operations and maintenance manual 2

8/11/2019 Operations and Maintenance Manual 2

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SEBU7892-07

March 2011

Operation andMaintenanceManual

525C, 535C and 545CWheel Skidders

5251-Up (Machine)5351-Up (Machine)5451-Up (Machine)

SAFETY.CAT.COM


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i03991620

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and

could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identied by the Safety Alert Symbol and followed by a Signal Word such asDANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

A n on-exhaustive list of operations that may cause product damage are identied by NOTICE labels

on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. You must

not use this product in any manner different from that considered by this manual without rstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specic rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.

The information, specications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specications, torques, pressures,measurements, adjustments, illustrations, and other items can change at a ny time. These changes can

affect theservice that is given to the product. Obtain the complete and most current information beforeyou start any job. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recom-

mends using Cat replacement parts or parts with equivalent specica-tions including, but not limited to, physical dimensions, type, strengthand material.

Failure to heed this warning can lead to premature failures, productdamage, personal injury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.


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SEBU7892-07 3Table of Contents

Table of Contents

Foreword .................................................................................................. 5

Safety Section

Safety Messages ..................................................................................... 9

Additional Messages ................... ........................................................... 23

General Hazard Information .................................................................. 28

Crushing Prevention and Cutting Prevention ......................................... 34

Burn Prevention ..................................................................................... 35

Fire Prevention and Explosion Prevention ............................................. 36

Fire Extinguisher Location ..................................................................... 44

Tire Information ...................................................................................... 45

Electrical Storm Injury Prevention .......................................................... 46

Before Starting Engine ........................................................................... 47

Visibility Information ............................................................................... 47

Engine Starting ...................................................................................... 48

Before Operation ................................................................................... 49

Operation ............................................................................................... 50

Engine Stopping .................................................................................... 51

Parking ................................................................................................... 51

Slope Operation ..................................................................................... 52

Work Tools ............................................................................................. 54

Equipment Lowering with Engine Stopped ............................................ 55


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4 SEBU7892-07Table of Contents

Sound Information and VibrationInformation ........................................ 55

Operator Station .................................................................................... 57

Product Information Section

General Information ............................................................................... 58

Identication Information ........................................................................ 75

Operation Section

Before Operation ................................................................................... 83

Machine Operation ................................................................................ 88

Engine Starting .................................................................................... 143

Adjustments ......................................................................................... 146

Parking ................................................................................................. 150

Transportation Information ................................................................... 157

Towing Information ............................................................................... 163

Engine Starting (Alternate Methods) .................................................... 168

Maintenance Section

Tire Ination Information ...................................................................... 174

Lubricant Viscosities and Rell Capacities .......................................... 177

Maintenance Support ........................................................................... 184

Maintenance Interval Schedule ........................................................... 186

Reference Information SectionReference Materials ............................................................................. 338

Index Section

Index .................................................................................................... 344


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SEBU7892-07 5Foreword

Foreword

Literature Information

This manual should be stored inthe operator's compartment in theliterature holder or seat back literature storage area.

This manual contains safety information, operation instructions,transportation information, lubrication information and maintenanceinformation.

Some photographs or illustrations in this publication show details orattachments that can be different from your machine. Guards and coversmight have been removed for illustrative purposes.

Continuing improvement and advancement of product design mighthave caused changesto your machine which are not included in thispublication. Read, study and keep this manual with the machine.

Whenever a question arises regarding your machine, or this publication,please consult your Caterpillar dealer for the latest available information.

Safety

The safety section lists basic safety precautions. In addition, this sectionidenties the text and locations of warning signs and labels used on themachine.

Read and understand the basic precautions listed in the safety sectionbefore operating or performing lubrication, maintenance and repair onthis machine.

Operation

The operation section is a reference for the new operator and a refresherfor theexperienced operator. This section includes a discussion ofgauges, switches, machine controls, attachment controls, transportationand towing information.

Photographs and illustrations guide the operator through correctprocedures of checking, starting, operating and stopping the machine.


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SEBU7892-07 7Foreword

Certied Engine Maintenance

Proper maintenance and repair is essential to keep the engine andmachine systems operating correctly. As the heavy duty off-road dieselengine owner, you are responsible for the performance of the requiredmaintenance listed in the Owner Manual, Operation and MaintenanceManual, and Service Manual.

It is prohibited for any person engaged in the business of repairing,servicing, selling, leasing, or trading engines or machines to remove,alter, or render inoperative any emission related device or element of

design installed on or in an engine or machine that is in compliance withthe regulations (40 CFR Part 89). Certain elements of the machine andengine such as the exhaust system, fuel system, electrical system, intakeair system and cooling system may be emission related and should notbe altered unless approved by Caterpillar.

Machine Capacity

Additional attachments or modications may exceed machine designcapacity which can adversely affect performance characteristics. Includedwould be stability and system certications such as brakes, steering, androllover protective structures (ROPS). Contact your Caterpillar dealer forfurther information.

Caterpillar Product Identication Number

Effective First Quarter 2001 the Caterpillar Product Identication Number(PIN) has changed from 8 to 17 characters. In an effort to provide uniformequipment identication, Caterpillar and other construction equipmentmanufacturers are moving to comply with the latest version of the productidentication numbering standard. Non-road machine PINs are denedby ISO 10261. The new PIN format will apply to all Caterpillar machinesand generator sets. The PIN plates and frame marking will display the 17character PIN. The new format will look like the following:


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8 SEBU7892-07Foreword

g00751314Illustration 1

Where:

1. Caterpillar's World Manufacturing Code (characters 1-3)

2. Machine Descriptor (characters 4-8)

3. Check Character (character 9)

4. Machine Indicator Section (MIS) or Product Sequence Number(characters 10-17). These were previously referred to as the SerialNumber.

Machines and generator sets produced before First Quarter 2001 willmaintain their 8 character PIN format.

Components such as engines, transmissions, axles, etc. and work toolswill continue to use an 8 character Serial Number (S/N).


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SEBU7892-07 9Safety Section

Safety Messages

Safety Section

i03239202

Safety Messages

SMCS Code: 7000

There are several specic safety messages on this machine. The exactlocation of the hazards and the description of the hazards are reviewed inthis section. Please become familiarized with all safety messages.

Make sure that all of the safety messages are legible. Clean the safetymessages or replace the safety messages if you cannot read the words.Replace the illustrations if the illustrations are not legible. When youclean the safety messages, use a cloth, water and soap. Do not usesolvent, gasoline, or other harsh chemicals to clean the safety messages.Solvents, gasoline, or harsh chemicals could loosen the adhesive thatsecures the safety message. Loose adhesive will allow the safetymessage to fall.

Replace any safety message that is damaged, or missing. If a safetymessage is attached to a part that is replaced, install a safety messageon the replacement part. Any Caterpillar dealer can provide new safety

messages.


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10 SEBU7892-07Safety SectionSafety Messages




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Safety Messages

Do Not Operate (1)

This warning is located on the rewall above the ROPS/FOPS plate.

g01370904

Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation and Maintenance

Manuals. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.


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No Ether (2)

This warning is located near the rain cap for the engine air intake. Thiswarning is located near the engine air precleaner (if equipped).

g01372254

Explosion hazard! Do not use ether! This machineis equipped with an air inlet heater. Using ether

can create explosions or res that can cause per-sonal injury or death. Read and follow the startingprocedure in the Operation and Maintenance Man-ual.


