545D WHEEL SKIDDER

S/N 4L500001-UP

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 
 
 
 
 
 
 
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-09 Publication Date -01/01/2018 Date Updated -02/01/2018

s02215701

Foreword
California Proposition 65 Warning




Wash hands after

handling.

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 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i05907103

Articulation Bearings - Lubricate

SMCS - 7057-086-BD; 7065-086-BD; 7066-086-BD

Crushing Hazard. Connect the steering frame lock between front and
rear frames before servicing the machine in the articulation area.
Disconnect the steering frame lock and secure it in the stored position
before resuming operation. Failure to do so could result in serious
injury or death.

Ensure that the machine ignition switch is in the OFF position and that the parking brake is
engaged before entering the articulation area.

Refer to Operation and Maintenance Manual, "Steering Frame Lock"

before entering the articulation joint.

Wipe all fittings before applying grease.

Illustration 1 g03719180

Illustration 2 g03719182

Apply grease to one fitting on the upper pivot bearing and one fitting on the lower pivot bearing.

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:14:32 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i05325226

Axle Oscillation Bearings - Lubricate

SMCS - 3278-086-BD

Illustration 1 g03385753
Illustration 2 g03385754

Open the engine access door on the left-hand side of the machine.

Wipe off the fittings before you apply any lubricant.

Apply lubricant through two remote fittings (1) and (2) in order to grease the bearings for the
oscillating axle.

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:14:49 UTC+0530 2024
All Rights Reserved.
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 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i07469252

Backup Alarm - Test

SMCS - 7406-081

1. Turn the engine start switch to the ON position. Do not start the engine.

2. Move the transmission direction control switch to the REVERSE position.

3. The backup alarm should immediately sound. The backup alarm will continue to sound until the
transmission control is moved to the NEUTRAL position or to the FORWARD position.

Illustration 1 g03719197

The backup alarm (1) is mounted on the rear of the machine.

Access to the backup alarm requires removal of upper rear access panel.

Note: On machines equipped with a High Rotation Seat, an additional alarm is mounted at the front of
the machine. Which alarm sounds will depend on seat position.

A three-position switch at the rear of the backup alarm regulates the sound of the alarm (HIGH,
LOW, and MEDIUM).

The alarm is set at the maximum sound level when the machine is shipped from the factory. The
setting should remain on HIGH unless the job site requires a lower sound level.

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:15:03 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
This is the sample of the sample click on
the download link for complete manual
DOWNLOAD LINK
For some reason if link demos not work
download this pdf and then click
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i05325279

Battery - Clean
SMCS - 1401-070

Personal injury may occur from failure to properly service the batteries.

Batteries give off flammable fumes that can explode. Electrolyte is an

acid and can cause personal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could cause vapors to explode.
Do not allow jumper cable ends to contact each other or the engine.
Improper jumper cable connections can cause an explosion.

Always wear protective glasses when working with batteries.

Illustration 1 g03385980

Before you can clean the battery terminals, remove the front lower engine compartment access panel.
The front lower engine compartment access panel is bolted to the machine.

Remove bolts from the engine compartment access panel.

Illustration 2 g03386187

Loosen and remove the battery cover knob (1).

Remove the battery hold down plate (2).

Clean the battery terminals and the surfaces of the batteries with a clean cloth. Coat the battery
terminals with petroleum jelly. Make sure that the battery cables are installed securely.

Reinstall the battery hold down plate, the battery hold down knob and the engine compartment access
panel.

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:15:17 UTC+0530 2024
All Rights Reserved.
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 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i08232552

Battery - Recycle
SMCS - 1401-561

Always recycle a battery. Never discard a battery. Return used batteries to one of the following
locations:

• A battery supplier

• An authorized battery collection facility

• A recycling facility

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:15:31 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i05326609

Battery Hold-Down - Tighten

SMCS - 7257-527

Illustration 1 g03386656
The batteries are located in the front engine access compartment of the machine. The access door for
the batteries is located on the left-hand side of the machine.

Illustration 2 g03386628

Open the access door on the left-hand side of the machine to access the battery hold down knob.
Illustration 3 g03386807

Tighten the knob by turning clockwise.

