperature

Engine Speed   RPM

Hydraulic Oil Temperature °C or °F
Torque Converter Oil °C or °F
Temperature

Table 13

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

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

Note: The
screen by pressing the Home button.

g01107317
Illustration 94

The arrow buttons switch the page from one screen

to another screen.

g01107297
Illustration 92

The following screen will now be displayed.

 

SEBU7763-02 69
Operation Section
Machine Operation

Settings Menu

g01365893
Illustration 95

The “Settings” menu allows the user to adjust Operating condit

Operating conditions,
ions, preferences of the operat
operator,
or,
parameters for the following: and requirements for ef ficient operation inform the
operator that adjustments to the parameters are
•   Advisor display needed. The setup of the machine determines the
display
display of adjust
adjustable
able parameters. The attach
attachments
ments
•   Implement operation on the machine are determined by the software
versions
version s that are contained in the availab
available
le ECM. The
•  Operation of the power train  Advisor reviews the version of the software in order 
to determine the set of parameters that are displayed
•  Reverse fan function and the set of parameters that are variable.

See the “Quick Reference Guide for Setting the Note:  Cat ET can be used to access parameters and
Note: Cat
Operatorr Profile by Using Advisor” at the end of this
Operato CAT ET can be used to change parameters.
section
section for more information.
 

70 SEBU7763-02
Operation Section
Machine Operation

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

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

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

g01107800
Illustration 96 Langua
Language
ge –  Select a language.

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

Backlightt in Night Mode –  Adjust the level of 

Backligh
brightness at night.

Backlightt in Day Mode –   Adjust the level of 

Backligh
brightness
brightness during the day
day..

Settings for the Implements

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

nse –  Standard,  fi ne, fast

Response
Blade Respo

Illustration 97
g01376916 Blade
Blad Floatt –  The  fl oat is ON in FORWARD. The
e Floa
fl
oat is OFF
is  OFF in FORWARD.
The Quick
Quick Dro
Drop p (D9T) –  Enabled, disabled

Ripper auto
auto stow function (If equip
equipped)
ped) –  The
 function contain
function contains
s the following components: Ripper 
raise, ripper
raise,  ripper shank in, and ripper shank out.

SEBU7763-02 71
Operation Section
Machine Operation

Pitch (If equipped

Auto Blade Pitch equipped)) –   This function Settings for Engine Setup
performs
performs the following operations: Loading, carrying,
and spreading.
spreading. Password Protection
Blade Tilt
Tilt Mode for Dual Tilt
Tilt (If equipped)
equipped) –  Single  Adjustment to the engine settings for engine reverse
tilt or dual tilt fan is password protected. See the “Service Menu”
section in this article. Follow the instruction for 
The submenu for the auto pitch feature allows the “Service Password” in order to access to the reverse
operator to adjust settings (%) for the current pitch fan functio
function.
n.
and  the actual pitch position for each function
position and the
(if equipp
equipped).
ed). See the “Procedures for the Reverse Fan Function
(If Equipped)” in the “Operator Controls” story in this
“Load” dozer blade pitch is set when the
“Load” –  The dozer manual for more information.
blade is loading.

“Carry”
“Carry ” –  The  setting of the dozer blade pitch is
Procedures for the Reverse Fan Function
positioned when the machine is in the carry function. (If equipped)
equipped)

“Spread” –  Th
“Spread” e setting of the dozer blade pitch
 The Make sure that the machine is in PARK and on level
is positioned when the machine is in the spread ground. The transmission is in NEUTRAL when you
function. begin this procedure to set the purge cycles with the
 Advisor monitor display.
These parameters may be adjusted in the same
fashion as the adjustable parameters from the 1.  Highlight
Press thethe
OK“Settings”
button. on the “Home” screen.
 Setup” menu.
“Implement Setup”
“Implement

2.  Highlight the setup for the “Engine”. Press the OK

for the Power Train
Settings for button.
From the “Power Train Setup” menu, use the 3.  Use the service password in order to set up the
appropriate
appropriat e arrow button to highlight the desired “engine
“engine revers
reverse
e fan”.
parameter. Then press the “OK” button. This will
allow access to that parameter’s screen. Then follow 4.  Set the automatic mode for the “engine reverse
prompts on the screen in order to adjust the
the prompts fan” to “Enable”. Press the OK button.
parameter. The parameters in this category relate
the operator’s preferences for operational modes of  a.  If necessary, set the mode for the “engine
the power  train.
  train. The following parameters may be reverse fan” to “Disable”.
adjusted:
5.  Turn on the fan control switch. The fan control
Downshift
Auto Downshift
switch is located under the Advisor monitor display
in front of the bulldozer control lever. The fan
•   Off  begins to operate in the reverse direction.

•   Low Note:  The following instruction may vary with

Note: The
machines. The active software that operates the
•   Medium reverse fan function will determine the actual
response to the fan.
•   High
6.  The operator will set the purge interval. When
Bidirectional
Bidirectional gears (shift) the fan is active in the reverse mode, set the
purge interval. Press the fan control switch for  fi ve
•   Inactive seconds in order to set the interval.

•   “1F-2R” a.  Select the segment of the reverse fan function

which is to change.
  “2F-2R”
• b.  Set the cycle times for the ramp up and ramp
•   “2F-1R” (D8T)
(D8T) only down for the desired purge intervals.

7.   The new settings are active until the ignitio

ignition
n key is
 turned off.

72 SEBU7763-02
Operation Section
Machine Operation

Note:  In order to

Note: In to save the desired settings, make
sure that you have selected a pro file.

Service Menu
 

SEBU7763-02 73
Operation Section
Machine Operation
 g01364896
Illustration 98

74 SEBU7763-02
Operation Section
Machine Operation

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

Codes in the display screen “Diagnostics” are visible

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

From the Service Menu, use the appropriate arrow

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

Diagnostics

g01024789
ion 100
Illustration
Illustrat
Diagnostic message screen

Illustration 100 repres

Illustration represents
ents a typical message
message.. Press
the “OK” key in order to acknowledge the message.
the appropriate Warning Category for the
Consult the
proper instruction.
g01363437
Illustration 99
“Diagnostics” menu option will show a complete
The “Diagnostics”
The
The Se
Serv
rvic
ice
e Me
Menu
nu co
conta
ntains
ins the follow
followin
ing
g 7 categ
categor
ories
ies.. list of all active events, logged events, and diagno
diagnostic
stic
codes. #
•   Diagnostics
Each line that is listed contains the following
•   Calibrations information about that event or that code.

•   System Status –   Module Identifier 

MID – 

•   ECM Summary Code – C

–  Com ponent Identifier and Failure Mode
omponent
Identifier (CID/FMI)
•   Limp Home mode
Occ – Numb er of occurrences
–  Number
•   Configuration
–  Service meter hour of the  fi rst occurrence
First – Service
•   Service Password
Last – Service
–  Service meter hours of the last occurrence
Note: The
Note:  The options for the Calibration mode will not
Act – “X”
–  “X” means
means the event or the code is currently
be displayed until the “Service Mode” is enabled. active.
 The options for the Con figuration mode will not
Note: The
Note:
be displayed until the “Service Mode” is enabled.
 

SEBU7763-02 75
Operation Section
Machine Operation

Fault Log Clear ing

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

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

System Status

g01364333
Illustration 102

The “Limp Home” menu option allows slow

incremental
incremental movement of the following functions.

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

Illustration 101
g01364434 •   Winch
This movement is done without using the implement
The “System Status” menu option allows the operator 
control levers. “Limp Home” mode may be selected
or the technician to view the real time data from
by the operator or the technician in order to move
components
compo nents in the machine’s major systems.
implements
implemen ts to a safe position. This is needed in order 
to move the machine in the event of a system failure
From the Service Menu, use the appropriate arrow
that causes a major repair. Some examples are a
button in order to highlight the appropriate function.
steering failure or a failure of the dozer control.
Then, select the “System Status”. Then, press the
“OK” button in order to access the menu for “System
Note:  If a steering fault light (“Level III” warning)
Note: If
Status”. This menu organizes the systems into the
is displayed on the screen, perform the following
following categories.
actions. Select an option from the alert as a direct
link to the “Limp Home” menu.
 •   Steering

76 SEBU7763-02
Operation Section
Machine Operation

From the “Service”

“Service” menu, use the appropriate Service Passwo rd
Password
arrow button to highlight the “Limp Home” option.
Then press the “OK” button in order to access the The Service Password menu option allows the
menu. This menu will display a list of 
“Limp Home” menu. to  enter a service password of four digits.
technician to enter
implements that may be slowly moved in increments This password allows the display of the “Calibra
“Calibrations”
tions”
by using the keys on the Advisor display monitor. option and the “Configuration” option from the
menu. Then, access to the options is
“Service” menu.
To move an implement in this fashion, use the allowed.
appropriate arrow button to highlight the desired
function from the menu. Then press
implement function Engine Rever sing
sing Fan (If equipped)
the “OK” button in order to access that function.
This action will result in a screen that will display The service password allows access to the reverse
instructio ns for moving the implement. Follow the
instructions fan functio
functionn, if equipped. Use the operator settings in
prompts and directions on the screen in order to order to enable the engine reversing fan option. Use
move the implement. the “Operator Settings” in order to disable the engine
reversing
reversi fan, if necessary.
ng fan,
ECM Summary
Summary
Option
Totals Menu Option

g01364829
g01364829
Illustration 104

The “Totals” display allows the operator or the

serviceman to access lists of collected data about
machine systems.
systems. This data is useful in order to
g01364435 determine
determine when service work needs to be performe
performed.
d.
Illustration 103

The “ECM Summary” menu option allows the user to  Also, the  Cat ET service tool may be used to access
the Cat
display a list of all the ECM’s. Also, the corresponding this data.
software part numbers on the machine are provided.

Configuration
The “Configuration” menu option is password
protected. First, you must successfully enter the
password. Then, the screen on the “Service” menu
displays the menu option. See Illustration 98 for the
operating functions that can be de fined from this
menu.
 

SEBU7763-02 77
Operation Section
Machine Operation

Time in Gear “Hr s”

s” or Distance Travelled
“km/mi”

•   Total hours in Neutral

in  Neutral Coast Function

•   Total forward travel distance

•   Total reverse travel distance

•   Operating times
times “1F, 2F, 3F” gear 

•  Operating time in “N” gear 

•  Operating times “1R, 2R, 3R” gear 
•   Power train oil
oil   filter bypass

The following “Engine Totals” information may be

using the “Totals” screens.
viewed by using

g01364847
Fuel Consumption
Illustration 105

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

•   Total maximum fuel
maximum  fuel “Gal or L”

Engine Data

•  Number of engine starts

•   Total engine 
engine   revolutions (lifetime)

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

g01364880
Illustration 106

Use the appropriate arrow button to highlight the

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

The following information for the power train system

(“Ptrain Totals”) may be viewed by using the “Totals”
 screens.

78 SEBU7763-02
Operation Section
Machine Operation

Quick Reference Guide for Setting

the “Operator Profile” by Using
Advisor 

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

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

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

8.  Use the Arrow buttons in order to highlight the a.  Then, highlight the “Select Pro file”.
desired change. Press the OK button.
 b.  Press the OK button.

SEBU7763-02 79
Operation Section
Machine Operation

desired profile.
c.  Highlight the desired

d.   Press the
the OK button.

Reference: See
Reference:  See Operation and Maintenance Manual,
“Operator Controls” for additional information on the
procedures for the“Auto Blade Assist” and
operating procedures
for the “Engine Reverse Fan”.

Listing of Abbreviations and Terms

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

Table 14

 Abbreviation and Term For Advisor Monitor Display

 Abbreviation   Term
 Abbreviation Abbreviation   Term Abbreviation   Term
aba Auto Blade km kilometer     rt   right
 Assist

act   active kPa kilopascal   scrn screen

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

cyl cylinder     max   maximum   snsr sensor  

DC   direct current Mi Miles sol solenoid

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

80 SEBU7763-02
Operation Section
Machine Operation

(Table 14, contd)

filt   filter    Nm Newton temp temperature

meter 
forwrd forward   occ occurrence   term   terminal
 Abbreviation Term Abbreviation Term Abbreviation Term

freq frequency p/n   part number    trans   transmission

ft feet   pos   position V volt
ftlb foot pound   pres pressure

Gal US Gallon   press pressure

Gal/Hr “US Gallons / PSI Pounds per  

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

hyd hydraulic   r reverse

IGal   Imperial rel release

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

i02648039 •  Hardware, which includes the following, data

module, antenn
module, antenna,
a, wiring, and additio
additional
nal mounting
Link
Product Link hardware.
(If Equipped)
•   Satellite
Satellite System and Caterpillar Network
SMCS Code: 7
Code:  7606
606
•   PC Software
Product Link is a satellite communication device
transmits information regarding the machine to
that transmits
Caterpillar
Caterpi llar and to Caterpillar dealers and customers.
customers.
The device contains a Global Positioning System and This machine is equipped with a Caterpillar Prod-
satellite transmitter/rec
a satellite transmitter/receiver.
eiver. All logged events and uct Link
Link commu
communica
nication
tion device
device whwhich
ich must be de de--
diagnostic codes that are available to the Caterpillar  ac
activ
tivate
ated
d wit
withi
hin
n 12 m (40 ft) of a b
blas
lastt zone
zone.. Fa
Failu
ilure
re
Electronic Technician (ET) on the CAT data link to do so could result in serious injury or death.
sent to the satellite. Information can also
can be sent
be sent to the Product Link from the satellite. The
information that is sent by the Product Link goes to If the machine is required to work within 12 m
satellite, and then to the receiving station. The
the satellite, (40 ft) of a blast area, then the operator must take
receiving station transmits the data to Caterpillar. The one of the following precautions:
information can then be sent to Caterpillar dealers
and customers.
customers. •  Disconnect the Product Link module from the
power source by discon
disconnecting
necting the wiring harness
Note:  Product Link is automatically activated when
Note: Product at the Product Link module.
battery disconnect switch is in the ON position.
the battery
  Temporarily remove the Product Link module fr
from
om
 The system consists of three main components: the machine
machine..

SEBU7763-02 81
Operation Section
Machine Operation

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

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

•   The operating
operating frequency range for the Product Link
150  MHz.
is 148 - 150 MHz.

Refer to System Operation, Troubleshooting,

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

Regulatory Compliance
g01108817
Illustration 109

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

prevent the machine from moving.

4.  Start the engine.

5.   Raise all attachments enough to clear any

unexpected obstacles.

g01131982
Illustration 108

Consult your Caterpillar dealer with any questions

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

i02767609

Operation Information
SMCS Code:
Code: 7000
 7000 Illustration 110 g01384474

Differential steering control and transmission direction selector 

To prevent injury, make sure that no maintenance
is  being performed on the machine or near the
work is being
 machine. Keep the machine under control at all times
in order to prevent injury.

82 SEBU7763-02
Operation Section
Machine Operation

6.  Release the par k

king
ing brake by pushing down on a.  To return to high
high idle from an intermediate
parking brake knob (3). This unlocks the parking engine speed, push in and release the top part
brake, the transmission control, and the steering of the engine speed control switch.
lever.
b.  To return to low idle from an intermediate
Note: When the parking brake is set, the transmission speed, push in and release the bottom part of 
neutral. When the parking brake is
defaults to neutral. speed control switch.
the engine speed
released the transmission will stay in neutral. To
select the direction of machine
machine ttravel,
ravel, return direction 13. Use the differential steering control in order to
selector
select (4)  to neutral.
or (4) to machine.
turn the machine.

7.  Then, move direction selector (4) to the desired 14. Drive the machine forward for best visibility and
direction. Use transmission gear selector (5) to
direction. for control.
select the desired
desired gear.
gear.

service brake pedal (2) in order to allow

8.  Release service
Changing Dir ection
ection and Gear 
the machine to move.
NOTICE
For
For opera
operator
tor comfo
comfort
rt and
and max
maximu
imum
m servi
service
ce lif
life
e of pow-
pow-
components, deceleration and/or braking is
er train components,
recommended before any directional shifts are made.

Speed are
speed chang
changes
es and directional changes at full engine
possible.

decrease engine speed, push down on

1.  In order to decrease
the decelerator pedal (1).

machine slows, shift the transmission to

2.  When the machine
the desired direction with directi
direction
on selector (4).

g01016002 the engine speed by releasing the

3.   Increase the
Illustration 111
111
decelerator
decelerator pedal (1).
Engine speed control
desired gear with transmission gear 
4.   Select the desired
9.  To select high idle, push in on the top of the engine selector (5). Push button (6) for upshift. Push
speed control switch and release. The engine button (7) for downshift.
speed immediately moves to high idle.

10. To select low idle, push in on the bottom of the i02209587

engine speed control switch and release. The
engine speed immediately moves to low idle. Battery Disconnect Switch
11. Select an intermediate speed in the following SMCS Code: 1411
Code:  1411
manner:

a.  Set the engine speed to high idle.

b.  Select the desired engine speed with the

decelerator
deceler ator (1).

c.   Push in on the switch of the engine speed

control and hold for three seconds in order to
lock in the engine speed. This speed is now
the maximum operating
operating speed
speed..

12. Change an intermediate speed in the following

manner:
g01115494
Illustration 112
 

SEBU7763-02 83
Operation Section
Machine Operation

The battery disconnect

disconnect switch is on the left side of  i02764675
the machine next to the battery compartment.
Engine Overspeed
SMCS Code: 1000
Code:  1000

the  engine speed to exceed 3150 rpm.

Do not allow the engine
Severe engine damage may result.

g00406959
Illustration 113

ON –   To activate the electrical system,

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

OFF – To
–  To deactivate the electrical
system, turn the battery disconnect switch
counterclockw
counter clockwise
ise to the OFF position.
position.

The battery disconnect

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

Turn the battery disconnect switch to the OFF g01383974

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

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.
•   Forward action
action lamp (1) lights with a   flashing red
color.
•   Rearward action lamp (4) lights a fl ashing red color.
Note: Rearward
Note:  Rearward action lamp (4) is located on the

right
of theconsole.
operator.The action
If the lampis
operator isfacing
near the right elbow
rearward, this
will alert the operator.
 

84 SEBU7763-02
Operation Section
Machine Operation

 A warning level
level 3
 3 will occur at 3150 rpm. Warning
level 3 requires immediate reduction of engine rpm in
order to prevent severe damage to the engine. At this
following events will occur:
level, the following

•   Forward action
action lamp (1) lights with a  fl ashing red
color.

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

•  The action alarm sounds.

 Alter the operation of the machine. Use the service
operation
brake in order to reduce engine speed immediately.
immediately.

See the Topic “Machine

Topic  “Machine on an Up Slope or Down
Slope”. This article is located in the “Bulldozing”
section of this manual.
 

SEBU7763-02 85
Operation Section
Engine Starting

Engine Starting
i01951496

Engine Starting
SMCS Code: 1000;
Code:  1000; 7000
b attery disconnect
ON –  Turn the battery disconnect switch to
the right in order to activate all of the cab
circuits.

g01015655
Illustration 118

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

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

The indicator light for the parking brake will stay

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

If
orthe action monitoring
machine alarm does displays
not sound during
are this test
not function-
ing, do not operate the machine until the cause
has been corrected. Machine operation with faulty
action alarms or displays could result in injury or 
death as any Warning Category 3 noti fications will
not be relayed to the operator.

g01017004
Illustration 117
5.  Turn engine start switch key (3) to the START
position. Crank the engine. Release the key when
2.  Move direction selector (1) to the NEUTRAL the engine starts.
position.
See the Topic “Starting With Engine Prelubrication
Prelubrication
3.  Engage parking brake (2). System”. This article is located in the “Engine
Starting” section of this manual.
 

86 SEBU7763-02
Operation Section
Engine Starting

i02229120

NOTICE
the engine for more than 30 seconds. Al-
Do not crank the engine
Engine Startin
Engine Startingg with
with
low the starter to cool for two minutes before cranking Prelubricati on System
Prelubrication
again. Turbocharger damage can result if the engine
kept  low until the oil gauge display veri fies
rpm is not kept low SMCS Code: 1000;
Code:  1000; 7000
that the oil pressure is suf ficient.
If equipped:
equipped:

Ether Starting Aid transmission direction control lever to

1.  Move the transmission
the NEUTRAL positio
position.
n.
If engine coolant temperature is below 0 °C (32 °F),
the engine ECM will automatically inject ether during 2.  Engage the par king
king brake.
engine cranking and during engine warm-up. The
duration and the amount of ether increases with 3.  Move the implement control levers to the HOLD
colder temperatures
temperatures at start-up
start-up.. position.
position. Use
Use the
 the switch for hydraulic lockout
control in order to deactivate the inputs to the
The system is automatic. Manual operation of ether  hydraulic control circuit.
starting system is not permitted. Do not introduce
any additional ether into the inlet air system. The 4.  Turn the battery disconnect switch to the ON
additional ether may damage the engine. position.
positio n. The battery discon
disconnect
nect switch is inside of 
ne
the left engine
engi compartment access cover on the
For starting below − 18°C (0°F), the use of the cold left side of the machine.
weatherr starting aids is recomme
weathe recommended.
nded. A fuel heater,
heater,
a jacket water heater, and extra battery capacity may key  start switch to the START position.
5.  Turn the key start
be required.
required. Hold the key in the START position. The
prelubrication system is now activated. When the
 At temperatures below  − 23°C (−10°F), consult your  pressure sensor detects inadequate
engine oil pressure
Caterpillar dealer. For information on starting the engine oil pressure, the prelubrication system
engine in cold weather, refer to the Operation and will operate. When the engine oil pressure
Maintenance
Mainten ance Manual, SEBU589
SEBU5898, 8, “Cold Weather  sensor detects
detects adequate engine oil pressure,
Recommendations for all Caterpillar Machines”. the prelub
prelubrication
rication stops.
stops. Then,
 Then, the system will
automatically
automati cally crank the engine.

6.  When the engine starts, release the key start

switch.

Note:  If the engine is being restarted within two

Note: If
minutes, the prelubrication system is bypassed.
When the key key start switch is turned to the START
position,, the engine will crank immediat
position immediately
ely..

i02053781

Engine and Machine Warm-Up

SMCS Code: 1000;
Code:  1000; 7000

 After the engine has been started, allow the

monitoring system to complete the self test.

1.   Allow a cold engine to warm up at LOW

IDLE for at least   five minutes. To help the
hydraulic components to warm up faster, engage
the attachment controls and disengage the
attachment controls.

2.  You can begin to operate the machine with a

 reduced load.

SEBU7763-02 87
Operation Section
Engine Starting

3.  When the engine coolant

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

4.  Look at the indicators and the gauges frequently

during operation.

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

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

The hydrauli
hydraulic c oil will warm up faster, if the dozer 
blade control is held in the CLOSE position for short
periods of ten seconds or less. This will allow the
hydraulic
hydrau oil to reach relief pressure, which causes
lic oil
the hydraulic oil to warm up more rapidly.

co ntrols in order to allow warm hydraulic

Cycle all controls
oil to circulate through all hydraulic cylinders and
through all hydrau
hydrauliclic lines.

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

•   Allow the engine to warm up for approximately

approximately 15
minutes when the temperature is higher than 0°C
(32°F).

•   Allow the engine to warm up for approximately

approximately 30
minutes or  more
  more when the temperature is below
0°C (32°F).

•   More time may

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

Additional
Additional Low Idling
Idling Speed
Note:  If the engine is running at low idle with the
Note: If
parking
parkin g brake ON and the engine coocoolant
lant tempera
temperature
ture
is below 70 °C (158.0°F) for a period of ten minutes,
engine speed will automatically increase to 1000
the engine
RPM. This increases the heat in the jacket water.
 

88 SEBU7763-02
Operation Section
Operating Techniques

Operating Techniques Dozer Blade Pitch for the U-Blade

and SU-Blade
i02765096

Operating
Operating Technique
echnique

Information
SMCS Code: 7000
Code:  7000

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

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

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

The EXTENDED position pitches the blade forward.

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

The RETRACTED position pitches the blade

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

Machine Adjustments in the Operating

Refer to Machine
Section of this manual.

Straight
Straight Dozin
Dozing
g

g00666988
Illustration 119

General Rule For Selecting a Gear As You Are

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

g00040620
Illustration 121

Straight Dozin
Straight Dozing
g –  Maintain a level cut for the best
performance. Fill the bulldozer blade. Carry the load
to the dump.
 •   Avoid lugging
lugging or stalling the machine.

SEBU7763-02 89
Operation Section
Operating Techniques

•   Avoid excessive
excessive spinning of the track.

•   If turning the machine with a loaded blade is

use the bulldozer tilt cylinders instead
necessary, use
of the steering lever in order to steer the machine.

performing levelling work, a full

When you are performing
bulldozer blade manages better than a partially
loaded bulldozer blade.

Slot Dozing

g00040628
Illustration 124

When you are digging parallel slots, the center should

be removed from the rear. This procedure permits
the operator to maintain a slot until the center is
removed. The center berm should be wide enough to
stand up without collapsing. Maximum width should
be approximately 1/3 of the bulldozer blade.

Machine on a Slope
Illustration 122
g00040626
Machine on a Side Slope

Slot Dozing
Slot Dozing –  When you trap material in a slot, you
can carry larger loads in front of the bulldozer blade.

The depth of the slot should not be deeper than the

top corner of the bulldozer blade.

g00040630
Illustration 125

When possible, work on a slope vertically. This

method is better than working horizontally.

When you are working on banks, use caution. When

g00040622
Illustration 123 you are workin
working
g on slopes
slopes,, use caution. Avoid tipping
the machin
machine.
e.
Start the slot at the dump or the spoil end and work
rearward. See Figure (A) in Illustration 123. You If the machine starts to sideslip on a slope, lighten
can load the blade as you are moving downhill. the load and turn the machine downhill.
 Also, you can then carry the load on a level surface.

The technique
ficient
ef  that is shown
as the technique thatinisFigure
shown(B) is not as
in Figure (A). If
topyou
of are
the working horizontally
slope. Work downhill.onMaintain
a slope,astart at the
windrow
In  fi gure (B), the machine is pushing a load uphill of material on the low side of the machine in order 
and the operator does not utilize the slot. Dozing to provide stability.
 level through the entire pit is inef ficient because the
average distance for pushing the material to the Use caution in order to not undercut the slope.
dump will be greater. Undercutting the slope will increase the slope.