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Safety Messages

Water Cleaning System Under Pressure (3)

This warning label is located near the ller plug on the water tank on thetop of the cab.

g01379094

Do not remove the ll plug until the pressure in thewater tank has been relieved. Personal injury may

result.

This ll plug has a cross drilled hole that allowsthe pressure to be relieved without disengagingthe threads.

Do not replace this ll plug with any other plug.

For more information, refer to Operation and Maintenance Manual, WaterCleaning System (Pressurized).


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Seat Belt (4)

This warning is located on the left ROPS post.

g01371636

A seat belt should be worn at all times during ma-chine operation to prevent serious injury or deathin the event of an accident or machine overturn.Failure to wear a seat belt during machine opera-tion mayresult in serious injury or death.


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Safety Messages

ROPS/FOPS Structure (5)

This warning is located on the LH structural beam under the dash.

g01211895

Structural damage, an overturn, modication, al-teration, or improper repair can impair this struc-ture's protection capability thereby voiding this

certication. Do not weld on or drill holes in thestructure. This will void the certication. Consulta Caterpillar dealer to determine this structure'slimitations without voiding its certication.

This machine has been certied to the standards that are listed on thecertication plate. The maximum mass of the machine, which includesthe operator and the attachments without a payload, should not exceedthe mass on the certication plate.


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Compressed Spring (6)

This warning is located on the parking brake actuator.

g01379131

Do not attempt to remove spring(s), they are notserviceable. Do not cut, saw, torch or modify thischamber, serious injury or death may result.


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Safety Messages

No Clearance (7)

This warning is located on both sides of the machine near the articulationjoint.

g01371644

Crushing Hazard! Stay back a safe distance. Thereis no clearance for a person in this area when the

machine turns. Failure to follow these instructionscould cause serious injury or death.


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Safety Messages

Pressurized System (9)

This warning is located on the bottom of the radiator access door.

g01371640

Pressurized system! Hot coolant can cause seri-ous burns, injury or death. To open the coolingsystem ller cap, stop the engine and wait until

the cooling system components are cool. Loosenthe cooling system pressure cap slowly in order torelieve the pressure. Read and understand the Op-eration and Maintenance Manual before perform-ing any cooling system maintenance.


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Crushing hazard (10)

This warning is located near the articulation joint on the right side of themachine.

g01371647

Connect the steering frame lock between the frontand the rear frames before lifting, transporting, or

servicing the machine in the articulation area. Dis-connect the steering frame lock and secure thesteering frame lock before resuming operation.Severe injury or death could occur.


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Safety Messages

High Pressure Cylinder (11)

This warning is located on the mounting bracket of the brakeaccumulators.

g01372252

High Pressure Cylinder!

Do not remove any valve, hydraulic tting, or valvecore, nor disassemble any parts until pressurehas been relieved, or personal injury may occur.

To relieve pressure:

1. Refer to the Service Manual for the correctmethod of dissipating hydraulic systempressure.

2. Relieve gas pressure in the accumulatorcylinder by opening the charging valve oneturn only.

Charge the cylinder with dry nitrogen gas.

See your Caterpillar dealer for tools and detailedinformation required for charging cylinders.


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Battery (12)

This warning is located on the right side of the radiator guard.

g01370909

Explosion Hazard! Improper jumper cable connec-tions can cause an explosion resulting in seriousinjury or death. Batteries may be located in sep-

arate compartments. When using jump start ca-bles, always connect the positive (+) cable fromthe source to the positive (+) terminal of the bat-tery that is connected to the starter solenoid. Con-nect the negative () cable from the source to thenegative () terminal of the starter. If the machineis not equipped with a starter negative terminal,connect the negative () cable to the engine block.Follow the procedure in the Operation and Main-tenance Manual.


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Additional Messages

Product Link (13)

If your machine is equipped with the product link system, this warningis located in the cab.

g01370917

This machine is equipped with a Caterpillar Prod-uct Link communication device which must be de-

activated within 12 m (40 ft) of a blast zone. Failureto do so could result in serious injury or death.

i03991610

Additional Messages

SMCS Code: 7000

There are several additional messages on this machine. Please becomefamiliarized with all messages.


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24 SEBU7892-07Safety Section

Additional Messages


Make sure that all of the additional messages are legible. Clean themessages or replace the messages if you cannot read the words. Replace

the illustrations if the illustrations are not legible. When you clean themessages, use a cloth, water, and soap. Do not use solvent, gasoline,or other harsh chemicals to clean the messages. Solvents, gasoline, orharsh chemicals could loosen the adhesive that secures the message.Loose adhesive will allow the message to fall.

Replace any message that is damaged, or missing. If a message isattached to a part that is replaced, install a message on the replacementpart. Any Caterpillar dealer can provide new messages.

Winch (1)


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Additional Messages


This additional message is located next to the controls for the winch onthe RH console.

Reference: Refer to Operation and Maintenance Manual, OperatorControls for more information on the operation of the winch.

Window Cleaning (2)


This additional message is located on the bottom left corner of all cabwindows.

Clean the windows with a wet cloth or a wet sponge. A dry cloth or a drysponge may scratch the windows.


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26 SEBU7892-07Safety Section

Additional Messages

Reference:For more information, refer to Operation and MaintenanceManual, Windows - Clean.

Product Link (3)


If your machine is equipped with the Product Link System, this additionalmessage is located in the cab.

The Product Link System is a satellite communication device that

transmits information regarding the machine back to Caterpillar andCaterpillar dealers and customers. All logged events and diagnosticcodes that are available to the Caterpillar Electronic Technician (ET) onthe CAT data link can be sent to the satellite. Information can also be sentto the Product Link System. The information is used to improve Caterpillarproducts and Caterpillar services.

Refer to Operation and Maintenance Manual, Operator Controls formore information.

Fire Points (Engine) (4)


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Additional Messages


This message is located in two places on each side of the enginecompartment.

This message describes the re points that are available on the enginecompartments. Use the apertures in order to suppress re hazards inthe engine compartment.

Do not use an unsafe method in order to suppress re hazards in theengine compartment.


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28 SEBU7892-07Safety SectionGeneral Hazard Information

i04010649

General Hazard Information

SMCS Code: 7000


Attach a Do Not Operate warning tag or a similar warning tag to thestart switch or to the controls. Attach the warning tag before you servicethe equipment or before you repair the equipment. These warning tags(Special Instruction, SEHS7332) are available from your Cat dealer.

Operating the machine while distracted can resultin the loss of machine control. Use extreme cau-tion when using any device while operating themachine. Operating the machine while distractedcan result in personal injury or death.

Know the width of your equipment in order to maintain proper clearancewhen you operate the equipment near fences or near boundary obstacles.

Be aware of high voltage power lines and power cables that are buried.If the machine comes in contact with these hazards, serious injury ordeath may occur from electrocution.


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Wear a hard hat, protective glasses, and other protective equipment,as required.

Do not wear loose clothing or jewelry that can snag on controls or onother parts of the equipment.

Make sure that all protective guards and all covers are secured in placeon the equipment.

Keep the equipment free from foreign material. Remove debris, oil, tools,and other items from the deck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools, and other items thatare not a part of the equipment.

Know the appropriate work site hand signals and the personnel thatare authorized to give the hand signals. Accept hand signals from oneperson only.