Illustration 4 g03386658

Over time, the vibration of an operating machine can cause the battery hold-down to loosen. To help
prevent loose batteries and the possibility of loose cable connections, tighten all fastening hardware
refer to Operation and Maintenance Manual, "Battery - Clean" for proper access to battery.

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:15:45 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i08185587

Battery or Battery Cable - Inspect/Replace

SMCS - 1401-040; 1401-510; 1402-510; 1402-040

Personal injury may occur from failure to properly service the batteries.

Batteries give off flammable fumes that can explode. Electrolyte is an

acid and can cause personal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could cause vapors to explode.
Do not allow jumper cable ends to contact each other or the engine.
Improper jumper cable connections can cause an explosion.

Always wear protective glasses when working with batteries.

1. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, Prepare the
Machine for Maintenance.

2. Turn the engine start switch key OFF. Turn all of the switches OFF.

3. Turn the battery disconnect switch OFF. Remove the key.

4. Disconnect the negative battery cable from the disconnect switch.

Note: Do not allow the disconnected battery cable to contact the disconnect switch.

5. Disconnect the negative battery cable at the battery.

 6. Disconnect the positive battery cable at the battery.

7. Inspect the battery terminals for corrosion. Inspect the battery cables for wear or damage.

8. Make any necessary repairs. If necessary, replace the battery cables or the battery.

9. Connect the positive battery cable at the battery.

10. Connect the negative battery cable at the battery.

11. Connect the battery cable at the battery disconnect switch.

12. Install the key and turn the battery disconnect switch ON.

Recycle the Battery

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following locations:

• A battery supplier

• An authorized battery collection facility

• Recycling facility

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:16:02 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
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

Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i05877651

Belt - Inspect
SMCS - 1357-040; 1357; 1397-040

Illustration 1 g03073936
Typical example

To maximize the engine performance, inspect the belt (1) for wear and for cracking. Replace the belt
if the belt is worn or damaged.

• Inspect the belt for cracks, splits, glazing, grease, displacement of the cord and evidence of
fluid contamination.

The belt must be replaced if the following conditions are present.

• The belt has a crack in more than one rib.

• More than one section of the belt is displaced in one rib of a maximum length of 50.8 mm (2
inch).

To replace the belt, refer to Disassembly and Assembly, "Alternator Belt - Remove and Install". If
necessary, replace the belt tensioner. Refer to Disassembly and Assembly, "Alternator Belt - Remove
and Install" for the correct procedure.

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:16:19 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i05731200

Belt - Inspect/Adjust/Replace
SMCS - 1397-025; 1397-040; 1397-510

Note: This engine is equipped with a belt tightener that automatically adjusts the belt to the correct
tension.

Illustration 1 g03642922

1. Gain access to the belt through the right-hand lower engine access door.

2. Inspect the belt for wear and for cracking.

3. If the belt requires replacement, perform Step 3.a through Step 3.e.
 Illustration 2 g03642930

a. Rotate the belt tensioner clockwise in order to remove the belt.

b. Remove the belt.

c. Install a new belt.

d. Rotate the belt tensioner clockwise in order to install the belt.

e. Install the upper fan guard.

f. Close the engine access door.

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:16:33 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL SKIDDER

Model: 545D WHEEL SKIDDER 4L5
Configuration: 545D WHEEL SKIDDER 4L500001-UP (MACHINE) POWERED BY C7.1 Engine

Operation and Maintenance Manual

525D, 535D, 545D, 555D Wheel Skidder
Media Number -SEBU8540-15 Publication Date -01/08/2019 Date Updated -12/08/2019

i05877649

Belt Tensioner - Check

SMCS - 1358-535

Illustration 1 g03074016
Typical example

Remove the belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install".

Ensure that the belt tensioner is securely installed. Visually inspect the belt tensioner (1) for damage.
Check that the pulley on the tensioner rotates freely and that the bearing is not loose. Some engines
have an idler pulley (2). Ensure that the idler pulley is securely installed. Visually inspect the idler
pulley for damage. Ensure that the idler pulley can rotate freely and that the bearing is not loose. If
necessary, replace damaged components.

Install the belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install".

Copyright 1993 - 2024 Caterpillar Inc. Thu May 30 11:16:48 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
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