90 SEBU7763-02
Operation Section
Operating Techniques

Up  Slope or Down Slope

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

Backfilling

g00641146
Illustration
Illustratio n 126

Reduce ground speed of the machine to an

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

V-Ditching

g00040067
g00040067
Illustration 129

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

are hanging
hanging overhea
overhead.
d.

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

g00040633
Illustration 127
 

SEBU7763-02 91
Operation Section
Operating Techniques

The sizing of the

the material is controlled by the depth of 
the pass and by the width of the pass. If the material
will be loaded with a wheel dozer, then the size of 
should be smaller. The material should
the material should
be still smaller, if the material will be loaded into a
scraper.

NOTICE
Do not turn or back the machine while shanks are in
th
the
e grou
ground
nd.. Twis
wisti
ting
ng str
strai
ain
n on the shank
shanks
s and
and ti
tips
ps ma
may
y
cause failure.

NOTICE
g00040073 Inspectt the ripper tips frequently for excess
Inspec excessive
ive wear.
Illustration 130

•   If additional
additional leverage is needed
needed,, you can doze a
small ramp near the base of the tree. The ramp
allows the machine to make higher contact on the
tree. Push the tree in the direction of the intended
fall. Advance cautiously. The ball of the root may
hang up under the bulldozer blade. This could drag
the machine off the ramp.
Stump Removal
The multishank ripper is intended
intended for high produc
production.
tion.
Use the multishank ripper in hard, packed soil and
embedded rock. The multishank ripper is
loosened, embedded
for use in material that can be ripped with AT LEAST
two shanks. Use the multishank ripper with a single
shank less than 20 percent of the time.
center shank
The multishank ripper is NOT intended for high
 in rock with a single center shank.
production in
production
 A single ripper shank in an outside pocket of the
NOT recommended. If necessary, locate the
ripper is NOT
shank in the highest position. Operate the machine
at reduced speed. The frame of the ripper is not
designed
design for ripping with a single outside shank at
ed for
full horsepower.

multishank ripper is NOT intended for ripping in

The multishank
deep applications. Only use shanks of the speci fied
length.

Use a single shank ripper when deep ripping is

required.

Illustration 131
g00561004
Packed Soil, Hardpan, Clay, Shale
Stump Removal
Stump Removal –  Make sure that roots are cut or 
or Cemented Gravel
loosened. Remove the stump by pushing or digging.

Ripping
Use FIRST gear for ripping operations. Use additional
shanks instead of increasing the speed or using a
higher gear.

Use the decelerator in order to match the drawbar 

pull. Also, use the decelerator in order to prevent
spinning the track.
Rip the ground as deep as possible. Sometimes, you
may rip at partial depth. You can remove the material g00040571
 in natural layers. Illustration 132
Multishank
Multishank ripper with three shanks

92 SEBU7763-02
Operation Section
Operating Techniques

Three shanks work

work well in these materials. Use the Adjustable Ripper 
greatest possible number of shanks to break the
material to the desired size. However, the number of  the  ripper has angle adjustments and
The shank on the ripper
shanks that ar e used should not cause the machine length adjustment feature
features.
s.
to stall.
the  shank must be varied in order to
The angle of the shank
achieve
achiev e the maximum performan
performance
ce through
throughout
out each
Rock with
Planes Fractures,
kness Faults and
of Weakness
Wea
ripping pass.

Illustration 135 g00040595

g00040576
Illustration 133
Multishank ripper with two shanks
 
Using two shanks will cause the rocks to break out
in smaller pieces, so that the machine can manage
the job easily. When the machine begins to stall, use
only the center shank. If the tracks spin, use only the
center shank.
Insert the ripper into the material that is being ripped.
Adjust the angle of the shank slightly beyond the
vertical position. This will give you the correct tip
angle for entering the material. The angle will change
because of the different materials that need to be
ripped.

Single Shank Ripper 

g00040600
Illustration 136

Lower the ripper into the material while you move

g00562861 the machine forward. When you reach the desired
Illustr ation
ation 134
ripping depth, move the shank forward in order to
achieve the correct angle for best performance. This
Solid Rock, Granite or “Hard-to-Rip” angle is usually between the vertical position of the
Materiall
Materia shank and the forward position of the shank.

Use one shank in material that tends to break out in

slabs or in large pieces.
large slabs
 

SEBU7763-02 93
Operation Section
Operating Techniques

Push Loading

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

2.  The machine should not be moving more than

5 km/h (3 mph).

3.  When possible, maintain a straight push.

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

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

order to help the scraper get out of the cut.

g00040607
Illustration 138

 Adjust the  length of the shank according to the

following procedure.

1.  Maintain a length
a  length of the shank so that the machine
can ef ficiently pull the shank through the material.

Maintain  suf ficient clearance under the lower 

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

3.  Keep the lower frame assembly as parallel to the

as  possible. This will evenly distribute the
ground as possible.
stress.

you  remove material with a scraper or with

4.  When you remove
a loader, shallow ripping is recommended.

you  are ripping for a scraper,

5.  When you are scraper, rip in the same
direction as the scraper that is being loaded.
rip to a deeper depth than the depth of the
6.  Never rip
material that is being removed.
 you are removing material with an excavator 
7.   When you are
or with a bulldozer,
bulldozer, deep ripping is recommended.
recommended.

94 SEBU7763-02
Operation Section
 Adjustments

Adjustments 2.  Activate the bulldozer

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

U and SU Three-Position Tilt Brace

If equipped:

g01017200
Illustration 142

3.  Place a wood block between the tilt brace and

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

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

Pin the brace in the RETRACTED position and

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

g01023331
Illustration 143

5.  Start the machine and activate the bulldozer tilt

control in the FLOAT position. The tilt brace will
slide forward or the tilt brace slides rearward on
94
g00561194
g005611
Illustration 141 the push arm. Extending the cylinder will slide the
(N) Neutral brace forward. Retracting the cylinder will slide
(E) Extende
Extendedd the brace rearward. Align the holes in the tilt brace
(R) Retracted and the push arm bracket and assemble the pin
to the desired location. Alignment of the push
Position  the machine on a hard   flat surface and
1.   Position the arm may require the rotation of the push arm, if 
lower the bulldozer blade to the ground. Place the clearances at the joint allow rotation.
bulldozer control in the FLOAT position. Engage
 parking brake. Remove the retainer bolts and
the parking
plates.

SEBU7763-02 95
Operation Section
 Adjustments

6.   Shut down the machine.

ma chine. Return the bulldozer 
control to the HOLD position. Keep the parking
brake engaged.

7.   Reinstall
Reinstall the retainer bolts and the retainer plate.

Note:  The pin in

Note: The in the right arm to tilt cylinder is
retained on the side toward the track, and the pin in
the left arm to the tilt brace is retained on the outside.

Angling the Blade

If equipped:

g00561282
Illustration 145

Turn the handle to the left (counterclockwise

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

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

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

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

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

each side).
side).
3.  Remove the retainer pins.

4.  Pull the coupling pin out of the housing.

the bulldozer blade at the desired angle.

5.  Position the

6.  Install the coupling pins in the new positions.

7.  Install the retainer pins.

he bolts.
8.   Install tthe

Blade Manual
Tilt the Blade Manually
ly
If equipped:
 

96 SEBU7763-02
Operation Section
 Adjustments

i01953041

Tracks
SMCS Code: 4170;
Code:  4170; 7000

g01015715
Illustration 146

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

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

Follow the procedures in the Maintenance

Maintenance Section for 
adjustment.
 

SEBU7763-02 97
Operation Section
Parking

Parking i02229132

Stopping the Engine

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

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

g01022276
Illustration 147 Illustration 148
g01124621

2.   Move the transmission

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

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

98 SEBU7763-02
Operation Section
Parking

i01969312 The Procedure Before The

Stopping the Engine if an Accumulator
Accumu lator Bleeds Down
Malfunction
Electrical Malfunction Occurs When the engine is running, the bulldozer blade can
be lowered by pushing the work tool control forward.
SMCS Code: 1000;
Code:  1000; 7000 For a short period of time, after the engine has been

If the engine does not stop after turning the engine stopped,
pushing
pushin theimplement
g the bulldozer blade
controlcan beforward.
lever lowered by
start switch key to the OFF position, perform the
following
following pro cedure.
procedure.

1.  Apply the parking brake.

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

3.   Exit the cab.

4.   Locate the battery disconnect

disconnect switch.

g01109010
Illustration 150

that hydraulic lockout switch (1) has

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

LOWER –  Push the work tool control (2)

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

LOWER –  Mo
LOWER ve ripper raise/lowe
 Move raise/lowerr control
OFF – Turn
–  Turn the key counterclockwise in
(3) in a counterclockwise direction in order 
order to stop the engine. Remove the key.
to lower the ripper. Release the lever. The
lever will
will return to the HOLD position.
Reference:  Refer to Operation and Maintenance
Reference: Refer
Manual, “Operator Controls” for further information.
information. The Procedure After The
Note:   Do not operate the machine until the
Accumulator
Accumu lator Bleeds Down
malfunction
malfunc tion has been corrected.
the  engine has been stopped for a short
 After the engine
period of time the control levers will not lower the
i02229167 implements to the ground.

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

lower the attach
attachments.
ments.
Engine Stopped
SMCS Code: 7000
Code:  7000

Make sure that no one is endangered before you

lower the attachm
attachments.
ents.
 

SEBU7763-02 99
Operation Section
Parking

Blade
Lower Dozer Blade
1.  Connect the drain hose to quick pressure tap (6).
to  the hydraulic tank  fi ller neck.
Run the hose to the

2.  Remove quick pressure tap (7).

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

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

Note: The
Note:  The drain hose is not required.
g01118072
Illustration 151
2.   Slowly insert bolt
insert  bolt (5) in order to lower the ripper.
Remove access cover (4).
3.  Return bolt (5) to the storage position and return
quick pressur e tap (7).

4.  Return access cover (4).

i01953131

Leaving the Machine

SMCS Code: 7000
Code:  7000

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

block the machine.

 Apply the service brake in order to stop the machine.

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

dozer/ripper valves are located at the center of 

The dozer/ripper
the fuel tank behind the operator module (cab).
 A bolt (5) with “9/16 - 18 x 64 mm” threads is stored
inside the access cover. This bolt may be used to
lower the implements.
Lower all implements to the ground.
Turn the engine start switch key to the OFF position,
and remove the key.
Turn the key for the battery disconnect switch to the
OFF position. Remove the key when you exit the
machine for an extended period of time.
 g01124638
Illustr ation
ation 153
 Arrangement with dozer/ripper valve and auxiliary valve (front
view)

100 SEBU7763-02
Operation Section
Parking

g01014705
Illustration 154

1.   When you dismount, use the steps and the

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

2.   Inspect
Inspect the engine compa
compartment
rtment for debris. Clean
out any debris and paper in order to avoid a  fi re.

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

disconnect
discon nect switch and remove the key.

4.   Close and lock

lock all cab windows
windows.. Use the vandalism
vandalism
protection
protection covers and install all the padlocks.
padlocks. Lock
the cab doors.

Padlocks are provided for the following areas:

•  Both engine enclosures

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

•   Washer  fl uid bottle compart

compartment
ment

•   Fuel cap
•   Fuel drain
•  Hydraulic tank cap
 

SEBU7763-02 101
Operation Section
Transportation Information

Transportation Information 7.  Lock the door and

and lock the access covers. Attach
any vandalism protection.

i00052187 tie-downs at several locations and block

8.  Install the tie-downs
the tracks in the front and in the rear.
Shipping the Machine
9.   Cover
Cover ththe
e opening
opening for th
the
e engin
engine
e exha
exhaus
ust.
t. Rotat
Rotation
ion
SMCS Code: 7000;
Code:  7000; 7500 of the turbocharger without engine operation can
result in damage to the turbocharger.
Investigate the travel route for overpass clearances.
Investigate
Make sure that there is adequate clearance for  Consult your Caterpillar dealer for shipping
the machine that is being transported. This is instructions
instructions for your machine.
especially true for machines that are equipped with a
ROPS/FOPS structure, a cab, or a canopy.
i02696521
Remove ice, snow,
snow, or other slippery material
material from the
loading dock and from the truck bed before loading.
Lifting and Tying Down the
Removing ice, snow, or other slippery material will Machine
prevent the machine from slipping as you load the
machine. Removing ice, snow, or other slippery SMCS Code: 7000;
Code:  7000; 7500
material will prevent the machine from slipping in
transit.

NOTICE Improper lifting and improper tie-downs can allow

Obey all state and local laws governing the weight, the loadto shift
the loadto hift or fail
fail and cause
cause injur
injury
y or damag
damage.
e.
width and length of a load.
Use only properly rated cables and slings with lift
and tie down points provided.
Observe all regula
regulations
tions governing wide loads.
Follow the ins
Follow instru
tructio
ctions
ns in Oper
Operatio
ation
n and Main
Main--
tenan
tenance
ce Man
Manua ual,
l, “Lift
“Lifting
ing and
and Tyin
ying
g Do
Down
wn ththee
Machine”
Machine ” f or
o r the proper technique for securing
the machine. Refer to Operation and Maintena
Maintenance
nce
Manual, “Specificatications
ons” ” for specific we
speci weigh
ightt in-
in-
formation..
formation

NOTICE
Improperr lifting or tiedowns
Imprope tiedowns can allow load to shift and

can cause injury and damage.

The weights that are listed in the table below and

the following instructions describe units that are
g00040011 manufactured
manufac tured by Caterpi
Caterpillar
llar Inc.
Illustration 155
Table 15
1.  Place blocks under the trailer wheels or under the
rail car wheels before loading, as shown. Approximate Machine Shipping Weight
D8
D8T
T without a Ripper 34019 kg (75
(75000 lb)
2.  Lower all attachments to the  fl oor of the transport
machine. Move the transmission control lever to D8T shipping weight  (1) 29553 kg (65153 lb)
the NEUTRAL position. D8
D8T
T (m
(max
axim
imum
um weig
weight
ht)) 45
4536
360
0 kg (1
(100
0000
000
0 lb
lb))
(1) Shipping weight includes the following components: coolant,
3.  Engage the parking brake switch. lubricant, 20% fuel, ROPS, FOPS, and 560 mm (22 inch) (MS
shoes)

4.  Stop the engine.

Engage the parking brake before you sling the
5.   Turn the start switch key to the OFF position. Lock machine and before you secure the machine with
the parking brake switch. Remove the key. tie-downs.
 6.  Turn the battery disconnect switch to the OFF
position. Remove the key.

102 SEBU7763-02
Operation Section
Transportation Information

Move the hydraulic

hydraulic activation control lever to the
Locked position.

Caterpillar dealer for shipping

Consult your Caterpillar
instructions for your machine.
instructions

g00561816
Illustration 156

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

eye.

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

ripper must be raised.

C –  Lifting a machine without a ripper attached.

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

of the track.

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

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

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

Use properly rated cables and properly rated slings to

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

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

(A). Use the inside edge of the track shoe (D) to
secure the side tie-downs. Secure the side tie-downs
on three places per side. Use the drawbar, the ripper,
or
thethe outer
rear edge ofUse
tie-downs. the corner
track shoe (E) to on
protectors secure
sharp
corners.
 Check all of the laws that govern the load
characteristic
characteristics
s (height, weight, width, and length).

SEBU7763-02 103
Operation Section
Towing Information

Towing Information These towing instructions

instructions are for moving a disabled
machine for a short distance at low speed. Move the
machine at a speed of 2 km/h (1.2 mph) or less to a
i01484554 location for repair
convenient location repair.. These instructio
instructions
ns are
only for emergen
emergencies.
cies.
Towing the Machine
 Always haul the machine if long distance moving is
SMCS Code: 7000
Code:  7000 required. When any towed machine is loaded, the
machine must be equipped with a brake system that
is operable f rom
rom the operato
operator’s
r’s compartment.
compartment.

Personal injury or death could result when towing
a disabled machine incorrectly.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if  towing machine must be able to control
blocked.
it is not blocked.
Normally, the towing machine should be as large as
the disabled  machine, or larger than the disabled
disabled
machine. Make sure that the towing machine has
enough brake capacity, enough weight, and enough
power. The towing
both machines for the grade that is involved and for 
the distance that is involved.

Do not use a chain for pulling a disabled machine.

 A chain link can break. This may cause possible
Personal injury or death can result from worn wire personall injury. Use a wire cable with ends that have
persona
rope cable. loops or rings. Put an observer in a safe position in
order to watch the pulling procedure. A safe position
Worn or frayed cable could break causing injury. at  a distan
would be at a distance
ce away from either machine that
is greater than two times the length of the towing
Check the wire rope cable. If cable is worn or is cable. The observer can stop the procedure, if 
frayed install a new cable. necessar y.
y. The procedure should be stopped if the
cable starts to break. Also, stop the procedure if the
cable starts to unravel. Stop pulling whenever the
machine moves without moving the towed
towing machine
machine.
When the axle shafts are removed, the machine
parking brakes. The machine can roll and
has NO parking Shields  must be provided on both machines. This
Shields must
cause personal injury or death. will protect the operator if either the tow line or the
bar breaks.
Bl
Bloc
ock
k the tr acks
the acks sec
secure
urely
ly so that
that the machi
machine
ne ca
can-
n-
not move. Before towing, make sure that the tow line or the
bar is in good condition. Make sure that the tow
The towing connection
connection must be rigid, or towing the bar has enough strength for the towing
line or the
must be done by two machines of the same size procedure that is involved. The strength of the towing
or larger than the towed machine. Connect a ma- line or of the bar should be at least 150 percent of the
each end of towed machine.
chine on each weight of the towing machine. This is true for 
gross weight
a disabled machine that is stuck in the mud and for 
Be sur
suree all nece
necessa
ssary
ry rep
repair
airss and adjust
adjustment
mentss towing on a grade.
made before a machine that has been
have been made
towed to a service
service area, is pu
putt back into operation.
operation. For towing, only attach the tow line to the tow eyes
on the frame, if equipped.
machine is equipped with spring applied brakes.
This machine Keep the tow line angle to a minimum. Do not exceed
These brakes are also oil pressure released brakes. a 30 degree angle from the straight ahead position.
If the power train oil system for pressure oil is
inoperab le, the brakes are applied and the machine
inoperable, Quick machine movement could overload the tow
cannot be moved. line or the bar. This could cause the tow line or the
to  break. Gradual, steady machine movement will
bar to break.
Do not allow
allow an operator to be on the machine that be more effective.
is being towed unless the operator can control the
steering and/or the braking. Do not attempt to tow
 machine  without reading and understanding the
a machine without
following procedures.

104 SEBU7763-02
Operation Section
Towing Information

 All situation r e

equirements
quirements cannot be listed. Minimal
towing machine capacity is required on smooth,
level surfaces. Maximum towing machine capacity is
inclines or on surfaces that are in poor 
required on inclines
condition.
Consult your  Caterpillar
 Caterpillar dealer for the equipment
equipment that
is necessary for towing a disabled machine.
Running Engine
engine  is running, the machine can be towed for 
If the engine is
a short distance under certain conditions. The power 
train and the steering system must be operable.
machine for a short distance only.  For 
Tow the machine
example, pull the machine out of mud or pull the
machine to the side of the road.
The operator on the towed machine must steer the
machine in the direction of the tow line.
Carefully follow all instructions that are outlined in
the Towing Information. Ensure that the instructions
followed exactly.
are followed
Stopped Engine or Drive Line
Engine
Defect
towi ng machines must provide suf ficient
One or more towing
control and suf ficient braking when you are moving a
disabled machine downhill. This may require a larger 
machine and additional machines that are
towing machine
connected to the rear. This will prevent the machine
from rolling away out of control.
Consult your Caterpillar dealer or refer to the
machine’s
machin e’s Service Manual for axle shaft removal and
installation
installatio n procedures.
For the second method, use a brake release
pump. If
pump. brake release pump is used to tow the
 If a brake
machine, the brakes can not be applied with the
service brake pedal or with the parking brake control.
brake  release pump is used and you need to
If the brake release
apply the brakes, the brakes must be applied with the
brake release pump that is being used.
Note:  The axles must not be removed when you use
Note: The
a brake release pump.
Connection
Connection of Brake Release Pump
Note:  This machine is free to move. This machine is
Note: This
free to roll away. This machine has no braking ability
parking brake or with the service brake when
with the parking
both brakes have been released.

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

If an internalremove
suspected, transmission
the axleorshafts.
a drive line failure is

For the  fi rst method, remove the axle shafts.Y

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

If you are towing a machine without axle shafts,

you may notnot be able to use the implements to stop
the machine. The implement hydraulic system is
pilot controlled. With an inoperable engine or an
inoper able
able hydraulic pump, the accumulator pressure
will bleed off rapidly. The implement controls will
not operate when there is no pressure in the
lator. The implements can not be lowered
accumulator.
accumu
with the implement control lever in order to stop a
towed machine when there is no pressure in the
 accumulator.
accumulator.

SEBU7763-02 105
Operation Section
Towing Information

g00775200 g00775222
Illustration 157 Illustration 158

(1)   FT1973  Adapter Gp

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

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

4.  Adjust the opening pressure of the relief valve.

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

106 SEBU7763-02
Operation Section
Towing Information

Connection for the Pump

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

3.   Remove the seat and the   floorplate from the

operator’s
operator’s station.

4.  Remove the pressure test   fittings from the top of 

Illustration 159 g00775205
1.  Remove the components that were used to plug
the pressure hose. The components are   9J-6190
 Adapter Union,  04-6683  Nipple,   5P-8018
 Adapter Union,   8M-0547  Elbow, and   5P-2909
Plug. The components are indicated by shaded
area (A).
brake valve ports (9).
5.  Install one   123-0525  Adapter (7) into each of the
brake valve ports.
6.  Connect the   FT1973  Adapter to the   123-0525
 Adapters.
7.   Route the pressure hose through the rear
rear,, around
the side, and through the door of the cab. Connect
the pressure hose to the pump. Install the pump
temporarily on the platform.

8.   Replace the  fl oorplate and the seat.

9.   Place the brake release pump in front of the

operator.

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

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

2.   Connect   FT1973  Adapter (1) to the pump

pressure hose. The adapter will be downstream
 from the relief valve.

SEBU7763-02 107
Operation Section
Towing Information

Brake Release Brake Engag

Engagement
ement

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

1.   Turn bypass valve handle (5) to the closed Open bypass valve (5) in order to apply the brakes.
position. This will completely dump the oil.

2.  Initially, rapidly move the pump handle. This will
produce a large volume of oil  fl ow.
3.  The brake piston seal must be fully seated. The
seating of the seal is evident by a sudden rise in
the oil pressure.
The brake system can only be applied by turning
the bypass valve. The service brake pedal and the
steering levers do not function.
 After towing, remove the brake release pump. Repair 
the machine. Install the  fl oorplate and the seat.

When the seal is properly seated, the pressure Consult your Caterpillar dealer for towing a disabled
rises to the relief valve setting. The setting is machine.
3030
303 0 ± 70 kPa (440 ± 10 psi).
psi).

4.  Now, the machine can be towed.

NOTICE
Do no
nott allo
allow
w pres
pressu
sure
re to dr
drop
op be
belo
low
w 27
2756
56 kPa
kPa
(400 psi) while towing.

Partial brake engagement could occur and can result

in brake damage.

Brakes must be fully released when towed machine is

moving.
 

108 SEBU7763-02
Operation Section
Engine Starting (Alternate Methods)
Methods)

Engine Starting (Alternate

NOTICE
Methods) When starting f rom
rom another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
i01953305

Engine Starting
Starting with Jump Turnboost
the on (close) the battery
connection disconnect
to prevent damageswitch prior to
to electrical
Start Cables  the
components on the
on stalled machine.

SMCS Code: 10 00; 7000

Code:  1000; Severely disch
Severely discharged
arged maintenanc
maintenance
e free batteries do
recharge from the alternator after jump start-
not fully recharge
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable
unusab are   still rechargeable.
le are
Batteries give off  fl
 fl ammable fumes which can ex-
plode.
This machine has a 24 volt starting system. Use only
voltage for jump starting. Use of a welder or 
the same voltage
To avoid injury or death, do not strike a match,
higher voltage damages the electric
electrical
al system.
ca
caus
use
e a spar
spark,
k, or smok
smoke
e in th
the
e vi
vici
cini
nity
ty of a batt
batter
ery
y.
Refer to Special
Special Instruction, Battery Test Procedure,
SEHS7633, available from your Caterpillar dealer
SEHS7633, dealer,, for 

complete
complete testing and chargin
charging
g informat
information.
ion.
Failure to pro
Failure proper
perly
ly ser
service
vice the batteri
batteries
es may cause
cause
peronal injury.
Use of Jump Start Cables
Preven
Preventt sparks
sparks near the batterie
batteries.
s. They
They could
could
When the auxiliary start receptacles are not available,
cause vapors to explode. Do not allow the jump
use the followin
following
g proced
procedure.
ure.
startt cab
star cable
le   en
ends
ds to co
conta
ntact
ct ea
each
ch other
other or th
the
e
machine.
1.  Place the transmission control on the stalled
machine in the NEUTRAL position. Engage the
Do not smok e when checking battery electrolyte
smoke
levels. brake switch. Lower all attachments to the
parking brake
ground. Move all controls to the HOLD position.
Electrolyte
Electroly te is an acid and can cause personal in-
 jury if it contacts skin or eyes. stalled machine, turn the start switch key to
2.  On a stalled
the OFF position. Turn off the accessories.
wear eye protection when starting a ma-
Always wear
chine with jump start cables. 3.   On a stalled
stalle dswitch.
disconnect machine, turn on the battery

Improper jump start procedures can cause an ex-

Improper
machines togeth
4.  Move the machines together
er in order for the cables
plosion resulting in personal injury.
to reach. DO
reach.  DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
Always connect
connect the battery positive (+) to battery
positive (+) and the battery negative ( ) to battery
−

5.  Stop the engine on the machine that is the

negative ( ).
−

electrical source. When you use an auxiliary

Jump start only with an energy source with the source, turn off the charging system.
power source,
same voltage as the stalled machine.
6.  Check the battery caps for correct placement
Turn off all lights and accessories on the stalled correct tightness. Make these checks on
and for correct
both machines. Make sure that the batteries in
machine
mac hine.. Otherwis
Otherwise,e, they
they will operat
operate
e when
when the
the stalled machine are not frozen. Check the
source is connected.
energy source connected.
es for low electrolyte.
batteries
batteri
 

SEBU7763-02 109
Operation Section
Engine Starting (Altern
(Alternate
ate Method
Methods)
s)

13. Allow the elect

13. Allow electrical
rical source to charge the batteries
for two minutes.

start the stalled engine. Refer to

14. Attempt to start
14. Attempt
Operation and Maintenance Manual, “Engine
Starting”. See the beginning of this topic. Allow
electrical source to charge the batteries for 
the electrical
two minutes.
minutes.