Do not smoke when you service an air conditioner. Also, do not smoke ifrefrigerant gas may be present. Inhaling the fumes that are released froma ame that contacts air conditioner refrigerant can cause bodily harm

or death. Inhaling gas from air conditioner refrigerant through a lightedcigarette can cause bodily harm or death.

Never put maintenance uids into glass containers. Drain all liquids intoa suitable container.

Obey all local regulations for the disposal of liquids.


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Use all cleaning solutions with care. Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Unless you are instructed otherwise, perform maintenance with theequipment in the servicing position. Refer to Operation and MaintenanceManual for the procedure for placing the equipment in the servicingposition.

When you perform maintenance above ground level, use appropriatedevices such as ladders or man lift machines. If equipped, use the

machine anchorage points and use approved fall arrest harnesses andlanyards.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or hot water to beblown out. The debris and/or hot water could result in personal injury.

When pressurized air and/or pressurized water is used for cleaning, wearprotective clothing, protective shoes, and eye protection. Eye protectionincludes goggles or a protective face shield.

The maximum air pressure for cleaning purposes must be reduced to205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used

with an effective chip deector and personal protective equipment. Themaximum water pressure for cleaning purposes must be below 275 kPa(40 psi).

Trapped Pressure

Pressure can be trapped in a hydraulic system. Releasing trappedpressure can cause sudden machine movement or attachment movement.Use caution if you disconnect hydraulic lines or ttings. High-pressureoil that is released can cause a hose to whip. High-pressure oil thatis released can cause oil to spray. Fluid penetration can cause seriousinjury and possible death.

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine hasbeen stopped. The pressure can cause hydraulic uid or items such aspipeplugs to escape rapidly if the pressure is not relieved correctly.


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Do not remove any hydraulic components or parts until pressure has beenrelieved or personal injury may occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relieved or personal injurymay occur. Refer to the ServiceManual for any procedures that arerequired to relieve the hydraulic pressure.


Always use a board or cardboard when you check for a leak. Leaking uidthat is under pressure can penetrate body tissue. Fluid penetration cancause serious injury and possible death. A pin hole leak can cause severe

injury. If uid is injected into your skin, you must get treatment immediately.Seek treatment from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken in order to ensure that uids are contained duringperformance of inspection, maintenance, testing, adjusting, and repairof the equipment. Prepare to collect the uid with suitable containersbefore opening any compartment or disassembling any component thatcontains uids.

Refer to Special Publication, NENG2500, Caterpillar Dealer Service ToolCatalog for the following items:

Tools that are suitable for collecting uids and equipment that is suitablefor collecting uids

Tools that are suitable for containing uids and equipment that issuitable for containing uids


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Obey all local regulations for the disposal of liquids.

Inhalation


Exhaust

Use caution. Exhaust fumes can be hazardous to your health. If youoperate the machine in an enclosed area, adequate ventilation isnecessary.

Asbestos Information

Cat equipment and replacement parts that are shipped from Caterpillarare asbestos free. Caterpillar recommends the use of only genuine Catreplacement parts. Use the following guidelines when you handle anyreplacement parts that contain asbestos or when you handle asbestosdebris.

Use caution. Avoid inhaling dust that might be generated when youhandle components that contain asbestos bers. Inhaling this dust canbe hazardous to your health. The components that may contain asbestosbers are brake pads, brake bands, lining material, clutch plates, and

some gaskets. The asbestos that is used in these components is bound ina resin or sealed in some way. Normal handling is not hazardous unlessairborne dust that contains asbestos is generated.

If dust that may contain asbestos is present, there are several guidelinesthat should be followed:


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Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestos materials.

A vacuum cleaner that is equipped with a high efciency particulateair lter (HEPA) can also be used.

Use exhaust ventilation on permanent machining jobs.

Wear an approved respirator if there is no other way to control the dust.

Comply with applicable rules and regulations for the work place. Inthe United States, use Occupational Safety and Health Administration(OSHA) requirements. These OSHA requirements can be found in29 CFR 1910.1001.

Obey environmental regulations for the disposal of asbestos.

Stay away from areas that might have asbestos particles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten the environment. Potentiallyharmful uids should be disposed of according to local regulations.


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34 SEBU7892-07Safety SectionCrushing Prevention and Cutting Prevention

Always use leakproof containerswhen you drain uids. Do not pour wasteonto the ground, down a drain, or into any source of water.

i01359664

Crushing Prevention and CuttingPrevention

SMCS Code: 7000

Support the equipment properly before you perform any work ormaintenance beneath that equipment. Do not depend on the hydrauliccylinders to hold up the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Do not work beneath the cab of the machine unless the cab is properlysupported.

Unless you are instructed otherwise, never attempt adjustments while themachine is moving or while the engine is running.

Never jump across the starter solenoid terminals in order to start theengine. Unexpected machine movement could result.

Whenever there are equipment control linkages the clearance in thelinkage area will change with the movement of the equipment or themachine. Stay clear of areas that may have a sudden change in clearancewith machine movement or equipment movement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to perform maintenance,always install the guards after the maintenance is performed.

Keep objects away from moving fan blades. The fan blade will throwobjects or cut objects.

Do not use a kinked wire cable or a frayed wire cable. Wear gloves when

you handle wire cable.

When you strike a retainer pin with force, the retainer pin can y out. Theloose retainer pin can injure personnel. Make sure that the area is clear ofpeople when you strike a retainer pin. To avoid injury to your eyes, wearprotective glasses when you strike a retainer pin.


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Burn Prevention

Chips or other debris can y off anobject when you strike the object. Makesure that no one can be injured by ying debris before striking any object.

i01329099

Burn Prevention

SMCS Code: 7000

Do not touch any part of an operating engine. Allow the engine to coolbefore any maintenance is performed on the engine. Relieve all pressure

in the air system, in the oil system, in the lubrication system, in the fuelsystem, or in the cooling system before any lines, ttings or related itemsare disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot.The coolant is also under pressure. The radiator and all lines to theheaters or to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allowcooling system components to cool before the cooling system is drained.

Check the coolant level only after the engine has been stopped.

Ensure that the ller cap is cool before removing the ller cap. The llercap must be cool enough to touch with a bare hand. Remove the ller capslowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can cause personalinjury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils

Hot oil and hot components can cause personal injury. Do not allow hot oilto contact the skin. Also, do not allow hot components to contact the skin.

Remove the hydraulic tank ller cap only after the engine has beenstopped. The ller cap must be cool enough to touch with a bare hand.Follow the standard procedure in this manual in order to remove thehydraulic tank ller cap.


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36 SEBU7892-07Safety SectionFire Prevention and Explosion Prevention

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do notallow electrolyte to contact the skin or the eyes. Always wear protectiveglasses for servicing batteries. Wash hands after touching the batteriesand connectors. Use of glovesis recommended.

i03863998

Fire Prevention and Explosion Prevention

SMCS Code: 7000


General

Much of the material that is found in forestry applications is highlyammable. This includes the following pieces: limbs, bark, leaves,sawdust, small wood chips, and pine tree's needles. When this debrisfrom forestry applications is soaked with fuel or lubricants, the risk ofre is greatly increased. Perform a daily inspection before every shift ormoreoften when the amount of work output and buildup of debris is thebest way to prevent a machine re. Frequent inspections and thoroughcleanings of the machine are critical when the machine is engaged inforestry applications. Even minor leaks or electrical malfunctions shouldbe repaired as soon as possible.

