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First thing to know: this is Caterpillar's own family publication, titled D3C, D4C and D5C Series III Hystat Track-Type Tractors, so it covers all three machines, serial prefixes 5HS00001-Up, 7PS00001-Up and 6CS00001-Up. It is a compiled SIS service set built from the real Cat modules: Specifications SENR1249/SENR1252, Systems Operation SENR1250/SENR1253, Testing and Adjusting SENR1257, Disassembly and Assembly SENR1251/SENR1255, plus the 3046 engine supplement SENR1248. You get the full hydrostatic drive coverage a Hystat owner actually needs: charge pressure targets, relief valve tests, speed sensing and underspeed valve adjustment, along with the 3046 engine, Nippondenso fuel system, implement hydraulics, undercarriage and the Hystat hydraulic and electrical schematics.
What's Inside This Caterpillar D3C, D4C, D5C Series III Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Air Inlet and Exhaust System | 2-47 | Turbocharger, Inlet and Exhaust Manifolds, Air Cleaner |
| Basic Engine | 48-373 | Cat 3046 Engine, Cylinder Head, Crankshaft, Pistons, Flywheel |
| Cooling System | 374-433 | Water Pump, Thermostat, Radiator |
| Electrical and Starting System | 434-1353 | Denso Alternators, Starting System, Batteries, Product Link, EquipmentManager, Air Conditioning R134a |
| Engine Arrangement | 1354-1427 | Engine Mounting and Arrangement |
| Frame and Body | 1428-1449 | Frame, Body Panels |
| Fuel System | 1450-1721 | Nippondenso Fuel System, Injection Pump, Injectors, Priming |
| Hydraulic System | 1722-2016 | Implement Hydraulics, Pumps, Valves, Cylinders, Testing and Adjusting |
| Implements | 2017-2037 | Blade and Implement Linkage |
| Lubrication System | 2038-2085 | Engine Oil Pump, Oil Filter |
| Machine Arrangement | 2086-2117 | Machine Arrangement and Layout |
| Operator Station | 2118-2513 | Cab, Controls, Seat, Air Conditioning |
| Power Train | 2514-2912 | Hydrostatic Drive, Charge Pressure Relief, Crossover Relief, Pressure Override Relief, Speed Sensing Valve, Underspeed and Overspeed Valves, Hydrostatic System Test and Adjust, Parking Brake |
| Schematic | 2913-2946 | Hystat Hydraulic Schematic, Electrical Schematic, Graphic Symbol Legends |
| Service Equipment and Supplies | 2947-3018 | Service Tooling and Supplies |
| Steering and Braking System | 3019-3023 | Steering and Brake Controls |
| Torque Specifications | 3024-3072 | Metric ISO Fasteners, English SAE Fasteners, Fittings, Plugs, Hose Clamps |
| Undercarriage | 3073-3222 | Track, Idlers, Rollers, Track Tension |
| Work Tools | 3223-3240 | Work Tool Mounting |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Charge pressure startup target | 2650 +/- 225 kPa (385 +/- 35 psi) | |
| Minimum charge pressure before engine start | 1500 kPa (220 psi) | |
| Charge circuit maximum fill pressure | 4000 kPa (580 psi) | |
| Parking brake release pressure threshold | 200 kPa (30 psi) | |
| Hydraulic system capacity | 58.6 litres (15.5 US gal) | |
| Hydraulic oil type | 10W | |
| Hydraulic oil test temperature | 40 to 55 C (104 to 131 F) | |
| Hydraulic oil temperature limit | 99 C (210 F) | |
| Charge pump filter fill volume | 7.6 to 11 litres (2.0 US gal) | |
| Speed and direction lever hold time | 90 +/- 30 seconds | |
| Cover bolt torque | 55 +/- 10 N m (40 +/- 10 lb ft) | |
| Footrest and guard bolt torque | 100 +/- 20 N m (75 +/- 15 lb ft) | |
| Oil filter part number | 102-2828 | |
| Engine fitted | Caterpillar 3046 with Nippondenso fuel system |
Caterpillar D3C, D4C, D5C Series III Common Problems This Manual Covers
Machine is slow, weak, or will not drive at all
Start with a charge pressure test before condemning the pump or motor. The book gives the startup target of 2650 +/- 225 kPa (385 +/- 35 psi) and walks you through hydrostatic system test and adjust with the oil at 40 to 55 C, so you isolate charge circuit leakage from pump and motor wear instead of guessing.
Manual Section: Power Train - Hydrostatic System Test and Adjust p. 2591Parking brake will not release
The brake releases on charge pressure and stays locked below 200 kPa (30 psi), so low charge pressure and a stuck brake are usually one problem, not two. The procedure has you confirm charge pressure at the test port first, then check the brake valve, which saves pulling the brake apart for no reason.
Manual Section: Power Train - Parking Brake, Testing and Adjusting p. 2530Engine hard to start or down on power
The 3046 runs a Nippondenso injection pump and injectors, and the Fuel System section covers testing, timing and removal and installation for both. Work through fuel delivery and injector condition per the printed procedures before blaming compression, then the Basic Engine section covers the head, pistons and crankshaft if it goes deeper.
Manual Section: Fuel System - Nippondenso Injection Pump and Injectors p. 1450Track wear, thrown tracks, or tension that will not hold
The Undercarriage section covers track tension adjustment plus inspection and replacement of idlers and rollers. Correct tension per the procedure is the cheap fix that slows wear on everything else, and the disassembly steps show how to service idlers and rollers without fighting the machine.
Manual Section: Undercarriage - Track, Idlers and Rollers p. 3073Frequently Asked Questions
Is my D3C or D4C covered, or is this D5C only?
All three. Every module in this set is Cat's family book titled D3C, D4C and D5C Series III Hystat Track-Type Tractors. The procedures, specs and schematics apply to all three models, with serial prefixes 5HS00001-Up (D3C), 7PS00001-Up (D4C) and 6CS00001-Up (D5C) printed right in the manuals.
What should charge pressure be on a Hystat?
The book gives you the numbers to test against: 2650 +/- 225 kPa (385 +/- 35 psi) at startup, with a minimum of 1500 kPa (220 psi) before you even crank the engine, and a maximum fill pressure of 4000 kPa (580 psi) in the charge circuit. Test with the oil between 40 and 55 C (104 to 131 F) for valid readings. The Testing and Adjusting section walks you through where to tee in the gauge. p. 2619
Why will my parking brake not release?
On these machines the parking brake is held off by charge pressure, and it will not release below 200 kPa (30 psi). So a tired charge pump or a leaking charge circuit gives you the classic double symptom: the tractor will not move and the brake stays locked. The manual has you verify charge pressure first, then work through the brake valve, instead of tearing into the brake itself for nothing.
Does it cover the hydrostatic pumps and motors, not just the engine?
Yes, the Power Train coverage is the heart of this set. Charge pressure relief, crossover relief, pressure override relief, the speed sensing valve, and the underspeed and overspeed valves all get their own test and adjust procedures with printed pressure specs. Disassembly and assembly for the hydrostatic components is in there too.
Are the schematics included?
Yes. The set includes the Hystat hydraulic schematic and the electrical schematic, both titled for the D3C, D4C and D5C Series III, plus graphic symbol legends so you can actually read them. For pressure diagnosis on a hydrostatic machine, tracing the charge and drive loops on the schematic is half the job. p. 2913
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