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 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

s00037320

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 Cat
dealer for the latest available information.

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

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

Operation
The operation section is a reference for the new operator and a refresher for the experienced 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.

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 specific service interval. Items without specific 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 first.

Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified
in the maintenance intervals chart might be necessary.

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

Certified 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 modifications may exceed machine design capacity which can adversely
affect performance characteristics. Included would be stability and system certifications such as
brakes, steering, and rollover protective structures (ROPS). Contact your Cat dealer for further
information.

Cat Product Identification Number

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

Illustration 1 g00751314

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).

Copyright 1993 - 2023 Caterpillar Inc. Wed Jul 26 22:56:15 UTC+0530 2023
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 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

i01760422

Articulation Bearings - Lubricate

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

1. Park the tractor on a hard, level surface. Stop the engine. Engage the parking brake.

Illustration 1 g00872476

2. Wipe off the fittings before any lubricant is applied.

3. Apply 5P-0960 Molybdenum Grease to the two fittings.

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 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

i01899615

Battery - Clean
SMCS - 1401-070

All lead-acid batteries contain sulfuric acid which can burn the skin and
clothing. Always wear a face shield and protective clothing when
working on or near batteries.
Illustration 1 g00990809

Tilt the cab upward. The batteries are located under the cab.

Reference: Refer to Operation and Maintenance Manual, "Cab Tilting" for the tilting procedure.

Clean the battery surface with a clean cloth. Keep the terminals clean and keep the terminals
coated with petroleum jelly. Install the post cover after you coat the terminal post with petroleum
jelly.

Copyright 1993 - 2023 Caterpillar Inc. Wed Jul 26 23:02:25 UTC+0530 2023
All Rights Reserved.
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This is the sample of the manual if
you need complete
manual
Click Here to download
 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

i06543763

Battery - Recycle
SMCS - 1401-561

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 - 2023 Caterpillar Inc. Wed Jul 26 23:02:35 UTC+0530 2023
All Rights Reserved.
Private Network For SIS Licensees.
 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

i01899618

Battery or Battery Cable - Inspect/Replace

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

Failure to properly service the batteries may cause personal injury.

Prevent sparks near the batteries. They could cause vapors to explode.
Do not allow the jump start cable ends to contact each other or the
machine.

Do not smoke when checking battery electrolyte levels.

Electrolyte is an acid and can cause personal injury if it contacts the

skin or eyes.

Always wear eye protection when starting a machine with jump start
cables.

Improper jump start procedures can cause an explosion resulting in

personal injury.

When using jumper cables, always connect the positive (+) jumper cable
to the positive (+) battery terminal first. Next, connect the negative (-)
jumper cable to the frame away from the batteries. Follow the
procedure in the Operation and Maintenance Manual.

Jump start only with an energy source of the same voltage as the stalled
machine.

Turn off all lights and accessories on the stalled machine. Otherwise,
they will operate when the energy source is connected.
1. Turn off the engine start switch and all cab switches.

Illustration 1 g00998693

The battery disconnect switch is located on the left side of the machine.

2. Turn the battery disconnect switch counterclockwise to the OFF position.

 Illustration 2 g00990809

3. Tilt the cab upward. The batteries are located under the cab.

Reference: For the tilting procedure, refer to Operation and Maintenance Manual, "Cab
Tilting".

4. Disconnect the negative battery cable at the battery.

5. Disconnect the negative battery cable at the battery disconnect switch.

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

6. Disconnect the positive battery cable at the battery.

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

Reference: For cleaning procedures, refer to Operation and Maintenance Manual, "Battery -
Clean".

8. Perform the necessary repairs. If necessary, replace the battery cables or the battery.

Reference: For more information, refer to Special Instruction, SEHS7633, "Battery Test
Procedure".

9. Connect the positive battery cable at the battery. Connect the other end of the positive
battery cable to the battery disconnect switch.
 10. Connect the negative battery cable at the battery. Connect the other end of the negative
battery cable to the battery disconnect switch.

11. Tilt the cab downward.

12. Turn the battery disconnect switch clockwise to the ON position.

Copyright 1993 - 2023 Caterpillar Inc. Wed Jul 26 23:02:50 UTC+0530 2023
All Rights Reserved.
Private Network For SIS Licensees.
 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

i01899621

Belts - Inspect/Adjust/Replace
SMCS - 1357-040; 1357-510; 1357-025

Note: Stop the engine in order to inspect the belts.

Note: The tension of a used belt with more than 30 minutes of operation at rated speed should be
400 ± 44 N (90 ± 10 lb). The tension of a new belt with 30 minutes of operation or less at rated
speed should be 534 ± 22 N (120 ± 5 lb).

Note: Never replace one belt. Always replace two belts, if equipped.

554 Forwarder
Air Conditioner Belt
Illustration 1 g01001622

(1) Mounting Bracket

(2) Adjustment Bolt

(3) Mounting Bolt

(4) Compressor

(5) Air Conditioner Belt

Inspection

1. Inspect the condition of air conditioner belt (5). Check the tension of the air conditioner
belt.

If the air conditioner belt requires adjustment or replacement, proceed to the adjustment
procedure.

Adjustment

1. Loosen mounting bolt (3). Loosen adjustment bolt (2).

2. Insert a ratchet with a square drive into the hole in mounting bracket (1). Use the ratchet as
a lever in order to rotate compressor (4) until the correct belt tension is achieved.
 3. Tighten adjustment bolt (2). Tighten mounting bolt (3) .

4. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

Replacement

1. Loosen mounting bolt (3). Loosen adjustment bolt (2).

2. Insert a ratchet with a square drive into the hole in mounting bracket (1). Use the ratchet as
a lever in order to rotate compressor (4) until the belt is loose.