All fuels, most lubricants, and some coolant mixtures are ammable.


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To minimize the risk of re or explosion, Caterpillar recommends thefollowing actions.

Always perform a Walk-Around Inspection, which may help you identify are hazard. Do not operate a machine when a re hazard exists. Contactyour Caterpillar dealer for service.

Understand the use of the primary exit and alternative exit on themachine. Refer to Operation and Maintenance Manual, Alternative Exit.

Do not operate a machine with a uid leak. Repair leaks and clean up

uids before resuming machine operation. Fluids that are leaking orspilled onto hot surfaces or onto electrical components can cause a re. Are may cause personal injury or death.

Keep the access doors to major machine compartments closed andaccess doors in working condition in order to permit the use of resuppression equipment, in case a re should occur.

Highly ammable debris can collect on equipment and in equipment thatis used in forestry applications. This debris includes the following pieces:leaves, twigs,sawdust, small wood chips, , and pine tree's needles. Ifthe debris is allowed to accumulate, the debris can rapidly become thefuel agent of a machine re. Clean all accumulations of forest debris inthe engine compartment or around other hot areas and hot parts on the

machine at the completion of each work shift. Perform this activity morefrequently when working in conditions with large amounts of forest debrisare present.

Clean all accumulations of ammable materials such as fuel, oil anddebris fromthe machine.

Do not operate the machine near any ame.

Keep shields in place. Exhaust shields (if equipped) protect hot exhaustcomponents from oil spray or fuel spray in case of a break in a line, in ahose, or in a seal. Exhaust shields must be installed correctly.

Do not weld or ame cut on tanks or lines that contain ammable uids

or ammable material. Empty and purge the lines and tanks. Then cleanthe lines and tanks with a nonammable solvent prior to welding or amecutting. Ensure that the components are properly grounded in order toavoid unwanted arcs.


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Dust that is generated from repairing nonmetallic hoods or fendersmay be ammable and/or explosive. Repair such components in a wellventilated area away from open ames or sparks. Use suitable PersonalProtection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration. Replace damagedlines and hoses. The lines andthe hoses should have adequate supportand secure clamps. Tighten all connections to the recommended torque.Damage to the protective cover or insulation may provide fuel for res.

Store fuels and lubricants in properly marked containers away from

unauthorized personnel. Store oily rags and ammable materials inprotective containers. Do not smoke in areas that are used for storingammable materials.


Use caution when you are fueling a machine. Do not smoke while youare fueling a machine. Do not fuel a machine near open ames or sparks.

Always stop the engine before fueling. Fill the fuel tank outdoors. Properlyclean areas of spillage.


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Follow practices for safe fueling that are described in the Operationsection of the Operation and Maintenance Manual section and follow localregulations. Never store ammable uids in the operator compartmentof the machine.

Battery and Battery Cables


Caterpillar recommends the following in order to minimize the risk of reor an explosion related to the battery.

Do not operate a machine if battery cables or related parts show signs ofwear or damage. Contact your Caterpillar dealer for service.

Follow safe procedures for engine starting with jump start cables.Improper jumper cable connections can cause an explosion that mayresult in injury. Refer to Operation and Maintenance Manual, Engine

Starting with Jump Start Cables for specic instructions.

Do not charge a frozen battery. This may cause an explosion.

Gases from a battery can explode. Keep any open ames or sparks awayfrom the top of a battery. Do not smoke in battery charging areas.


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Never check the battery charge byplacing a metal object across theterminal posts. Use a voltmeter in order to check the battery charge.

Daily inspect battery cables that are in areas that are visible. Inspectcables, clips, straps, and other restraints for damage. Replace anydamaged parts. Check for signs of the following, which can occur overtime due to use and environmental factors:

Fraying

Abrasion

Cracking

Discoloration

Cuts on the insulation of the cable

Fouling

Corroded terminals, damaged terminals, and loose terminals

Replace damaged battery cable(s) and replace any related parts.Eliminate any fouling, which may have caused insulation failure or relatedcomponent damage or wear. Ensure that all components are reinstalled

correctly.

An exposed wire on the battery cable may cause a short to ground if theexposed area comes into contact with a grounded surface. A battery cableshort produces heat from the battery current, which may be a re hazard.

An exposed wire on the ground cable between the battery and thedisconnect switch may cause the disconnect switch to be bypassed ifthe exposed area comes into contact with a grounded surface. Thismay result in an unsafe condition for servicing the machine. Repaircomponents or replace components before servicing the machine.


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Fire on a machine can result in personal injuryor death. Exposed battery cables that come intocontact with a grounded connection can result inres. Replace cables and related parts that showsigns of wear or damage. Contact your Caterpillardealer.

Wiring

Check electrical wires daily. If any of the following conditions exist, replaceparts before you operate the machine.

Fraying

Signs of abrasion or wear

Cracking

Discoloration

Cuts on insulation

Other damage

Make sure that all clamps, guards, clips, and straps are reinstalledcorrectly. This will help to prevent vibration, rubbing against other parts,and excessive heat during machine operation.

Attaching electrical wiring to hoses and tubes that contain ammableuids or combustible uids should be avoided.

Consult your Caterpillar dealer for repair or for replacement parts.

Keep wiring and electrical connections free of debris.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike high pressure lines. Do notinstall any lines that are bent or damaged. Use the appropriate backupwrenches in order to tighten all connections to the recommended torque.


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Check lines, tubes and hoses carefully. Wear Personal ProtectionEquipment (PPE) in order to check for leaks. Always use a board orcardboard when you check for a leak. Leaking uid that is under pressurecan penetrate body tissue. Fluid penetration can cause serious injury andpossible death. A pin hole leak can cause severe injury. If uid is injectedinto your skin, you must get treatment immediately. Seek treatment froma doctor that is familiar with this type of injury.

Replace the affected parts if any of the following conditions are present:

End ttings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are swelling or ballooning.

Flexible parts of the hoses are kinked.

Outer covers have exposed embedded armoring.

End ttings are displaced.Make sure that all clamps, guards, and heat shields are installed correctly.During machine operation, this will help to prevent vibration, rubbingagainst other parts, excessive heat, and failure of lines, tubes and hoses.


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Do not operate a machine when a rehazard exists. Repair any linesthat are corroded, loose or damaged. Leaks may provide fuel for res.Consult your Caterpillar dealer for repair or for replacement parts. Usegenuine Caterpillar parts or the equivalent, for capabilities of both thepressure limit and temperature limit.

Ether

Ether (if equipped) is commonly used in cold weather applications. Etheris ammable and poisonous.

Follow the correct cold engine starting procedures. Refer to the section inthe Operation and Maintenance Manual with the label Engine Starting.

Do not spray ether manually into an engine if the machine is equippedwith a thermal starting aid for cold weather starting.

Use ether in well ventilated areas. Do not smoke while you are replacingan ether cylinder or while you are using an ether spray.

Do not store ethercylinders in living areas or in the operator compartmentof a machine. Do not store ether cylinders in direct sunlight or intemperatures above 49 C (120.2 F). Keep ether cylinders away fromopen ames or sparks.

Dispose of used ether cylinders properly. Do not puncture an ethercylinder. Keep ether cylinders away from unauthorized personnel.