15. Immediately  after the stalled engine starts,

disconnect
disconnect the jump start cables in reverse order.

i01953306

Engine Starting with Auxiliary

Start Receptacle
SMCS Code: 1000;
Code:  1000; 1463; 7000

g01015884
Illustration 164

(1) Battery disconnect switch

(2) Positive cable
(3) Positive
Positive cable terminal
(4) Negative
Negative cable terminal
(5) Negative
Negative cable

NOTICE
Do no
nott allow
allow po
posit
sitiv
ive
e cabl
cable
e clamp
clamps
s to conta
contact
ct an
any
y met-
met-
al except for battery terminals.

Note:  Some positive cables and some covers for 

Note: Some
positive terminals are red for correct identi fication. g01114158
Illustration 165

7.   Connect the positive jump start cable to the
positive
positive cable terminal of the discharged battery
battery..
8.  Batteries in series may be in separate
compartments.
compart ments. Use the termina
terminall that is connected
connected
to the starter solenoid. Trace this cable in order  There are two cable assemblies that can be used
to make sure that the cable is connected to the
starter.
9.   Connect the positive jump start cable to the
positive terminal of the electrical source. Use the
procedure from Step 7 in order to determine the
correct terminal.
terminal.
10. Connect one end of the negative jump start cable
to the negative terminal of the electrical source.
 A permanent auxiliary start receptacle is standard on
this machine. The receptacle is always available for 
 jump starting. The receptacle is located on the left
side of the engine next to the air cleaner housing.
to jump the stalled machine. You can jump the
machine from another machine that is equipped
with this receptacle or an auxiliary power pack. Your 
Caterpillar dealer can provide the correct cable
lengths for your application
application..
1.  Place the transmission control in the NEUTRAL
position on the stalled machine. Engage the
parking brake. Lower all attachments to the
ground.

11. Make the  fi nal connection. Connect the negat

negative
ive 2.  On the stalled machine, turn the start switch key
cable to the frame of the stalled machine. Make to the OFF position. Turn all accessories to the
this connection
connection away from the battery,
battery, the fuel, the OFF positio
position.
n.
hydraulic lines, or moving parts.
3.  Turn the battery disconnect switch ON.
 12. Start the engine on the machine that is the
electrical source. Also, you can energize the
charging
chargi ng system on the auxiliary
auxiliary power source.

110 SEBU7763-02
Operation Section
Engine Starting (Alternate Methods)
Methods)

4.  Move the machine

machin e that is used for the electrical
source close to the stalled machine. The cables
must reach. DO
reach.  DO NOT ALLOW THE MACHINES
CONTACT WITH EACH OTHER.
TO COME INTO CONTACT

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

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

6.   On the stalled machine, connect

connect  9S-3664  Cables
to the auxiliary start receptacle.

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

source.

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

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

el ectrical source to charge the batteries

9.  Allow the electrical
for two minutes.

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

10. Attempt
 Articles on“Engine Starting” in this manual.

11. Immediatel
Immediatelyy after the stalled engine starts,
disconnect the jump start cable from the electrical
source.

12. Disconnect the other end of this cable from the

stalled machine.
 

SEBU7763-02 111
Maintenance Section
Cooling System Specifications

Maintenance Section The following problems

the coolin
cooling
problems may indicate a need to check
g system
system::

•   Engine overheating
overheating
Cooling Syste
Cooling Systemm
•   A strong, unusual
unusual odor from the coolant
Specifications
•   Contamination
Contamination of the cooling system

i02240514
•   A change in the color
the  color of the coolant
Model Specific Coolant •  Foaming within the radiator 
Information
 Air pockets can form in the cooling system if the
SMCS Code: 1000
Code:  1000 cooling system is   filled at a rate that is greater than
20 L (5 US gal ) per
p er minute.
NOTICE
 Adding coolant to an overheated engine could result in  After you drain the cooling system and after you refill
damage to the engine. Allow the engine to cool before system, operate the engine. Operate
the cooling system,
adding coolant. the engine without the radiator cap until the coolant
reaches normal operating temperature and the
If the machine
machine is tto
o be stored
stored in
in,, or shippe
shipped
d to, an area
area level stabilizes. Make sure that the coolant is
coolant level
maintained to the proper level.
with freezing to
be protected temperatures, the cooling
the lowest outside system
(ambient) must
temper-
ature. NOTICE
Never operate an engine without water temperature
The
The enengigine
ne cooli
cooling
ng syst
system
em is nor
normal
mally
ly pr
prote
otect-
ct- regulators in the cooling system. Water temperature
ed to a mi mini
nimu
mumm of −29
29°C
°C (−20°F) with Caterpillar 
Caterpillar  regulators help to maintain the engine coolant at the
 Antifreeze, when shipped from the factory unless proper operating temperature. Cooling system prob-
specia requirements are defined.
speciall requirements lems can develop without water temperature regula-
tors.
NOTICE
Frequently check the specific gravity of the coolant to For more detailed information, refer to the following
ensure proper freeze protection and anti-boil protec- publication: Special Publication, REHS1063, “Special
tion. Instruction - Know Your Track-Type Tractor Cooling
System”.

NOTICE Many engine failures are related to the cooling

Never use water alone as a coolant. Water alone is system. Cooling system failures include the followin
following
g
corrosive
corrosive at engine operating
operating temperat
temperatures
ures and does problems: overheating, leakage of the water pump,
provide adequate
not provide adequate anti-boil
anti-boil protection.
protection. plugged radiators, and cylinder liner pitting. These
failures could be avoided with proper cooling system
maintenance. Maintenance of the engine coolant is
NOTICE important to the engine life and to the performance.
 All Caterp illar diesel engines equipped with air-to-air 
Caterpillar Maintaining the quality of the engine’s coolant is as
aftercoo
aftercooling
ling (A
(ATTAAC)
AAC) requ
require
ire a min
minimum
imum of 30 per
percen
centt important as maintaining the quality of the engine’s
glycol to prevent water pump cavitation. fuel and lubricating oil.

Extended Life Coolant (ELC) is used at the factory for 

Extended Coolantt is normally composed of three elements:
Coolan
the D9TTrack-Type Tractor .
•   Water
Water is used for transferr
transferring
ing heat from the engine
Reference:  Refer to Service Manual, SEBU6250,
Reference: Refer to the atmosphere.
“Caterpillar
“Caterpillar Machine Fluids Recomm
Recommendatio
endations”,
ns”,
•   Additives
Additives are used for corrosion protecti
protection.
on.
“Cat
“ELCExtended
Exte ndedSystem
Cooling Life Coolant (ELC)”. See
Maintenance” the section
in order to
maintain your cooling system. However, maintaining •   Glycol is used for anti-boil protection and antifreeze
cooling system is preferred. Also, see the
an ELC cooling protection.
 topics“Coolant
topics“Coolant Recom
Recommendati
mendations”
ons” and “S·O·S
Coolant Analysis”.

112 SEBU7763-02
Maintenance Section
Lubricant
Lubric Viscosities and Refill Capacities
ant Viscosities

Lubricant Viscosities and

Refill Capacities
i02547347

Lubricant Viscosities
Viscosities
SMCS Code: 7581
Code:  7581

Selecting the Viscosity

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

The proper oil viscosity grade is determined by the

minimum outside ambient temperature. This is the
ure when the machine is started and while
temperature
temperat
the machine is operated. In order to determine the
proper oil viscosity grade, refer to the “Min” column
table. This information re flects the coldest
in the table.
ambient temperature condition for starting a cold

machine
to andcolumn
“Max”
the “Max” for operating a coldinmachine.
in the table Refer 
order to select
the oil viscosity grade for operating the machine at
the highest temperature that is anticipated. Unless
specified otherwise in the “Lubricant Viscosities for 
 Ambient Temperatures” tables, use the highest oil
viscosity that is allowed for the ambient temperature
you start the machine.
when you

Machines that are operated continuously should

oils that have the higher oil viscosity in the  fi nal
use oils
drives and in the differentials. The oils that have the
higher oil viscosity will maintain the highest possible
oil   film thickness. Consult your dealer if additional
information
informa tion is needed
needed..
 

SEBU7763-02 113
Maintenance Section
Lubricant Visco
Lubricant sities and Refill Capacities
Viscosities Capacities

Lubricant Viscosities for Ambient

Temperatures
Table 16

Lubricant Viscosities for Ambient Temperatures

Compartment or    Application   Oil Type and   Oil Viscosities °C °F

System Classification
cation Min Max Min Max
SAE 60   −7 50 19 122
Cat FDAO(1)(2)
Moderate Usage commercial FD-1(1) SAE 50   −15 32 5 90
or Intermittent Cat TDTO
Operation Cat TDTO-TMS SAE 30   −25 15   −13 59
commercial TO-4
Cat TDTO-TMS(3) −35 15   −31 59
Final Drive
Cat FDAO(1)(2) SAE 60   −25(4) 50   −13(4) 122
Severe Usage commercial FD-1(1)
or Continuous Cat TDTO SAE 50   −33(4) 14   −27(4) 58
Operation (Multiple Cat TDTO-TMS SAE 30   −40(4) 0   −40(4) 32
Shifts/ Day) commercial TO-4
Cat TDTO-TMS(3) −40(4) 0   −40(4) 32
SAE 75W-90   −30 40   −22 104

End Pin Joints for  Cat GO SAE 75W-140 -30 45 -22 113
the Equalizer Bar,
Cat Synthetic GO(5)
Bogie Cartridge Normal SAE 80W-90   −20 40   −4 104
commercial API
Pins, and Track
GL-5 gear oil SAE 85W-140
85W-140   −10 50 14 122
Pins
SAE 90   0 40 32 104
SAE 0W-20(6
(6)) −40 10   −40 50
SAE 0W-30(7
(7)) −40 20   −40 68
Power Shift SAE 5W-30(7
(7)) −30 20 −22 68
Cat TDTO  
Transmissions
commercial TO-4
and Winches Normal SAE 10W   −20 10   −4 50
Cat TDTO-TMS
(mechanical
Cat Arctic TDTO SAE 30(8) 0 35 32 95
drive)
SAE 50(8)(9) 10 50 50 122
Cat TDTO-TMS(3)(8) −10 35 14 95
SAE 0W-20   −40 40   −40 104

Cat HYDO SAE 0W-30   −40 40   −40 104

Cat DEO
SAE 5W-30   −30 40   −22 104
Cat MTO
Cat TDTO SAE 5W-40   −30 40   −22 104
Cat TDTO-TMS
Cat DEO SYN SAE 10W   −20 40   −4 104
Cat Arctic DEO SYN
Hydraulic SAE 30   10 50 50 122
  Normal Cat Arctic TDTO
Systems
Cat ECF-1 SAE 10W-30   −20 40   −4 104
Cat BIO HYDO
(HEES) SAE 15W-40   −15 50 5 122
API CG-4
Caterpillar MTO   −25 40   −13 104
API CF
commercial TO-4 Cat BIO HYDO
commercial BF-1(10)(11)   −25 43   −13 110
(HEES)(10)(11)
Cat TDTO-TMS(3) −15 50 5 122
(continued)
 

114 SEBU7763-02
Maintenance Section
Lubricant
Lubric Viscosities and Refill Capacities
ant Viscosities

(Table 16, contd)

Lubricant Viscosities for Ambient Temperatures

Compartment or    Oil Type and °C °F

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

SEBU7763-02 115
Maintenance Section
Lubricant Visco
Lubricant sities and Refill Capacities
Viscosities Capacities

(Table 16, contd)

Lubricant Viscosities for Ambient Temperatures

Compartment or    Oil Type and °C °F

  Application   Oil Viscosities
System Classification Min Max Min Max
SAE 30   −20 25   −4 77
CatCat
DEODEO
SYN SAE 40 −10 40 14 104
Track Idlers and  
  Normal Cat ECF-1
Track Rollers
API CG-4
API CF   SAE 5W-40   −35 40   −31 104

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

116 SEBU7763-02
Maintenance Section
Lubricant
Lubric Viscosities and Refill Capacities
ant Viscosities

i01956951 Ecology
Ecology Drains
Drains
Capacities (Refill) Table 18

Ecology Drain (Components)

SMCS Code: 7560
Code:  7560
Lo
Loca
cati
tio
on (D
(Dra
raiin) Neede
eeded
d Compo
ompon
nen
entt
Table 17

Approximate Refill Capacities Coolant   None

12.7 mm (0.5 inch)
Compartment or    Imperial Transmission pipe with 1/2-14 NPTH
  Liters US gal
System gallon thread
Cooling System 76.8 20.3 16.9 12.7 mm (0.5 inch)
Fuel Tank 643.5 170 141.6 Torque Converter  pipe with 1/2-14 NPTH
thread
Crankcase
Engine Crankcase
  37.9 10 8.3   25.4 mm (1 inch) pipe with
and Filter  Engine Oil
1-11 1/2 NPTH thread
Power Train Oil
  155 41 34 126-7914   OilDrain
System and Filters
Coupling
Hydraulic Tank Oil 75.0 19.8 16.5 Hydraulic Tank or 
25.4 mm (1 inch) pipe with
Final Drive (each) 12.5 3.3 2.8 1-11 1/2 NPTH thread
Recoil Spring
Sprin 4C-8563   Oil Drain
Compartment (each)   65 17.2 14.3 Coupling
Winch Sump Bevel Gear Case or 
  15 4 3.3 25.4 mm (1 inch) pipe with
(PA110VS)
NPTH  thread
1-11 1/2 NPTH thread
Pivot Shaft 40 10.6 8.8

i01822901
Note:  When you are operating on severe slopes
Note: When
(greater than 25 degrees or greater than 47 percent), S·O·S Information
the quantity of oil in the power train can be increased
by as much as 10 percent. When you are operating SMCS Code: 75 42
Code:  7542
with the increas
increased
ed oil quantit
quantity
y, prolong
prolonged
ed operation
operation
in some machines can cause high power train oil S·O·S Services is a highly recommended process
temperatures. After the work on the severe slopes Caterpillar customers to use in order to minimize
for Caterpillar
has been completed, drain the excessive oil quantity owning and operating cost. Customers provide
from the bevel gear case. oil samples, coolant samples, and other machine
Note:  For severe slope operation, engine oil should
Note: For informatio n. The dealer uses the data in order to
information.
provide the customer with recommendations for 
be maintained on the full mark. The engine should management of the equipment. In addition, S·O·S
never be over filled with oil. can help determine the cause of an existing
Services can
product problem
problem..

Special Publication, SEBU6250, “Caterpillar 

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

Refer to the Operation and Maintenance Manual,

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

your Caterpillar dealer for complete

Consult your
information and assistance in establishing an S·O·S
program for your equipment.
 

SEBU7763-02 117
Maintenance Section
Maintenance Support

Maintenance Support
i01821998

Welding on Machines and

Engines
Controls with Electronic
SMCS Code: 1000;
Code:  1000; 6700; 7000

Proper welding procedures are necessary in order 

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

1.  Turn off the engine.

2.  Turn the battery disconnect switch to the OFF

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

3.  Clamp the ground cable from the welder to the

component that will be welded. Place the clamp
as close as possible to the weld. Make sure that
the electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure in order to reduce the possibility of 
damage to the following components:

•  Bearings of the drive train

•   Hydraulic components
•   Electrical components
 Other components of the machine
•
NOTICE
Do NOT use
use elec
electri
trica
call co
compo
mpone
nent
nts
s (ECM
(ECM or ECM
ECM se
sen-
n-
sors)
sors) or electron
electronic
ic compon
component
ent ground
grounding
ing points
points for 
grounding
groundin g the welder.

4.  Protect any wiring harnesses from the debris

created from welding. Protect any wiring
which is created
harnesses from the splatter which is created from
welding.

5.   Use standard welding

welding procedures in order to weld
the materials together.
 

118 SEBU7763-02
Maintenance Section
Maintenance Interval Schedule

i02704014 Hydraulic System

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

SEBU7763-02 119
Maintenance Section
Maintenance Interval Schedule

Winch Oil and Br e

eather
ather - Chan
Change/Clea
ge/Clean
n ............ 178

Every 2000 Service Hours

Oil  - Change ........................
Final Drive Oil - ....................................
.............. 145
Final Drive Seal Guard Packing - Replace ......... 148
Hydraulic
Hydrau lic System Oil - Change ............
......................
...............
..... 156
Hydraulic System
System Oil Filter (Pilot) - Replace ....... 157
Radiatorr Guard Pin Joint - Inspect
Radiato Inspect ......................
...................... 163
Track Roller Frame - Inspect .............................. 170
ck Roller Fr ame
Track
Tra ame Guides - Inspect .................. 170

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

Every 3 Years After Date of Installation or 

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

Every 4000 Service Hours

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

Service Hours or 3 Years

Every 6000 Service
Cooling System Coolant Extender (ELC) - Add .. 131
Cooling System WaterWater Temperature Regulator -
Replace
Replac e ...........
.......................
........................
........................
........................
..............
.. 134

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 129
 

120 SEBU7763-02
Maintenance Section
Backup Alarm - Test

i01957816 i02196906

Backup Alarm - Test Battery or Battery Cable -

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

Inspect
Battery Inspect

Illustration 166 g01017699

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

g01117315
Illustration 169

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

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

The nonadjustable backup alarm is set at the 3.  Close the battery access covers.
appropriate
approp riate sound level when the machine
machine is shipped
from the factory.
factory.
Battery Recycle
 Always recycle a battery. Never discard a battery.
  Always return used batteries to one of the following
locations:

SEBU7763-02 121
Maintenance Section
Belt - Inspec
Inspect/Adjust
t/Adjust/Replac
/Replace
e

•   A battery supplier 
supplier 

•   An authorized battery collection

collection facility

•   Recycling facility

Battery Disconnect Switc

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

2.  Turn the battery disconnect switch to the OFF

position. Remove the key.

3.   Disconnect the battery cable at the battery

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

4.  Disconnect the negative battery cable at the

battery.
g01117063
Illustration 170

5.   Replace
Replace the disconnect
disconnect switch, the battery cables,
or the batter ies,
ies, as required.

6.   Connect
Connect the negativ
negative
e battery cable at the battery.
battery.

7.  Connect the negative battery cable at the battery

disconnect switch.

8.  Install the key and turn the battery disconnect

switch to the ON position.

i02229215

Belt - Inspect/Adjus
Inspect/Adjust/Repl
t/Replace
ace
Code:  1357-025; 1357-040; 1357-510
SMCS Code: 1357-025;

Your engine is equipped with a serpentine belt

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

122 SEBU7763-02
Maintenance Section
Bottom Guard (Power) - Clean

6.  Turn the batter y disconnect switch to the ON

position.

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

2.  Turn the battery disconnect switch to the OFF

position.

3.  Open the engine access doors.

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

7.  Close the engine access doors.

8.  Turn the battery disconnect switch to the ON
position.

i02248240

Bottom Guard (Power) - Clean

SMCS Code: 7 153-070
Code:  7153-070

NOTICE
Do not operate the machine with the guard in the
lowered position. Damage to the machine or actuator  g01131976
Illustration 173
could result.
result.

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

2.  Remove the bolts from the bottom guard and

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

If the guard lowers completely onto the jack, it is

possible that the actuator has failed. Use the jack
to support the guard and lower the guard to the
ground.
 3.  If the guard remains supported above the jack,
remove the jack.

4.  Lower the guard to the lowest position.

SEBU7763-02 123
Maintenance Section
Braking System - Test

5.  Remove all foreign

fore ign debris from the underside of  4.  Release the par k
king
ing brake.
the engine compartment.
compartment.
5.  While the brake pedal is depressed, move the
6.   Move the switc
switchh upward in order to raise the control to the SECOND SPEED
directional control
guard. FORWARD position.

7.   Position
the bolts.the jack
jack
The under
head the jack
of the guard prior to
should replacing
not be 6.  Gradually
speed. Theinc
increase
rease the
machine engine
should notspeed
move.to full load
touching the guard.
7.   Move the direc tional control to the NEUTRAL
directional
8.  Install the bolts. position.

engine speed to LOW IDLE. Engage

8.  Reduce the engine
i01958206
the parking brake. Lower all attachments to the
Braking System - Test ground. Apply a slight down pressure. Stop the
engine.
SMCS Code: 41 00-081; 4267-081
Code:  4100-081;
NOTICE
If the machi
machine
ne mo
move
vedd while
while te
test
sting
ing the brake
brakes,
s, cont
contac
actt
Caterpillar dealer. Have the dealer inspect and,
your Caterpillar
if necessary, repair the service brake before returning
If the machine moves during the test, reduce the
the machine to operation.
engine speed immediately, and engage the park-
ing brake.

If the machin
machinee mov
moved
ed whil
while
e tes
testing
ting the brakes
brakes,, i02229253

consult your Caterpillar dealer for brake inspec-

tion and repair. Damaged brakes must be repaired
Bulldozer Tilt Brace and Tilt
before returning
returning the machine to operation. Cylinders - Lubricate
SMCS Code: 6050-086
Code:  6050-086
Note: The machine can drive through the brakes
in   first gear .
Lubricate the two  fi ttings with CA
CAT
T multipurp
multipurpose
ose type
grease with molybd
molybdenumenum disulfide (MPGM).
Make sure that the area around the machine is clear 
of personnel and clear of obstacles.

Test the brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

1.  Start the engine.

2.  Raise all attachments.

g01117177
tion 175
Illustration
Illustra

One  fi tting is located at the left front brace assembly

tilt cylinder (if equipped).
or left tilt

 fi
The other 
nder. tting is located at the rod end of the right
tilt cylinder.
cyli
 g01017767
Illustration 174

he brake pedal.
3.  Depress tthe

124 SEBU7763-02
Maintenance Section
Cab Filter (Fresh Air) - Clean/Inspect/Replace

Personal injury can result from air pressure.

Personal injury can result without following prop-

er pr
proc
oced
edur
ure.
e. Whe
Whenn using
using pr
pres
essu
sure
re air
air,, wea
wearr a pr
pro-
o-
tective face shield and protect
protective
ive clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

2.   The   filter element can be cleaned by using

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

Cab Filter (Fresh Air) - i01971627

Clean/Inspect/Replace (Recirculation) -
Cab Filter (Recirculation)
Code:   7342-040; 7342-070; 7342-070-FI;
SMCS Code: 
Clean/Inspect/Replace
7342-510; 7342-510-FI SMCS Code: 7 342-040; 7342-070; 7342-510
Code:  7342-040;

The recirculation  fi lter is positioned to the left of the

operator’s seat in the cab.
operator’s

g01118586
Illustration 177

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

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

1.  Unscrew the bolt to the cover of the recirculation

filter and   remove the cover. Remove the
 recirculation   filter element.
element.

SEBU7763-02 125
Maintenance Section
Cooler Cores and A/C Condenser - Clean

Personal injury can result from air pressure.

Personal injury can result without following prop-

Personal
er pr
proce
ocedur
dure.
e. When
When using
using pres
pressu
sure
re air
air, wea
wearr a pro-
pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

2.   The recirculation   filter element can be cleaned by

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

4.  Install the recirculation  fi lter element. Make sure

 fi  fi Remote A/C Condenser Core
that thed the
centered
centere lter element is centered.
system will Ifnthe
not function
functio lter is
properly
properly.. not
In some machine arrangements, the a/c condenser 
Note:  Clean the  fi lters more often in dusty conditi
Note: Clean conditions.
ons. core is remotely located. A remote mounted a/c
condenser core is cooled by fans with electric drive.

i02771652

Cores and A/C

Cooler Cores
Condenser - Clean
Code:   1064-07
SMCS Code:  064-070;
0; 1353-070;
1353-070; 1374-070;
1374-070;
7320-070

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

Hydraulic oil cooler core

Hydraulic core –  The hydraulic oil cooler 
core cools hydraulic oil.

Radiator core –  The AMOCS radiator cores cool

the engine coolant.

A/C Condens
Condenser er Core –  The air conditioning
condenser core cools the refrigerant in the air 
ning system.
conditioning
conditio
 g01117129
Illustration 181
conditioner condenser on the top of the machine
 Air conditioner

126 SEBU7763-02
Maintenance Section
Cooler Cores and A/C Condenser - Clean

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

Personal injury can result without following prop-

er pr
proc
oced
edur
ure.
e. Whe
Whenn using
using pr
pres
essu
sure
re air
air,, wea
wearr a pr
pro-
o-
tective face shield and protect
protective
ive clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Radiator cores, aftercoole

Radiator aftercoolerr cores
cores,, hydrau
hydraulic
lic oil cooler 
cores, and a/c condenser cores needed to be cleaned
regularly. Adjust the frequency of cleaning according
to the effects of the operating environment.

Blow out the cores with compressed air. Move the

air nozzle in a systematic pattern so that the air 
flow covers the whole core that includes areas in

the corner. core

aftercooler Cleanand
thethe
middle space between
a/c condenser the
core. Also,
clean the space between the hydraulic oil cooler and
g01385726 the AMOCS radiator cores.
Illustration 182

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

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

Dry
If steam or water is used to clean the cores, make
sure that the cores are completely dry before the
track-type tractor is put back to work.
Use compressed air to blow dry the wet cores, the
 engine, engine access doors, and the hood.

Close both engine access doors.

SEBU7763-02 127
Maintenance Section
Cooler Cores and A/C Condenser - Clean

If the machine isis in a clean environment, start the  
engine and allow the fan to run until the cooling
system has completely dried. Allow the machine to
sit overni
overnight  before operating the machine in the
ght before
work mode.
Access to the cores
cores is through the engine access
doors from the rear of the cores which results in
blowing air in the same direction as the normal air 
flow through thethe fan. The wood chip and Waste
Handling
Handlin g arrangements offer two options for blowing
air in the opposite direction of normal fan air   flow.