3. Remove the belt.

4. Replace the belt with a new belt.

5. Insert a ratchet with a square drive into the hole in mounting bracket (1). Use the ratchet as
a lever in order to rotate compressor (4) until the correct belt tension is achieved.

6. Tighten adjustment bolt (2). Tighten mounting bolt (3) .

7. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

Alternator Belt

Illustration 2 g01001618
(7) Alternator

(8) Mounting Bolt

(9) Mounting Bracket

(10) Adjustment Bolt

(11) Alternator Belt

Inspection

1. Inspect the condition of alternator belt (11). Check the tension of the alternator belt.

If the alternator belt requires adjustment or replacement, proceed to the adjustment

procedure.

Adjustment

1. Loosen mounting bolt (8). Loosen adjustment bolt (10) .

2. Insert a ratchet with a square drive into the hole in the mounting bracket (9). Use the ratchet
as a lever in order to rotate alternator (7) until the correct belt tension is achieved.

3. Tighten adjustment bolt (10). Tighten mounting bolt (8) .

4. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

Replacement

1. Loosen mounting bolt (8). Loosen adjustment bolt (10) .

2. Insert a ratchet with a square drive into the hole in the mounting bracket (9). Use the ratchet
as a lever in order to rotate alternator (7) until the belt is loose.

3. Remove the old belt.

4. Install a new belt.

5. Insert a ratchet with a square drive into the hole in the mounting bracket (9). Use the ratchet
as a lever in order to rotate alternator (7) until the correct belt tension is achieved.

6. Tighten adjustment bolt (10). Tighten mounting bolt (8) .

7. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

564 and 574B Forwarders

Air Conditioner Belt
Illustration 3 g01004184

(1) Compressor

(2) Mounting Bolt

(3) Adjustment Bolt

(4) Mounting Bracket

(5) Air Conditioner Belt

Inspection

1. Inspect the condition of air conditioner belt (5). Check the tension of the air conditioner
belt.

If the air conditioner belt requires adjustment or replacement, proceed to the adjustment
procedure.

Adjustment

1. Loosen mounting bolt (2). Loosen adjustment bolt (3).

2. Insert a ratchet with a square drive into the hole in mounting bracket (4). Use the ratchet as
a lever in order to rotate compressor (1) until the correct belt tension is achieved.
 3. Tighten adjustment bolt (3). Tighten mounting bolt (2) .

4. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

Replacement

1. Loosen mounting bolt (2). Loosen adjustment bolt (3).

2. Insert a ratchet with a square drive into the hole in mounting bracket (4). Use the ratchet as
a lever in order to rotate compressor (1) until the belt is loose.

3. Remove the belt.

4. Replace the belt with a new belt.

5. Insert a ratchet with a square drive into the hole in mounting bracket (4). Use the ratchet as
a lever in order to rotate compressor (1) until the correct belt tension is achieved.

6. Tighten adjustment bolt (3). Tighten mounting bolt (2) .

7. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

Alternator Belt

Illustration 4 g01004187
(7) Mounting Bracket

(8) Adjustment Bolt

(9) Alternator

(10) Mounting Bolt

(11) Alternator Belt

Inspection

1. Inspect the condition of alternator belt (11). Check the tension of the alternator belt.

If the alternator belt requires adjustment or replacement, proceed to the adjustment

procedure.

Adjustment

1. Loosen mounting bolt (10). Loosen adjustment bolt (8) .

2. Rotate alternator (9) until the correct belt tension is achieved.

3. Tighten adjustment bolt (8). Tighten mounting bolt (10) .

4. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

Replacement

1. Loosen mounting bolt (10). Loosen adjustment bolt (8) .

2. Rotate alternator (9) until the belt is loose.

3. Remove the old belt.

4. Install a new belt.

5. Rotate alternator (9) until the correct belt tension is achieved.

6. Tighten adjustment bolt (8). Tighten mounting bolt (10) .

7. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure.

Copyright 1993 - 2023 Caterpillar Inc. Wed Jul 26 23:03:13 UTC+0530 2023
All Rights Reserved.
Private Network For SIS Licensees.
 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

i01929742

Blade Cylinder Bearings - Lubricate - If Equipped

SMCS - 6060-086

S/N - KBN1-UP

S/N - RLS1-UP

The blade consists of two cylinders.

Illustration 1 g01003891

Side View of the Blade

1. Wipe off the four grease fittings before any lubricant is applied.
 2. Apply 5P-0960 Molybdenum Grease to the grease fitting on each bearing.

Copyright 1993 - 2023 Caterpillar Inc. Wed Jul 26 23:04:12 UTC+0530 2023
All Rights Reserved.
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 Product: FORWARDER
Model: 564 FORWARDER KBN
Configuration: 564 FORWARDER KBN00001-UP (MACHINE) POWERED BY 3056E Engine

Operation and Maintenance Manual

554, 564 and 574B Forwarders
Media Number -SEBU7796-01 Publication Date -01/01/2004 Date Updated -30/01/2004

i01929751

Blade Linkage - Lubricate - If Equipped

SMCS - 6060-086

S/N - KBN1-UP

S/N - RLS1-UP

Illustration 1 g01003897
There are two bearings on the blade linkage.

1. Wipe off the grease fittings before any lubricant is applied.

2. Apply 5P-0960 Molybdenum Grease to the grease fitting on each bearing.

Copyright 1993 - 2023 Caterpillar Inc. Wed Jul 26 23:04:23 UTC+0530 2023
All Rights Reserved.
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This is the sample of the manual if
you need complete
manual
Click Here to download