Fire Extinguisher

As an additional safety measure, keep a re extinguisher on the machine.

Be familiar with the operation of the re extinguisher. Inspect the reextinguisher and service the re extinguisher regularly. Follow therecommendations on the instruction plate.

Consider installation of an aftermarket Fire Suppression System, if theapplication and working conditions warrant the installation.


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44 SEBU7892-07Safety SectionFire Extinguisher Location

i02399496

Fire Extinguisher Location

SMCS Code: 7000

Make sure that a re extinguisher is on the machine. Make sure that youare familiar with the operation of the re extinguisher. Inspect the reextinguisher and service the re extinguisher. Obey the recommendationson the instruction plate.


The recommended location for mounting the re extinguisher is the insideof the left cab door.

The re extinguisher may be mounted on the Rollover ProtectiveStructure (ROPS) instead. Do not weld the ROPS in order to install there extinguisher. Also, do not drill holes in the ROPS in order to mountthe re extinguisher on the ROPS.

Strap the mounting plate to a leg of the ROPS in order to mount the reextinguisher. If the weight of the re extinguisher is more than 4.5 kg(10 lb), mount the re extinguisher as low as possible on one leg. Do notmount the re extinguisher on the upper one-third area of the leg.


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Tire Information

i04160129

Tire Information

SMCS Code: 7000

Explosions of air inated tires have resulted from heat-induced gascombustion inside the tires. Explosions can be caused by heat that isgenerated by welding, by heating rim components, by external re, orby excessive use of brakes.

A tire explosion is much more violent than a blowout. The explosion canpropel the tire, the rim components, and the axle components from themachine. Stay out of the trajectory path. Both the force of the explosionand the ying debris can cause property damage, personal injury, ordeath.


Typical example of tire is shown

Do not approach a hot or an apparently damaged tire.

Caterpillar recommends against using water or calcium as a ballast forthe tires except in machines designed for this additional mass. For thoseapplicable machines, the maintenance section will contain instructions onthe correct tire ination and lling procedures. Ballast, such as uid in thetires, increases overall machine weight and may affect braking, steering,power train components, or the certication of the protective structuresuch as the ROPS. The use of tire/rim rust preventatives or other liquidadditives is not required.


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46 SEBU7892-07Safety SectionElectrical Storm Injury Prevention

Dry nitrogen gas is recommended for ination of tires. If the tires wereoriginally inated with air, nitrogen is still preferred for adjusting thepressure. Nitrogen mixes properly with air.

Nitrogen inated tires reduce the potential of a tire explosion becausenitrogen does not aid combustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration ofrubber, and corrosion of rim components.

To avoid overination, proper nitrogen ination equipment and training inthe usage of the equipment are necessary. A tire blowout or a rim failurecan result from improper equipment or from misused equipment.

When you inate a tire, stand behind the tread and use a self-attachingchuck.

Servicing tires and rims can be dangerous. Only trained personnel thatuse proper tools and proper procedures should perform this maintenance.If correct procedures are not used for servicing tires and rims, theassemblies could burst with explosive force. This explosive force cancause serious personal injury or death. Carefully obey the specicinstructions from your tire dealer.

i01122596

Electrical Storm Injury Prevention

SMCS Code: 7000

When lightning is striking in the vicinity of the machine, the operatorshould never attempt the following procedures:

Mount the machine.

Dismount the machine.

If you are in the operator's station during an electrical storm, stay in theoperator's station. If you are on the ground during an electrical storm, stayaway from the vicinity of the machine.


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Before Starting Engine

i00934890

Before Starting Engine

SMCS Code: 1000; 7000

The steering frame lock must be in the unlocked position in order to steerthe machine.

Start the engine only from the operator compartment. Never short acrossthe starter terminals or across the batteries. Shorting could bypass theengine neutral start system. Shorting could also damage the electricalsystem.

Inspect the condition of the seat belt and the condition of mountinghardware. Replace any parts that are worn or damaged. Regardless ofthe appearance, replace the seat belt after three years of use. Do not usea seat belt extension on a retractable seat belt.

Adjust the seat so that there is full pedal travel while the operator's backis against the back of the seat.

Make sure that the machine is equipped with a lighting system that isadequate for the job conditions. Make sure that all lights are workingproperly.

Before you start the engine or before you move the machine, make surethat no one ison the machine, underneath the machine, or around themachine. Make sure that there are no personnel in the area.

i03162317

Visibility Information

SMCS Code: 7000

Before you start the machine, perform a walk-around inspection in orderto ensure that there are no hazards around the machine.

While the machine is in operation, constantly survey the area around themachine in order to identify potential hazards as hazards become visiblearound the machine.


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48 SEBU7892-07Safety SectionEngine Starting

Your machine may be equipped withvisual aids. Some examples of visualaids are Closed Circuit Television (CCTV) and mirrors. Before operatingthe machine, ensure that the visual aids are in proper working conditionand that the visual aids are clean. Adjust the visual aids using theprocedures that are located in this Operation and Maintenance Manual.If equipped, the Work Area Vision System shall be adjusted accordingto Operation and MaintenanceManual, SEBU8157, Work Area VisionSystem.

It may not be possible toprovide direct visibility on large machines to allareas around the machine. Appropriate job site organization is required

in order to minimize hazards that are caused by restricted visibility. Jobsite organization is acollection of rules and procedures that coordinatesmachines and people that work together in the same area. Examples of

job site organization include the following:

Safety instructions

Controlled patterns of machine movement and vehicle movement

Workers that direct trafc to move when it is safe

Restricted areas

Operator training

Warning symbols or warning signs on machines or on vehicles

A system of communication

Communication between workers and operators prior to approachingthe machine

Modications of the machine conguration by the user that result in arestriction of visibility shall be evaluated.

i03690423

Engine Starting

SMCS Code: 1000; 7000

If a warning tag is attached to the engine start switch or to the controls, donot start the engine and do not move any controls.


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Before Operation

Move all hydraulic controls to the HOLD position before you start theengine.

Move the transmission controlto the NEUTRAL position.

Engage the parking brake.

Diesel engine exhaust contains products of combustion which can beharmful to your health. Always operate the engine in a well ventilatedarea. If you are in an enclosed area, vent the exhaust to the outside.

Briey sound the horn before you start the engine.

Check for the presence of personnel. Ensure that all personnel are clearof the machine.

i01360271

Before Operation

SMCS Code: 7000

Make sure that there are no personnel on the machine or in the areaaround the machine.

Perform a walk-around inspection. Check all of the uid levels. Look forloose bolts, leaks, and parts that are worn or broken. Inspect the conditionof the attachments and the condition of the hydraulic components.

Clear all obstacles from the path of the machine. Beware of hazards suchas wires, ditches, etc.

Make sure that all windows are clean. Secure the doors and the windowsin the shut position.

Adjust the rear view mirrors (if equipped) for the best vision of theareanear the machine.

Make sure that the horn, the backup alarm (if equipped), and all other

warning devices are working properly.

Fasten the seat belt securely.


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Engine Stopping

Turn the machine downhill.

Avoid operating the machine across the slope. When possible, operatethe machine up the slopes and down the slopes.

Avoid any conditions that can lead to tipping the machine. The machinecan tip when you work on hills,on banks and on slopes. Also, the machinecan tip when you cross ditches, ridges, or other unexpected obstructions.

Maintain control of themachine. Do not overload the machine beyondthe machine capacity.

Never straddle a wire cable. Never allow other personnel to straddle awire cable.

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure (ROPS) installed duringmachine operation.

i02624835

Engine Stopping

SMCS Code: 1000; 7000

Do not stop the engine immediately after the machine has been operatedunder load. This can cause overheating and accelerated wear of enginecomponents.

After the machine is parked and the parking brake is engaged, allow theengine to run for two minutes before shutdown. This allows hot areas ofthe engine to cool gradually.

i03907830

Parking

SMCS Code: 7000

Park the machine on a level surface. If you must park the machine on adowngrade, block the tires.

Apply the service brake in order to stop the machine. Move thetransmission control to the NEUTRAL position.


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52 SEBU7892-07Safety SectionSlope Operation

Engage the parking brake.

Lower all work tools to the ground. Activate any control locks.

Stop the engine.

Turn the engine start switch to the OFF position and remove the key.

Always turn the battery disconnect switch to the OFF position beforeleaving the machine.

If the machine will not be operated for a month or more, remove thebattery disconnect switch key.

i03745198

Slope Operation

SMCS Code: 7000

Machines that are operating safely in various applications depend onthese criteria: the machine model, conguration, machine maintenance,operating speed of the machine, conditions of the terrain, uid levels,and tire ination pressures. The most important criteria are the skill and

judgment of the operator.

A well trained operator that follows the instructions in the Operationand Maintenance Manual has the greatest impact on stability. Operatortraining provides a person with the following abilities: observation ofworking and environmental conditions, feel for the machine, identicationof potential hazards, and operating the machine safely by makingappropriate decisions.

When you work on side hills and when you work on slopes, consider thefollowing important points:

Speed of travel At higher speeds, forces of inertia tend to make themachine less stable.

Roughness of terrain or surface The machine may be less stablewith uneven terrain.


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Slope Operation

Direction of travel Avoid operating the machine across the slope.When possible, operate the machine up the slopes and operate themachine down the slopes. Place the heaviest end of the machine uphillwhen you are working on an incline.

Mounted equipment Balance of the machine may be impeded bythe following components: equipment that is mounted on the machine,machine conguration, weights, and counterweights.

Nature of surface Ground that has been newly lled with earth maycollapse from the weight of the machine.

Surface material Rocks and moisture of the surface material maydrastically affect the machine's traction and machine's stability. Rockysurfaces may promote side slipping of the machine.

Slippage due to excessive loads This may cause downhill tracksor downhill tires to dig into the ground, which will increase the angle ofthe machine.

Width of tracks or tires Narrower tracks or narrower tires furtherincrease the digging into the ground which causes the machine to beless stable.

Implements attached to the drawbar This may decrease the weight

on the uphill tracks. This may also decrease the weight on the uphill tires.The decreased weight will cause the machine to be less stable.

Height of the working load of the machine When the working loadsare in higher positions, the stability of the machine is reduced.

Operated equipment Be aware of performance features of theequipment in operation and the effects on machine stability.

Operating techniques Keep all attachments or pulled loads low tothe ground for optimum stability.

Machine systems have limitations on slopes Slopes can affect theproper function and operation of the various machine systems. These

machine systems are needed for machine control.

Note: Safe operation on steep slopes may require special machinemaintenance. Excellent skill of the operator and proper equipmentfor specic applications are also required. Consult the Operation andMaintenance Manual sections for the proper uid level requirements andintended machine use.


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54 SEBU7892-07Safety SectionWork Tools

i04159629

Work Tools

SMCS Code: 6700

Only use work tools that are recommended by Caterpillar for use onCat machines.

Use of work tools, including buckets, which are outside of Caterpillar'srecommendations or specications for weight, dimensions, ows,pressures, and so on. may result in less-than-optimal vehicle performance,including but not limited to reductions in production, stability, reliability,and component durability. Caterpillar recommends appropriate worktools for our machines to maximize the value our customers receivefrom our products. Caterpillar understands that special circumstancesmay lead a customer to use tools outside of our specications. In thesecases, customers must be aware that such choices can reduce vehicleperformance and will affect their ability to claim warranty in the event ofwhat a customer may perceive as a premature failure.

Work tools and work tool control systems, that are compatible with yourCat machine, are required for safe machine operation and/or reliablemachine operation. If you are in doubt about the compatibility of aparticular work tool with your machine, consult your Cat dealer.

Make sure that all necessary guarding is in place on the host machineand on the work tool.

Keep all windows and doors closed on the host machine. A polycarbonateshield mustbe used when the host machine is not equipped with windowsand when a work tool could throw debris.

Do not exceed the maximum operating weight that is listed on the ROPScertication.

If your machine is equipped with an extendable stick, install the transportpin when you are using the following work tools: hydraulic hammers,augers, and compactors

Always wear protective glasses. Always wear the protective equipmentthat is recommended in the operation manual for the work tool. Wear anyother protective equipment that is required for the operating environment.

To prevent personnel from being struck by ying objects, ensure that allpersonnel are out of the work area.


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Equipment Lowering with Engine Stopped

While you are performing any maintenance, any testing, or anyadjustments to the work tool stay clear of the following areas: cuttingedges, pinching surfaces, and crushing surfaces.

Never use the work tool for a work platform.

i01329161

Equipment Lowering with Engine Stopped

SMCS Code: 7000

Before lowering any equipment with the engine stopped, clear the areaaround the equipment of all personnel. The procedure to use will vary withthe type of equipment to be lowered. Keep in mind most systems use ahigh pressure uid or air to raise or lower equipment. The procedure willcause high pressure air, hydraulic, or some other media to be releasedin order to lower the equipment. Wear appropriate personal protectiveequipment and follow the established procedure in the Operation andMaintenance Manual, Equipment Lowering with Engine Stopped in theOperation Section of the manual.

i00457455

Sound Information and VibrationInformation

SMCS Code: 7000

The operator sound exposure Leq (equivalent sound pressure level)measured according to the work cycle procedures specied in ANSI/SAEJ1166May90 is 85 dB(A). This applies to the cab offered by Caterpillar,when properly installed and maintained and tested with the doors andwindows closed.

The operator sound pressure level measured according to the proceduresspecied in SAE J919Jun86 is 85 dB(A), for the cab offered byCaterpillar, when properly installed and maintained and tested with the

doors and windows closed and with the machine in middle gear rangeand moving.


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56 SEBU7892-07Safety SectionSound Information and Vibration Information

The exterior sound pressure level for the standard machine measured ata distance of 15 m (49.2 ft) according to the test procedures specied inSAE J88Jun86, with the machine in middle gear range and moving,is 88 dB(A).

Sound Performance for Machines Offered inEuropean Union Countries and in Countries thatAdopt the EU Directives

The operator sound pressure level is 85 dB(A) measured according

to the static test procedures and conditions specied in ISO 6394 or86/662/EEC.

As manufactured by Caterpillar, this machine's exterior sound power levelmeets the criteria specied in the European Directives noted on thecerticate of conformance and the accompanying labels.

The operator sound pressure level is 85 dB(A) measured accordingto dynamic test procedures and conditions specied in ISO 6396 or95/27/EC.

As manufactured by Caterpillar, this machine's exterior sound power levelmeets the criteria specied in the European Directives noted on thecerticate of conformance and the accompanying labels.

Vibration Level

The hands and arms are exposed to a weighted root mean squareacceleration that is less than 2.5 m/sec2.

The whole body is exposed to a weighted root mean square accelerationthat is less than 0.5 m/s2.

Measurements are obtained on a representative machine using theprocedures in the following standards:

ISO 2631/1

ISO 5349

SAE J1166


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Operator Station

i03634321

Operator Station

SMCS Code: 7000

Any modications to the inside of the operator station should not projectinto the operator space or into the space for the companion seat (ifequipped). The addition of a radio, re extinguisher, and other equipmentmust be installed so that the dened operator space and the space forthe companion seat (if equipped) is maintained. Any item that is broughtinto the cab should not project into the dened operator space or thespace for the companion seat (if equipped). A lunch box or other looseitems must be secured. Objects must not pose an impact hazard in roughterrain or in the event of a rollover.


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58 SEBU7892-07Product Information SectionGeneral Information

Product Information Section

General Information

i02207491

Specications

SMCS Code: 7000

Specications for the 525C

Three sizes of grapple are available for the 525C Wheel Skidder.

The 525C is equipped with a C7 Engine.


Bunching and Thinning Grapple

The bunching head is primarily used when the diameters of the logs areconsistent or when the diameters of the logs are under 305 mm (12 inch).The bunching head is suited for operations that use a feller buncher.


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SEBU7892-07 59Product Information Section

General Information


Sorting Grapple

Table 1

525C Grapple Continuous Rotation

Sorting Bunching Thinning

A Grapple

Capacity0.83 m2

(9 ft2)1.16 m2

(12.5 ft2)1.34 m2

(14.4 ft2)

B Tip to TipHeight

2045 mm

(80.5inch)

1920 mm

(75.6inch)

1981 mm(78 inch)

C Tong

Opening2540 mm(100 inch)

3050 mm(120 inch)

3124 mm(123 inch)

D Full Open

Height

1590 mm(62.6inch)

1677 mm(66 inch)

1832 mm(72.1 inch)

EMinimum

StemDiameter

76 mm(3 inch)

155 mm(6 inch)

190 mm(7.5 inch)

FFully

Closed

Height

1829 mm(72 inch)

1285 mm(50.6

inch)

1371 mm(54 inch)


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Dual Function


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General Information


Single Function


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Table 2

525C Function Arch

SingleFunction

Dual Funtion

A Lift Highest,

Retracted2212 mm

(87.1 inch)2623 mm

(103.3 inch)

B Lift Highest,

Farthest1944 mm

(76.5 inch)

C Lift Maximum

Reach

1336 mm

(52.6 inch)

D Lift Lowest,

Retracted752 mm

(29.6 inch)

E Lift Lowest,

Farthest600 mm

(23.6 inch)259 mm

(10.2 inch)

F Loaded Tire

Radius(1)843 mm(33 inch)

843 mm(33.2 inch)

GReach

Highest,Retracted

1630 mm(64.2 inch)

1513 mm(59.6 inch)

H Reach Lowest,

Retracted1469 mm

(57.8 inch)

I Reach Lowest,

Farthest2521 mm

(99.3 inch)2488 mm(98 inch)

JReach

Highest,Farthest

2765 mm(108.9 inch)

K Reach

Maximum2880 mm

(113.4 inch)

(1) With 30.5 x 32 tires


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General Information



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Table 3

525C Machine Dimensions

Ground Level to Top Boom(Grapple)

Dual FunctionSingle Function

4103 mm (161.5 inch)3760 mm (148 inch)

Ground Level to Top Roller(Cable)

2794 mm (110 inch)

Ground Level to AxleCenter Line(1)

843 mm (33.2 inch)

Rear Axle Center Line to Pin 1798 mm (70.8 inch)

Wheel Base 3534 mm (139.2 inch)

Overall Length (Grapple)Dual Function

Single Function

7626 mm (300.2 inch)8369 mm (329.4 inch)

Overall Length (Cable) 6945 mm (273.4 inch)

Ground Clearance 581 mm (22.9 inch)

Decking Blade Lift Height 1381 mm (54.4 inch)

Decking Blade Dig Depth 456 mm (17.9 inch)

Heightto Top of Cab(2) 3184.4 mm (125.4 inch)

Decking Blade Width 3138 mm (123.5 inch)

Tread Width 2622 mm (103.2 inch)

Overall WidthTurning Radius Over Tires(1)

3398mm (133.8 inch)6000mm (226.2 inch)

Approximate Maximum Weightwith Attachments

18416 kg (40600 lb)

(1) With 30.5 x 32 tires(2) Add 188 mm (7.4 inch) if equipped with optional lights or water

tank.


Two sizes of grapple is available for the 535C Wheel Skidder.

The 535C is equipped with a C-7 engine.


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General Information


The bunching head is primarily used when the diameters of the logs areconsistent or when the diameters of the logs are under 305 mm (12 inch).

The bunching head is suited for operations that use a feller buncher.


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Table 4


Bunching Thinning

A Grapple

Capacity1.34 m2

(14.4 ft2)1.54 m2

(16.6 ft2)

B Tip to Tip

Height1981 mm(78 inch)

2108 mm(83 inch)

C Tong Opening 3124 mm

(123 inch)3226 mm(127 inch)

D Full Open

Height1832 mm

(72.1 inch)1905 mm(75 inch)

EMinimum

StemDiameter

190 mm(7.5 inch)

183 mm(7.2 inch)

F Fully Closed


1371 mm(54 inch)



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General Information

Table 5

535C Dual Function Arches

StandardBoom

ExtendedBoom

A Lift Highest,

Retracted2623 mm

(103.3 inch)2847 mm

(112.1 inch)

B Lift Highest,

Farthest1944 mm

(76.5 inch)2192 mm

(86.3 inch)

C Lift Maximum

Reach1336 mm

(52.6 inch)1336 mm

(52.6 inch)

D Lift Lowest,

Retracted752 mm

(29.6 inch)764 mm

(30.1 inch)

E Lift Lowest,

Farthest259 mm

(10.2 inch)286 mm

(11.3 inch)

F Loaded Tire

Radius(1)843 mm(33 inch)

843 mm(33.2 inch)

GReach

Highest,Retracted

1513 mm(59.6 inch)

1546 mm(60.9 inch)

H Reach Lowest,

Retracted1469 mm

(57.8 inch)1666 mm

(65.6 inch)

I Reach Lowest,

Farthest2488 mm(98 inch)

2706 mm(106.5 inch)

JReach

Highest,Farthest

2765 mm(108.9 inch)

2825 mm(111.2 inch)

K Reach

Maximum2880 mm

(113.4 inch)3037 mm

(119.6 inch)



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General Information

Table 6


Ground Level to Top Boom(Grapple)StandardExtended

4103 mm (161.5 inch)4304 mm (169.4 inch)

Ground Level to Top Roller(Cable)

2794 mm (110 inch)


843 mm (33.2 inch)



Overall Length (Grapple)Standard BoomExtended Boom

7626 mm (300.2 inch)7514 mm (295.8 inch)


Ground Clearance 533 mm (21 inch)



Heightto Top of Cab(2) 3184.4 mm (125.4 inch)




3398mm (133.8 inch)6000mm (226.2 inch)

Approximate Maximum Weightwith Attachments

18689 kg (41200 lb)


tank.


Two sizes of grapple are available for the 545C Wheel Skidder.

The 545C is equipped with a C-7 engine.


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The bunching head is primarily used when the diameters of the logs areconsistent or when the diameters of the logs are under 305 mm (12 inch).

The bunching head is suited for operations that use a feller buncher.


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General Information

Table 7


Bunching Thinning

A Grapple

Capacity1.54 m2

(16.6 ft2)1.78 m2

(19.0 ft2)

B Tip to Tip


2159 mm(85 inch)

C Tong Opening 3226 mm

(127 inch)3429 mm(135 inch)

D Full Open


1880 mm(74 inch)

EMinimum

StemDiameter

183 mm(7.2 inch)

241 mm(9.5 inch)

F Fully Closed


1473 mm(58 inch)



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Table 8

545C Dual Function Arch

Continuous Rotation

A Lift Highest, Retracted 2817 mm (111 inch)

B Lift Highest, Farthest 2163 mm (85 inch)

C Lift Maximum Reach 1443 mm (57 inch)

D Lift Lowest, Retracted 1014 mm (40 inch)

E Lift Lowest, Farthest 335 mm (13 inch)

F Loaded Tire Radius(1) 843 mm (33 inch)

G Reach Highest,

Retracted 1653 mm (65 inch)

H Reach Lowest,

Retracted 1775 mm (70 inch)

I Reach Lowest,

Farthest 2762 mm (109 inch)

J Reach Highest,

Farthest 2978 mm (117 inch)

K Reach Maximum 3121 mm (123 inch)



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General Information



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Table 9


Ground Level to Top Boom(Grapple)

4302 mm (169.4 inch)

Ground Level to TopRoller (Cable)

2771 mm (109 inch)


843 mm (33.2 inch)



Overall Length (Grapple) 8028 mm (316 inch)


Ground Clearance 533 mm (21 inch)



Height to Top of Cab(2) 3184.4 mm (125.4 inch)




3398mm (133.8 inch)6400mm (252 inch)

Approximate MaximumWeight with Attachments

19913 kg (43900 lb)


tank.


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Identication Information


i03698294

Plate Locations and Film Locations

SMCS Code: 1000; 7000

The Product Identication Number (PIN) will be used to identify a poweredmachine that is designed for an operator to ride.

Caterpillar products such as engines, transmissions, and majorattachments that are not designed for an operator to ride are identiedby Serial Numbers.

For quick reference, record the identication numbers in the spaces thatare provided below the illustration.



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76 SEBU7892-07Product Information SectionIdentication Information


Machine PIN (1)________ _______________________________________________________________

CE Plate(2)_______ ______________________________________________________________________

Year of Manufacture(3)________ ______________________________________________________

Country of Origin(4)_______ ___________________________________________________________

Year of Manufacture(5)________ ______________________________________________________


Identication lm for the Software and the ECM __ ____ ________________________


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The serial number plate for the winch is located on the right side of thewinch case.

Winch Serial Number________ ________________________________________________________

Certication

ROPS/FOPS Structure

This message is positioned on the ROPS on the left side of the machineabove the door.


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Structural damage, an overturn, modication, al-teration, or improper repair can impair this struc-ture's protection capability thereby voiding thiscertication. Do not weld on or drill holes in thestructure. This will void the certication. Consulta Caterpillar dealer to determine this structure's

limitationswithout voiding its certication.

This machine has been certied to the standards that are listed on thecertication lm. The maximum mass of the machine, which includesthe operator and the attachments without a payload, should not exceedthe mass on the certication lm.


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CE Mark


This plate is positioned on the bottom left side of the plate for the PIN.

Note: The CE plate is on machines that are certied to the EuropeanUnion requirements that were effective at that time.

For machines compliant to 2006/42/EC, the following information isstamped onto the CE plate. For quick reference, record this information inthe spaces that are provided below.

Engine Power Primary Engine (kW)___________________________________________

Engine Power for Additional Engine (If Equipped) ___ ____ __________________

Typical Machine Operating Weight for European Market (kg)_______ _____

Year of Construction_______ ________________________________________________________

Machine Type ______________________________________________________________________


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This plate is positioned on the bottom left side of the plate for the PIN.

Note: The CE plate is on machines that are certied to the EuropeanUnion requirements that were effective at that time.

For machines compliant to 98/37/EC and 89/392/EEC, the followinginformation is stamped onto the CE plate. For quick reference, record thisinformation in the spaces that are provided below.

Engine Power Primary Engine (kW)___________________________________________

Typical Machine Operating Weight for European Market (kg)_______ _____

Year___________________________________________________________________________________

For manufacturer name and address and the country of origin, see thePIN plate.


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Sound


A typical example of this lm is shown. Your m achine may have adifferent value.

If equipped, the certication lm is used to verify the environmental soundcertication of the machine to the requirements of the European Union.The value that is listed on the lm indicates the guaranteed exterior soundpower level LWAat the time of manufacture for the conditions that arespecied in ISO 6395 and EU 2000/14/EC Annex III A2.1b.

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Emissions Certication Film

SMCS Code: 1000; 7000; 7405

Note:This information is pertinent in the United States, in Canada and inEurope.

Consult your Cat dealer for an Emission Control Warranty Statement.

This label is located on the engine.


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SEBU7892-07 83Operation SectionBefore Operation

Operation Section

Before Operation

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Mounting and Dismounting

SMCS Code: 7000


Typical example

Mount the machine and dismount the machine only at locations that havesteps and/or handholds. Before you mount the machine, clean the stepsand thehandholds. Inspect the steps and handholds. Make all necessaryrepairs.

Face the machine whenever you get on the machine and whenever youget off the machine.

Maintain a three-point contact with the steps and with the handholds.

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


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84 SEBU7892-07Operation SectionBefore Operation

Do not mount a moving machine. Do not dismount a moving machine.Never jump off the machine. Do not carry tools or supplies when you tryto mount the machine or when you try to dismount the machine. Use ahand line to pull equipment onto the platform. Do not use any controls ashandholds when you enter the operator compartment or when you exitthe operator compartment.

Machine Access System Specications

The machine access system has been designed to meet the intent ofthe technical requirements in ISO 2867 Earth-moving Machinery

Access Systems. The access system provides for operator access to theoperator station and to conduct the maintenance procedures described inMaintenance section.

Alternate Exit

Machines that are equipped with cabs have alternate exits. For additionalinformation, see Operation and Maintenance Manual, Alternate Exit.


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SEBU7892-07 85Operation SectionBefore Operation

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Daily Inspection

SMCS Code: 1000; 7000

For a maximum service life of the machine, complete a thorough dailyinspection before you mount the machine and before you start the engine.

Inspect the area aroundthe machine and under the machine. Look forloose bolts, trash buildup, oil, coolant leakage, broken parts, or worn parts.

Make sure that all covers and guards are securely attached.

Adjust the mirrors for the correct rear view of the machine.

Note: Watch closely for leaks. If you observe a leak, nd the source ofthe leak and correct the leak. If you suspect a leak or you observe a leak,check the uid levels more frequently.

Daily, perform the maintenance requirements that are applicable to yourmachine.

Reference:For more information on the daily maintenance requirements,refer to Operation and Maintenance Manual, Maintenance IntervalSchedule.

Note:Make all necessary repairs before you operate the machine.


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Steering Frame Lock

SMCS Code: 7506

Personal injury or death can result from machinearticulation or movement.

operations and maintenance manual 2

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