Wood Chip or Waste Handling First,

reverse themode.
reverse
reverse fan
This function
allows has a continuous
prolonged periods of the
Arrangement (If
Arrangement  (If Equipped) reverse  fl ow while the machine is parked. Next, slots
provided in both sides of the radiator guard for 
are provide
Cooler Cores use with a   307-6728  Air Nozzle which concentrates
concentrates
air  fl ow backward through the cores.
The wood chip and waste handling arrangements
have a remote mounted a/c compressor,
compressor, and a single Blow out the cores with compressed air. Move the
plane of the f ollowing
ollowing cores: hydraulic oil cooler  air nozzle in a systematic pattern so that the air  fl ow
core, AMOCS radiator cores, and aftercooler core. whole core that includes the areas in the
covers the whole
 Additionally, these
t hese arrangements have a hydraulic corners. Do not use steam or high pressure water 
reverses the direction of air  fl ow in order to
fan that reverses for cleaning frequently. If steam or high pressure
purge debris. required to dislodge any debris that is held
water is required
deep in the cores, make sure that the cleaning is
thorough. This may require opening radiator doors
Clean
removing debris guards for access. Incomplete
and removing

cleaning
to hardenwith waterUse
in place. maylights
causeand
remaining debris
wire probes in
ensure that the cleaning is thorough and
order to ensure
Personal injury can result from air pressure. complete. If the debris has hardened in the center 
of the cores, these cores may need to be removed
Personal injury can result without following prop-
Personal the  machine for thorough cleaning. If steam or 
from the machine
er pr
proce
ocedur
dure.
e. When
When using
using pres
pressu
sure
re air
air, wea
wearr a pro-
pro- water pressure is used to clean the cores, make sure
tective face shield and protective clothing. that the pressure is controlled in order to prevent the
from  bending.
fins from bending.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. If you use a degreaser or special cleaning agents,
wash the  core with detergent and hot water.
Thoroughly rinse the core with clean water. Dry the
NOTICE cores completely before operating the machine in
Pressurized
Pressur ized air: To avoid possible engine damage, the wor k mode.
shutt off eng
shu engine
ine before
before perf
performi
orming
ng mainten
maintenance
ance to
clea
clean the coo
n the oolin
ling
g syst
system
em.. Insta
Install
ll ai
airr no
nozzl
zzle
e in
into
to
access slot before starting air supply. Read and un- Dry
derstand
derstan d Operation
Operation and Maintena
Maintenance
nce Manual.
If steam or water is used to clean the cores, make
sure that the cores are completely dry before the
In applications with high levels of airborne debris, type tractor is put back to work.
track-type
track-
a regular schedule for cleaning the cooling cores
must be established. The frequency of cleaning Use compressed air to blow dry the wet cores, the
and the cleaning method must be tailored to the engine,, engine access doors, and the hood.
engine
specific debris accumulation on the job site. In order 
to maintain clean cores, the cleaning will need to be Close both engine access doors.
done at least daily. Cleaning may be needed on a
more frequent basis. The clean out schedule
schedule must be If the machine is in a clean environment, start the
followed even when ambient temperatures are low. engine and allow the fan to run continuously in the
This will prevent debris accumulation in the cores rever se
se mode until the cooling system has completely
and future pluggin
plugging.
g. dried. Allow the machine to sit overnight before
operating the machine in the work mode.

Typical Cleaning Procedure That Uses

 Compressed
Compressed Air 
The wood chip and waste handling arrangements
have special cleaning features.
features.

128 SEBU7763-02
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

•   continuous reverse
reverse fan function Note:  Do not activate
Note: Do activate the air supply until you have
inserted the air nozzle into the access slot. Use the
•   307-6728 Air Nozzle in access slots in the radiator  work tool safely.
guard
7.  Move the air nozzle in a pattern in order to clean
These tools can be used to develop a cleaning the cores from the front side of the cores. Blow out

proces
process
s that
sequence
sequence forbcleaning
est suits
cleanin your
g is application.
outlined below.One possible
below. the cores on thethe left side of the cooling system.
8.   Turn off the air supply when the nozzle clea cleaning
ning of 
side  cores is completed.
the left side cores

9.   Remove the air nozzle from the access slot. Close

cover.
the access cover.

10. Repeat Steps 5 through 9 from the left side of the

machine in or der
der to clean the cores on the right
side of the machine.

11. Use a regular  air

  air nozzle in order to blow off the
cores from the rear and clean the entire engine
compartment.

12. Close both of the engine access doors.

the  engine. Operate the fan in the forward
13. Restart the engine.
direction
direction continu
continuously
ously for 2 minutes
minutes..

the  air   flow. Operate the fan in the

14. Reverse the air 
reverse mode continuously for 2 minutes.
g01385729
Illustration 183
operating the machine in work mode.
15. Return to operating
1.  At the proper cleaning area, park the machine in
Note:  Adjust the frequency of cleaning according to
Note: Adjust
NEUTRAL and engage the parking brake.
the effects of
effects  of the operating environment. Modify the
typicall cleaning
typica cleaning proced
procedure
ure above for optimal results,
results,
2.   Depress the fan control switch and hold for 
as needed.
three seconds in order to enter the continuous
reverse mode. Run the fan in the reverse mode
continuously
continuously for 2 minute
minutes.
s. i02111232

3.  Turn off the engine. Make sure that the fan has Cooling System Coolant
stopped rotation. (Level 2) - Obtain
Sample (Level
4.  Open both of engine access doors (1). Use a Code:  1350-008; 1395-008; 1395-554; 7542
SMCS Code: 1350-008;
regular air nozzle to clean the cores from the rear 
side. Blow off the hood, engine access doors, and
the entire engine compartment. On machines that Level 2 Analysis
are equipped with the woodchip arrangement,
open the grill doors and blow off the radiato
radiatorr guard NOTICE
shelf.  Always use a designated pump for oil sampling, and
use a sep
separat
arate
e des
design
ignated
ated pump for coo
coolan
lantt sampli
sampling.
ng.
5.  Open the cover to access slot (6) on both sides the  same pump for both types of samples may
Using the same
of the radiator guard. Insert the   307-6728  Air  contaminate the samples that are being drawn. This
Nozzle into the access slot on the right side of the contaminate may cause a false analysis and an incor-
machine in order to clean the cores on the left
side of the machine. rect inte
interpretation
dealers
dealer s rpretation
and customthat
customers. could lead to concerns by both
ers.
 Note:  Cleaning the cores from the opposite side of 
Note: Cleaning
the machine allows better cleaning in the corners.

6.  Turn on the air supply.

SEBU7763-02 129
Maintenance Section
Cooling System Coolant (ELC) - Change

Submit the sample

samp le for Level 2 analysis.
NOTICE
Ca
Care
re must
must be ta ken to ens
tak ensururee th
that
at fluid
uidss are contain
contained
ed
i02762742
during performance of inspecinspection,
tion, maintenance, test-
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oducuct.
t. Be pre
prepar
pared
ed to Cooling System Coolant (ELC)
collectt the   fluid with suitable containers before open-
collec
ing
nentany compartment
containing   fluids.
or disassembling any compo- - Change
Code:  1395-044
SMCS Code: 1395-044
Refer to Special Publication,
Publication, NENG2500, “Caterpillar 
Tools
ools an
andd Shop
Shop Pro
Produc
ducts
ts Guid
Guide”
e” for to
tools
ols an
and
d supp
supplie
liess For information about adding an extender to your 
suitabl
sui e to collect and contai
table n   fluid
contain uids
s on Caterpil
Caterpillar 
lar  cooling system, see the Topic “Cooling System
products. Coolant Extender (ELC) - Add” in this manual or 
consultt your Caterpi
consul Caterpillar
llar deale
dealer.
r.
Dispose
Dispos all  fl uids according to local regulations and
e of all
mandates. NOTICE
Make sure you read and understand the information
Testing the coolant can be done at your Caterpillar  in the topics Safety and Cooling System Speci fica-
Caterpillar S·O·S Coolant Analysis is the best
dealer. Caterpillar tions for all information pertaining to water
water,, antifreeze
antifreeze
way to monitor the condition of your coolant and your  and supplemental coolant additive requirements be-
cooling system. S·O·S Coolant Analysis is a program fore you proceed with maintenance of the cooling sys-
based on periodic samples. See Operation
that is based tem.
and Mainten
Maintenance
ance Manual, SEBU6250, “Caterpillar 
Machine
Machin e Fluid Recommendati
Recommendations”,
ons”, “S.O.S Coolant
 for more information.
 Analysis” for
 Analysis” To Drain the Cooling System
Perform a Coolant Analysis (Level 2) at initial 500 The  fi ller cap is located inside the access door on the
systems that contain extended life coolant
hours for systems top of the radiator guard.
(ELC). Perform the analysis yearly after the initial
500 hours.

g01113455
tion 185
Illustration
Illustra

g01017880
Illustration 184

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

engine at low idle speed.

2.  Open the left side engine compartment. Remove

the protective cap from the sampling valve.

3.  Obtain a sample. For additional information

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

4.  Replace the protective cap. Close the left side

engine compartment.

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

 If you change

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

g01017961
g01017961
Illustration 186

3.   Direct the drain hoses into suitable containers.

containers. g00475722
Illustration 187
drain valve. Allow the coolant to drain
4.   Open the drain
into a suitable
suitable container.
container. 10. Look into   filler tube (1). Maintain coolant level
between area (2) and area (3) of the  fi ller tube.
the  system with water. Flush the system
5.   Flush the system  Adding coolant above this area of the  filler tube will
until the draining water is clear. cause the coolant to over flow the cooling system.

Note:  If the cooling system is already using ELC,

Note: If 11. If the gasket is damaged, replace the   filler cap.
cleaning agents are not required to be used at Install the   filler cap.
the specified coolant change interval. Cleaning
12. Stop the engine.
agents are only
are
contaminated byrequired if theofsystem
the addition has been
some other type of 
coolant or by cooling system damage. Clean water is
 only  cleaning agent that is required when ELC is
the only cleaning
drained from the cooling system.

SEBU7763-02 131
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

Table 19

“Catt ELC
“Ca ELC Ext
Extend
ender”
er” and the Coolin
Cooling
g Sys
System
tem Cap
Capaci
acity
ty
Recommended
Cooling System Capacity  Amount of “Cat
ELC Extender”

84 L to 114 L (2
(22
2 to 30 US gal
gal) 2.
2.15
15 L ((72
72 oz)
oz)

When a Caterpillar Extended Life Coolant (ELC)

is used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
determined by the cooling system capacity.
g01117259
Illustration 188
For additio
additional
nal information about adding an extend
extender,er,
13. Clean the radiator cores with compressed air. You see Specia
Speciall Publica
Publication,
tion, SEBU62
SEBU6250,
50, “Caterp
“Caterpillar 
illar 
may need to use water in order to remove debris. Machine Fluids Recommendations”
Recommendations” or consu
consult
lt your 
Caterpillar dealer.
14. Allow the radiator cores to dry completely before
14. Allow
operating the machine in the work mode.
Extended Life Coolant (ELC)
Reference: See
Reference:  See Operation and Maintenance Extender 
Manual, “Cooler Cores and A/C Condenser 
- Clean” for information on a typical cleaning Use a  8T-5296  Coolant Conditioner Test Kit to
procedure. check the concentration of the coolant.

For additional information about the cooling

system coolant, see Operation and Maintenance
Manual, SEBU6250, “Caterpillar Machine Fluids Personal injury can result from hot coolant, steam
Recommendation
Recomme ndations”,
s”, “Cat Extended
Extended Life Coolan
Coolantt and alkali.
(ELC)” or consul
consultt your Caterpillar dealer
dealer..
At ope
operat
rating
ing temp
tempera
eratur
ture,
e, eng
engine
ine coo
coolant
lant is hot
i02111126
and under pressure
pressure.. The radiator
radiator and all line
lines
s
to heaters or the engine contain hot coolant or 
Cooling System Coolant steam. Any contact can cause severe burns.
Extender (ELC) - Add
Remove   filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
SMCS Code: 1395-538
Code:  1395-538 enough to touch with your bare hand.

NOTICE Cooling Sys

Cooling System
tem Con
Conditi
ditione
onerr con
contain
tains
s alk
alkali.
ali. Avoid
Avoid
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed contact with skin and eyes.
performance
during performanc e of inspection,
inspection, maintenance
maintenance,, test-
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to
collectt the   fluid with suitable containers before open-
collec
compartment or disassembling any compo-
ing any compartment
nent containing   fluids.

to   Special Publication, NENG2500, “Caterpillar 

Refer to 
Tools
ools an
andd Shop
Shop Pro
Produc
ducts
ts Guid
Guide”
e” for to
tools
ols an
and
d supp
supplie
liess
suitabl
suitable
e to collec contain   fluid
collectt and contain uids
s on Caterpil
Caterpillar 
lar 
s.
products.
product

Dispose of all  fl uids according to local regulations and

mandates.
mandates.
 g01018030
Illustration 189

132 SEBU7763-02
Maintenance Section
Cooling System Coolant Level - Check

1.   The  fi ller cap is located

is  located inside the access door on i02762816
the top, left side of the radiator guard. Loosen the
radiator cap slowly in order to relieve pressure. Cooling System Coolant Level
radiator cap.
Remove the radiator - Check
2.  It may be necessary to drain some coolant from SMCS Code: 1353-535-FLV;
Code:  1353-535-FLV; 1395-535-FLV
the radiator 
cooling   so
so that Extender can be added to the
system.

 Always   discard drained   fluids according to

Note: Always
Note:
local regulations. At oper
operatin
ating
g temp
tempera
eratur
ture,
e, the eng
engine
ine coo
coolan
lantt is
hot and under pressure.
NOTICE Steam can cause personal injury.
Care
Ca re mu
musst be take
aken n to e
ensu
nsure that fluid
re that uids
s are contain
contained
ed
during performance of inspec
inspection,
tion, maintenance, test- Check the coolant level only after the engine has
ing, adjusting and repair of the machine. Be prepared
prepared been stopped and the   fill cap is cool enough to
to colle
collect
ct th e   fluid with suitabl
the suitable
e contain
containers
ers befo
before
re touch with your bare hand.
opening any compartment or disassembling any com-
ponent containing   fluids. Remove the  fi ll cap slowly to relieve pressure.
Refer to Special Publication,
Publication, NENG2500, “Caterpillar  Cooling system conditioner contains alkali. Avoid
Tools and Shop Products Guide”, for tools and sup- co
conta
ntact
ct wit
with
h the
the skin
skin and
and eyes
eyes to prev
preven
entt pers
person
onal
al
plies suitable
suitable to collect and
and contain  fl uids in Caterpillar 
contain injury.
machines.

e of all  fl uids according to local regulations and

Dispose
Dispos This machine’s radiator has a surge tank. There
mandates. is no top tank in this cooling system. The surge
tank has a   filler cap and a sight glass. It is not
necessary to remove the  fi ller cap in order to check
3.  Add 2.15 L (72 oz) of Extender to the cooling
the coolant level. The sight glass is inside the engine
system.
compartment that is on the front left side of the
machine.
machin e. The   filler cap is beneath the access door 
4.  Start the engine. Run the engine without the  fi ller 
that is on the top left side of the radiator guard.
the thermostat opens and the coolant
cap until the
level stabilizes. Check for leaks.

g01075680
g01075680
Illustration 191
g00475722
Illustration 190
1.  Observe the sight glass in order to verify the level
5.   Look into  fi ller tube (1). If necessary, add premixed of the coolant. If the coolant completely covers the
coolant in order to correct the coolant level. glass, the coolant level is okay. If the coolant
sight glass,
Maintain the coolant level between area (2) and level is visible in the sight glass, the coolant is low.
area (3) of the  fi ller tube. Adding coolant above  Add coolant in order to  fi ll the system.
this area of the  fi ller tube will cause the coolant to
 over flow the cooling system.

6.   Replace the radiator cap if the cap gasket is

damaged. Install the radiator cap.

SEBU7763-02 133
Maintenance Section
Cooling System Coolant Level - Check

Note: The
Note: factory   fill is Extended Life Coolant
 The factory
(ELC). Refer to Operation and Maintenance
Manual, SEBU6250, “Caterpillar Machine Fluids
ons” for additional information.
Recommendations”
Recommendati
Maintaining the system as ELC is preferred. See
the sections “Coolant Recomm
Recommendatio
endations”
ns” and “ELC

Cooling System
System Maintenance”.

g01117259
Illustration 194

Use compressed air, high pressure water, or steam

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

 Allow the radiator cores to dry completely before

g01075619 operating the machine in the work mode.
Illustration 192

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

Personal injury can result from air pressure.

injury can result without following prop-

Personal injury
er pr
proc
oced
edur
ure.
e. Whe
Whenn using
using pr
pres
essu
sure
re air
air,, wea
wearr a pr
pro-
o-
tective face shield and protect
protective
ive clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
g00475722
tion 193
Illustration
Illustra
NOTICE
3.  Look into  fi ller tube (1). Maintain the coolant level Pressurized
Pressu rized air: To avoid possible engine damage,
damage,
 area (2) and area (3) of the   filler tube.
between area
between shutt off eng
shu engine
ine bef
before
ore per
perform
forming
ing maintena
maintenance
nce to
 Adding coolant above this area of the   filler tube clean
clean th
thee co
cooli
oling
ng syst
system.
em. In
Insta
stall
ll air nozz
nozzle
le int
into
o
will cause the coolant to over flow the cooling access slot before starting air supply. Read and un-
system.  If you need to add coolant daily, check the
system. If derstand Operation and Maintenance Manual.
cooling system for leaks.

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

5.  Install the   filler cap.

 6.  Inspect the radiator core for debris. Clean the
radiator core, if necessary.

134 SEBU7763-02
Maintenance Section
Cooling System Water Temperat
Temperature
ure Regulat
Regulator
or - Replace

i01958847

Cooling System Water 

Regulator -
Temperature Regulator
Replace
SMCS Code: 135 5-510
Code:  1355-510

NOTICE
Failure to replace the engine’s thermostat on a regu-
larly
larly schedu
scheduled
led bas
basis
is cou
could
ld cau
cause
se sev
severe
ere eng
engine
ine dam-
age.

NOTICE
Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of 
problems with the cooling system.

 A new thermostat should be installed af

after
ter the cooling
Illustration 195
g01382652 system has been cleaned. Install the thermostat while
Wood chip or waste handling arrangement (if equipped) the cooling system is completely drained or while
cooling system coolant is drained to a level thatthe
is
Some components are removed for clarity. below the thermostat housing.

Use   307-6728  Air Nozzle (1) (not shown) in order to

clean debris from the cooling system. Use the work NOTICE
tool safely. Caterpillar engines incorporate a shunt design
Since Caterpillar
cooling system, it is mandatory to always operate the
1.  Turn off the engine. engine with a thermostat.

a.  Make sure that the fan has stopped rotation.
2.  Open the cover to the access slot (2) on the right
side of the radiator guard.
Depending on load, failure to operate with a thermo-
stat could result in either an overheating or an over-
condition.
cooling condition.

3.  Insert the air nozzle into the slot. Reference:  Refer to Disassembly and Assembly,
Reference: Refer
Temperature Regulator - Remove” and
“Water Temperature
4.  Turn on the air supply. Disassembly and Assembly, “Water Temperature
Regulator - Install” for more information. Fill the
5.  Move the air nozzle in a suf ficient pattern to clean cooling system. Refer to Operation and
engine cooling
debris from the cooling system which includes the Maintenance
Mainten ance Manual, “Cater
“Caterpillar
pillar Machine
Machine Fluids
radiator cores. Recommendations” and Operation and Maintenance
ies (Refill)”.
“Capacities
Manual, “Capacit
a.  Turn off the air supply when the nozzle cleaning
is complet
completed.
ed.

6.  Remove the air nozzle from the slot. Close the

access cover.

 After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core, if necessary. Stop
the engine. Inspect the core for cleanliness. Repeat
the cleaning, if necessary.
 

SEBU7763-02 135
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace

i01959143 8.   Raise the bulldozer

bulldozer blade and remove the
blocking. Lower the bulldozer blade to the ground.
Cutting Edges and End Bits -
Inspect/Repl ace
Inspect/Replace 9.  After you oper ate
ate the machine for a few hours,
check all bolts for proper torque.
SMCS Code: 6801-040;
Code:  6801-040; 6801-5
6801-510;
10; 6804-040;
6804-040;
6804-510 i02061807

Unit Injector -
Electronic Unit
Inspect/Adjust
SMCS Code: 12 90-025; 1290-040
Code:  1290-025;

The Ele
Electr
ctronic
onic Cont
Control
rol module
module pro
produc
duceses high
voltage. To prevent personal injury make sure the
Electronic
Electr onic Control Module is not powered and the
unit injecto
injectorr soleno
solenoids
ids are disconnected.
disconnected.

g01018242
Illustration 196 NOTICE
The camshafts
camshafts must be correctly timed with the crank-
1.   Raise the bulldozer blade and block up the shaft before an adjustment of the unit injector lash
bulldozer blade. When you remove the cutting The   timing pins must be removed from the
is made. The 
edges and the end bits, maintain the bulldozer  camshafts before the crankshaft is turned or damage
blade at a minimum height. to the cylinder block will be the result.

2.  Remove the bolts. Then remove the cutting edge

and the end bits. The operation of Caterpillar engines with improper 
adjustments of the electronic unit injector can reduce
3.   Thoroughly
Thoroughly clean all contac
contactt surfaces. engine ef ficiency. This reduced ef ficiency could result
in excessive fuel usage and/or shortened engine
4.   Inspec
Inspectt the opposite side of the cutting edge.
edge. If  component life.
the opposite side of the cutting edge is not worn,
turn the opposite side of the cutting edge outward  Adjust the electronic unit injector at the same interval
and install the cutting edge. as the valve lash adjustment.

5.  If both sides of the cutting edge are worn, install a Refer to your machine’s Service Manual or your 
new cutting edge section. Caterpillar dealer for the complete adjustment
procedur e
e..
Note:  When the cutting edge is within 10 mm
Note: When
(0.4 inch) of the bottom of the support, change the
i02229305
i02229305
cutting edge. Do
edge.  Do not allow wear to occur on the
support. Engine Air Filter Primary
6.  If the bottom edge or the outside edge of the end Element - Clean/Replace
-  Clean/Replace
bit is worn, install a new end bit.
SMCS Code: 1051-070;
Code:  1051-070; 1051-510-PY; 1054-070-PY;
Note:  When the end bit is within 10 mm (0.4 inch) of 
Note: When 1054-51 0-PY
1054-510-PY
the bottom of the support, change the end bit. When
the end bit is within 10 mm (0.4 inch) of the outside NOTICE
edge of the support, change the end bit.  Do not Service the primary   filter element only when the alert
allow any wear to occur on the support. indica
indicator intake air filt
tor for the intake er is flashin
lter ashing.
g. Do not
not open
open
lterr compartment unless it is time for service.
the   filte
 7.  Install all bolts and tighten the bolts to a Opening the   filter compartment can cause dirt to get
torque of 1150 ± 150 N·m (850 ± 110 lb ft). into the clean side of the  fi lter housing.
housing.
Refer to Specifications, SENR3130, “Torque
Specifications”, “Torques for Ground Engaging
Tools”.

136 SEBU7763-02
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

NOTICE
Extremely shor t air 
  fi
fi lter life can result if the preclean-
malfunctions. If air  fi lter life is drastically
er system malfunctions. drastically re-
duced from typical for the operating conditions, con-
Caterpillar Dealer.
sult your Caterpillar Dealer. The exhaust system dust
ejector for the strata tube precleaner must pull a min-
imum vacuum of 508 mm (20 inch) of water.

NOTICE
Service the engine air   fi
fi lters with the engine stopped.
Engine damage could result.
result.

g00470857
NOTICE Illustration 198
 Always leave the secondary   filter element in place
while
while you clean the primary
primary eleme
element,
nt, or while
while you 5.  Clean the inside of the air cleaner housing. Keep
c leaner housing.
clean the air cleaner the secondary   filter element in place while you
clean the housing.

NOTICE 6.  If the primary  fi lter element has not been cleaned
Do not use the  fi lter for longer than one year. six times, inspect the primary   filter element. If 
the primary   filter element has been cleaned six
times, replace the primary  fi lter element. Procee
Proceed d
1.  Open the engine compartment’s access door, if  to Step 9.
equipped.
7.  Inspect the primary   filter element. Inspect the
filter element for holes and for tears by looking
through the  fi lter element. Look toward a bright
light. Inspect the element for damaged gaskets or 
for dented metal parts. Replace damaged  fi lters.
 Always crush damaged  fi lter elements. Properly
Properly
discard the   filter elements. If you replace the
primary  fi lter element, proceed to step 9.

8.  If the primary   filter element is not damaged and

the element has not been previously cleaned six
times, clean the element. The  fi lter element can
be cleaned by using pressure air. Use a maximum
air pressure of 205 kPa (30 psi). Direct the air 
g00470852 from the clean side to the dirty side. In order to
Illustration 197
show that the   filter element has been cleaned,
mark the element. The primary  fi lter element can
2.  Remove the air cleaner cover (1). Pull out in order 
be cleaned up to six times.
to remove the element.

3.  Remove the primary  fi lter element (2) from the air  NOTICE
cleaner housing.
4.  Mark the secondary  fi lter element in order to show
that the primary  fi lter element has been serviced.
The secondary   filter element should be replaced
when the primary  fi lter element is serviced for the
third time. Refer to Operation and Maintenance
Manual, “Engine Air Filter Secondary element -
Replace”.
clean the  fi lter elements by bumping or tapping
Do not clean
them. Do not use  filter elements with damaged pleats,
gaskets, or seals. Do not wash the  fi lter elements.
elements.
9.   Push the  fi lter element  fi rmly in order to properly
seat the element. Write the date on the element, if 
the primary
primary element is replaced.
10. Install the air cleaner cover.
 11. Close the access door, if equipped.

SEBU7763-02 137
Maintenance Section
Engine Air Filter Primary Element - Replace

i01505166

Engine Air Filter Primary

Replace
Element - Replace
SMCS Code: 1054-510-PY
Code:  1054-510-PY

NOTICE
Do not use the  fi lter for longer than one year.

Refer to Operation and Maintenance Manual, “Engine

 Air Filter Pri mary Element-Clean/Replac
Primary Element-Clean/Replace”
e” in this
publication.
g00470240
Illustration 199
date  on the element, if the element is
Write the date on
replaced.
5.  Remove the secondary   filter element. Pull out in
order to remove the element.
i01454983
6.  Install a new secondary   filter element. Push
Filter Secondary
Engine Air Filter elementt   firmly in order to properly seat the
the elemen
element. Write the date on the element, if the
Element - Replace element is replace
replaced.d.
SMCS Code: 10 51-510-SE; 1054-510-SE
Code:  1051-510-SE;
7.   Install the primary fi lter element and the air cleane
primary cleaner 
r 
housing cover.
NOTICE
 Always replace the secondary   filter element. Never  8.   Close the engine access door
door,, if equipped.
equipped.
attempt to reuse it by cleaning.

