Caterpillar 525c Skidder Operation Manual

Full download: http://manualplace.com/download/caterpillar-525c-skidder-operation-manual/

SEBU7892-07
March 2011

Operation and
Maintenance
Manual
525C, 535C and 545C Wheel Skidders

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

SAFETY.CAT.COM

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 i03991620

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identied 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! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-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 rst
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specic rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the 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 that
was available at the time that the publication was written. The specications, torques, pressures,
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 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, strength
and material.
Failure to heed this warning can lead to premature failures, product
damage, personal injury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7892-07 3
Table 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

4 SEBU7892-07
Table of Contents

Sound Information and Vibration Information ........................................ 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 Section

Reference Materials ............................................................................. 338

Index Section
Index .................................................................................................... 344
SEBU7892-07 5
Foreword

Foreword
Literature Information
This manual should be stored in the operator's compartment in the
literature holder or seat back literature storage area.

This manual contains safety information, operation instructions,

transportation information, lubrication information and maintenance
information.

Some photographs or illustrations in this publication show details or

attachments that can be different from your machine. Guards and covers
might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might

have caused changes to your machine which are not included in this
publication. Read, study 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 section
identies the text and locations of warning signs and labels used on the
machine.

Read and understand the basic precautions listed in the safety section
before operating or performing lubrication, maintenance and repair on
this machine.

Operation
The operation section is a reference for the new operator and a refresher
for the experienced operator. This section includes a discussion of
gauges, switches, machine controls, attachment controls, transportation
and towing information.

Photographs and illustrations guide the operator through correct

procedures of checking, starting, operating and stopping the machine.
6 SEBU7892-07
Foreword

Operating techniques outlined in this publication are basic. Skill and

techniques develop as the operator gains knowledge of the machine and
its capabilities.

Maintenance
The maintenance section is a guide to equipment care. The Maintenance
Interval Schedule (MIS) lists the items to be maintained at a specic
service interval. Items without specic intervals are listed under the "When
Required" service interval. The Maintenance Interval Schedule lists the
page number for the step-by-step instructions required to accomplish the
scheduled maintenance. Use the Maintenance Interval Schedule as an
index or "one safe source" for all maintenance procedures.

Maintenance Intervals
Use the service hour meter to determine servicing intervals. Calendar
intervals shown (daily, weekly, monthly, etc.) can be used instead of
service hour meter intervals if they provide more convenient servicing
schedules and approximate the indicated service hour meter reading.
Recommended service should always be performed at the interval that
occurs rst.

Under extremely severe, dusty or wet operating conditions, more frequent

lubrication than is specied in the maintenance intervals chart might be
necessary.

Perform service on items at multiples of the original requirement. For

example, at every 500 service hours or 3 months, also service those
items listed under every 250 service hours or monthly and every 10
service hours or daily.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead
compounds. Wash hands after handling.
SEBU7892-07 7
Foreword

Certied Engine Maintenance

Proper maintenance and repair is essential to keep the engine and
machine systems operating correctly. As the heavy duty off-road diesel
engine owner, you are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation and Maintenance
Manual, 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 with
the regulations (40 CFR Part 89). Certain elements of the machine and
engine such as the exhaust system, fuel system, electrical system, intake
air system and cooling system may be emission related and should not
be altered unless approved by Caterpillar.

Machine Capacity
Additional attachments or modications may exceed machine design
capacity which can adversely affect performance characteristics. Included
would be stability and system certications such as brakes, steering, and
rollover protective structures (ROPS). Contact your Caterpillar dealer for
further information.

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 uniform
equipment identication, Caterpillar and other construction equipment
manufacturers are moving to comply with the latest version of the product
identication numbering standard. Non-road machine PINs are dened
by ISO 10261. The new PIN format will apply to all Caterpillar machines
and generator sets. The PIN plates and frame marking will display the 17
character PIN. The new format will look like the following:
8 SEBU7892-07
Foreword

g00751314
Illustration 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 Serial
Number.

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

Components such as engines, transmissions, axles, etc. and work tools

will continue to use an 8 character Serial Number (S/N).
SEBU7892-07 9
Safety Section
Safety Messages

Safety Section
i03239202

Safety Messages
SMCS Code: 7000

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

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

Replace any safety message that is damaged, or missing. If a safety

message is attached to a part that is replaced, install a safety message
on the replacement part. Any Caterpillar dealer can provide new safety
messages.
10 SEBU7892-07
Safety Section
Safety Messages

g01379082
Illustration 2

g01379087
Illustration 3
SEBU7892-07 11
Safety Section
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 unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. 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.
12 SEBU7892-07
Safety Section
Safety Messages

No Ether (2)
This warning is located near the rain cap for the engine air intake. This
warning is located near the engine air precleaner (if equipped).

g01372254

Explosion hazard! Do not use ether! This machine

is 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 starting
procedure in the Operation and Maintenance Man-
ual.
SEBU7892-07 13
Safety Section
Safety Messages

Water Cleaning System Under Pressure (3)

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

g01379094

Do not remove the ll plug until the pressure in the

water tank has been relieved. Personal injury may
result.

This ll plug has a cross drilled hole that allows

the pressure to be relieved without disengaging
the threads.

Do not replace this ll plug with any other plug.

For more information, refer to Operation and Maintenance Manual, “Water

Cleaning System (Pressurized)”.
14 SEBU7892-07
Safety Section
Safety Messages

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 death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
SEBU7892-07 15
Safety Section
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 the
structure. This will void the certication. Consult
a Caterpillar dealer to determine this structure's
limitations without voiding its certication.

This machine has been certied to the standards that are listed on the
certication plate. The maximum mass of the machine, which includes
the operator and the attachments without a payload, should not exceed
the mass on the certication plate.
16 SEBU7892-07
Safety Section
Safety Messages

Compressed Spring (6)

This warning is located on the parking brake actuator.

g01379131

Do not attempt to remove spring(s), they are not

serviceable. Do not cut, saw, torch or modify this
chamber, serious injury or death may result.
SEBU7892-07 17
Safety Section
Safety Messages

No Clearance (7)
This warning is located on both sides of the machine near the articulation
joint.

g01371644

Crushing Hazard! Stay back a safe distance. There

is no clearance for a person in this area when the
machine turns. Failure to follow these instructions
could cause serious injury or death.
18 SEBU7892-07
Safety Section
Safety Messages

Pressurized System (8)

This warning is located on the top surface of the hydraulic tank near the
ller cap.

g01371640

Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. To open the cooling
system ller cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.
SEBU7892-07 19
Safety Section
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 cooling
system ller cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.
Caterpillar 525c Skidder Operation Manual
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20 SEBU7892-07
Safety Section
Safety Messages

Crushing hazard (10)

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

g01371647

Connect the steering frame lock between the front

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

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