The secon dary filter

secondary lter eleme
element
nt shou
should
ld be rep
replac
laced
ed at th
the
e i01959145
time the primary element is serviced for the third time.
Engine Air  Precleaner
  Precleaner - Clean
The secondary  fi lter element should also be replaced
if the yellow piston in the   filter element indicator en- SMCS Code: 1050-070
Code:  1050-070
ters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.

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

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

1.  Open the engine

eng ine access door, if equipp
equipped.
ed.
g01018245
Illustration 200
2.   Remove the air cleaner
cleaner housing cover.
1.   Inspe
Inspect
ct the screen in engine air precleaner (1) that
3.   Remove the primary   filter element. Refer to sits above engine hood (3) for dirt accumulation.
Operation
Operati on and Maintenanc
Maintenancee Manual,
Manual, “Engine Air 
Primary Element - Clean/R
Filter Primary Clean/Replace”.
eplace”. 2.  Loosen retainer (2) and remove the screen.
 4.  Clean the inside of the air cleaner housing. 3.   Clean the screen with compresse
compressed
d air or water.

4.  Replace the screen.

138 SEBU7763-02
Maintenance Section
Engine Crankcase Breather - Clean

i02760299 14. Close the left access

access door.

Engine Crankcase Breather -

i01959267
Clean
Level - Check
Engine Oil Level
SMCS Code: 1317-070
Code:  1317-070
SMCS Code: 1302-535-FLV;
Code:  1302-535-FLV; 1326-535-FLV
1.  Stop the engine. Open the left access door.

Hot oil and components can cause personal in-

 jury.

Do not
not allow
allow hot
hot oil or compo
compone
nent
nts
s to conta
contact
ct
skin.

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

g01124723 1.  Open the engine access door (if equipped) on the

Illustration 201 left side of the machine.
Top view

2.  Loosen the hose clamps on the outlet hose from

the breather. Remove the hose from the breather 
assembly.

3.  Remove the clamp from the base of the breather 

assembly.

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

remove the assembly.

5.   Check the condition

condition of the cover seal. Replace the
cover seal if the cover seal is damaged.
g01025526
Illustration 202
6.   Clean the breather in a clean non flammable
solvent.

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

may also use pressure air to dry the breather.

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

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

10. Install clamp (3).

11. Install the hose and breather outlet hose clamps

(1).
 12. Open the doors to the radiator grill. Examine the
g00489188
bottom of the breather. Remove any debris that is on 204
Illustration
Illustrati
clogging the breather tube.

13. Close the doors to the radiator grill.

SEBU7763-02 139
Maintenance Section
Engine Oil Sample - Obtain

2.  Check the “LOW IDLE”

IDLE” side of dipstick (1) Obtain the sample
sample of the engine oil as close as
while the engine is running. The oil should be possible
possib le to the recommended sampling interval. The
at operating temperature. Maintain the oil level recommended
recomme nded sampling interval is every 250 service
“ADD” mark and the “FULL” mark.
between the “ADD” order to receive the full effect of S·O·S oil
hours. In order
This is the only accurate
accurate way to check the oil level. analysis, you must establish a consistent trend of 
data. In order to establish a pertinent history of data,
Check the
dipstick “EN
“ENGINE
while GINE
the STOPPED”
engine side
is stopped. of oil
The theshould perform
spaced. consistent
consistent oil samplings that are evenly
be cold. Maintain the oil level between the “LOW”
“FULL” mark. This method should
mark and the “FULL” ob tain an oil sample, operate the
1.   Before you obtain
be used as reference only, before the engine is machine until the oil is warm and the oil is well
started. circulated.

Note:  When you operate the machine on severe

Note: When 2.  Open the engine access door (if equipped) on the
slopes, the oil level in the engine crankcase must left side of the machine.
“FULL” mark on the “LOW IDLE” side of 
be at the “FULL”
dipstick
dipstick (1).

3.  Remove oil  fi ller cap (2) and add oil, if necessary.

4.  Clean the oil  fi ller cap and install the oil  fi ller cap.

5.   Close the engine access door (if equipp

equipped).
ed).

i02489844

Engine Oil Sample - Obtain

SMCS Code: 
Code:   1348-554-SM; 1348; 7542
g01025758
Illustration 205

3.  Remove the protective cap.

Hot oil and   components can cause personal in-
 jury. 4.  Obtain a sample of the engine oil from the engine
oil sampling valve. The sampling valve is located
Do not allo
alloww hot oi
oill or compo
compone
nent
nts
s to cont
contac
actt in the engine compartment on the left side of the
skin. machine. Refer to Special Publication, SEBU6250,

“S·O·S
to Oil Analysis”
obtaining a sample forofinformation
the engine that pertains
oil. Refer to
NOTICE Special Publication, PEHP6001, “How To Take
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed  A Good Oil Sample” for more information about
during performance of inspecinspection,
tion, maintenance, test- obtaining a sample of the engine oil.
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to
collectt the   fluid with suitable containers before open-
collec Note:  In order to obtain an oil sample from the engine
Note: In
ing any compartment or disassembling any compo- compartment, it may be necessary to increase the
nent containing   fluids. engine’s speed. Normally, the oil sample is taken at
low idle. If the   flow rate is too low, increase engine
Refer to Special Publication,
Publication, NENG2500, “Caterpillar  speed to high idle in order to obtain the oil sample.
Dealer Service Tool Catalog” for tools and supplies
suitabl
suitable
e to collec contain   fluid
collectt and contain uids
s on Caterpil
Caterpillar 
lar  5.  Replace the protective cap.
products.
6.   Close the engine access door (if equipped).
Dispose of all  fl uids according to local regulations and

mandates. For additional

Operation andinformation
Operation Mainte about
Maintenance
nance oil sampling,
Manual, SEBU625 see
SEBU6250,0,
 Caterpillar Machine Fluids Recomm
Caterpillar Recommendatio
endations
ns or 
consultt your Caterpi
consul Caterpillar
llar deale
dealer.
r.

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

i02771121 Table 20

Engine Oil and Filter - Change D8T Series

Engine Oil Change Interval(1)
SMCS Code: 1308;
Code:  1308; 1318-510 Operating Conditions
Normal(2) Severe
Selection of the Oil Change Interval Multigrade High
Fuel Altitude
Oil Type Sulfur  above
NOTICE Load from 1830 m
Factor (3)
(3)l
0.3% (6000 ft)
This machine is is equipped with an engine that meets
EPA Tier III, Euro Stage II, or MOC Step 2 emission to
regulations. A 500 hour engine oil change interval is 0.5%
available, pr ovided
ovided that operating conditions and rec- Cat DEO
ommended multigrade oil types are met. When these   500 hr 500 hr 500 hr 250 hr(5  )
Preferred
requirem
requ irements
ents are not met, sho
shorten
rten the oil change
change
250 hours, or use an S·O·S oil sampling
interval to 250 ECF-1
10.0
and analysis program to determine an acceptable oil
minimum 500 hr 500 hr 500 hr 250 hr(5  )
change interval. TBN(3)
(3)

Preferred
If you select an interval for oil and  fi lter change that is
too long, you may damage the engine. ECF-1
  250
TBN(4)
(4) 500 hr 500 hr   (4)
(4)
  250 hr (5)
below 10.0 hr 
CAT oil  fi lters are recomme
recommended.
nded.
  250
 API CG-4   500 hr 250 hr(4)
 )
(4   250 hr (5)
hr (4)
(4)
 Abnormally   harsh operating cycles or harsh
(1) The standard oil change interval for the D8T is every 500
environments can shorten the service life of 
hours. If the operating conditions, fuel rates, and recommended
the engine oil. Arctic temperatures, corrosive oil types for your engine are listed in the table20 are met. The
environments,
environmen ts, or extremely dusty conditions traditional
tradit ional oil change interval for engines
engines is 250 hours. The
may require a reduction in engine oil change standard
standa rd oil chang
change e interval in this machine is 500 hours, if the
intervals from the recommendations in Table 20. operating conditions and recommended oil types that are listed
 Also refer  to
  to Manual, SEBU5898, “Cold Weather  in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
Recommendatio
Recomme ndationsns for all Caterpil
Caterpillar
lar Machines”.
Machines”. Poor  permitted for other machines. Refer to the applicable Operation
maintenance of air   filters or of fuel  fi lters requires
requires and Maintenance Manuals for the other machines.
reduced
reduce oil change intervals. See your Caterpillar 
d oil (2) Normal conditions
conditions includ
includee these factors: Fuel sulfur below
dealer for more information if this product will 0.5%, altitude below 1830 m (6000 ft), and good air  fi lter and
experience
experience abnormally harsh operating
operating cycles or  fuel  fi lter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
environments.
harsh environments. (3) Load factors are de fined as a function of fuel consumption rate.
High load factors can shorten the service life of your enginenginee oil.
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average fuel
consumption of your D8T exceeds 51 L (13.5 US gal) per hour,
follow the “High Load Factor” recommendations in Table 20. To
determine average fuel consumption, measure average fuel
consumption for a period of 50 to 100 hours. If the application
of the machin
machine e is chang
changed,
ed, the averag
averagee fuel consum
consumption
ption may
change.
(4) In order to verify an oil change interval of 500 hours, refer to

“Program A” below.
(5) Use “Program B” below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note:  Your Caterpillar dealer has additional

information on these programs.

 Program A

Verification for an Oil Change Interval of 500 Hours

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

This program consists

consists of three oil change intervals of 
500 hours. Oil sampling and analysis is done at 250 NOTICE
hours and 500 hours for each of the three intervals Care
Care mumust
st be ta ken to ensu
tak ensure re tha
thatt fluids are contai
contained
ned
s ix oil samples. The analysis includes
for a total of six during performance of inspection,
inspection, maintenance
maintenance,, test-
oil viscosity and infrared (IR) analysis of the oil. If  ing,, adjus
ing adjusti
ting
ng and
and repa
repair
ir of the produ
productct.. Be prepa
prepared
red to
all of the results are satisfactory, the 500 hour oil collect the  fl uid with suitable containers before open-
change inter Repeat
application. v
val
al is acceptable
Program Aforif the
youmachine
change in
thethat ing any compartment or disassembling any compo-
nent containing   fluids.
containing
application of the machine.
Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
If a sample does not pass the oil analysis, take one Dealer Service Tool Catalog” for tools and supplies
of these actions: suitabl
sui e to coll
table ollect
ect and con
contai n   fluid
tain uids
s on Cat
Caterpi
erpillar 
llar 
products.
•   Shorten the oil change interval
interval to 250 hours.
all  fl uids according to local regulations and
Dispose of all
•   Proceed to Pr ogram
ogram B. mandates.

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

 Oil Change Intervals

Optimizing Oil
Optimizing

Begin with a 250 hour oil change interval. The oil

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

If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade
multigrad e oil type in the listing above.
g01025579
Illustration 206
References
If the machine is equipped with a high speed oil
Reference: Form,
Reference:  Form, PEDP7035, “Optimizing Oil change, use a   126-7539  Nozzle.
Change Intervals”
Reference: Form,
Reference:  Form, PEDP7036, “S·O·S Fluid Analysis”

Reference:  Form, PEHP707

Reference: PEHP7076,
6, “Understanding
“Understanding the
S·O·S Oil Analysis Tests”

Procedure for Changi

Procedure Changing
ng the Engin
Engine
e
Filter 
Oil and Filter 

Hot oil and components can cause personal in-

 jury.
g00490801
g00490801
Illustration 207
Do no
nott allow
allow hot oi
oill or compo
compone
nent
nts
s to cont
contact
act
skin. 1.  Remove two bolts in order to remove the
 crankcase drain access cover, which is in the
se guard.
crankcase
crankca

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

Instructions f o
Instructions orr the installation of the   filters are
printed on the side of each Caterpillar spin-on
filter
lter.. For non-Cat erpillar   filters, refer to the
non-Caterpillar 
installation  instructions that are provided by the
supplier of the   filter.

9.  Remove oil   fithe

new oil. See ller topic
cap (3). Fill the and
Operation crankcase with
Maintenance
Manual, “Capac
Manual, ities (Re fill)” in this manual. Clean
“Capacities
cap  (3) and install the oil  fi ller cap.
oil  fi ller cap (3)

10. To ensure that the correct amount of oil was

always measure the oil level with the
added, always
dipstick
dipstick (2).
g00670611
Illustration 208

2.   Remove the   4P-0520  Plug Adapter from the

drain valve, if equipped.

3.  Install a 25.4 mm (1.00 inch) pipe into the drain

valve. The pipe requires a 1-11 1/2 NPTF pipe
thread.
Illustration 210 g00489188

4.  Open the drain valve. Allow the oil to drain into a

suitable container. A drain hose may be attached
to the pipe to aid in draining.
5.  When the oil has completed draining from the
crankcase, close the drain valve. Remove the
pipe. Install the   4P-0520  Plug Adapter. Install the
access cover.
11. Check the “ENGINE STOPPED” side of the
dipstick while the engine is stopped. The oil should
be cold. Maintain the oil level between the “LOW”
mark and the “FULL” mark. This method should
be used as reference only, before the engine is
started.

Illustration 211 g00489186

12. Check the “LOW IDLE” side of the dipstick

while the engine is running. The oil should be
at operating temperature. Maintain the oil level
between the “ADD” mark and the “FULL” mark.
This is the only accura
accurate
te way to check the oil level.
g01025590
Illustration 209 13. Install the access cover for the crankcase drain.

e ngine oil   filter element (1) and discard

6.  Remove engine For additional information about oil types, see Special
the engine oil  fi lter element properly. Make sure Publication, SEBU6250, “Caterpillar Machine Fluids
that all of the old   filter seal is removed from the Recommendations” or consult your Caterpillar dealer.
base.
filter base.

7.  Apply a thin coat of oil to the seal on the new  fi lter.

 8.   Install th
the oil  fi lter element by hand.
e new engine oil

SEBU7763-02 143
Maintenance Section
Engine Valve
Valve Lash - Check/A
Check/Adjust
djust

i02763245

Engine Valve Lash -

Electrical
Electrical shock hazar
hazard.
d. The electro
electronic
nic unit injec-
Check/Adjust tor system uses 90-120 volts.

SMCS Code: 1102-025;
Code:  1102-025; 1102

To prevent possible injury, do not use the starter 

motor to turn the   flywheel.

Hot engine components can cause burns. Allow

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

g00941949
Electrical shock hazard
Electrical hazard.. The electronic unit injec- Illustration 212
tor system uses 90-120 volts.

1.  Start the engine. Run the engine at low idle.

NOTICE
Operation of Caterpillar engines with improper valve
adjustme
adjustments
nts will red
reduce engine ef ficie
uce engine ciency
ncy.. This re-
duced ef ficiency could result in excessive fuel usage
and/or shortened engine component life.

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

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

 If a  damaged valve rotator is not replaced,

Note: If
Note:
some valve face guttering could result. Metal particles

Whe
When n ins
glasses
glassesinspe
pectin
or cting
eg shie
face
fac theldvalv
shieldvalve
e rotator
and rotators,
protect
pro s,
iveprotec
tectiveprotective
tive
clothin
clothingg from
causethe
davalve
magecould
damage to thefall into head
piston the cylinder. Thiscylinder 
and to the could
 must be worn, to prevent being burned by hot oil head.
or spray.

144 SEBU7763-02
Maintenance Section
Equalizer Bar End Pins Oil Level - Check

i01251387 4.  Check the oil level.

level. Oil level (4) should be at the
top of the hex head on the  fi tting.
Equalizer Bar End Pins Oil
Level - Check leve l is low, apply the gear oil through
5.  If the oil level
fitting (3) until the gear oil reaches oil level (4) at
SMCS Code: 7206-535
Code:  7206-535 the top of the hex head on the   fitting. Remove
any
The excess
gear oiloil.
oimust
l. This
bewill maintain
applied withaavolume of air.
  7H-1680
NOTICE
Lubrication Pump or a suitable grease gun. Use
 Apply gear oil  through the   fittings with a hand oper-
GL-5, 80W-90 API GL-5, 85W-140
75W-90 API GL-5,
ated lubrication pump or a suitable grease gun. Use
 API GL-5, or 90 API GL-5 gear oil. The gear oil
of pressure
pressure operated
operated lubrica
lubricating
ting equipme
equipment
nt damages
damages
has excellent load carrying capacity.
the seals.
6.  Be sure that seals (1) are not pushed out. Push
NOTICE back the seals if the seals are pushed out.
Before and after the equalizer bar end pin is  fi lled with
ge
gear
ar oi
oil,
l, se
seal
al (1) must be flus
(1) must ush
h with
with th
the
e eq
equa
ualiz
lizer
er bar
bar. If  7.  Install plug (2).
the seals are not  fl ush, damage to the seals can result
by over filling. GREASE IS ALLOWED ONLY
Note: MPGM GREASE
FOR A FAILED SEAL. THE SEAL SHOULD
BE REPLACED AS SOON AS POSSIBLE. THE
ON OF GEAR OIL AND MPGM IS NOT
COMBINATION
COMBINATI
HARMFUL TO THE MACHINE.
op erate the machine in arctic conditions,
When you operate
lubricate the equalizer bar with EMGARD EP 75W90
gear lubricant. EMGARD EP 75W90 gear lubricant is
synthetic lubricant. This lubricant is available from
a syntheti
Hudson Corporation.

g00586840
Illustration 214

g00586858
Illustration 215

1.  Clean the areas that are around the end pin with a
high pressure wash. Inspect the condition of the
seal (1).
 2.  Check the area for oil leakage. Be sure that the
seal is in a neutral position.

3.  Remove plug (2).

SEBU7763-02 145
Maintenance Section
Ether Starting Aid Cylinder - Replace

i01959542

Ether Starting Aid Cylinder -

Replace
SMCS Code: 1456-510-CD
Code:  1456-510-CD

Breathi
Bre athing
ng eth
ether
er vap
vapors
ors or repeat
repeated
ed contact
contact of 
skin can cause personal injury. Person-
ether with skin
al injury may occur from failure to adhere to the
following procedures.
g01018418
Use ether only in well ventilated areas. Illustration 217

while changing ether cylinders.

Do not smoke while
Use ether with care to avoid   fires.
Do not store replacement ether cylinders in living
2.  Loosen the retaining clamp. Remove the old
canister by turning the canister counterclockwise.
3.  Remove the old gasket. Install the new gasket.

areas or in the operator’s compartment. 4.   Install the new

clockwise. Handcanister. Turn
tighten the the canister 
canister. Tighten the
Do not store ether cylinders in direct sunlight or  clamp around the caniste
canister.
r.
at temperatures above 49 °C (120 °F).
5.   Close the engine access door (if equipped).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.
i01959689

Keep ether cylinders out of the reach of unautho-

rized personnel.
Final Drive Oil - Change
Code:  4050-535-FLV
SMCS Code: 4 050-535-FLV
To av
avoid
oid po
poss
ssibl
ible
e in
injur
jury
y, be sure
sure th
the
e br
brake
akes
s ar
are
e ap
ap--
plied and all controls are in Hold or Neutral when
the engine.
starting the

Hot oil and   components can cause personal in-

 jury.

Do not allow ho
not allo hott oil or compo
compone
nents
nts to conta
contact
ct
skin.

NOTICE
Ca
Care
re mus
mustt be tak
takenen to ensu
ensure re that fluids are contai
that contained
ned
during performance of inspection,
inspection, maintenance
maintenance,, test-
ing,, adjus
ing adjusti
ting
ng and
and repa
repair
ir of the produ
product
ct.. Be prepa
prepared
red to
collect the  fl uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent contain ing   fluids.
containing
g01018416
tion 216
Illustration
Illustra Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
Tools
ools and
and Shop
Shop Pro
Produc
ducts
ts Gui
Guide
de”” fo
forr too
tools
ls and
and supp
supplie
liess
1.  Open the engine access door (if equipped) on suitab
suitable
le to coll
collect
ect and cont ain   fluid
contain uids s on Cat
Caterpi
erpillar 
llar 
the left side
s ide of the machine. The ether canister  products.
is mounted inside the compartment on the side
 of the engine. Dispose of all  fl uids according to local regulations and
mandates.

146 SEBU7763-02
Maintenance Section
Final Drive Oil Level - Check

i01959718

Final Drive Oil Level - Check

SMCS Code: 4050-535-FLV
Code:  4050-535-FLV

Hot oil and components can cause personal in-

 jury.

Do not
not allow
allow hot
hot oil or compo
compone
nent
nts
s to conta
contact
ct
skin.

g01018450
Illustration 218

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

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

2.  Remove oil  fi ller plug (2).

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

suitable container.

4.   Inspect
Inspect the drain plug seal. Replace the drain plug
seal if the drain plug seal is damaged.

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

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

8.  Repeat Step 1 to Step 7 in order to change the oil 4.  Wipe the magnet in order to clean the plug.
in the other   final drive.
5.  Install oil   filler plug (2).
For additio
additional
nal information about  final drive oil, see
information
Special Publication, SEBU6250, “Caterpillar Machine 6.  Repeat Step 1 to Step 5 in order to check the oil
Fluids Recommendations”
Recommendations” or consult
consult your Caterpi
Caterpillar 
llar  level in the other   final drive.
dealer.
 

SEBU7763-02 147
Maintenance Section
Final Drive Oil Sample - Obtain

i02229659

Final Drive Oil Sample - Obtain

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

Hot oil and components can cause personal in-

 jury.

Do no
nott allow
allow hot oi
oill or compo
compone
nent
nts
s to cont
contact
act
skin.
g01117789
Illustration 220
NOTICE
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed 2.  Remove the cover plate.
during performance of inspecinspection,
tion, maintenance, test-
ing, adjust
adjustiningg an
and
d repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pr
prep
epar
ared
ed to 3.  Obtain an oil sample. The use of a sampling gun
collectt the   fluid with suitable containers before open-
collec that is inserted into the sump is the preferred
ing any compartment or disassembling any compo- method for obtaining a sample.

nent containing   fluids.

contain Note:  Do not use the drain stream method to obtain
Note: Do
Refer to Special Publication,
Publication, NENG2500, “Caterpillar  a sample of the  fi nal drive oil. A stream of dirty oil
Tools Shop Pro
ools and Shop Produduct
cts
s Guid
Guide”
e” for to
tool
ols
s an
and
d supp
supplie
liess from the bottom of the compartment will contaminate
suitabl
suitable
e to collec
collectt and contain
contain   fluid
uids
s on Caterpil
Caterpillar 
lar  the sample. Likewise, never dip an oil sample from
products. an oil container or pour a sample from a used  fi lter.

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

1.   Run the machine until operat

operating
ing temperature has
been reached. The sample must be at operating
ure in order to take an accurate sample.
temperature
temperat
 

148 SEBU7763-02
Maintenance Section
Final Drive Seal Guard Packing - Replace

i02774981

Final Drive Seal Guard Packing

- Replace
(If Equipped)
SMCS Code: 405 2-510
Code:  4052-510

The design of the seal guard has a packing that

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

2.   Inspect the packing and the seal guard for 

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

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

g00939700
Illustration 221  Each   final drive seal guard requires two
Note: Each
Note:
(4) Bolt 137-9810  Seals (packing). The sections of packing
(5) Washer  are installed on top of each other in the groove of 
(6) Retainer 
Retainer 
the seal guard.
1.  Remove bolts (4) and washers (5). Remove
retainers
retainers (6).
 

SEBU7763-02 149
Maintenance Section
Final Drive Seal Guard Packing - Replace

g00941695 g00940433
Illustration 223 Illustration 224
(7) Inner packing
packing (9) Outer packing
packing
in the inner packing
(8) Joint in Joint  in the outer packing
(10) Joint in
Diameter (A)
(A) Diameter Diameter (A)
(A) Diameter
(B) 180 degrees
degrees
3.   Install inner packing (7). Place a thin   film of 
 G rease on diameter (A). Stretch the
129-1928  Grease 4.  Install the outer packing (9).  Offset the joint in
packing
packin g during installati
installation.
on. Smooth the packing packing (8) and the outer packing
the inner packing
and keep the packing uniform. Minimize the joint degrees.  Stretch the packing during
(10) at 180 degrees. Stretch
the  ends of the inner packing (7).
(8) at the ends installation. Smooth the packing and keep the
uniform. Minimize the joint (10) at the
packing uniform.
ends of the outer packing (9).
 

150 SEBU7763-02
Maintenance Section
Fuel System - Prime

1.   Turn the ignition

ignition switch to the “OFF” position.

g01124784
Illustration 226

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

3.  Hold the switch for the electric fuel priming pump

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

6.   Hold the switch for the electric fuel priming

5.   Assemble
Assemble retainers (6) to seal gua
guard
rd (3) with
washers (4) and bolts (5). The clearance at area pump (2) in order to be in the ON position for 20
seconds. This will allow the air to be completely
(D) should be 2 mm (0.079 inch).
removed from the system.
6.  Repeat steps 3 through 5 in order to replace the
packing on the other  fi nal drive, if necessary. NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
i02229667
minutes before cranking the engine again.
Fuel System - Prime
7.  Start the engine. If you cannot start the engine,
SMCS Code: 1258
Code:  1258 the engine needs more priming. If the engine
continues to mis fire or to smoke, more priming is
If the engine does not start, air may be trapped in the necessary. Repeat step 6 if the engine will not
fuel lines to the engine. Use the following procedure start.
in order to purge air from the fuel lines.
Note: The
Note:  The electric fuel priming pump will only operate
Electric Fuel Priming Pump if the engine start switch key is in the OFF position.
Shut off the engine before any additional priming.

NOTICE
Use a suitable container to catch any fuel that might 8.  Run the engine at the LOW IDLE position until the
engine runs smoothly.
 engine runs smoothly.
spill. Clean up any spilled fuel immediately.
Note:  Do not activate the priming pump while you
Note: Do
The electric fuel priming pump is located in the crank the engine.
engine compartment on the left side of the machine.

SEBU7763-02 151
Maintenance Section
Fuel System Primary Filter - Clean/Replace

Refer to Operation
Operation and Maintenance Manual, “Fuel
System Secondary Filter - Replace” for information
on replacing the   filter.

i01969411

Fuel System Primary Filter -

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

Personal injury or death can result from a  fi re. Illustration 227

g01113804

Fuel leaked or spilled onto hot surfaces

surfaces or electri- 2.  Open the engine access door on the left side of 
cal components can cause a  fi re. the machine
machine..

Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.

Turn the disconnect switch OFF or disconnect the

battery when changing fuel   filters.

NOTICE
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed
during performance of inspecinspection,
tion, maintenance, test-
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to
collectt the   fluid with suitable containers before open-
collec
ing any compartment or disassembling any compo-
nent containing   fluids.
g01022363
ion 228
Illustration
Illustrat
Refer to Special Publication,
Publication, NENG2500, “Caterpillar 
Tools
ools an
andd Shop
Shop Pro
Produc
ducts
ts Guid
Guide”
e” for to
tools
ols an
and
d supp
supplie
liess 3.  Drain water separator bowl (3) into a suitable
suitabl
suitable
e to collec contain   fluid
collectt and contain uids
s on Caterpil
Caterpillar 
lar  container  and
  and remove the bowl from the bottom
products. of the   filter element. Clean the water separator 
bowl and inspect the seal. If the seal is worn or 
Dispose of all  fl uids according to local regulations and  install a new seal.
damaged, install
damaged,
mandates.
4.   Remove   filter element (2). Properly discard the
element.
filter element.
NOTICE
fuel   filter with fuel before installing the fuel
Do not   fill fuel
5.   Clean the   filter base. Be sure that all of the old
filter. Contaminated fuel causes accelerated wear to
removed.
seal is removed.
fuel system parts.
6.  Coat the seal of the new  fi lter element with clean
1.   Turn the red lever (1) in order to shut off fuel diesel f uel.
uel.
supply.
7.  Install the new  fi lter element hand tight until the
the   filter contacts the base. Note the
seal of the
position of the index marks on the  fi lter in relation
to a  fi xed point on the  fi lter base.
 Note:  There are rotation index marks on the   filter 
Note: There
that are spaced 90 degrees or 1/4 of a turn away
each other. When you tighten the  fi lter, use the
from each
rotation index marks as a guide.

152 SEBU7763-02
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain

the  fi lter according to the instructions

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

8.  Coat the seal of the water separator bowl with

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

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

supply.

fuel system. See the Topic “Fuel

10. Prime the fuel
System - Prime” in this manual.

engine and run the engine. Check  fi lter 

11. Start the engine g01022350
on 229
Illustration
Illustrati
(2) and water separator bowl (3) for leaks.
engine access door.
12. Close the engine

i01969397

Fuel System Primary Filter 

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

Fuel leaked or spilled onto hot surfaces or elec-

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

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

NOTICE p resent, drain the water from the bowl.
If water is present,
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed
during performance of inspecinspection,
tion, maintenance, test- 1.   Open drain (3). The drain is a self-venti
self-ventilated
lated drain.
ing, adj
adjuust
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to d raining
Catch the drainin g water in a suitab
suitable
le container.
container.
collectt the   fluid with suitable containers before open-
collec Dispose
Dispose of the water proper
properly
ly..
ing any compartment or disassembling any compo-
containing   fluids.
nent containing 2.   Close drain (3).
drain

Refer to Special Publication,

Publication, NENG2500, “Caterpillar  NOTICE
and Shop
Tools and Shop Pro
Produduct
cts
s Guid
Guide”
e” for to
tool
ols
s an
and
d supp
supplie
liess The water separator is under suction during normal
suitabl
suitable
e to collec contain   fluid
collectt and contain uids
s on Caterpil
Caterpillar 
lar  ration. Ensure that the drain valve is tight-
products. engine
en
ened ope
ed secu
securel
rely
y to help
help pre
preve
vent
nt ai
airr from
from ent
enter
ering
ing th
the
e fu
fuel
el
 system.
Dispose of all  fl uids according to local regulations and
mandates.

SEBU7763-02 153
Maintenance Section
Fuel System Secondary Filter - Replace

i01969432

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE
Code:  1261-510-SE

Personal injury or death can result from a  fi re.

Fuel leaked or spilled onto hot surfaces

surfaces or electri-
cal components can cause a  fi re.
g01113804
Clean up all leaked or spilled fuel. Do not smoke Illustration 231
while working on the fuel system.
1.   Turn
Turn the red lev
lever
er (1) in order to shut off fuel
Turn the disconnect switch OFF or disconnect the supply.
battery when changing fuel   filters.
2.  Open the engine access door on the left side of 
the machine
machine..
NOTICE
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed
during performance of inspecinspection,
tion, maintenance, test-
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to
collectt the   fluid with suitable containers before open-
collec
ing any compartment or disassembling any compo-
nent containing   fluids.

Refer to Special Publication,

Publication, NENG2500, “Caterpillar 
Tools
ools an
andd Shop
Shop Pro
Produc
ducts
ts Guid
Guide”
e” for to
tools
ols an
and
d supp
supplie
liess
suitabl
suitable
e to collec contain   fluid
collectt and contain uids
s on Caterpil
Caterpillar 
lar 
products.

Dispose of all  fl uids according to local regulations and

mandates.
g01022384
ion 232
Illustration
Illustrat

NOTICE 3.  Remove the secondary fuel  fi lter (2). Discard the

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

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

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

Rotation  index marks are positioned on the  fi lter 

Rotation index
at 90 degree intervals. Use these rotation index
marks as a guide when you tighten the  fi lter.
 7.  Turn lever (1) in order to resume fuel supply.

8.  Prime the
the fuel system. See the Topic “Fuel System
- Prime” in this manual.

9.   Close th
thee engine access door.

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

i01969542 5.  Inspect the tank

tank cap seal. If the seal is damaged,
replace the seal.
Fuel Tank Cap Filter and
Replace/Clean
Strainer - Replace/Clean 6.   Replace the  fi lter assembly, the valve, the gaskets,
and the screws. Use a   9X-2205  Cap Filter Kit.
SMCS Code: 1273-070-STR;
Code:  1273-070-STR; 1273-070-Z2
7.   Install the strainer.
strainer.
8.  Install the fuel cap. Rotate the fuel cap clockwise
tabs (7) drop into the slots in the
until three tabs
adapter. Rotate lever (5) clockwise until the lever 
stops. Lower lever (5) over locking tab (6).

Fast Fill Fuel Adapter (If Equipped)

See illustration 233.

Machines that that are equipped with a fast  fi ll fuel adapter 

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

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

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

NOTICE
Ca
Care
re mus
mustt be tak
taken
en to ensu
ensurere that fluids are contai
that contained
ned
during performance of inspection,
inspection, maintenance
maintenance,, test-
ing,, adju
ing adjustingand rep
stingand repair
air of theproduc
theproduct. t. Be pre
prepa
pared
red to
collect the  fl uid with suitable containers before open-
ing any compartment or disassembling any compo-
containing   fluids.
nent containing

Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
Dealer Ser vice
vice Tool Catalog” for tools and supplies
suitab
suitable
le to coll
collect
ect and cont ain   fluid
contain uids
s on Cat
Caterpi
erpillar 
llar 
products.

g01110732
g01110732 Dispose of all  fl uids according to local regulations and
Illustration 234
mandates.
1.  Lift lever (5) in order to remove the fuel tank   filler 
cap. Turn the lever counterclockwise until the
stops. Lift the cap straight up in order to
lever stops.
remove the cap.

th e fuel strainer from the  fi ller neck.

2.  Remove the

3.  In order to replace the  fi lter assembly, remove two

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

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

nonflammable solvent.
g01113920
Illustration 235

SEBU7763-02 155
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset

The drain valve is

valve  is under the fuel tank at the rear of 
the machine.
machine.

drain  valve with the yellow handle. Allow

1.  Open the drain valve
the water and the sediment to drain into a suitable
container.

2.  Close the drain valve.

i02606338

Fuses and Circuit Breakers -

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

ECM engine monitoring

monitoring (3) (Power train EC
ECM)
M) –
NOTICE 15 Amp
 Always replace fuses with the same type and capacity
capacit y
fuse that was removed. Otherwise, electrical damage Rear ROPS   flood
oodligh
lights
ts (4) –  15 Amp
could result.
Auxilia
Auxiliary
ry (5) –  10 Amp
NOTICE
Spare
Spare 1 (6) –  20 Amp
If it is necessary to replace fuses frequently, an elec-
trical problem may exist.
GPS/Radio
GPS/Radio Transmissio
Transmission
n Antenna (7) –  15 Amp
Contactt your Caterpi
Contac Caterpillar
llar dealer
dealer..
Seat, Ripper,
Ripper, or Implements (8) –  15 Amp

Standard
Standard Conver
Converter
ter (9) –  10 Amp
Spare
Spare 2 (10
(10)) –  15 Amp

“AccuGrade”
“AccuGrade” (1
(11)
1) –  15 Amp

Wipers
Wipers (12
(12)) –  15 Amp

Ignition
Ignition Ke
Key
y (13) –  10 Amp

Fender Floodligh
Floodlights
ts (14) –  15 Amp

Horn (15) – 15

–  15 Amp
g01118158
Illustration 236 CAES Display (16) –  10 Amp
Display

Open the cover

the fuses.co verisfor
This access
inside thetooperator
the circuit breakers
station belowand Secondary
Secondary Brake ((17)
17) –  10 Amp
 the left armrest above the   floorplate. Unswitched
Unswitched Auxilia
Auxiliary
ry (18) –  15 Amp

Produc
Productt Link (19
(19)) –  10 Amp

Advisor Panel (20

(20)) –  15 Amp

156 SEBU7763-02
Maintenance Section
Horn - Test

(21) – 15
Implement ECM (21) –  15 Amp
NOTICE
Impleme
Implement
nt ECM (22) –  15 Amp Care
Care mumust
st be ta ken to ensu
tak ensure re tha
thatt fluids are contai
contained
ned
during performance of inspection,
inspection, maintenance
maintenance,, test-
Engine
Engine ECM (23)
(23) –  20 Amp ing,, adjus
ing adjusti
ting
ng and
and repa
repairir of the produ
productct.. Be prepa
prepared
red to
collect the  fl uid with suitable containers before open-
24 VA   −

 12 VA Converter
Converter (24) (Attachment)
(Attachment) –  20 ing any compartment or disassembling any compo-
 Amp nent contain ing   fluids.
containing

Cover
Cover (25)
(25) –  Fu se panel
 Fuse Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
Tools
ools and
and Shop
Shop Pro
Produc
ducts
ts Gui
Guide
de”” fo
forr too
tools
ls and
and supp
supplie
liess
Fuse
Fuse (26
(26)) –  175 Amp suitabl
sui e to coll
table ollect
ect and con
contain   fluid
tain uids s on Cat
Caterpi
erpillar 
llar 
products.
Fuse
Fuse cove
coverr (27) –  Plastic
all  fl uids according to local regulations and
Dispose of all
Power outlet (28)
(28) –
– 12
 12 Volt mandates.

Starting/Charging
Starting/Charging Analyzer (29) (Plug) –  70-pin
Connector  Operate the machine in order to warm the oil.

HVAC
HVAC blower (30) (Reset butto
button)
n) –  15 Amp Park the machine on level ground. Lower the
bulldozer blade and the ripper to the ground and

Fuse
Fuse Pulle
Pullerr (31) –  Auto Stop apply
brake slight
sligh
and tstop
downwa
downwardrd pressure. Engage the parking
the engine.

i02054663 1.  Make sure th at all work tools are lowered to the

that
ground.
Horn - Test
SMCS Code: 7402-081
Code:  7402-081

Test the horn on a daily basis. Press downward on

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

i02229763

Hydraulic System Oil - Change

SMCS Code: 5 050-044
Code:  5050-044
g01022926
Illustration 238
Cross section view

At operating tempe
operating tempera
ratu
ture
re,, th
the
e hydr
hydraul
aulic
ic ta
tank
nk is ho
hott
2.   Remove hydraulic tank  fi ller cap (1) slowly in order 
and under pressure.
pressure.
to relieve any pressure.
components can cause personal in-
Hot oil and components
3.   Wash the  fi ller strainer and the  fi ller cap in a clean
 jury. Do not allow hot oil or components to contact
 jury.
nonflammable solvent.
skin.
4.  Remove oil drain plug cover (3) that is under the
Remove the   fille
Remove llerr cap
cap on
only
ly when
when the engine
engine is
hydraulic tank.
pped,, and the   fill
stopped
sto ller
er ca
capp is co
cool
ol en
enou
ough
gh to
with  your bare hand. Remove the   filler cap
touch with your
slowly to relieve
relieve pressu
pressure.
re.
 

SEBU7763-02 157
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace

g01022927 g01022619
Illustration 239 Illustration 240
(4) Oil drain plug. The arrow indicates the “FULL” mark.
(5) Sight gauge Enlarged view of the sight gauge

5.  Remove the oil drain plug. The oil drain plug is 16. Maintain the oil level to the “FULL” mark in the
located under right fender (4). sight gauge. Check with the attachments on the
ground and with cold oil. Add oil, if necessary.
6.  Attach a hose to a   126-7914  Swivel. Install the
swivel and the hose into the drain plug opening. A 17. Stop the engine.
pipe nipple 10 cm (4 inch) and a hose can also be
used. Use a 25.4 mm (1 inch) pipe with 1-11 1/2 For additio
additional
nal informa
information
tion about hydraul
hydraulic
ic system
NPTF threads. Do not tighten the pipe. oil, see Special Public
Publication,
ation, SEBU6250, “Caterpillar 
Machine Fluids Recommendations”
Recommendations” or consu
consultlt your 
7.  Rotate the swivel clockwise in order to open the Caterpillar dealer.
internal drain valve. Allow the oil to drain into a
suitable container.
i02214240

8.  Remove the swivel. The valve for the hydraulic

tank will close.
Hydraulic System Oil Filter 
(Pilot) - Replace
9.  Clean the drain plug and install the drain plug.
Tighten the drain plug to a torque of 68 ± 7 N·m SMCS Code: 5068-510-PS;
Code:  5068-510-PS; 5068-510; 5092-510
(50 ± 5 lb ft). Install the oil drain plug cover.

10. Change the hydraulic system   filters. Case

drain  fi lter (2) is shown. See the Operation and
At oper
operati
ating
ng tem
tempe
pera
ratu
ture
re,, the hydr
hydrau
aulic
lic tan
tank
k is hot
hot
Maintenance Manual, “Hydraulic System Oil
and under   pressure.
pressure.
Filters - Replace”.
Hot oil and components can cause personal in-
11. Install the  fi ller strainer.
 jury. Do not allow
allow ho
hott oil
oil or comp
compon
onen
ents
ts to conta
contact
ct
skin.
12. Fill the hydraulic oil tank. See the Operation and
Maintenance Manual, “Capacities (Refill)” in order 
Remove th
Remove e   filler
the ller cap only when the
the engin
engine
e is
to determine the amount of hydraulic oil that is
stopped,, and the   fill
stopped ller
er cap
cap is cool
cool enou
enough
gh to
needed to   fill the hydraulic oil tank.
touch with your bare hand. Remove the   filler cap
in order to relieve pressure.
slowly in
13. Inspect the  fi ller cap gasket. Replace the gasket if 
damage or wear is evident.

14. Install the   filler cap. Pilot Hydraulic

Hydraulic Oil Filter 
 1.  Lower the bulldozer and the ripper to the ground.
15. Start the engine. Run the engine for a few
Turn off  the
  the engine.
minutes.

158 SEBU7763-02
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace

coa t of oil to seal on the new   filter.

5.  Apply a thin coat
Install a new pilot hydraulic oil  fi lter hand tight until
the seal of the pilot hydraulic oil  fi lter contacts the
the  position of the index marks on the
base. Note the position
filter in relation to a  fi xed point on the  fi lter base.

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

6.   Tighten the   filter according to the instructions

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

7.   Install the access cover.

8.  Start the engine.

g01117647
Illustration
Illustra tion 242

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

g01022619
Illustration 244

9.   Maintai
Maintain
n the hydraulic oil to the “FULL” mark in the
sight gauge that is on the outside of the hydraulic
tank.

10. Install hydraulic tank  fi ller cap (2).

11. Install access cover (3).

12. Stop the engine.

For additio
additional
nal information about hydraul
hydraulic
ic syste
systems,
ms,
g01117748 refer to Specia
Speciall Publication,
Publication, SEBU6250, “Caterpillar 
Illustration 243
 Machine
Machin e Fluids Recommend
Recommendations
ations or consu
consult
lt your 
Rear view
Caterpillar dealer.
4.   Remove spin-on type type   filter (4) that is the pilot
hydraulic oil   filter. The pilot hydraulic oil   filter 
is attached below the accumulator manifold.
Properly
Properl y discard the   filter element.
element.

SEBU7763-02 159
Maintenance Section
Hydraulic System Oil Filters - Replace

i02769408 dra in  fi lter (3) and properly discard

4.  Remove case drain
the case drain   filter.
Hydraulic System Oil Filters -
Replace strainer, the  fi lter housing, and the oil
5.  Clean the strainer,
filler cap in a clean, nonflammable solvent.
SMCS Code: 5068-510
Code:  5068-510
c ase drain   filter.
6.  Install a new case
7.   Install the strainer
strainer,, the cover
cover,, and the four bolts.
Hot oil and components can cause personal in-
 jury.

Do no
nott allow
allow hot oi
oill or compo
compone
nent
nts
s to cont
contact
act
skin.

NOTICE
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed
during performance of inspecinspection,
tion, maintenance, test-
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to
collectt the   fluid with suitable containers before open-
collec
ing any compartment or disassembling any compo-
nent containing   fluids.
g01103238
on 246
Illustration
Illustrati
Refer to Special Publication,
Publication, NENG2500, “Caterpillar 
Steering charge   filter 
Dealer Service Tool Catalog” for tools and supplies
suitabl
suitable
e to collec contain   fluid
collectt and contain uids
s on Caterpil
Caterpillar 
lar 
products. 8.  Change the steering charge  fi lter.

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

hydraulic system with new oil. See

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

Reference:  See Operation and Maintenance

Reference: See 10. Start the engine.
Manual, “Stopping the Machine” for additional
information.

g01022619
Illustration 247
g01076258
g01076258
Illustration 245 11. Maintain the oil level to the “FULL” mark in the
 sight gauge for the hydraulic oil tank. Check with
2.   On the right side of the machine,
machine, remove hydraulic the attachments on the ground and cold oil. Add
oil   filler cap (1) in order to relieve the tank oil, if necessary.
pressure.. Remove the   filler strainer.
pressure
12. Stop the engine.
3.   Remove four bolts (2) in order to remove the cover 
case drain  fi lter.
from the case 13. Close the acces
access
s door
door..

160 SEBU7763-02
Maintenance Section
Hydraulic System Oil Level - Check

For additio
additional
nal information
 information about hydraulic
hydraulic system i01960922
oil, see Specia
Speciall Publication,
Publication, SEBU6250, “Caterpillar 
Machine
Machin e Fluids Recommenda
Recommendations”
tions” or consult
consult your  Hydraulic System Oil Sample
llar dealer.
Caterpillar
Caterpi - Obtain
SMCS Code: 5095-008
Code:  5095-008
i01969751

Hydraulic System Oil Level -

Check
Hot oil and components can cause personal in-
SMCS Code: 5056-535-FLV;
Code:  5056-535-FLV; 7479  jury.

Do not
not allow
allow hot
hot oil or compo
compone
nent
nts
s to conta
contact
ct
skin.

At opera
operatin
ting
g tem
tempe
pera
ratur
ture,
e, th
the
e hydr
hydraul
aulic
ic ta
tank
nk is ho
hott
and under pressure.
pressure. NOTICE
Ca
Care
re mus
mustt be tak
takenen to ensu
ensure re that fluids are contai
that contained
ned
Hot oil and components can cause personal in- during performance of inspection,
inspection, maintenance
maintenance,, test-
 jury. Do not allow hot oil or components to contact
 jury. ing,, adjus
ing adjusti
ting
ng and
and repa
repair
ir of the produ
product
ct.. Be prepa
prepared
red to
skin. collect the  fl uid with suitable containers before open-
ing any compartment or disassembling any compo-
Remove the   fille
Remove llerr cap
cap on
only
ly when
when the engine
engine is nent contain ing   fluids.
containing
pped,, and the   fill
stopped
sto ller
er ca
cap
p is co
cool
ol en
enou
ough
gh to
touch with your bare hand. Remove the   filler cap Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
slowly in order to relieve pressure. Tools
ools and
and Shop
Shop Pro
Produc
ducts
ts Gui
Guide
de”” fo
forr too
tools
ls and
and supp
supplie
liess
suitab
suitable
le to coll
collect
ect and cont ain   fluid
contain uids s on Cat
Caterpi
erpillar 
llar 
products.
Lower the bulldozer and the ripper to the ground.
Place the ripper shanks in the vertical position.
Dispose of all  fl uids according to local regulations and
mandates.
The hydraulic tank is on the right rear side of the
machine.

g01018666
Illustration 249
g01022619
Illustration 248
Obtain a sample of the hydrau
hydraulic
lic oil from the sampling
Maintain the oil level to the “FULL” mark in the
1.   Maintain valve. The sampling valve is located behind the
sight gauge. Check the oil level when the oil is access door on the right side of the cab. Remove
cold. Verify that the oil level is below the “FULL” the protective cap from the oil sampling port that is
ore you remove the   filler cap.
mark bef ore above the steering charge   filter. Refer to Special
Publication, SEBU6250, “S·O·S Oil Analysis” for 
 2.   If the hydraulic system requires additional information that pertains to obtaining a sample of the
ic oil, remove the  fi ller cap slowly in order 
hydraulic
hydraul oil. Refer to Special Publication, PEHP6001, “How To
to relieve the pressure. Add oil through the  fi ller  Take A Good Oil Sample” for more information about
tube. obtaining a sample of the oil.

3.  Clean the   filler cap and install the  fi ller cap.

SEBU7763-02 161
Maintenance Section
Indicators and Gauges - Test

For additio
additional
nal information
 information about hydraulic
hydraulic system •   “X10” readout
oil, see Specia
Speciall Publication,
Publication, SEBU6250, “Caterpillar 
Machine
Machin e Fluids Recommenda
Recommendations”
tions” or consult
consult your  •  Symbol for the hour meter 
llar dealer.
Caterpillar
Caterpi
•   “8.8.8.X.8.8” readout

i01961867 The pointers inin the gauges point upward. Then, the
Indicators and Gauges - Test pointers point to the left. Then, the pointers point
to the right. Then, the pointers point to the   final
SMCS Code: 7450-081;
Code:  7450-081; 7490-081 positions.

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

“km/h”.

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

i01959914

Lift Cylinder Yoke Bearings -

Cylinder
Lubricate
Code:  5102-086-BD
SMCS Code: 5102-086-BD

g01113652
Illustr ation
ation 250

The operator must observe the indicators and the

gauges inin order to determine whether gauge module
(1), action light (2), alert indicators (3), and the LCD

display (4) are operating properly. The self test lasts

 for appr oximately
oximately three seconds.

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

The digital display shows the following readouts:

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

162 SEBU7763-02
Maintenance Section
Oil Filter - Inspect

The  fi ttings are on

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

i02106227

Inspect
Oil Filter - Inspect
SMCS Code: 1318-507;
Code:  1318-507; 3067-507; 5068-507

Inspect a Used Filter for Debris

g01118433
Illustration 253

Oil must be visible through the sight gauge.

g00100013
Illustration 252
The element  is shown with debris.
element is

Use a   filter cutter to cut the   filter element open.

Spread apar t the pleats and inspect the element for 
metal and for other debris. An excessive amount of 
debris in the   filter element can indicate a possible
failure.

If metals are found in the  fi lter element, a magnet can Illustration 254
g01018551

be used to differen
differentiate
tiate between ferrous metals and Front view
nonferrous
nonferrous metals.

metals can indicate wear on steel parts and

Ferrous metals access door to the battery box on the left
Open the access
on cast iron parts. fender.

Nonferro us metals can indicate wear on the

Nonferrous To   fill the r e
eservoir,
servoir, add oil through the dipstick
aluminum parts of the engine such as main bearings, opening.
rod bearings, or turboch
turbocharger
arger bearings.
the oil level to the FULL mark on the dipstick.
Maintain the
Small amounts of debris may be found in the  fi lter 
element. This could be caused by friction and by Note:  The initial  fi ll of pivot shaft may trap air in the
Note: The
wear. Consult your Caterpillar dealer in order 
normal wear. The  level of the oil may fall as air escapes.
tube. The level
to arrange for further analysis if an excessive amount The reservoir must be  fi lled several times in order to
of debris is found. remain consi
consistently
stently full.

Using an oil   filter element that is not recommended

 by Caterpillar can result in severe engine damage
engine bearings, to the crankshaft, and to other 
to engine
parts. This can result in larger particles in un filtered
oil. The particles could enter the lubricating system
the  particles could cause damage.
and the particles

SEBU7763-02 163
Maintenance Section
Radiator Guard Pin Joint - Inspect

i01107744

Radiator Guard Pin Joint -

Inspect
SMCS Code: 7155-040
Code:  7155-040

1.  Park on a level surface.

2.  Raise the bull dozer blade.

bulldozer

g01018567
Illustration 256
Rear view

1.  Open the access cover to the radiator cap on

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

2.  Slowly remove the radiator cap in order to relieve

system pressure.

g00584863 3.  Inspect the radiator cap for damage, for deposits,

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

4.  Lower the bulldozer blade. Apply suf ficient down

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

6.  Check the other three pin locations. Contact your 

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

Radiator Pressure Cap - Do not

not allow
allow hot
hot oil or compo
compone
nent
nts
s to conta
contact
ct
skin.
Clean/Replace
SMCS Code: 1353-070-Z2;
Code:  1353-070-Z2; 1353-510-Z2

Pressurized system: Hot coolant can cause seri-

 ous burn. To open cap, stop engine, wait until ra-
is cool. Then loosen cap slowly to relieve
diator is
the pressure.

164 SEBU7763-02
Maintenance Section
Refrigerant Dryer - Replace

i01957783

Refrigerant Dryer - Replace

SMCS Code: 7322-510;
Code:  7322-510; 7322-535

Pe
Pers
rson
onal
al injur
injury
y can
can resu
result
lt fr
from
om con
conta
tact
ct wit
with
h refri
refrig-
g-
erant.

Contact
Conta ct wit
with
h refr
refrig
iger
eran
antt can
can cause
cause fr
fros
ostt bite.
bite. Kee
Keep
p
face and hands away to help prevent injury.

g01018614 Protective goggles must always be worn when re-

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

Personal injury or death can result from inhaling

refrigerant
refrigerant through a lit cigarette.
cigarette.

Inhaling air conditioner refrigerant gas through a

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

Do not smoke when servicing air conditioners or 

wherever
wherev er refrigerant gas may be presen
present.
t.

Use
Use a ce rtiified reco
cert recove
very
ry and
and recy
recycli
cling
ng cart
cart to prop-
prop-
g01110810 erly remove the refrigerant
refrigerant from the air conditio
condition-
n-
ion 258
Illustration
Illustrat
ing system.
3.  Maintain the oil level above the top of the track
adjusting
adjustin g cylinder (1). Do not  fi ll the oil above the
track adjustment valve (2).

he cover plate.
4.   Install tthe

5.   Repeat the procedure for the other recoil

ent.
compartment.
compartm

g01118524
Illustration 259
 The in-line dryer is located under the cab on the left
hand side of the machine.

The in-line dryer is accessible by removing the  fl oor 

panel in the cab.

SEBU7763-02 165
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate

i01286780

Ripper Linkage and Cylinder 

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

g01017640
Illustration 260

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

Note: The
replaced
replaced annual
annually
ly.. Extrem
Extremely
ely humid operating
operating
conditions
conditions may require more frequent replacement of 
the dryer. The dryer should also be replaced if the air 
conditioning
conditioning system has been leaking or if the system
has been opened for service repair.
Reference:  For the correct procedure, refer to
Reference: For
 Air Conditioning and Heating Service Manual,
SENR5664 or the Disassembly and Assembly
Manual for your machine.

Note:  A qualified mechanic should replace the

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

g00681900
Illustration 261

Lubricate twelve grease   fittings (six per side). Use

Lubricate
MPGM Grease.

i00925689

Ripper
Ripp er Tip and
and Shan
Shank
k Prot
Protec
ecto
tor 
r 
- Inspect/Replace
SMCS Code: 6808-040;
Code:  6808-040; 6808-510; 6810; 6812-040;
6812-510

If equipped:
equipped:
 

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

i01961853

Rollover Protective Structure

Inspect
(ROPS) - Inspect
SMCS Code: 7325-040
Code:  7325-040

g00550432
Illustration 262

When the ripper tip is worn close to the shank,

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

6.  If the shank protector is worn, drive out the pins.
Remove the shank protector.
7.  Clean the pin retainers and the pins.
If the ROPS has any cracks in the welds, in the
castings, or in any metal section, consult your 
Caterpillar
Caterpi llar dealer for repairs.

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

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

SEBU7763-02 167
Maintenance Section
Seat Belt - Replace

g01152685
Illustration 265
g00932801 in stallation (retractor)
(1) Date of installation
Illustration 264
in stallation (buckle)
(2) Date of installation
Typical example manufacture
(3) Date of manufactur e (tag) (fully extend
extended
ed web)
manufacture (underside) (buckle)
(4) Date of manufacture
Check the seat belt mounting hardware (1) for wear 
or for damage. Replace any mounting hardware that Consult your Caterpilla
Consult Caterpillarr dealer for the replace
replacement
ment of 
is worn or damaged. Make sure that the mounting and the mounting hardware.
the seat belt and
bolts are tight.
If your machine is equipped with a seat belt
Check buckle
buckle (2) for wear or for damage. If the buckle extens ion, also perform this replacement procedure
extension,
is worn or damaged, replace the seat belt. for the seat belt extension.

Inspect the seat belt (3) for webbing that is worn or 
i02773461
frayed. Replace the seat belt if the seat belt is worn
or frayed. Steering Charge Filter -
Consult your Caterpillar dealer for the replacemen
Consult replacementt of  Replace
the seat belt and the mounting hardware.
SMCS Code: 431F
Code:  431F
Note:  Within three years of the date of installation or 
Note: Within
within  fi ve years of the date of manufacture, replace NOTICE
the seat belt. Replace the seat belt at the date which Ca
Care
re mus
mustt be tak
takenen to ensu
ensure re th at fluids are contai
that contained
ned
occurs  fi rst. A date label for determining the age of  during perf o ormance
rmance of inspect
inspection,
ion, maintenance, test-
the seat belt is attached to the seat belt, the seat belt ing,, adjus
ing adjusti
ting
ng and
and repa
repair
ir of the produ
productct.. Be prepa
prepared
red to
buckle, and the seat belt retractor. collect the  fl uid with suitable containers before open-
compartment or disassembling any compo-
ing any compartment
If your machine is equipped with a seat belt nent contain ing   fluids.
containing
extension,
extens ion, also perform this inspection procedure for 
the seat belt extension. Special Publication, NENG2500, “Caterpillar 
Refer to Special
Dealer Service Tool Catalog” for tools and supplies
suitab
suitable
le to coll
collect
ect and cont ain   fluid
contain uids
s on Cat
Caterpi
erpillar 
llar 
i02429594
products.
Seat Belt - Replace
Dispose of all  fl uids according to local regulations and
SMCS Code: 7327-510
Code:  7327-510 mandates.

Within three years of the date of installation or within

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs  fi 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.

168 SEBU7763-02
Maintenance Section
Track
Track - Check/A
Check/Adjust
djust

Grease is under high pressure.

Grease coming out of the relief valve under pres-

sure
sure can penet
death. penetrate
rate the bod
body
y caus
causing
ing inju
injury
ry or 

Do not watch the relief valve to see if grease is es-

caping. Watc
caping. Watch h the track or track adjustm
adjustment
ent cylin-
der to see if the track is being loosened.

Loosen the relief valve only one turn.

g01103238
Illustration 266
1.  Move the machine forward. Allow the machine
to coast to a stop without the use of the service
1.  Open the access door on the right side of the cab. brakes. Adjust the tracks while you are in the
machine’s
machine ’s typical operati
operating
ng conditi
conditions.
ons. If packin
packing
g
2.  Remove the steering charge   filter. Discard the conditions prevail on the workplace, the tracks
used  fi lter element properly. Make sure that all of  should be adjusted without removing the packed
the old  fi lter seal is removed from the  fi lter base. material.
3.  Clean the  fi lter base with a clean cloth. 2.  To measure the sag in the track, stretch a string
over the grousers that are between the sprocket
4.  Install the new  fi lter element by hand. and the front idler. Take the measurement from
the string to the top of the grouser at the maximum
Instructions for the installation of the   filters are measurement. Dimension (A) is the maximum
printed on the side of each Caterpillar spin-on distance
distanc e betwee
between n the string and the grouser
grouser..
filter non-Caterpillar   filters, refer to the
lter.. For non-Caterpillar 
installation instructions that are provided by the
supplier of the  fi lter.

i01961509

Track - Check/Adjust
SMCS Code: 4170-036
Code:  4170-036

g01109482
g0110948 2
Illustration 268

If a machine does not have carrier rollers, the sag in

the track is measured between the sprocket and the
idler. The correct adjustment of dimension (A) is
front idler.
115 ± 10 mm (4.5 ± .4 inch).

g01015715
g01015715
Illustration 267
 Check the track adjustment. Check the track for wear 
and for excessive dirt buildup.

SEBU7763-02 169
Maintenance Section
Track
Track - Check
Check/Adjust
/Adjust

g01118207 g01019116
Illustration 269 Illustration 271

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

4.  Remeasure dimension (D).

Tight Track Adjustment

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

2.  Close the relief valve.

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

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

4.   Install the access cover.

tion 270
Illustration
Illustra g01019107

Bolt Torque for Track Shoes

NOTICE
Do nonott attem
attempt
pt to tighte
tighten
n track
track wh
when
en di
dimen
mensision
on The torque requirement for track shoe bolts is
(D) is 174 mm (6.8 inch) or more. The hard bottom 650 ± 70 N·m (480 ± 50 lb ft). Tighten the bolts for 
attachme
attachment nt can be tightene
tightened d to the point were (D) an additional 120 degrees. If you are using bolts
is no more
more ththan
an 152
152 mm (6. (6.0
0 in
inch
ch)Co
)Cont
ntac
actt your 
your  with a master link, tighten the bolts to a torque of 
Caterpillar
Caterp illar dealer for track service
service or instructions.
instructions. 650 ± 70 N·m (480 ± 50 lb ft). Then, tighten the bolts
for an additional 120 degrees.
1.   Remove the access cover.
 

170 SEBU7763-02
Maintenance Section
Track Pins - Inspect

i01967541 i02039992

Track Pins - Inspect Track Roller Frame - Inspect

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

Fingers can be burned from hot pins and bush-

ings.

The pins and bushings in a dry joint can become

very hot. It is possible to burn the  fi ngers if there
is mo
more
re th
than brieff cont
an brie contact
act with these
these componen
components.ts.

Use the recommendations in order to extend the life

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

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

i01967485

Roller Frame Guides -

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

indicate a dry joint.

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

3.  Do not hit the ends of the track pins with a sledge
hammer in order to loosen the track joints.

NOTICE Illustration 274

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

SEBU7763-02 171
Maintenance Section
Transmission Breather - Clean

4.  Put a mark on the tubular

the  tubular section of the front roller 
frame. This mark should corresp
correspond
ond with the mark
on the rear roller frame. Measure the distance
two marks on the front roller frame.
between the two

If the distance between the two marks is greater 

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

entire procedure for the other side of the

Repeat the entire
machine.

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

g00785460
Illustration 278

If dimension
dimension (X) is less than 45.3 mm (1.78 inch),
replace the track roller frame guides. Consult your 
Caterpillar dealer for information or for service.
g01021605
Illustra tion 276
Illustration

Some components are removed for clarity. i02771281

3.  Raise the front of the machine with the hydraulics Transmission Breather - Clean
of the dozer. Place the block under the inside edge
same track grouser. Lower the machine
of the same Code:  3030-070
SMCS Code:
onto the block.
 g01019203
g01021583 Illustration 279
Illustration 277
Some components are removed for clarity.

172 SEBU7763-02
Maintenance Section
Transmissio
Transmission
n System Oil and Screens - Change/Clean
Change/Clean

access  cover for the transmission  fi ller 

1.  Open the access cover
tube on the right side of the cab. The breather 
attaches to the  fi lle
llerr tube on top of a 90 degree
degree
Unscrew and remove the breather.
elbow. Unscrew

2.   Clean the breather in clean, nonflammable

solvent.

3.  Install the breather and close the cover.

i02694959

Transmission System Oil and

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

Use a   126-7538  Nozzle if the machine is equipped

At opera
operatin
ting
g tem
tempe
pera
ratur
ture,
e, th
the
e hydr
hydraul
aulic
ic ta
tank
nk is ho
hott with the high speed oil change arrangement. This
and under pr essure.
essure.
arrangement removes oil from the sump in the bevel
gear case. The high speed oil change does not
Hot oil and components can cause personal in- remove oil from the torque converter or from the
 jury. Do not allow
 jury. allow ho
hott oil or co
compo
mpone
nent
nts
s to conta
contact
ct transmission case.
skin.

Remove the   fille

Remove llerr cap
cap on
only
ly when
when the engine
engine is
pped,, and the   fill
stopped
sto ller
er ca
cap
p is co
cool
ol en
enou
ough
gh to
touch with your bare hand. Remove the   filler cap
relieve pressure.
slowly to relieve

NOTICE
Ca
Care
re mu
must st be ta
take
ken
n to en
ensu
sure that fluid
re that uidss are contain
contained
ed
during performance of inspecinspection,
tion, maintenance, test-
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair
ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to
collectt the   fluid with suitable containers before open-
collec
ing any compartment or disassembling any compo-
nent containing   fluids.
g00484767
Illustration 281
Refer to Special Publication,
Publication, NENG2500, “Caterpillar 
Dealer Service Tool Catalog” for tools and supplies 1.  Remove thethe plug from the drain in the bevel gear 
suitabl
suitable
e to collec
collectt and contain
contain   fluid
uids
s on Caterpil
Caterpillar 
lar  case. Install a   4C-8563  Swivel into the valve.
products. Clamp a hose to the swivel. A 25.4 mm (1 inch)
and  hose can be used. Use a 25.4 mm
pipe and hose
Dispose of all  fl uids according to local regulations and (1 inch) pipe with 1-11 1/2 NPTF threads. Do not
mandates. tighten the pipe.

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

Drain the Oil and Change the the internal drain valve. Allow the oil to drain into a
Transmission Oil Filter Elements suitable
suitabl e container.
 Operate the machine
train oil. The machinein order
must betolevel.
warmLower
the power 
the 3.  Remove the rear bottom guard.
attachments
attach ments with slight down pressure.

See the Operation and Maintenance Manual,

“Transmission and Torque Converter Oil Filters -
Replace” in this manual for the procedure to change
the   filters.

SEBU7763-02 173
Maintenance Section
Transmission System Oil and Screens - Change/Clean

11. Close the drain valve

drain  valve in the torque converter.
Close the drain valve in the transmission case.

hoses and remove the pipes from

12. Remove the hoses
the drains.

13. Remove the swivel

swivel or remove the pipe from the
drain in the bevel gear case. The drain valve will
close.

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

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

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

into a suitable
suitable container.
container.

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

suitable container.

g01124858
Illustration 284

1.  Remove torque converter scavenge line (7).

Remove the screen.

g01023184
g01023184
Illustration 283

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

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

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

ssion. Install a 12.7 mm (.5 inch) pipe into
transmission.
transmi
the transmission valve. Use a 12.7 mm (0.50 inch)
pipe with 1/2-14 NPTF threads. Clamp a hose to
pipe  in order to drain the oil into a suitable
the pipe in g01356854
g01356854
container. Illustration 285
 drain valve (4) and drain the oil into a
9.   Open drain 2.  Remove cover (8) from the transmission scavenge
suitable container. screen. Remove the screen
screen..

the   filter element. See the Topic

10. Change the
“Transmiss
“Transmission
ion System Oil Filter-R
Filter-Replace
eplace”” in this
manual.

174 SEBU7763-02
Maintenance Section
Transmission System Oil Level - Check

5.   Maintain the oil

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

6.  Clean oil  fi ller cap (5). Install the oil  fi ller cap.

7.  Install the r ear

ear bottom guard.

For addition
additional
al informat
information
ion about transmission system
Special Publication,
oil, see Special Publication, SEBU6250,
SEBU6250, “Caterp
“Caterpillar 
illar 
Machine Fluids Recommendations”
Recommendations” or consu
consult
lt your 
g01356715
Caterpillar dealer.
Illustration 286
(A) Right side view
(B) Front view i02112969

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

5.  Clean the three screens in clean, non flammable

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

g01019160
g01019160
Illustration 288
Some components are removed for clarity.

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

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

and Maintenance
Maintenance Manual, “ Capacities
Capacities (Re fill)”.

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

SEBU7763-02 175
Maintenance Section
Transmission System Oil Sample - Obtain

Hot Oil i01960903

Transmission System Oil

Obtain
Sample - Obtain
SMCS Code: 3030-008
Code:  3030-008

g00493905
Illustration 289
Hot oil and components can cause personal in-
 jury.
Use the “TRANSMISSION IN NEUTRAL, ENGINE
 AT LOW IDLE, AND OIL AT OPERATING
Do not
not allow
allow hot
hot oil or compo
compone
nent
nts
s to conta
contact
ct
TEMPERATURE” side of the dipstick (2). Check
skin.
when the transmission is in NEUTRAL and the
engine is running at LOW IDLE. The oil should be at
operating
operating tempera
temperature.
ture. Maintain the oil level between NOTICE
the “OPERATING ZONE” marks. This is the only Ca
Care
re mus
mustt be tak
taken
en to ensu
ensure re that fluids are contai
that contained
ned
accurate way to check the oil level. during performance of inspection,
inspection, maintenance
maintenance,, test-
ing,, adjus
ing adjusti
ting
ng and
and repa
repair
ir of the produ
product
ct.. Be prepa
prepared
red to
Cold Oil collect the  fl uid with suitable containers before open-
ing
nentany compartment
containing   fluids. or disassembling any compo-
containing

Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
Tools
ools and
and Shop
Shop Pro
Produc
ducts
ts Gui
Guide
de”” fo
forr too
tools
ls and
and supp
supplie
liess
suitab
suitable
le to coll
collect
ect and cont ain   fluid
contain uids s on Cat
Caterpi
erpillar 
llar 
products.

Illustration 290
g00493912 Dispose of all  fl uids according to local regulations and
mandates.
“ENGINE STOPPED COLD OIL” side of 
Check the “ENGINE
dipstick (2) while the engine is stopped. Maintain the Obtain the sample of the transmission oil as close
oil between the “OPERATING ZONE” marks. This as possible to the recommended sampling interval
interval..
should be used as reference only.
method should The recommended sampling interval is every 500
service hours. In order to receive the full effect of 
Note: When you are operating the machine on severe S·O·S oil analysis, you must establish a consistent
slopes, the quantity
the  quantity of oil in the transmission can be trend of data. In order to establish a pertinent history
increased up to 10 percent. When you are operating of data, perform consistent oil samplings that are
with the increas
increased
ed oil quantit
quantity y, prolong
prolonged
ed operation
operation evenly spaced.
machines can cause high transmission oil
in some machines
temperatures. After the work on the severe slopes
has been completed, drain the excessive oil quantity
bevel gear case.
from the bevel

1.  If the oil level on dipstick (2) indicates that oil is

remove  fi ller cap (1) and add the oil.
needed,, remove
needed

2.  Clean the   filler cap and install the  fi ller cap.

3.  Close the access door.

 g01019134
g01019134
Illustration 291

1.  Open the access door on the right side of the cab.

176 SEBU7763-02
Maintenance Section
Transmissio
Transmission
n and Torque
Torque Converter Oil Filters - Replace
Replace

NOTICE
Care
Care mumust
st be ta ken to ensu
tak ensure re tha
thatt fluids are contai
contained
ned
during performance of inspection,
inspection, maintenance
maintenance,, test-
ing,, adjus
ing adjusti
ting
ng and
and repa
repairir of the produ
productct.. Be prepa
prepared
red to
collect the  fl uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent contain ing   fluids.
containing

Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar 
Dealer Service Tool Catalog” for tools and supplies
suitabl
sui e to coll
table ollect
ect and con
contai n   fluid
tain uids
s on Cat
Caterpi
erpillar 
llar 
products.

g01018659 all  fl uids according to local regulations and

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

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

5.  Replace the protective cap.

6.  Close the access door and secure the door.

For additio
additional
nal informat
information
ion about transmissio
transmission
n system
oil, see Specia
Speciall Publication,
Publication, SEBU6250, “Caterpillar 
Machine
Machin e Fluids Recommenda
Recommendations”
tions” or consult
consult your 
Caterpillar dealer.
g01023030
Illustration 293
i02763393
1.  Open the access door above the right fender.
Transmission and Torque Remove drain plugs (1) in order to remove a small
amount of oil. Use a wrench in order to remove
Converter Oil Filters - Replace filter housings (2).

SMCS Code: 3067-510
Code:  3067-510
2.  Remove the  fi lter elements and properly discard
the   filter elements.
elements.

3.  Clean the  fi lter element housings and clean   filter 

Hot oil and components can cause personal in- bases (3) with a clean cloth.
 jury.
4.  Inspect the seals. If the seals are damaged,
 Do
skin.no
nott allow
allow hot oi
oill or compo
compone
nent
nts
s to cont
contact
act replace the seals.
5.  Install new  fi lter elements. Install the  fi lter element
element
housing covers.

6.  Start the engine.

SEBU7763-02 177
Maintenance Section
Walk-Around Inspection

Methodically inspec
inspectt all expos
exposed,
ed, easily accessib
accessible
le
areas of the machine for the following items:loose
fasteners,
fastene rs, missing parts, damaged parts, cracked
cracked
broken  parts, worn parts, debris buildup, oil
parts, broken parts,
leaks, coolant leaks, and fuel leaks.

rective action for   fluid leaks, damaged

Initiate cor rective
parts, excessively
excessively worn parts, loose fasteners, and
missing parts.fluid leaks, damaged parts, excessively
loose fasteners, and missing parts.
worn parts, loose
Remove accumulated trash, dirt, grease, or oil from
the tractor.

During this genera

generall machin
machinee inspec
inspection,
tion, give special
g01023041
focus to the following items.
Illustration 294
Some components are removed for clarity. •   Inspec
Inspectt the tracks, track roll
roller
er frames, idlers,
idlers, and
rollers for oil leaks, and excessive wear. Visually
7.  Check the oil. evaluate
evalua the tightness of the track. See the Topic
te the
“Tracks Check/Adjust” in this manual.
HOT OIL:
•   Inspect the
the   final drives for debris that may be
Use the “TRANSMISSION
“TRANSMISSION IN NEUTRAL
NEUTRAL,, ENGINE wrapped around the drive. Check duo-cone seals
 AT LOW IDLE, AND OIL AT OPERATING for oil leaks, and sprocket segments for wear.
TEMPERATURE” side of the dipstick (4). Check
when the transmission is in NEUTRAL and the •   Inspect the GET (ground engaging tool(s))
engine is running at LOW IDLE. The oil should (bulldozer and ripper) and other wear surfaces for 
be at operating temperature. Maintain the oil level  wear and damage.
excessive wear
excessive
between the “OPERATING ZONE” marks. This is
the only accurate way to check the oil level. •   Inspect the linkage for the bulldozer and inspect the
for the ripper. Also, inspect the fasteners
linkage for
COLD OIL: for the linkage.

Check the “ENGINE STOPPED COLD OIL” side •   Inspect exposed

of the dipstick (4) while the engine is stopped.
Maintain the oil between the “OPERATING ZONE”
marks. This method should be used as reference
only.
8.   Remove  fi ller cap (5). If necessary, add oil.
9.  Clean the   filler cap and install the  fi ller cap.
exposed guards, shields, and covers
covers..
•  Inspect the winch for oil leaks.
•  Inspect the implement hydraulic cylinders for 
damaged rods or bent rods and for leaks.
•  Inspect exposed hoses and hose couplings for 
damage,, wear
damage wear,, and leaks.

10. Close the access door

door.. •  Inspect the radiator for debris buildup, coolant
leaks, and damaged   fins and tubes.
damaged
i02236117
•   Inspect
Inspect the aftercoo
aftercooler
ler for debris buildu
buildup,
p, coolant
Walk-Around Inspection leaks, and damaged   fins and tubes.
damaged

Code:  1000; 7000

SMCS Code: 1000; •   Inspect
Inspect the fan for damage to the blades or for oil
leaks.
 A thorough, regular visual inspection of the machine
is necessary to maintain machine performance, •   Inspect
Inspect the lights for broken bulbs and for broken
lenses. Inspect light guards and shields for 
 availability
availability,,ofand
beginning safety.
safety
every . Make
shift thethe
or make inspection
inspection at the
inspection after  damage.
every 10 hours.
•   Inspect exposed wiring and connectors for damage
and wear .

•  Inspect steps and handholds for damage and

cleanliness.
cleanliness.

178 SEBU7763-02
Maintenance Section
Winch Fairlead Rollers - Lubricate

•  Inspect the precleaner

pre cleaner screen for debris buildup. PA140VS
•  Inspect the engine compartment for   fluid leaks,
leaks,
debris or trash, loose fasteners, worn
buildup of debris
hoses,, and damaged wiring.
hoses

•  Inspect the cr ankcase

ankcase guard under the engine for 
debris buildup.

•   Inspect the rollover

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

•   Inspect the operator compartment for cleanliness.

g01076215
Refer to the Operation and Maintenance Manual, Illustration
Illustratio n 296
“Maintenance Interval Schedule” for the list of the
maintenance.
daily maintenance. 1.  Remove oil level plug (2) in order to check the oil
level. The oil
oil level should be maintained to the
bottom of the level plug hole.
i02112864

Winch Fairlead Rollers - y,, remove oil  fi ller plug (1) and add oil.
2.   If necessar y

Lubricate Check for oil leaks around the covers and around
Repair any oil leaks.
the hoses. Repair
SMCS Code: 5163-086
Code:  5163-086
i02773475
If equipped:
Winch Oil and Breather -
Change/Clean
SMCS Code: 5163-044
Code:  5163-044

If equipped:
equipped:

Hot oil and components can cause personal in-

 jury.

Do not
not allow
allow hot
hot oil or compo
compone
nent
nts
s to conta
contact
ct
g01076211 skin.
Illustration 295

Lubricate
Lubricate the  fi ve  fi ttings. Use MPGM Grease.

i02112874

Winch Oil Level - Check

Code: 5163-535-FLV
SMCS Code:  5163-535-FLV
 If equipped:

SEBU7763-02 179
Maintenance Section
Winch Wire Rope - Install

PA140VS i02094238

Winch Wire Rope - Install

(If Equipped)
SMCS Code: 5163-012
Code:  5163-012

Personal
Person al inju
injury
ry o
orr dea
death
th can result from worn
worn wire
rope cable.

Worn or frayed cable could break causing injury.

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

g01076796 frayed install a new cable.
Illustration
Illustratio n 297

1.  Remove oil  fi ller plug (1).

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

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

eng ine at low idle. Maintain the oil level

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

10. Install the oil level plug.

g01076208
Illustration 298
 1.  Put the cable in a straight line behind the tractor.

2.  Install the ferrule end into the socket.

3.  Reel in the cable.

180 SEBU7763-02
Maintenance Section
Window Washer Reservoir - Fill

i01961420 i02770681

Window Washer Reservoir - Window

Wind ow Wiper
Wipers
s -
Fill ace
Inspect/Replace
Inspect/Repl
(If Equipped) (If Equipped)
SMCS Code: 730 6-544
Code:  7306-544 SMCS Code: 730 5-040; 7305-510
Code:  7305-040;

NOTICE
When op
When oper
erat
atin
ingg in fr free
eezi
zing
ng te
temp
mper
erat
atur
ures
es,, us
use
e
Caterpillar or any commercially available nonfreezing
window washer  solvent.
  solvent.

g01018994
Illustration 300

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

i01083628

Windows - Clean
g01018997
Illustration 299 SMCS Code: 7310-070;
Code:  7310-070; 7340-070

Windshield Washer –  The washer  fl

Windshield Washer  fl uid
bottle is on the left side of the cab on the
front post, as shown. Open the access
cover. Remove the  fl uid bottle cap in order to  fi ll the
washer   fluid bottle.
If equipped:
equipped:
Use commercially available window cleaning
solutions to clean the windows.
To clean the outside of the rear window from the
inside of the cab, remove the sliding section of the
rear window. Use the following procedure in order to
remove the sliding section of the rear window.
 g00039956
g00039956
Illustration 301

SEBU7763-02 181
Maintenance Section
Windows - Clean

1.  Lift latch (1) in

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

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

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

small section of the window to opening

3.  Move the small
(4) in the upper window channel.

o f the window toward the inside of the

4.  Tilt the top of
cab. Remove the window.

the cab in order to clean the outside

5.  Stay inside the
of the rear window.

cleaning, install the sliding section of the rear 

6.   After cleaning,
window.
 

182 SEBU7763-02
Reference Information Section
Reference Materials

Reference Information •  Safety Manual, SEBU5311

Manual,  SEBU5311

Section •  Special Publication, PECP9067, “One Safe

Source”

•   Special Publication, PEHP7076, “Understanding

Reference Materials the S·O·S Oil Analysis
Analysis Test”

i02748866
•   Special
Special Publication, PEHP600
PEHP6001,
1, “How to Ta
Take
ke a
Sample”
Good Oil Sample”
Reference Material
•  System Operations, RENR8170, “Machine
SMCS Code: 1000;
Code:  1000; 7000 Monitoring System for D8T, D9T, and D10T”
Monitoring

Operation and Maintenance Manuals are available

Reference
Reference Material by Caterpi
Caterpillar 
llar  in other languages.
languages. Consult your Caterpillar dealer 
for information about obtaining these Operation and
The following literature can be obtained from any Maintenance Manuals.
Caterpillar dealer:

•  Special Publication, SEBD0518, “Know Your  Additional Reference Material

Cooling System”
 ASTM D2896,
normally “TBN Measurements”
be obtained This can
from your local technological
•   Special
Special Instruc
Instruction,
tion, SEHS7633, “Battery Test
Procedure” society, fr om
om your local library, or from your local
college.
•  Special Instruction, SEHS9031, “Storage
Procedure
Procedure for Caterpil
Caterpillar
lar Products
Products”” “Diesel Fuels” This can be found in the
SAE J313, “Diesel
SAE handbook. Also, this publication can be obtained
•  Special Instruction, TIBU5046, “Hydraulic Fan from your local technolog
technological
ical society
society,, from your local
System & Overheating Issues on D8T and D9T” library, or  from
  from your local college.

•  Special Instruction, SEHS6929, “Inspection, SAE J754, “Nomenclature” This can normally be
Maintenance and Repair of Rollover Protective the SAE handbook.
found in the
Structures
Structures (ROPS) and Attachme
Attachmentnt Installation
Installation
Guidelines” SAE J183, “Classification” This can normally be
found in the
the SAE handbook.
•   Service
Service Magazine, SEBD1587,
SEBD1587, 28 October 1985,
“What ROPS/FOPS Certification Means” Engine Manufacturers
Manufacturers Associa
Association
tion “Engine Fluids
Data Book”
•   Special
Special Publication, SEBU5898
SEBU5898,, “Cold Weath
Weather 
er 
Recommendations For All Caterpillar Equipment” Engine Manufacturers Association
LaSalle Street, Suite 2200
Two North LaSalle
•  Special Publication, SEBD0640, “Oil and Your  Chicago,, Illinoi
Chicago Illinois,
s, USA 60602
Engine” (312) 827-87
827-8700 00

•  Special Publication, SEBU6250, “Caterpillar  E-Mail: ema@enginemanufacturers.org

Machine Lubricant Recommendations” Facsimilie
827-8737
(312) 827-8737
•   Operation
Operation and Mainten
Maintenance
ance Manual, SEBU8257,
SEBU8257,
“The European Union Physical
Physical Agents (Vibration)
(Vibration) i01631981
Directive 2002/44/EC”
Decommissioning and
•  Special Instruction, SMBU6981, “Emissions
 Control Warranty Information” Disposal
SMCS Code: 1000;
Code:  1000; 7000
•   Service Manual, SENR5664
When the machine is removed from service, local
•   Service Manual, SENR8320
regulations will vary. Disposal of the machine will vary
with local regulat
regulations.
ions. Consult the neares
nearestt Caterpi
Caterpillar 
llar 
•  Parts Manual, SEBP3654
dealer for additio
additional
nal informat
information.
ion.

SEBU7763-02 183
Index Section

Index
A Cooling System Water T Temperatu
emperature re Regula
Regulator tor -
Replace............
Replace ........................
........................
........................
........................
..............
.. 134

 Additional Me
 AdjustmentsMessages
ssages
 Adjustments........... .............................
.................
....................... ........................
......................... ................
......................... .... 94
.......................
........... 16 Crushing
Cutting Prevention
Prevention
Edges and
and End Cutting
Bits Prevention ........135
- Inspect/Replace.... 19
 Alternate Exit ......................
.......... ........................
........................
.......................
........... 38

D
B
Inspection ...........
Daily Inspection .......................
........................
........................
..................
...... 37
Backup Alarm - Test ...............
...........................
........................
.................
..... 120 Decommissionin
Decommi ssioning
g and Dispos
Disposal al ..................
..........................
........ 182
Battery Disconnect
Disconnect Switch......................
Switch..................................
...............
... 82
Battery Cable
Battery or Battery Cable - Inspect/Replace
Inspect/Replace ......... 120
Battery Disconnect
Disconnect Switch ........................
...............................
....... 121 E
Battery Inspect .......................
...................................
........................
..............
.. 120
Recycle.............................
Battery Recycle................. ........................
...................
....... 120 Electrical Storm Injury Prevention ......................
Electrical .........................
... 23
Before Operation
Operation ............
........................
........................
.....................
......... 23, 37 Electronic
Electro nic Unit Injector - Inspect
Inspect/Adjust........
/Adjust...............
....... 135
Before Starting Engine ................................
..........................................
.......... 23 Emissions Certification Film .............................
..................................
..... 35
Belt - Inspect/ Adjust/Replace
Inspect/ Adjust/Replace .. ................
...........................
............... 121 Certification
cation Label
 Label for Emissio
Emissions.......
ns...................
.................
..... 35

Inspec
Inspect te.............................
...........
.......................
........................
Replace..................
Replac ........................
........................
....................... ..............
........................ .. 121
...................
....... 122 Engine Air Filter ........................
Replace............
Replace Primary........................
........................ Element - Clean/
........................
..............
.. 135
Bottom Guard (Power) (Power) - Clean............................ 122 Filter Primary Element - Replace....... 137
Engine Air Filter
Braking System - Test...... est.................
.......................
........................
.............. 123 Engine Air Filter
Filter Secondary
Secondary Element - Replac Replace e .. 137
Bulldozer
Bulldoz er Tilt Brace ......................
..................................
.......................
.............
.. 94 Engine Air Precleaner
Precleaner - Clean...................
Clean.............................
.......... 137
 Angling the Blad e............................
Blade................ ........................
...................
....... 95 Machine Warm-Up ........................
Engine and Machine .............................
..... 86
Tilt the Blade Manually....................
Manually................................
...................
....... 95 Idling ...........
.......................
......................
......................
........................
.....................
......... 87
U and SU Three-P
Three-Position
osition Til Tiltt Brace ...................
................... 94 Engine Crankcase
Crankcase Breather - Clean............
Clean....................
........ 138
Bulldozer Tilt BraceBrace and Tilt Cylinders - Engine Oil and FilterFilter - Change
Change ...........
.......................
.................
..... 140
Lubricate
Lubric ate ............
.......................
.......................
........................
........................
.............. 123 Procedure for Changing the Engine Oil and
Burn Prevent
Prevention..............
ion..........................
........................
........................
...............
... 20 Filter ...........
.......................
........................
........................
........................
................
.... 141
Batteries.................
Batterie s.............................
........................
........................
....................
........ 20 Selection of the the Oil Change Interval Interval ........
................
........ 140
Coolant...........
Coolan t.......................
........................
........................
........................
................
.... 20 Engine Oil Level - Check..................................... 138
Oils.........................
Oils............. ........................
........................
........................
....................
........ 20 Engine Oil Sample - Obtain ........... ......................
.....................
............ 139
Overspeed............................
Engine Overspeed................ ........................
.....................
......... 83
Engine Starting...............................
Starting...........................................
.................
..... 23, 85

C EtherStarting (Alter
Engine Starting (Alternate
Starting Aid ...........
.......................
........................
nate Methods)
Metho ds)........................
............
...........
................... 86
........ 108
Cab Filter (Fresh Air) - Clean/Inspect/Replac
Clean/Inspect/Replace.... e.... 124 Engine Starting
Starting with Auxiliary Start Receptacle .. 109
Cab Filter (Recirculation) - Clean/Inspect/ Engine Starting with Jump Start Cables.............. 108
Replace...........
Replac e.....................
......................
........................
........................
.................
..... 124 Start  Cables................................ 108
Use of Jump Start Cables................................
Capacities (Refill) .......................
...................................
........................
..............
.. 116 Engine Starting with Prelubrication
Prelubrication System...........
System........... 86
Ecology
Ecolog y Drains......................
Drains..................................
........................
................
.... 116 Engine Stopping ............
........................
.......................
.......................
.................
..... 25
Cooler Cores and A/C A/C Condenser
Condenser - Clean Clean .......... 125 Lash  - Check/
Engine Valve Lash - Check/Adjust
Adjust ...................
......................
... 143
Clean..............
Clean..........................
........................
........................
........................
..............
.. 126 Engine Valve
Valve Rotators - Inspect ...........
......................
...............
.... 143
Cooler Cores.......................
Cores...................................
........................
.................
..... 125 Equalizer
Equalizer Bar End Pins Oil Level - Check ......... ...........
.. 144
Waste  Handling Arrangement (If 
Wood Chip or Waste Handling Lowering with Engine Stopped...... 25, 98
Equipment Lowering
Equipped).................
Equippe d).............................
........................
.......................
..............
... 127 The Procedure After The Accumulator Bleeds
Cooling System Coolant (ELC) - Change............ 129 Down...............................
Down...........................................
........................
.....................
......... 98
Cooling System ........................
To Drain the Cooling ...........................
... 129 The Procedure Bef ore ore The Accumulator Bleeds
Cooling System Coolant Extender (ELC) - Add... 131 Down...............................
Down...........................................
........................
.....................
......... 98
Extended Life Coolant (ELC) Extender............ 131 Ether Starting Aid Cylinder - Replace..................
Replace.................. 145
 Cooling
WoodSystem
Chip or Coolant
Coo
Waste lantHandling
Level - Check...............
Arrangement (If 132
Equipped).................
Equippe d).............................
........................
.......................
..............
... 133 F
Cooling System CoolantCoolant Sample (Level 2) -
Obtain ......................
..................................
.......................
.......................
...................
....... 128 Final Drive Oil - Change .......................
...................................
...............
... 145
Level 2 Analysi
Analysis s .......................
..................................
.......................
.............. 128 Final Drive Oil Level - Check............................... 146
Cooling System Speci Specifications .......................
.............................
...... 111 Sample - Obtain........................... 147
Final Drive Oil Sample

184 SEBU7763-02
Index Section

Final Drive SealSeal Guard Packing - Replace (If  Important Safe

Important ty Information
Safety Information ............
........................
.......................
........... 2
Equipped)
Equipp ed) ..........
......................
.......................
.......................
........................
.............. 148 Indicators
Indicators and Gauges - Test......
est..................
.......................
.............
.. 161
Replacement
Replac ement of the Packing..........................
Packing............................ .. 148
Extinguisher Location................................
Fire Extinguisher Location..................................... ..... 22
Fire Prevention and Explosion Prevention Prevention ............ 20 L
Ether ......................
..................................
........................
........................
....................
........ 22
Fire Extinguisher
Extinguisher...........
.......................
........................
........................
.............. 22 Leaving the Machine
Machine .................
.............................
........................
................
.... 99
Lines, Tubes
Tubes and Hoses ........... ......................
.......................
..............
.. 22 Lift Cylinder Yoke
Yoke Bearings - Lubricate ...............
............... 161
Foreword
Forewo rd ........................
.....................................
.........................
........................
................
.... 5 Lifting and Tying Down the Machine..................
Machine.................... .. 101
osition
California Proposition
Prop 65 Warning ..........
......................
.............. 4 osities......................
Lubricant Viscosities..........
Visc ........................
.......................
........... 112
Caterpillar Product Identification Number ............ ............ 5 Lubricant
Lubric ant Visco
Viscosities
sities for Ambien
Ambientt
Certified Engine Maintenance............
Maintenance.......................
..................
....... 4 Tempera
emperatures
tures ............
........................
........................
........................
..............
.. 113
Literature
Literat Information......................
ure Information.......... ........................
.....................
......... 4 Viscosity
Selecting the Viscosit y ........................
....................................
..............
.. 112
Machine
Machin e Capacity
Capacity .....................
.................................
........................
...............
... 5 Lubricant Viscosities and Re fill Capacities...........
Capacities........... 112
Maintenance
Mainten ance ..........
......................
........................
.......................
......................
........... 4
Operation
Operat ion ..........
......................
........................
........................
........................
...............
... 4
Safety.....................
Safety......... ........................
........................
........................
......................
.......... 4 M
Fuel System - Prime.................................
Prime............................................
........... 150
Electric
Electri Priming Pump........................
c Fuel Priming Pump.................................... 150 Machine Operation
Operation ...........
.....................
......................
........................
...............
... 38
Fuel System Primary Filter - Clean/ReplaceClean/Replace ....... 151 Maintenance Interv
Maintenance Interval al Schedule
Schedule ...........
......................
.................
...... 118
Fuel System Primary Filter (Water Separator) - Maintenance Section............................................ 111
Drain ...........
.......................
........................
........................
........................
...................
....... 152 Support ...........
Maintenance Support .......................
........................
....................
........ 117
Fuel System Secondary Filter - Replace............. 153 Model Specific Coolant Information...................... 111
Fuel Tank Cap Filter and Strainer - Monitoring
Monitori ng System.........
System.....................
........................
.......................
................
..... 57
Replace/Clean
Replac e/Clean ..........
......................
........................
........................
................. 154
..... 154  Action Light ........................
............ ........................
........................
....................
........ 58
Fast Fill Fuel Adapter
Adapter (If EquippEquipped) ed) ...........
.................
...... 154 CAT
CA T Advisor Graphic Display Module................ 62
Fuel Tank
Tank Water and Sediment - Drain ............... ............... 154 Display Module ..........
......................
.......................
.......................
.................
..... 66
Fuses and Circuit BreakersBreakers - Replace/Reset ...... 155 Functional Test ........................
est............ ........................
........................
...............
... 57
Gauges ..........
......................
........................
........................
.......................
................
..... 60
Home Button..................
Button..............................
........................
........................
............ 63
G Abbreviations and Terms....................
Listing of Abbreviations Terms.................... 79
Menu for the Operator’s Pro file.......................... 63
General Hazard Information ...........
General .......................
.......................
........... 17 Performance
Perform ance Menu ...................
...............................
........................
.............. 67
 Asbestos Information
Information ..........
......................
.......................
...................
........ 19 Quick Reference Guide Guide for Setting the “Operator 
Containing
Contain ing Fluid Spillage ..........
......................
........................
.............. 18 Profile” by Using Adviso Advisor.....................
r.................................
.............. 78
Dispose
Dispos e of Was
Waste
te Properly ..................
..............................
..............
.. 19 Service
Servic e Menu.......................
Menu...................................
.......................
..................
....... 72
.......................
Fluid Penetration...........
Penetration ........................
........................
.............
. 18 Settings
Setting s for Engine
Engi ne Setup ...........
.......................
.......................
........... 71
Pressurized
Pressu rized Air and Water ........................
.................................
......... 18 Settings for the Power Train ...................
..............................
........... 71
Trapped
Trap ped Pressu
Pressure
re ............
........................
........................
......................
.......... 18 Settings Menu ............
........................
........................
.......................
................
..... 69
Information............................
General Information................ ........................
...................
....... 30 Status Indicators ............
........................
........................
........................
............ 59
Guards (Operator
(Operator Protec
Protection)
tion)............
........................
....................
........ 28 Totals Menu Option.................
Option.............................
........................
...............
... 76
Other Guards (If Equipped).......
Equipped)..................
.......................
..............
.. 29 Warning
Warn ing Levels ...........
.......................
........................
........................
...............
... 61
Rollover
Rollov er Protectiv
Protectivee Structure (ROPS), Falling Dismounting.....................
Mounting and Dismounting......... ........................
...............
... 37
Object Protective Structure (FOPS) or Tip Over 
Protection
Protecti on Structure (TOPS) ............
........................
................
.... 29
O

H Oil Filter - Inspect .................

.............................
........................
...................
....... 162
Filt er for Debris ....................... 162
Inspect a Used Filter
Horn - Test...................................
est...............................................
........................
............ 156
Hydraulic
Hydrau lic System Oil - Change ..................................
...............
..... 156
lic System Oil Filter (Pilot) - Replace ....... 157
Hydraulic
Hydrau
Pilot Hydraulic Oil Filter................
Filter............................
....................
........ 157
Hydraulic System Oil Filters - Replace................ 159
 Hydraulic
Hydrau Oil Level - Check
lic System Oil Check ....................
.................... 160
Hydraulic System Oil Sampl
Hydraulic Samplee - Obtain ................
................ 160

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

SEBU7763-02 185
Index Section

Operating Tech echnique

nique Information ....... ...................
...................
....... 88 P
 Adjustable Ripper...........
Ripper........................
..........................
.......................
.......... 92
Backfilling............
lling........................
......................
......................
........................
.............. 90 Parking ..........................
......................................
........................
......................
.......... 25, 97
Dozer Blade Pitch Pitch for the U-Blade and Oil  Level - Check............................... 162
Pivot Shaft Oil Level
SU-Blade...................
SU-Blade....... ........................
........................
........................
...............
... 88 Plate Locations and Film Locations....................
Locations....................... ... 32
Gear Selection .......................
...................................
.......................
................
..... 88 Certifications ...........
.....................
......................
........................
.....................
......... 34
Land Clearing..........
Clearing......................
........................
........................
...................
....... 90 European Union ..........
......................
........................
........................
...............
... 35
Machine
Machin e on a Slope ........................
....................................
...................
....... 89 Product Identification Plates .........................
..............................
..... 32
Packed Soil, Hardpan, Clay, Shale or Cemented Sound Certification
cation............
........................
........................
.....................
......... 34
Gravel..............
Gravel.. ........................
........................
........................
........................
.............. 91 Information Section .......................
Product Information ..................................
........... 30
Push Loading...............
Loading..........................
.......................
........................
...............
... 93 Product Link (If Equipped)..........
Equipped) ......................
.......................
...............
.... 80
Ripping...................
Ripping....... ........................
........................
.......................
....................
......... 91 Regulatory
Regula tory Complian
Compliance........
ce....................
.......................
..................
....... 81
Fractures, Faults and Planes of 
Rock with Fractures,
Weakness
Weakne ss ............
........................
........................
.......................
....................
......... 92
Single Shank Ripper .......... .....................
.......................
.....................
......... 92 R
Slot Dozing.............
Dozing.........................
.......................
.......................
.....................
......... 89
Straight Dozing ........................
....................................
........................
..............
.. 88 Radiator Guard Pin Joint - Inspect ........
Radiator ....................
..............
.. 163
Stump Remova
Removall .......................
..................................
.......................
...............
... 91 Radiatorr Pressure Cap - Clean/Repla
Radiato Clean/Replace ce ............
.............. 163
V-Ditching
V-Ditch ing ........................
....................................
........................
......................
.......... 90 Recoil Spring Compartment
Compartment Oil Level - Check.... 163
Operating Techniques............................................ 88 Reference
Referen ce Information Section ........... .......................
.................
..... 182
Operation..................
Operatio n..............................
........................
........................
.....................
......... 24 Reference
Referen ce Material ........................
....................................
......................
.......... 182
Operating Temperatur
Machine Operating Temperature e Range............ 24  Additional Refe rence Material......................
Reference Material.......................... .... 182
Machine
Machin e Operation........
Operation....................
........................
.......................
.............
.. 24 Reference
Refere nce Material by Caterpil Caterpillar lar .............
....................
....... 182
Operation
Operatio n Information..................
Information..............................
........................
..............
.. 81 Reference
Referen ce Materials .............
.........................
........................
...................
....... 182
Direction and Gear ............................ 82
Changing Direction Refrigerant
Refrige Dryerr - Replac
rant Drye Replace..........
e......................
.......................
........... 164
Operating
Operat ing The Machine ..................
.............................
...................
........ 81 Ripper Linkage and Cylinder Bearings -
Operation
Operatio n Section......................
Section.................................
.......................
.................
..... 37 Lubricate
Lubricat e ...........
.......................
........................
........................
........................
.............. 165
Operator Controls ...........
.......................
........................
........................
...............
... 42 Ripper Tip and ShankSha nk Protector - Inspect/
 Action Light (25).............
(25). .........................
.........................
.......................
........... 54 Replace............
Replace ........................
........................
........................
........................
..............
.. 165
 Adjustable Armrests (1) .......................
.......... ..........................
............... 44 Rollover Protective Structure (ROPS) - Inspect .. 166
 Advisor Monitor Display Display (12).............................. 50
 Auto Blade Assist (10) (if equipped) ..... ..................
............. 48
 Automatic Downshift (18) (Downshift)................
(Downshift).... ............ 53 S
 Auxiliary Power Switch Switch (13) (If Equipped).......... 51
Bidirectional
Bidirec tional Shift (17) (Direction Shift).............. 52 S·O·S Information
Information ......................
.................................
.......................
................
.... 116
Bulldozer
Bulldoz er Joystick Control (9) .....................
............................
....... 46 Safety Messages
Messages (D8T Track-T Track-Type ype Tractor )........... 6
Cab Door (34) (35) (36) (36) ........................
...................................
.............
.. 57 Safety Section .........................
.....................................
........................
....................
........ 6
Decelerator
Decele rator (8)............
(8) ........................
........................
........................
...............
... 46 Seat ............
........................
........................
........................
.......................
.......................
............ 38
Differential
Differential Steeri
Steering ng Control and Transmission
Transmission  Adjusting the Seat. Seat..............
..........................
..........................
...................
...... 38
Control (3) (4) (5) ........................
.................................... ......... 45
..................... Seat Belt.......................
Belt...................................
.......................
.......................
..................
...... 40
Engine Reverse
Reverse Fan (11) (if equipped).............. 49 Extension of the Seat Belt ................................. 42
Engine Start Switch
Switch (14) .....................
.................................
...............
... 51 Seat Belt Adjustment for Non-Retractable Seat
Engine Throttle (15) ............
........................
........................
...................
....... 51 Belts ............
........................
........................
.......................
.......................
..................
...... 40
Gauges and Indicators (6) ............................
.................................
..... 46 Seat Belt Adjustment for Retractable Seat
Heating and Air Conditioning Controls (33) ....... 56 Belts ............
........................
........................
.......................
.......................
..................
...... 42
Horn (27)...............
(27)...........................
........................
.........................
.....................
........ 54 Seat Belt - Inspect ..........
......................
........................
........................
.............. 166
Implement
Impleme nt Lockout Switch (16).......(16)..................
...................
........ 52 Seat Belt - Replace...........
Replace.....................
......................
.......................
.............
.. 167
Light Switches (21) (22) (23) (24) (31)............... 53 Shipping the Machine...............
Machine..........................
......................
................
..... 101
Mirror (37) ............
........................
........................
........................
......................
.......... 57 Information  and Vibration
Sound Information and Vibration Informat
Information ion ........ 25
Parking Brake Control (2) ..............................
..................................
.... 44 Sound Level Information..............................
Information.................................... ...... 25
Ripper Auto Stow switch (28)...........................
(28)............................. .. 54 Sound Level Information
Information for Machines in Europe European an
Raise/Lower (29).................................... 54
Ripper Raise/Lower Union Countries and an d in Countries that Adopt the
Ripper Shank In/Out Lever (26)......................... 54 “EU Directives”
Directives” ..........
......................
........................
........................
...............
... 26
Service
Servic e Brake Control (7)..................
(7)..............................
.................
..... 46 Sources.................
Source s.............................
........................
........................
.....................
......... 28
 Service
Servic e Brake Control (7)..................
(7)..............................
.................
..... 46 Sources.............................
Sources.........................................
........................
.....................
......... 28
Winch Control (30) (If   Equipped)
Equipped) ......................
...................... 55 “The European UnionUnion Physical Agents (Vibration)
Window (39)...............
(39)...........................
.......................
.......................
.................
..... 57 Directive
Directi ve 2002/44/EC”
2002/44/EC”...........
.......................
........................
...............
... 26
Window Wiper
Wiper and Window
Window Washe Washerr (32) .......... 55 Specifications ................................
............................................
........................
............ 30
Operatorr Station ........................
Operato ....................................
.......................
................
..... 28 Intended
Intende d Use...
Use...............
........................
........................
........................
...............
... 31
Steering Charge Filter - Replace......................... 167
Stopping
Stoppin g the Engine ...........
......................
......................
.....................
.............
... 97
Idling the Engine forfo r Extended Periods ............. 97

186 SEBU7763-02
Index Section

Stopping the Engine

Engine if an Electrical Malfunction Clean  ...........
Windows - Clean . ......................
........................
........................
..............
.. 180
Occurs ......................
..................................
........................
........................
...................
....... 98
Stopping
Stopping the Machine.......
Machine...................
.......................
.......................
..............
.. 97

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

Visibility
Visibility Informat
Information.........
ion.....................
.......................
.......................
...............
... 23

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

Walk-Around .......................
........................
...............
... 177
Welding on Machines and Engines with Electronic
Controls
Controls ............
........................
.........................
.........................
........................
.............. 117
Winch Fairlead Rollers - Lubricate ....................
......................
.. 178
 Winch Oil and Breather
Breather Change/Clean
Change/Clean .............
............. 178
PA140VS.......................................................... 179
Winch Oil Level - Check .......................
...................................
...............
... 178
PA140VS.......................................................... 178
In stall (If Equipped) .............. 179
Winch Wire Rope - Install
PA140VS.......................................................... 179
Window Washer
Washer Reservoir - Fill (If Equipped).....
Equipped)..... 180
Inspect/Replace
Window Wipers - Inspect/Re place (If Equip
Equipped)..
ped).. 180

Product and Dealer Information

Note:  For product identification plate locations, see the
Note: For t he section “Product Identification Information”
Information” in the Operation
and Maintenance
Maintenance Manual.
Manual.

Delivery
Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator
Generator Serial Number:

 Attachment Serial Numbers:

 Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

 Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service: