Cat Telehandler Personnel Work Platform Engine + Operation & Maintenance Manual - PDF DOWNLOAD

Operation & Maintenance Manual Original Instructions Keep this manual with machine at all times.

Models TH336, TH337, TH406, TH407, TH414, TH514, TH417 S/N TDE00100 & After S/N TDF00100 & After S/N TBX00100 & After S/N TBY00100 & After S/N TBZ00100 & After S/N TBW00100 & After S/N TBT00100 & After

31200368 Revised October 10, 2011

CALIFORNIA PROPOSITION 65

BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm.

WASH HANDS AFTER HANDLING! CALIFORNIA PROPOSITION 65

EXHAUST 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.

Revision Log Revision Log

REVISION LOG January 11, 2008 - A - Original Issue of Manual April 8, 2008 - B - Revised covers, Transfer of Ownership and pages a, b, c, 2-1, 2-4, 2-6, 2-8, 5-13, 7-1, 7-5, 7-16 & 9-1.

May 9, 2008 - C - Revised manual.

August 15, 2008 - D - Revised pages 2-4, 2-5, 2-6, 2-7, 2-8, 2-9, 7-1, 7-6, 7-7, 7-8 & 7-9.

October 10, 2008 - E - Revised manual. Added TH336, TH337, platform, quick couplers and other additional information.

April 13, 2009 - F - Revised pages 9-4 & 9-5.

August 13, 2009 - G - Revised pages b, d, 1-5, 1-6, 2-1, 2-3 thru 2-10, 2-12 thru 2-15, 3-2, 3-3, 3-6, 3-7, 3-8, 3-11 thru 3-20, 3-23 thru 3-28, 3-32, 4-1, 4-2, 4-4, 4-5, 4-7, 4-8, 4-10, 4-11, 5-1 thru 5-4, 5-6, 5-7, 5-8, 5-10, 5-11, 5-13 thru 5-24, 5-26 thru 5-44, 6-3, 7-2, 7-7 thru 7-9, 7-12, 7-18, 8-1, 9-4, 9-5, 9-7, 9-8 & 9-9.

November 16, 2009 - H - Revised cover and pages 5-2, 5-3, 5-4 & 9-3.

March 24, 2010 - I - Revised pages 2-5, 2-7, 2-10 thru 2-15, 3-13, 3-14, 3-23, 3-25, 4-2, 4-8, 4-9, 4-10, 5-2 thru 5-5, 6-1, 7-9, 7-18, 9-4, 9-5, 9-7, 9-8 & 9-10.

August 30, 2010 - J - Revised pages 2-5, 2-10, 2-14, 2-15, 3-14, 3-15, 7-4, 7-5, 7-6 & 8-1.

November 11, 2010 - K - Revised pages 2-5, 2-15, 3-14, 3-15, 3-16 & 8-1.

October 10, 2011 - L - Revised pages 5-5 & 9-1.

31200368

a

Read This First Read This First

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

Operator Qualifications The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

Operation within the U.S.A. requires training per OSHA 1910.178.

Operators of this equipment must possess a valid, applicable driver’s license, be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.

In addition, the operator must read, understand and comply with instructions contained in the following material furnished with the material handler: • This Operation & Maintenance Manual • Telehandler Safety Manual (ANSI only) • All instructional decals and plates • Any optional equipment instructions furnished The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and regulations.

Modifications Any modification to this machine must be approved by JLG.

b

31200368

Read This First This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local Caterpillar dealer representative for information regarding safetyrelated bulletins which may have been issued for this product.

JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.

JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product.

FOR: • Accident Reporting and Product Safety Publications • Current Owner Updates • Questions Regarding Product Applications and Safety • Standards and Regulations Compliance Information • Questions Regarding Product Modifications

CONTACT: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA In USA: Toll Free: 1-877-JLG-SAFE (1-877-554-7233) Outside USA: Phone: +1-717-485-6591 E-mail: ProductSafety@JLG.com

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c

Read This First Other Publications Available Service Manual..........................................................................................31200370 Parts Manual TH336, TH337, TH406, TH407............................................................31200369 TH414, TH514, TH417 ........................................................................31200488 THP18s & THP45s Platforms for TH414, TH514, TH417 Operation & Maintenance Manual (if equipped for platform).................Contact JLG Load Management Indicator System Operation & Maintenance Manual (if equipped)..............................................................................Contact JLG

Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard.

d

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Table of Contents

Table of Contents

TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ...................................................... b Modifications ...................................................................... b Other Publications Available .............................................. d

Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System ..............................................1-1 Safety Alert System and Safety Signal Words ................1-1 1.2 General Precautions ............................................................1-1 1.3 Operation Safety ..................................................................1-2 Electrical Hazards ...........................................................1-2 Tip Over Hazard..............................................................1-3 Travel Hazard .................................................................1-6 Load Falling Hazard........................................................1-7 Lifting Personnel .............................................................1-8 Driving Hazards on Slopes .............................................1-9 Pinch Points and Crush Hazards ..................................1-10 Fall Hazard....................................................................1-12 Chemical Hazards.........................................................1-13

Section 2 - Pre-Operation and Inspection 2.1 Pre-Operation Check and Inspection...................................2-1 2.2 Safety Decals.......................................................................2-3 TH336, TH337, TH406 & TH407 (CE & AUS) ................2-3 TH406 & TH407 (ANSI) ..................................................2-6 TH414, TH514 & TH417 (CE & AUS) .............................2-8 TH514 (ANSI) ...............................................................2-11 2.3 Walk-Around Inspection.....................................................2-14 2.4 Warm-Up and Operational Checks ....................................2-16 Warm-Up Check ...........................................................2-16 Operational Check ........................................................2-16 2.5 Operator Cab .....................................................................2-17 2.6 Windows ............................................................................2-18 Cab Door Window.........................................................2-18 Rear Window ................................................................2-19

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i

Table of Contents Section 3 - Controls and Indicators 3.1 General................................................................................ 3-1 3.2 Controls ............................................................................... 3-2 Instrument Panel ............................................................ 3-4 Display Screen ............................................................... 3-6 Keypad ........................................................................... 3-8 Ignition .......................................................................... 3-10 Park Brake.................................................................... 3-11 Parking Procedure........................................................ 3-11 Transmission Control Lever.......................................... 3-12 Load Stability Indicator - LSI (CE & AUS) .................... 3-14 Steering Column Adjuster............................................. 3-17 Joystick......................................................................... 3-18 Front Console Switches................................................ 3-22 Right Console Switches................................................ 3-23 Accessory Control Lever .............................................. 3-25 Reversing Fan (if equipped) ......................................... 3-26 3.3 Anti Theft ........................................................................... 3-28 3.4 Steer Modes ...................................................................... 3-29 Manual Steering Alignment Mode Change................... 3-29 All Wheel Assisted Steering Alignment Mode Change. 3-30 3.5 Operator Seat.................................................................... 3-31 Adjustments.................................................................. 3-31 Seat Belt ....................................................................... 3-33 3.6 Boom Indicators ................................................................ 3-34 Boom Extension ........................................................... 3-34 Boom Angle (AUS) ....................................................... 3-34

Section 4 - Operation 4.1 Engine ................................................................................. 4-1 Starting the Engine ......................................................... 4-1 Battery Boosted Starting................................................. 4-2 Normal Engine Operation ............................................... 4-3 Shut-Down Procedure .................................................... 4-3 4.2 Operating with a Non-Suspended Load .............................. 4-4 Lift Load Safely............................................................... 4-4 Picking Up a Load .......................................................... 4-4 Transporting a Load ....................................................... 4-5 Leveling Procedure......................................................... 4-5 Placing a Load................................................................ 4-6 Disengaging a Load........................................................ 4-6

ii

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Table of Contents 4.3 Operating with a Suspended Load ......................................4-7 Lift Load Safely ...............................................................4-7 Picking Up a Suspended Load........................................4-7 Transporting a Suspended Load.....................................4-8 Leveling Procedure .........................................................4-8 Placing a Suspended Load .............................................4-9 Disengaging a Suspended Load.....................................4-9 4.4 Road Operation (CE) .........................................................4-10 4.5 Loading and Securing for Transport ..................................4-11 Tiedown ........................................................................4-11 Lifting ............................................................................4-12

Section 5 - Attachments and Hitches 5.1 Approved Attachments ........................................................5-1 5.2 Unapproved Attachments ....................................................5-1 5.3 JLG Supplied Attachments ..................................................5-2 TH336, TH337, TH406 & TH407 ....................................5-2 TH414, TH514 & TH417 .................................................5-4 5.4 Telehandler/Attachment/Fork Capacity................................5-6 5.5 Use of the Load Chart..........................................................5-7 Capacity Indicator Locations...........................................5-7 Sample Load Chart (CE & ANSI) ....................................5-8 Sample Load Chart (AUS) ............................................5-10 Example ........................................................................5-12 5.6 Attachment Installation ......................................................5-13 CAT Quick Coupler .......................................................5-13 JD Coupler ....................................................................5-16 Manitou Coupler............................................................5-18 JCB Coupler..................................................................5-21 Hydraulic Operated Attachment....................................5-24 5.7 Platform Attachment (if equipped) .....................................5-24 5.8 Adjusting/Moving Forks......................................................5-25 5.9 Attachment Operation ........................................................5-26 Carriage w/Forks...........................................................5-27 Side Shift Carriage........................................................5-28 Rotate/Side Tilt Carriage...............................................5-30 Bucket ...........................................................................5-32 Multi-Purpose Bucket ....................................................5-34 Grapple Bucket .............................................................5-36 Manure Fork..................................................................5-38 Bale Handler .................................................................5-40 Coupler Mounted Hook .................................................5-42 Truss Boom...................................................................5-43 Platform (CE & AUS) ....................................................5-44 31200368

iii

Table of Contents 5.10 Hitches (TH336, TH337, TH406 & TH407) ....................... 5-45 Pin Hitch - CUNA C (Italy) ............................................ 5-45 Pin Hitch - CUNA D2 (Italy) .......................................... 5-46 Pin Hitch ....................................................................... 5-47 Auto Hitch ..................................................................... 5-48 Piton Frame and Auto Hitch ......................................... 5-49 Hydraulic Hitch ............................................................. 5-50

Section 6 - Emergency Procedures 6.1 Towing a Disabled Product ................................................. 6-1 Moving Short Distances.................................................. 6-1 Moving Longer Distance................................................. 6-1 6.2 Emergency Lowering of Boom ............................................ 6-2 6.3 Emergency Lowering of Boom If Equipped for Platform ..... 6-3 Auxiliary Power System.................................................. 6-3 6.4 Cab Emergency Exit............................................................ 6-4

Section 7 - Lubrication and Maintenance 7.1 Introduction.......................................................................... 7-1 Clothing and Safety Gear ............................................... 7-1 7.2 General Maintenance Instructions....................................... 7-2 7.3 Service and Maintenance Schedules .................................. 7-3 10, 1st 50 & 50 Hour Maintenance Schedule ................. 7-3 1st 150 & 250 Hour Maintenance Schedule ................... 7-4 500 & 1000 Hour Maintenance Schedule....................... 7-5 6000 & 12000 Hour Maintenance Schedule................... 7-6 7.4 Lubrication Schedules ......................................................... 7-8 50 Hour Lubrication Schedule ........................................ 7-8 500 Hour Lubrication Schedule .................................... 7-12 7.5 Operator Maintenance Instructions ................................... 7-14 Fuel System.................................................................. 7-14 Engine Oil ..................................................................... 7-16 Hydraulic Oil ................................................................. 7-17 Tires.............................................................................. 7-18 Engine Cooling System ................................................ 7-21 Air Intake System ......................................................... 7-22 Battery .......................................................................... 7-24 Windshield Washer System (if equipped)..................... 7-25

Section 8 - Additional Checks 8.1 8.2 8.3 8.4

iv

General................................................................................ 8-1 Load Stability Indicator System (CE & AUS)....................... 8-1 Boom Interlock (TH414, TH514 & TH417) .......................... 8-2 Auxiliary Power (If Equipped for Platform) .......................... 8-4

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Table of Contents Section 9 - Specifications 9.1 Product Specifications .........................................................9-1 Fluids ..............................................................................9-1 Fluid Capacities ..............................................................9-2 Tires ................................................................................9-3 Performance ...................................................................9-4 Dimensions .....................................................................9-7 Declaration of Vibration (CE) ........................................9-10 Noise Emission Level (CE) ...........................................9-10

Index Inspection, Maintenance and Repair Log

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v

Table of Contents

vi

31200368

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES 1.1

HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

OW0010

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

OW0021

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

OW0031

CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury.

1.2

GENERAL PRECAUTIONS

WARNING Before operation, read & understand this manual. Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.

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1-1

Section 1 - General Safety Practices 1.3

OPERATION SAFETY

Electrical Hazards

10 FT (3 M)

OW0040

• This machine is not insulated and does not provide protection from contact or being near electrical current.

• NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.

• Always check for power lines before raising the boom.

• Follow employer, local and governmental regulations for clearance from powerlines.

1-2

31200368

Section 1 - General Safety Practices Tip Over Hazard General • For additional load requirements, refer to the appropriate load chart.

OW0050

• Never use an attachment without the appropriate JLG approved load chart installed on the telehandler.

• Understand how to properly use the load charts located in cab.

• DO NOT exceed rated lift capacity.

• Be sure that the ground conditions are able to support the machine.

OW0080

• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on load chart.

4 FT (1,2 M)

OW0100

• DO NOT level machine with boom/attachment above 1,2 m (4 ft).

(AUS - DO NOT level machine with load more than 300 mm (11.8 in) above ground surface.)

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1-3

Section 1 - General Safety Practices

OH2291

• MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.

• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast.

OH20911

• Always wear the seat belt.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.

OH2221

If the telehandler starts to tip over: • DO NOT JUMP • BRACE YOURSELF and STAY WITH THE MACHINE • KEEP YOUR SEAT BELT FASTENED • HOLD ON FIRMLY • LEAN AWAY FROM THE POINT OF IMPACT

1-4

31200368

Section 1 - General Safety Practices Non-Suspended Load

OW0060

• DO NOT drive with boom raised.

Suspended Load

OW0150

• Tether suspended loads to restrict movement.

• Weight of all rigging (slings, etc.) must be included as part of load.

• Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines.

• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

When driving with a suspended load: • Start, travel, turn and stop slowly to prevent load from swinging.

• DO NOT extend boom.

• DO NOT raise the load more than 300 mm (11.8 in) above ground surface or the boom more than 45°.

• DO NOT exceed walking speed.

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1-5

Section 1 - General Safety Practices Travel Hazard 2-Wheel Front Steer

4-Wheel Circle Steer

4-Wheel Crab Steer

OAL2030

• Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated.

• DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary.

• Visually verify proper wheel alignment after each steer mode change.

• Ensure that adequate clearance is provided for both rear tail swing and front fork swing.

• Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view.

• Before moving be sure of a clear path and sound horn.

• When driving, retract boom and keep boom/attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel.

• Always look in the direction of travel.

• Always check boom clearances carefully before driving underneath overhead obstructions. Position attachment/load to clear obstacles.

• When driving in high speed, use only front wheel steer (if steering modes are selectable).

1-6

31200368

Section 1 - General Safety Practices Load Falling Hazard

OW0130

• Never suspend load from forks or other parts of carriage.

• DO NOT burn or drill holes in fork(s).

• Forks must be centered under load and spaced apart as far as possible.

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1-7

Section 1 - General Safety Practices Lifting Personnel

OW0170

• When lifting personnel, USE ONLY a JLG approved personnel work platform, with proper load chart displayed in the cab.

OW0190

• DO NOT drive machine from cab when personnel are in platform.

1-8

31200368

Section 1 - General Safety Practices Driving Hazards on Slopes

OW0200

To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, the rear of the machine is the “heavy end.” Drive with forks pointed downhill.

• When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill.

• For additional travel requirements, refer to the appropriate load chart.

• To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances.

• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.

• DO NOT park on a slope.

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1-9

Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler.

OW0210

• Stay clear of moving parts while engine is running.

OW0220

• Keep clear of steering tires and frame or other objects.

OW0230

• Keep clear from under boom.

1-10

31200368

Section 1 - General Safety Practices

OW0240

• Keep clear of boom holes.

OW0250

• Keep arms and hands clear of attachment tilt cylinder.

OW0260

• Keep hands and fingers clear of carriage and forks.

OW0960

• Keep others away while operating.

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1-11

Section 1 - General Safety Practices Fall Hazard

OW0280

• Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine.

• DO NOT get off the machine until the shutdown procedure on page 4-3 has been performed.

OW0290

• DO NOT carry riders. Riders could fall off machine causing death or serious injury.

1-12

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Section 1 - General Safety Practices Chemical Hazards Exhaust Fumes • DO NOT operate machine in an enclosed area without proper ventilation.

• DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.

• If spark arrestors are required, ensure they are in place and in good working order.

Flammable Fuel

OW0300

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.

Hydraulic Fluid

OW0950

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure.

• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.

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1-13

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14

31200368

Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION 2.1

PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder.

The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following: 1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

OAH1000

PARENT METAL CRACK

WELD CRACK

3. Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-3 for details.

4. Operation and Safety Manuals - Operation & Maintenance Manual and AEM Safety Manual (ANSI only) located in cab manual holder.

5. Walk-Around Inspection - See page 2-14 for details.

6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil and coolant.

When adding fluids, refer to Section 7 - Lubrication and Maintenance and Section 9 - Specifications to determine proper type and intervals. Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.

7. Attachments/Accessories - Ensure correct load charts are installed on the telehandler. If provided, reference the Operation & Maintenance Manual of each attachment or accessory installed for specific inspection, operation and maintenance instructions.

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2-1

Section 2 - Pre-Operation and Inspection 8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-16) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.

WARNING If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

2-2

31200368

Section 2 - Pre-Operation and Inspection 2.2

SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper load charts are legible and in place. Clean and replace as required.

Note: Part numbers referenced are for inspection and identification purposes only.

Refer to the Parts Manual when ordering replacement parts.

TH336, TH337, TH406 & TH407 (CE & AUS) 8005616

1706285

1001103466

8005671

8005670

ELC

3700016

3700016 1001103466

8005671

A

A

Manufactured by

JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034 Breitwaterstraat 12 3630 Maasmechelen - Belgium

20 8005617

1706281

Model: Year of Manufacture: VIN: Model Year: Type of engine: Output of engine, kW: Gross vehicle weight:

kg

Maximum capacity:

kg

Maximum capacity at max. Height:

kg 1001102937 B

20 - 2603207 40 - 2999964 (GERMANY)

3700016

1001102937 (CE) 1706098 B

1706098

1001111270 8005675 (AUS)

1706282 1001103430 (EARLY PRODUCTION ONLY)

VIEW A-A 1001100957

OAM1785

31200368

1001100957

2-3

Section 2 - Pre-Operation and Inspection 8005616 3700016

1001094171 (AUS)

A - 1706753 B - 1706754 C - 1706755

3700016

ABC

A

B

C

Manufactured by

JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034 Breitwaterstraat 12 3630 Maasmechelen - Belgium

Model: Year of Manufacture: VIN: Model Year: Type of engine: Output of engine, kW: Gross vehicle weight:

kg

Maximum capacity:

kg

Maximum capacity at max. Height:

kg 1001102937 B

8005675

1001102937 (CE - TH407 EARLY PRODUCTION ONLY)

8005617 8005671

8005671

20 - 2603207 40 - 2999964 (GERMANY)

8006612 (TH336, TH337)

20 8005870

8005870

3700015 (TH336 BEFORE S/N TDE00172) (TH337 BEFORE S/N TDF00202) (TH406 BEFORE S/N TBX00332) (TH407 BEFORE S/N TBY00641)

8006612 (TH406, TH407) 3700015 (TH336 S/N TDE00172 & AFTER) (TH337 S/N TDF00202 & AFTER) (TH406 S/N TBX00332 & AFTER) (TH407 S/N TBY00641 & AFTER)

2-4

OAM1796

31200368

Section 2 - Pre-Operation and Inspection 1001100473 (LOADER PATTERN)

1001127546

1001127546 A

1001110162 (IF EQUIPPED WITH BOOM FLOAT)

VIEW C-C

F N R 1001100473B

1001100474 (LIFT PATTERN)

(TH336 S/N TDE00335 & AFTER INCLUDING TDE00297-313, 328 & 332) (TH337 S/N TDF00320 & AFTER INCLUDING TDF00297, 299-302 & 317) (TH406 S/N TBX00454 & AFTER) (TH407 S/N TBY01110 & AFTER EXCLUDING TBY01121, 1122 & 1128) F N R 1001110162A

1001100474B

C

1001092878 1001101895 C 3m

B

B

1001094708

1001101895

1001102408 1001 1 02 4 0 8A

1001094708B

1705980 (74.5 kW ENGINE) L WA

1001111600 (AUS)

20 3700016

20 - 2603207 40 - 2999964 (GERMANY)

106

dB

1705980

1001102782 (93.1 kW ENGINE) L WA

107

dB

1001108742

1001102782

(TH336 BEFORE S/N TDE00335 EXCLUDING TDE00297-313, 328 & 332) (TH337 BEFORE S/N TDF00320 EXCLUDING TDF00297, 299-302 & 317) (TH406 BEFORE S/N TBX00454) (TH407 BEFORE S/N TBY01110 INCLUDING TBY01121, 1122 & 1128)

1001125452

LOAD CHARTS

(TH336 S/N TDE00335 & AFTER INCLUDING TDE00297-313, 328 & 332) (TH337 S/N TDF00320 & AFTER INCLUDING TDF00297, 299-302 & 317) (TH406 S/N TBX00454 & AFTER) (TH407 S/N TBY01110 & AFTER EXCLUDING TBY01121, 1122 & 1128)

XXXX

XXX mm - XXX mm

XXX kg MAX

75

14m

60

13m

50

12m

o

o

2000kg

o

D C

11m

40

10m

o

2500kg B

9m

10

20

o

4m 3m 2m

10

o

o

500kg 750kg

5m

350kg

6m

3700kg

1000kg 1500kg

30

8m

7m

A

1m

D

0m

0

o

XXX mm

-1m

50

9m

LB-FT

8m

7m

6m

5m

4m

3m

2m

1m

0m

EN 1459:1998-ANNEX B

(Nm )

50

150

1706209

EVERY 50

A

50

B

500

C

B

B

P

A

A

ON

OFF

P

B

B B

B

A

A

A A

A

A

A A

A C

C

1001108776

OAM2713

VIEW B-B

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2-5

Section 2 - Pre-Operation and Inspection TH406 & TH407 (ANSI) 1706301

8005616

1706302

1001103466 ELC

1706301A

1001103466

A

A

Model

Serial Number

Maximum Weight Without Attachments (lbs/kg)

Year Of Manfacture

Maximum Capacity (lbs/kg)

* Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all ratings.

As released from factory this truck meets specifications in ANSI/ITSDF B56.6-2005 Part III.

Manufactured by

1001102938 A

JLG Manufacturing Europe BVBA Inductrieterrein Oude Bunders 1034, Breitwaterstraat 12 3630 Maasmechelen - Belgium

8005617

1706297

1001102938 1706098 B

1706098 1001102750 1001103430 (EARLY PRODUCTION ONLY) 1706298A

VIEW A-A

1001100957

1001100957

2-6

OAM2183

31200368

Section 2 - Pre-Operation and Inspection 1001100473 (LOADER PATTERN)

1001110162 (IF EQUIPPED WITH BOOM FLOAT)

F N R 1001100473B

1001100474 (LIFT PATTERN)

1001110162A

8005616

1707078

1706302

Operator must be trained and must read and understand all capacity charts, operator and safety manuals.

MACHINE ROLL-AWAY could cause death or serious injury.

Fasten seat belt.

1001094708

WARNING CONTACTING POWER LINES will result in death or serious injury.

DO NOT place machine or load within 10 feet (3m) of power lines.

LOWERING BOOM or FALLING LOAD

Keep others away while operating.

can crush causing death or serious injury.

RUN-OVER HAZARD

JUMPING OFF of a tipping machine could result in death or serious injury.

F N R

could cause

death or serious injury.

1001100474B

1001094708B

1707078A

B B

ABC

C

1001 1 02 4 0 8A

A

B

Model

Serial Number

Maximum Weight Without Attachments (lbs/kg)

Year Of Manfacture

Maximum Capacity (lbs/kg)

* Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all ratings.

A - 1706753 B - 1706754 C - 1706755

As released from factory this truck meets specifications in ANSI/ITSDF B56.6-2005 Part III.

Manufactured by

1001102938 A

JLG Manufacturing Europe BVBA Inductrieterrein Oude Bunders 1034, Breitwaterstraat 12 3630 Maasmechelen - Belgium

1001102938 (TH407 EARLY PRODUCTION ONLY)

1706768

1001102408

1001108776 1001108742

LOAD CHARTS XXXX

XXX mm - XXX mm

XXX kg MAX

10

EVERY 50

A

50

B

500

C

75

14m

D

60

13m

50

12m

50

40

10m

C 2500kg B

B

7m

50

B

6m 5m

2m

0m

0

o

o

3700kg

8005870

o

XXX mm

-1m

A C

10

A

1m

A

A A

20

4m 3m

150

A A

A

500kg 750kg

B

A

A

350kg

B

B

o

1000kg 1500kg

30

9m

C

8005870

D

o

9m 8m

B

o

o

2000kg

o

11m

A

A

8005617

8m

7m

6m

5m

4m

3m

2m

1m

0m

EN 1459:1998-ANNEX B

1706209

P

ON

OFF

P

OAM2196

VIEW B-B

31200368

VIEW OF REAR WINDOW

2-7

Section 2 - Pre-Operation and Inspection TH414, TH514 & TH417 (CE & AUS) 8005670

1706285

8005616

8005675

8005671

1001103466 3700016

3700016 ELC

1001103466

8005671

A

A

Manufactured by

JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034 Breitwaterstraat 12 3630 Maasmechelen - Belgium

20 20 - 2603207 35 - 8009377 (GERMANY)

Model: Year of Manufacture: VIN: Model Year: Type of engine: Output of engine, kW: Gross vehicle weight:

kg

Maximum capacity:

kg

Maximum capacity at max. Height:

kg 1001102937 B

8005617

3700016

1001102937 (CE)

1706281 1706098 B

1706098

1001111270 (AUS)

8006612

1706282 1001100985 (EARLY PRODUCTION ONLY)

VIEW A-A

1001100957

1001100957

2-8

OAM1903

31200368

Section 2 - Pre-Operation and Inspection

3700016

8005616

A - 1706753 B - 1706754 C - 1706755 D - 1706756

1001094171 (AUS)

3700016

ABC

A

B

Manufactured by

JLG Manufacturing Europe BVBA Industrieterrein Oude Bunders 1034 Breitwaterstraat 12 3630 Maasmechelen - Belgium

20

Model: Year of Manufacture: VIN: Model Year: Type of engine: Output of engine, kW: Gross vehicle weight:

kg

Maximum capacity:

kg

Maximum capacity at max. Height:

kg 1001102937 B

1001102937 (CE - TH407 EARLY PRODUCTION ONLY)

8005671

8005675

8005671

8005617

20 - 2603207 35 - 8009377 (GERMANY)

20 - 2603207 35 - 8009377 (GERMANY)

20 8005870

1001104319

8005870

8006612

1001009211

31200368

OAM1914

2-9

Section 2 - Pre-Operation and Inspection 1001100473 (LOADER PATTERN)

F N R 1001100473B

1001100474 (LIFT PATTERN)

11001100472

1001092878

1001101895

F N R 1001100474B

3m

1001101895

B

1001 1 02 4 0 8A

B

1001094708B

1001094708 1001102408 L WA

106

dB

1705980

1705980

3700016 1001111600 (AUS)

3700016

1001108742 (TH414 BEFORE S/N TBZ00561) (TH514 BEFORE S/N TBW00201) (TH417 BEFORE S/N TBT00216) 1001125452 (TH414 S/N TBZ00561 & AFTER) (TH514 S/N TBW00201 & AFTER) (TH417 S/N TBT00216 & AFTER)

IF EQUIPPED FOR PLATFORM

LOAD CHARTS XXXX

10

XXX mm - XXX mm

XXX kg MAX

75

14m

D

60

13m

50

50

12m

o

o

2000kg

o

D C

11m LB-FT

40

10m

(Nm )

o

2500kg B

9m o

20

150

2m

10

o

o

350kg

5m 4m 3m

500kg 750kg

7m 6m

3700kg

1000kg 1500kg

30

8m

50

A

1m 0m

0

o

XXX mm

-1m 9m

8m

7m

6m

5m

4m

3m

2m

1m

0m

EN 1459:1998-ANNEX B

EVERY 50

A

50

A

B

500

A

A

A

1

A

A

1706209

A

A

B B

B

B

B

2

A

A

C B

B

A A A

A

1001104909 B

1001102837

2-10

A

A

A

ON

OFF

P

A

3

1001104909

P

B

A

C

C

TH414 - 1001108743 TH514 - 1001114772 TH417 - 1001115625

VIEW B-B

OAM2722

31200368

Section 2 - Pre-Operation and Inspection TH514 (ANSI) 8005616

1706301 1001103466

1706302

ELC

1706301A

1001103466

Model

Serial Number

Maximum Weight Without Attachments (lbs/kg)

Year Of Manfacture

Maximum Capacity (lbs/kg)

* Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all ratings.

As released from factory this truck meets specifications in ANSI/ITSDF B56.6-2005 Part III.

Manufactured by

1001102938 A

JLG Manufacturing Europe BVBA Inductrieterrein Oude Bunders 1034, Breitwaterstraat 12 3630 Maasmechelen - Belgium

8005617

1001102938

1706297 1706098 B

1706098

8006612

1001102750

1706298A

1001100957

1001100957

31200368

OAM2920

2-11

Section 2 - Pre-Operation and Inspection

8005616

A - 1001118967 B - 1001118968 C - 1001118969 D - 1001118970

1706302

ABC

A

B

8005617 8005675

8006612

8005870

8005870

8006612

OAM2930

2-12

31200368

Section 2 - Pre-Operation and Inspection 1001100473 (LOADER PATTERN)

F N R 1001100473B

11001100472

1001100474 (LIFT PATTERN)

F N R 1001100474B

1706768 1707078 Operator must be trained and must read and understand all capacity charts, operator and safety manuals.

MACHINE ROLL-AWAY could cause death or serious injury.

Fasten seat belt.

B

WARNING CONTACTING POWER LINES will result in death or serious injury.

DO NOT place machine or load within 10 feet (3m) of power lines.

LOWERING BOOM or FALLING LOAD can crush causing death or serious injury.

RUN-OVER HAZARD

Keep others away while operating.

B

JUMPING OFF of a tipping machine could result in death or serious injury.

could cause death or serious injury.

1707078A

1001094708B

1001 1 02 4 0 8A

1001094708

1001102408

1001114772 EVERY 50

A

50

A

B

500

A

A

A

A

A

C

A

A

B

A

A

B

B

B

B

B

B

B

A A A A

A

A

A

A A

C

C

1001108742

LOAD CHARTS XXXX

XXX mm - XXX mm

XXX kg MAX

10

75

14m

D

60

13m

50

12m

50

o

o

2000kg

o

D C

11m

40

10m

o

2500kg B

9m

20

o

150

2m

10

o

o

500kg 750kg

5m 4m 3m

350kg

6m

3700kg

1000kg 1500kg

30

8m

7m

50

A

1m 0m

0

o

XXX mm

-1m 9m

8m

7m

6m

5m

4m

3m

2m

1m

0m

EN 1459:1998-ANNEX B

1706209

P

ON

OFF

P OAM2940

VIEW B-B

31200368

2-13

Section 2 - Pre-Operation and Inspection 2.3

WALK-AROUND INSPECTION 20 19 2

1

18 17

3

16 15

4

5 5

14 6

13

12

7 8

11 9

10

5

OAM2093

Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including attachment for cracks, excessive corrosion and other damage.

1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders • Check front, top, side and rear wear pads for presence of grease.

• Pivot pins secure; hydraulic hoses undamaged, not leaking.

2. Front Axle - Steer cylinders undamaged, not leaking; pivot pins secure (if equipped); hydraulic hoses undamaged, not leaking.

3. Left Outrigger (TH414, TH514 & TH417) - Pins secure; hydraulic hoses and cylinder undamaged, not leaking.

4. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

2-14

31200368

Section 2 - Pre-Operation and Inspection 5. Mirrors - Clean and undamaged.

6. Cab and Electrical • General appearance; no visible damage.

• Frame level indicator(s) and window glass undamaged and clean.

• Gauges, switches, joystick, foot controls and horn operational.

• Check seat belt for damage, replace belt if frayed or cut webbing, damaged buckles or loose mounting hardware.

7. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

8. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure; hydraulic hoses undamaged, not leaking.

9. LSI Sensor (CE & AUS) - See inspection note.

10. Main Control Valve - See inspection note.

11. Wheel Chock (if equipped) - See inspection note.

12. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

13. Engine Compartment • Drive belts, check condition and replace as required.

• Engine mounts - See inspection note.

• Air precleaner (if equipped), check and clean as required.

• Battery cables tight, no visible damage or corrosion.

• Engine cover properly secured.

14. Boom Sensor (TH417 Before S/N TBT00216 - if equipped for platform), (TH336 S/N TDE00335 & After including TDE00297-313, 328 & 332, TH337 S/N TDF00320 & After including TDF00297, 299-302 & 317, TH406 S/N TBX00454 & After, TH407 S/N TBY01110 & After excluding TBY01121, 1122 & 1128, TH414 S/N TBZ00561 & After, TH514 S/N TBW00201 & After, TH417 S/N TBT00216 & After) - See inspection note.

15. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies.

16. Frame Level Cylinder (TH414, TH514 & TH417) - Pins secure; hydraulic hoses undamaged, not leaking.

17. Right Outrigger (TH414, TH514 & TH417) - Pins secure; hydraulic hoses and cylinder undamaged, not leaking.

18. Boom Prop (if equipped) - See inspection note.

19. Platform Recognition Sensor (AUS - if equipped for platform): See inspection note.

20. Attachment - Properly installed, see “Attachment Installation” on page 5-13.

31200368

2-15

Section 2 - Pre-Operation and Inspection 2.4

WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check During warm-up period, check: 1. Heater, defroster and windshield wiper (if equipped).

2. Check all lighting systems (if equipped) for proper operation.

3. Adjust mirror(s) for maximum visibility.

WARNING CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running.

Operational Check When engine warms, perform an operational check: 1. Service brake and parking brake operation.

2. Forward and reverse travel.

3. Each gear.

4. Steering in both directions with engine at low idle (steering lock to lock will not be reached). Check in each steering mode 5. Horn and back-up alarm. Must be audible from inside operators cab with engine running.

6. All joystick functions - operate smoothly and correctly.

7. Perform any additional checks described in Section 8.

2-16

31200368

Section 2 - Pre-Operation and Inspection 2.5

OPERATOR CAB

The telehandler is equipped with an open or enclosed ROPS/FOPS cab.

WARNING CRUSH HAZARD. Never operate telehandler unless the overhead guard and cab structure are in good condition. Any modification to this machine must be approved by JLG to assure compliance with ROPS/FOPS certification for this cab/machine configuration. If damaged, the CAB CANNOT BE REPAIRED. It must be REPLACED.

31200368

2-17

Section 2 - Pre-Operation and Inspection 2.6

WINDOWS

Keep all windows clean and unobstructed.

Cab Door Window

2 3

4

1

OAM2100

• Cab door (1) must be closed during operation.

• During operation the cab door window (2) must either be latched open or closed.

• Open the cab door window using lever (3) and secure it in the latch (4).

• Press the release inside the cab to unlatch the window.

2-18

31200368

Section 2 - Pre-Operation and Inspection Rear Window

6 5

OAM2110

• Lift lever (4) and push to open the rear window (5).

• Lift lever and pull to close.

31200368

2-19

Section 2 - Pre-Operation and Inspection

This Page Intentionally Left Blank

2-20

31200368

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS 3.1

GENERAL

This section provides the necessary information needed to understand control functions.

Note: The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices.

31200368

3-1

Section 3 - Controls and Indicators 3.2

CONTROLS 12 10

13

11

14 15

9

16 17

8 18

7 6

5 4 3 2

1

OAM1592

1. Park Brake: See page 3-11.

2. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed.

3. Service Brake Pedal: The further the pedal is depressed, the slower the travel speed.

4. Ignition Switch: Key Activated. See page 3-10.

5. Transmission Control Lever: See page 3-12.

6. Front Console Switches: See page 3-22.

7. Steering Column Adjuster: See page 3-17.

8. Steering Wheel: Turning the steering wheel to the left or right steers the machine in the corresponding direction. Three steering modes are available.

See “Steer Modes” on page 3-29.

9. Instrument Panel: See page 3-4.

3-2

31200368

Section 3 - Controls and Indicators 10. Frame Level Indicator: Enables operator to determine the left to right level condition of the telehandler.

11. Keypad: See page 3-8.

12. LSI Indicator (CE & AUS): See page 3-14.

13. Accessory Control Lever (if equipped): See page 3-25.

14. Power/Emergency Stop Switch (if equipped for platform): Push down to shut off power and stop engine.

15. Joystick: See page 3-18.

16. Longitudinal Level Indicator (AUS): Enables operator to determine the front to back level condition of the telehandler.

17. Power Outlet: 12V receptacle.

18. Right Console Switches: See page 3-23.

31200368

3-3

Section 3 - Controls and Indicators Instrument Panel

2

3

4

5

6 7

1 24

8

9

23 10

22 21 20 19 18 17 16 15 14 13 12 11

OZ2061

1. Low Fuel Indicator: Illuminates and buzzer sounds briefly when fuel level is low.

2. Fuel Gauge: Indicates amount of fuel in fuel tank.

3. Left Turn Signal Indicator: Illuminates when left turn signal is active.

4. Display Screen: See page 3-6.

5. Right Turn Signal Indicator: Illuminates when right turn signal is active.

6. Engine Temperature Gauge: Indicates engine operating temperature.

7. Engine Temperature Warning Indicator: Illuminates and buzzer sounds when engine temperature is too high.

8. Continuous Auxiliary Hydraulics Indicator: Illuminates when continuous auxiliary hydraulics are active.

9. Trailer Turn Signal Indicator: Illuminates when trailer turn signal is activated.

10. Clutch Lock Indicator: Illuminates when clutch lock feature is engaged.

11. High Beam Indicator: Illuminates when high beam lights are on.

12. Anti Theft Indicator: Illuminates and buzzer sounds briefly at start-up when anti theft feature is active. Enter anti theft code, see page 3-28.

13. Maintenance Indicator: Illuminates and buzzer sounds briefly when maintenance is required.

14. Engine Preheat Indicator: With ignition key in position II, illuminates until start temperature is reached. At temperatures below 0° C (32° F), do not start until indicator goes out.

15. Park Brake Indicator: Illuminates when park brake is applied. See page 3-11.

3-4

31200368

Section 3 - Controls and Indicators 16. System Distress Indicator: Illuminates and buzzer sounds when critical machine and engine faults exist.

17. Engine Fault Critical Indicator: Illuminates and buzzer sounds when a critical engine fault exists.

18. Engine Fault Warning Indicator: Illuminates and buzzer sounds when engine is operating outside the normal range.

19. Air Filter Restriction Indicator: Illuminates and buzzer sounds briefly when air filter(s) require maintenance.

20. Engine Oil Pressure Indicator: Illuminates and buzzer sounds when engine oil pressure is too low.

21. Battery Charge Indicator: Illuminates when battery is at low charge or charging system is not functioning properly.

22. Transmission Oil Temperature Indicator: Illuminates and buzzer sounds when transmission oil temperature is too high.

23. Steering Pressure Indicator: Illuminates and buzzer sounds when steering pressure is too low.

24. Hydraulic Filter Restriction Indicator: Illuminates and buzzer sounds briefly when hydraulic filter requires maintenance.

NOTICE EQUIPMENT DAMAGE. When the engine fault, system distress or a red indicator illuminates (except park brake), immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

Note: All indicators (except high beam and turn signals) perform a bulb check at system start up.

31200368

3-5

Section 3 - Controls and Indicators Display Screen DISPLAY SHOWN WITH CONTINUOUS AUXILIARY HYDRAULICS ACTIVE

1 2

3

00

F2

0000 0000 100 00

RPM

km/h

DISPLAY SHOWN WITH ANTI THEFT ACTIVE AT SYSTEM START

4 5 6

8

00

0000 0000

RPM

km/h

0

7

OAH1270

1. Joystick Mode: Displays current joystick mode. Joystick mode can be changed by the machine owner in Operator Tools Menu (level 2 password required). See Service Manual for information. a. Loader Joystick Pattern - Displays loader joystick pattern icon on left when active. See page 3-20. b. Lift Joystick Pattern - Displays lift joystick pattern icon on right when active.

See page 3-18.

2. Speed and Power to Platform: c. Speed - Telehandler travel speed displayed in kilometers per hour (km/h) or miles per hour (m/h). d. Transfer Power to Platform (if equipped for platform) - Assists with transferring power to platform. Refer to the THP18s & THP45s Platforms for TH414, TH514, TH417 Operation & Maintenance Manual.

3. Driving Direction and Gear: Displays current driving condition. a. Direction - Forward (F), Neutral (N) or Reverse (R). b. Gear - First (1), Second (2), Third (3), Fourth (4) or, if equipped, Fifth (5).

4. Engine Speed: Displays engine speed in revolutions per minute (rpm).

5. Operating Hours: Displays total hours of telehandler operation.

6. Boom Angle: Displays boom angle in degrees. 0 degrees indicates horizontal.

7. Continuous Auxiliary Hydraulics, Steering Mode Change and Platform Status: a. Continuous Auxiliary Hydraulics - Displays flow value (-100% to +100%) when continuous auxiliary hydraulics is activated. See Section 5 - Attachments and Hitches for details. b. Steering Mode Change - Assists with steering mode change. See “Steer Modes” on page 3-29 for details. c. Platform Status (if equipped for platform) - Displays status when platform is installed.

3-6

31200368

Section 3 - Controls and Indicators 8. Anti Theft Code Entry: If active, the four digit code must be entered after system start. See “Anti Theft” on page 3-28 for details.

9

MENU: HELP: PRESS ENTER

OAH2000

9. Menus: Menus display fault codes and other machine information while allowing modification of some operating parameters. Depress and hold the C and OK buttons on the keypad to access menus. a. Help - Displays active fault code. Depress OK button again and use keypad arrows to cycle through the last 25 fault codes. Active faults are denoted with an asterisk. b. Operator Tools - Speed, Temperature and Oil Pressure units and Steering Alignment Mode can be modified by the operator. Customer or Service level access code required to modify additional items.

• Machine Speed - Select units (km/h or m/h) to be displayed.

• Engine Temperature - Select units (Celsius or fahrenheit) to be displayed.

• Steering Alignment Mode - Select mode (manual or all wheel assisted) to be used when changing steering modes, see page 3-29. c. Personalities - View performance parameters. Customer or Service level access code required to modify parameters. d. Access Level - Code entry determines access level.

• Operator (Level 3) - No code required.

• Customer (Level 2) - See Service Manual for information.

• Service (Level 1) - Manufacturer service representative only. e. Diagnostics - View diagnostic information. f. System Test - Performs test of all system inputs and outputs. g. Machine Setup - View machine configurations. Service level access code required to modify configurations. h. Calibrations - Customer or Service level access code required.

31200368

3-7

Section 3 - Controls and Indicators Keypad 1

OZ2361

4

2

5

3

6

7

1. C (Clear or escape): Use in conjuction with display screen. Returns user interface one level during navigation. If at top level menu, depress and hold for one second to exit.

2. Up/Down Arrows: Use in conjuction with display screen. Navigate menu selections and change adjustable values.

3. OK (Enter): Use in conjuction with display screen. Confirms user interface inputs.

4. Steer Mode: Three steer modes available: 4-Wheel Circle Steer, 2-Wheel Front Steer and 4-Wheel Crab Steer. Illuminated LED indicates current steer mode.

See page 3-29.

Note: If machine is shut-down during steer mode change, it must be completed at restart.

5. LSI Override: Momentarily disables the automatic function cut-out. LED flashes while activated. Depress and hold up to 30 seconds while operating joystick to momentarily disable the automatic function cut-out.

WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.

6. Bucket Mode: LED lit while activated. Increases response to boom functions.

7. Joystick Function: LED lit while activated. Boom, auxiliary hydraulics and outrigger functions are enabled. Deactivate this function before traveling on public roads. See “Road Operation (CE)” on page 4-10.

Note: All LEDs perform a bulb check at system start up.

3-8

31200368

Section 3 - Controls and Indicators

This Page Intentionally Left Blank

31200368

3-9

Section 3 - Controls and Indicators Ignition

P

0

I II III

OZ2300

• Position 0 - Engine off.

• Position I - Voltage available for all electrical functions.

• Position II - Engine preheat at temperatures below 0° C (32° F). Wait to start engine until preheat indicator on instrument panel goes out.

• Position III - Engine start. In the event the engine does not start, rotate key to position 0 then back to position III to re-engage the starter.

• Position P (if equipped for platform) - Power transferred to platform.

Note: Key is removable in the 0 and P positions.

3-10

31200368

Section 3 - Controls and Indicators Park Brake

1 2

OAM1600

The park brake lever (1) controls the application and release of the park brake.

• Pull lever back to apply park brake.

• Squeeze release (2) and push lever forward to release park brake.

WARNING MACHINE ROLL-AWAY HAZARD. Always move park brake lever to "ON" position, lower boom to ground and stop engine before leaving cab.

WARNING CRUSH HAZARD. Applying park brake while traveling will cause unit to stop abruptly and could cause load loss. To stop the machine in an emergency, apply the park brake.

Parking Procedure 1. Using service brake, stop telehandler in an appropriate parking area.

2. Follow “Shut-Down Procedure” on page 4-3.

31200368

3-11

Section 3 - Controls and Indicators Transmission Control Lever Direction of Travel Selection

F N R

1

OAM1611

Transmission control lever (1) engages forward or reverse travel.

• Push lever forward for forward travel; pull lever rearward for reverse travel. Move lever to centered position for neutral.

• Forward or reverse travel can be selected while in any gear.

• When traveling in reverse, the back-up alarm will automatically sound.

• Drive in reverse and turn only at slow rates of speed.

• If clutch lock switch is activated (see page 3-22), do not increase engine speed with the transmission in forward or reverse and the service brake depressed in an attempt to get quicker hydraulic performances. This could cause unexpected machine movement.

WARNING TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before shifting transmission control lever. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

3-12

31200368

Section 3 - Controls and Indicators Gear Selection

2 1st 2nd 3rd 4th

OAM1621

Gear selection is located on the twist grip handle (2) of transmission control lever.

• Twist hand grip to select gear.

• If equipped with 5 speed transmission, when actively driving forward in fourth gear and proper conditions are met, the transmission will automatically shift into fifth gear. If a gear selection other than fourth gear is selected or proper conditions are met the transmission will automatically downshift out of fifth gear.

• Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when driving unloaded for longer distances.

• Slow down prior to downshifting. Do not downshift more than one gear at a time.

Horn

3

(BEFORE S/N TDE00169) (BEFORE S/N TDF00198) (BEFORE S/N TBX00324) (BEFORE S/N TBY00626) (BEFORE S/N TBZ00227)

3

(S/N TDE00169 & AFTER) (S/N TDF00198 & AFTER) (S/N TBX00324 & AFTER) (S/N TBY00626 & AFTER) (S/N TBZ00227 & AFTER) (S/N TBW00100 & AFTER) (S/N TBT00100 & AFTER)

OAM1631

Horn button (3) is located on the end of transmission control lever.

• Depress to sound horn.

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Section 3 - Controls and Indicators Load Stability Indicator - LSI (CE & AUS)

WARNING TIP OVER HAZARD. The LSI considers only longitudinal stability limitations, observe all operating parameters. Failure to follow operating parameters of the telehandler could damage the equipment and/or cause tip over.

TH336 Before S/N TDE00335 excluding TDE00297-313, 328 & 332, TH337 Before S/N TDF00320 excluding TDF00297, 299-302 & 317, TH406 Before S/N TBX00454, TH407 Before S/N TBY01110 including TBY01121, 1122 & 1128, TH414 Before S/N TBZ00561, TH514 Before S/N TBW00201, TH417 Before S/N TBT00216

1

4

5 7 6

3 2

POWER

TEST

8 OAM1642

The LSI (1) provides visual and audible indication of forward stability limitations when machine is static on firm, level surface.

• Green LED (2) will illuminate when LSI power is on.

• When approaching forward stability limitations LEDs progressively illuminate, green (3), then yellow (4) and finally red (5).

• The warning buzzer sounds as the first red LED illuminates.

• As the telehandler reaches forward stability limitations and the second red LED illuminates, the automatic function cut-out is activated. Certain functions are disabled (i.e. boom lift, extend, etc). Retract boom to re-enable functions.

Note: (TH336, TH337, TH406, TH407 - CE Only) If bucket mode is active (see page 3-8), automatic function cut-out is disabled.

• Press button (6) to disable the warning buzzer. When disabled, yellow LED (7) will illuminate. If last red LED illuminates, disable button is overridden and warning buzzer sounds.

• Test LSI (8) at the beginning of each work shift. See Section 8 - Additional Checks.

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Section 3 - Controls and Indicators TH336 S/N TDE00335 & After including TDE00297-313, 328 & 332, TH337 S/N TDF00320 & After including TDF00297, 299-302 & 317, TH406 S/N TBX00454 & After, TH407 S/N TBY01110 & After excluding TBY01121, 1122 & 1128, TH414 S/N TBZ00561 & After, TH514 S/N TBW00201 & After, TH417 S/N TBT00216 & After

9

15 13 11

12 14 10 OAM2961

The LSI (9) provides visual and audible indication of forward stability limitations when machine is static on firm, level surface.

• Green LED (10) will illuminate when LSI power is on.

• When approaching forward stability limitations LEDs progressively illuminate, green (11), then orange (12) and finally red (13).

• If the red LED illuminates the warning buzzer also sounds.

The LSI has two modes: Active Mode (TH336, TH337, TH406, TH407, TH414, TH514 & TH417) • As the telehandler reaches forward stability limitations and the red LED (13) illuminates, the automatic function cut-out is activated. All boom, frame level and outrigger functions are disabled except for boom retract (CE & AUS) and boom lift (CE). Retract boom to re-enable functions.

• In some instances the LSI system may slow down or stop boom functions if operated close to forward stability limitations. When LEDs begin to flash, certain functions can not be operated. Retract boom and/or return the joystick to neutral position for a short period to allow system to reset and LEDs to stop flashing before proceeding with operation.

Passive Mode (TH336, TH337, TH406 & TH407) • The orange LED (15) illuminates when either of the following occurs: • The boom is fully retracted.

• The park brake is not applied and transmission control lever is in the forward or reverse position.

• When approaching forward stability limitations, visual and audible indication is provided and the automatic function cut-out and/or slow down feature is disabled.

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Section 3 - Controls and Indicators • Travel in accordance with the requirements set forth in Section 1 - General Safety Practices.

• Test LSI (14) at the beginning of each work shift. See Section 8 - Additional Checks.

• When placing a load, ensure axles are not fully steered in either direction.

WARNING TIP OVER HAZARD. If the green, orange and red LEDs flash and warning buzzer sounds, retract and lower boom immediately. Determine cause and correct before continued use.

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Section 3 - Controls and Indicators Steering Column Adjuster

9

OAM1651

• Follow “Shut-Down Procedure” on page 4-3.

• Turn lever (9) counterclockwise to unlock.

• Place steering column in desired position.

• Turn lever clockwise to lock.

WARNING TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop and shutdown engine before adjusting steering column. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

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Section 3 - Controls and Indicators Joystick Lift Joystick Pattern

1

2

OAH1351

Verify the lift joystick pattern icon (2) is active on the display (1) and the joystick decal located inside the cab matches the machine controls.

TH336, TH337, TH406 & TH407 (IF EQUIPPED WITH BOOM FLOAT)

5

TH414, TH514 & TH417

6 4

7 8 OAM1662

The joystick (4) controls the boom, attachment, auxiliary hydraulics, outrigger and clutch lock functions.

Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom; move joystick right to extend boom; move joystick left to retract boom.

• The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.

• For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower and retract boom simultaneously.

WARNING TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, jerky movement of the load. Such movements could cause the load to shift or fall or could cause the machine to tip over.

3-18

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Section 3 - Controls and Indicators Attachment Functions Attachment tilt is controlled by the roller switch (5).

• Push the roller switch up to tilt attachment down; push the roller switch down to tilt attachment up.

Auxiliary Hydraulic Functions Auxiliary Hydraulics roller switch (6) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments and Hitches for approved attachments and control instructions.

Boom Float Function (TH336, TH337, TH406 & TH407, if equipped) Button (7) controls boom float. Boom float allows free movement of boom (lift/lower) while the attachment follows ground contours.

• With boom retracted and lowered, press and hold the button; move the joystick forward to activate boom float. Button and joystick position must be held to maintain boom float.

• Release button to deactivate boom float and move joystick to neutral position.

Outrigger Functions (TH414, TH514 & TH417) Button (7) controls both outriggers.

• Press and hold the button; move the joystick forward to lower both outriggers; move the joystick back to raise both outriggers.

• Press and hold the button; move the joystick left then forward to lower the left outrigger; move the joystick left then back to raise the left outrigger.

• Press and hold the button; move the joystick right then forward to lower the right outrigger; move the joystick right then back to raise the right outrigger.

• Outriggers operable with boom below 20 degrees. If equipped with boom retracted switch, outriggers operable with boom below 20 degrees or with boom fully retracted and between 20 and 55 degrees.

WARNING TIP OVER HAZARD. Outriggers increase stability and load capacity only if they are used properly. Using outriggers on soft surfaces could cause telehandler to tip over. Always ensure surface can support telehandler and load.

Clutch Lock Switch Clutch Lock is controlled by the joystick trigger (8).

• (CE & AUS) Squeeze and hold trigger to deactivate system and have transmission disengage while depressing service brake. Release trigger to activate system and keep transmission engaged while depressing service brake.

• (ANSI) Squeeze and release trigger once to deactivate system and have transmission disengage while depressing service brake. Quickly squeeze and release trigger twice to activate system and keep transmission engaged while depressing service brake.

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Section 3 - Controls and Indicators Loader Joystick Pattern

1

3

OAH1381

Verify the loader joystick pattern icon (3) is active on the display (1) and the joystick decal located inside the cab matches the machine controls.

TH336, TH337, TH406 & TH407 (IF EQUIPPED WITH BOOM FLOAT)

5

TH414, TH514 & TH417

6 4

7 8 OAM1672

The joystick (4) controls the boom, attachment, auxiliary hydraulics, outrigger and clutch lock functions.

Boom Functions • Move the joystick back to lift boom; move joystick forward to lower boom.

• Extend/retract is controlled by the roller switch (5). Push roller switch up to extend boom; push roller switch down to retract boom.

• The speed of boom functions depends upon the amount of joystick travel in corresponding direction. Increasing engine speed will also increase function speed.

• For two simultaneous boom functions, move the joystick between quadrants. For example; moving the joystick forward and to the left will lower boom and tilt attachment up simultaneously.

WARNING TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid, jerky movement of the load. Such movements could cause the load to shift or fall or could cause the machine to tip over.

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Section 3 - Controls and Indicators Attachment Functions Attachment tilt is controlled by the joystick.

• Move joystick right to tilt down; move joystick left to tilt up.

Auxiliary Hydraulic Functions Auxiliary Hydraulics roller switch (6) controls function of attachments that require hydraulic supply for operation. See Section 5 - Attachments and Hitches for approved attachments and control instructions.

Boom Float Function (TH336, TH337, TH406 & TH407, if equipped) Button (7) controls boom float. Boom float allows free movement of boom (lift/lower) while the attachment follows ground contours.

• With boom retracted and lowered, press and hold the button; move the joystick forward to activate boom float. Button and joystick position must be held to maintain boom float.

• Release button to deactivate boom float and move joystick to neutral position.

Outrigger Functions (TH414, TH514 & TH417) Button (7) controls both outriggers.

• Press and hold the button; move the joystick forward to lower both outriggers; move the joystick back to raise both outriggers.

• Press and hold the button; move the joystick left then forward to lower the left outrigger; move the joystick left then back to raise the left outrigger.

• Press and hold the button; move the joystick right then forward to lower the right outrigger; move the joystick right then back to raise the right outrigger.

• Outriggers operable with boom below 20 degrees. If equipped with boom retracted switch, outriggers operable with boom below 20 degrees or with boom fully retracted and between 20 and 55 degrees.

WARNING TIP OVER HAZARD. Outriggers increase stability and load capacity only if they are used properly. Using outriggers on soft surfaces could cause telehandler to tip over. Always ensure surface can support telehandler and load.

Clutch Lock Switch Clutch Lock is controlled by the joystick trigger (8).

• (CE & AUS) Squeeze and hold trigger to deactivate system and have transmission disengage while depressing service brake. Release trigger to activate system and keep transmission engaged while depressing service brake.

• (ANSI) Squeeze and release trigger once to deactivate system and have transmission disengage while depressing service brake. Quickly squeeze and release trigger twice to activate system and keep transmission engaged while depressing service brake.

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Section 3 - Controls and Indicators Front Console Switches 1 2 3 4 5

6 7 8 9

10

11 12 13

OAM1682

1. Roof Wiper Switch (if equipped): On/Off switch.

2. Rear Wiper Switch (if equipped): On/Off switch.

3. Driving Lights Switch (if equipped): On/Off switch.

4. Rear Cab Work Lights Switch (if equipped): On/Off switch.

5. Front Cab Work Lights Switch (if equipped): On/Off switch.

6. Beacon Light Switch (if equipped): On/Off switch. Place magnetic base of beacon on cab roof. Power supplied by 12V receptacle at rear left of cab roof.

7. Clutch Lock Switch: Depress front of switch to activate system and keep transmission engaged while depressing service brake. Depress back of switch to deactivate system and have transmission disengage while depressing service brake.

8. Boom Work Lights Switch (if equipped): On/Off switch.

9. Fog Lights Switch (if equipped): On/Off switch.

10. Hydraulic Quick Coupler Switch (if equipped): Used in conjuction with the joystick to hydraulically lock or unlock an attachment.

11. Boom Ride Control Indicator (TH336, TH337, TH406 & TH407, if equipped): Illuminates when boom ride control system is activated.

12. Hazard Lights Switch (if equipped): On/Off switch.

13. Reversing Fan Switch (if equipped): See page 3-26.

3-22

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Section 3 - Controls and Indicators Right Console Switches 14 15 16 17 20 21 22 23 18

19

OAM1692

14. Boom Ride Control Switch (TH336, TH337, TH406 & TH407, if equipped): Depress switch to activate boom ride control. While activated and traveling 5 kph (3 mph) or faster, the system acts to cushion boom movement. Depress switch again to deactivate boom ride control.

Auxiliary Power Switch (TH414, TH514 & TH417, if equipped for platform): Depress and hold in place to engage auxiliary power. See “Emergency Lowering of Boom If Equipped for Platform” on page 6-3.

15. Second Auxiliary Hydraulics Switch (if equipped): Depress switch to activate second auxiliary hydraulics on boom. See Section 5 - Attachments and Hitches for approved attachments and control instructions.

16. Continuous Auxiliary Hydraulics Switch: a. Depress and release switch for continuous operation of hydraulic powered attachments. Set continuous auxiliary hydraulic level (-100% to 100%) within 10 seconds using the keypad up/down arrow buttons (see page 3-8).

See Section 5 - Attachments and Hitches for approved attachments and control instructions. b. Relieves auxiliary hydraulic circuit pressure. See page 5-24.

17. Hydraulic Hitch Switch (TH336, TH337, TH406 & TH407, if equipped): Controls position of hydraulic hitch. Depress and hold right side of switch to raise hitch.

Depress and hold left side of switch to lower hitch. See page 5-50 for control instructions.

Frame Level Switch (TH414, TH514 & TH417): Controls the left to right frame level. Depress right side of switch to rotate frame right; depress left side of switch to rotate frame left. Frame level operable with boom below 20 degrees. If equipped with boom retracted switch, frame level operable with boom below 20 degrees or with boom fully retracted and between 20 and 55 degrees.

18. Power Outlet: 12V receptacle.

19. Hydraulic Hitch Safety Hook Release (TH336, TH337, TH406 & TH407, if equipped): Pull to release safety hooks on hydraulic hitch. See page 5-50 for control instructions.

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Section 3 - Controls and Indicators 14 15 16 17 20 21 22 23 18

19

OAM1692

Heater and Air Conditioning Controls (if equipped) 20. Fan Speed Switch: Adjustable rotary switch.

21. Recycle/Fresh Air Switch: Adjustable rotary switch.

22. Temperature Control Switch: Adjustable rotary switch.

23. Air Conditioning Switch: On/Off switch.

3-24

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Section 3 - Controls and Indicators Accessory Control Lever Turn Signals and Low/High Beam Headlights

1

4

2

3 OAM2172

• Push accessory control lever (1) forward (2) to activate left turn signal.

• Pull lever backward (3) to activate right turn signal.

• The lever must be manually returned to the center position to deactivate either turn signal. The lever will not cancel automatically after a turn.

• Pull lever up (4) to switch between low and high beam headlights.

Front Windshield Wiper 5

5

1

I

II

J

O

6

J

OAM2162

(S/N TDE00169 & AFTER) (S/N TDF00198 & AFTER) (S/N TBX00324 & AFTER) (S/N TBY00626 & AFTER) (S/N TBZ00227 & AFTER) (S/N TBW00100 & AFTER) (S/N TBT00100 & AFTER)

6 I

O

(BEFORE S/N TDE00169) (BEFORE S/N TDF00198) (BEFORE S/N TBX00324) (BEFORE S/N TBY00626) (BEFORE S/N TBZ00227)

• Rotate hand grip (5) to activate front windshield wiper.

O - Off, J - Interval (if equipped), I - Continuous or II - Fast • Depress end of lever (6) to activate windshield wiper fluid.

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3-25

Section 3 - Controls and Indicators Reversing Fan (if equipped)

1

2

OAM1701

Hydraulic Reversing Fan 1. In a clear area apply park brake, shift transmission to Neutral and ensure engine speed is less than 1000 rpm.

2. Depress and hold front of switch (1) to reverse the engine fan rotation to remove debris from the radiator grill (2).

3. If needed, engine speed can be increased at this time.

4. Reduce engine speed to less than 1000 rpm and release switch to return fan to normal operation.

Note: Limit operation to no more than 30 seconds.

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Section 3 - Controls and Indicators Pneumatic Reversing Fan

3 OAM2910

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.

3. Lift rubber cover (3) and set desired interval time between 6 to 66 minutes. Turn clockwise to increase or counterclockwise to decrease time in 2 minute increments.

4. Replace rubber cover and close and secure engine cover.

5. During machine operation move switch (1) to middle position to activate reversing fan timer. Fan blades automatically turn at set interval and reverse air flow briefly to remove debris from the radiator grill (2).

6. Depress and hold front of switch to override timer and operate reversing fan manually to remove debris from the radiator grill. Release switch to return to timer.

Note: Limit manual operation to no more than 30 seconds.

7. Depress back of switch to deactivate reversing fan function.

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Section 3 - Controls and Indicators 3.3

ANTI THEFT

Machines with the anti theft feature active require entering a numeric code before operation to prevent unauthorized use. Code entry is accomplished using the display and keypad.

00

0000 0000

2

3

RPM

km/h

0 1

OAH1430

1. Turn ignition switch to position I. If anti theft is active, the display (1) will prompt the operator for a numeric code.

2. Use the up/down arrow buttons (2) to select the first digit.

3. Depress OK button (3) to confirm and move to the next digit.

4. Continue until the code is complete.

5. If an incorrect code is entered, the buzzer will sound briefly and the display will prompt the operator again for the numeric code.

6. If the correct code is entered, normal start up can continue.

Note: If the anti theft feature is active and the current access code is not known, it may be viewed or changed by the machine owner in Operator Tools Menu (level 2 password required). See Service Manual for information.

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Section 3 - Controls and Indicators 3.4

STEER MODES

Three steer modes are available for operator use.

2-Wheel Front Steer

4-Wheel Circle Steer

4-Wheel Crab Steer

OAL2030

Note: 2-Wheel Front Steer mode is required for travel on public roads.

Manual Steering Alignment Mode Change If manual steering alignment mode is active under the Operator Tools menu (see page 3-7), use the following procedure for steer mode change.

Note: Steer mode will change immediately after selection.

1

2

3

OAM2381

1. Bring machine to a stop using service brake. If front steer mode (2) is active and rear wheels are aligned, go directly to step 4.

4

5

OAM2400

2. With circle steer (1) or crab steer (3) mode active, turn the steering wheel until the left rear wheel (4) is aligned with the side of the machine.

3. Select front steer mode (2).

4. Turn the steering wheel until the left front wheel (5) is aligned with the side of the machine.

5. Wheels are now aligned. Select desired steer mode.

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Section 3 - Controls and Indicators All Wheel Assisted Steering Alignment Mode Change If all wheel assisted steering alignment mode is active under the Operator Tools menu (see page 3-7), use the following procedure for steer mode change.

1. Bring machine to a stop using service brake.

1

2

3

OAM2381

2. Select desired steer mode: circle steer (1), front steer (2) or crab steer (3).

Note: Selected steer mode LED will flash and display will show steering alignment screens until the change is complete. After steering alignment is complete, steer mode LED will illuminate solid.

00

F1

0000 0000 00

RPM

km/h

6

00

F1

0000 0000 00

RPM

km/h

00

0000 0000 00

RPM

km/h

F1

7

8

OAM2391

3. Turn the steering wheel until the rear wheels are centered (6). This step will be skipped if changing from front steer mode and rear wheels are already centered.

4. Turn the steering wheel until the front wheels are centered (7). This step will be skipped if changing to front steer mode.

5. Wheels are now aligned and steer mode change is complete (8).

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Section 3 - Controls and Indicators 3.5

OPERATOR SEAT

Adjustments Prior to starting the engine adjust seat for position and comfort.

Mechanical Suspension Seat

4

5 1 2 3

OAM1720

1. Fore/Aft: Use handle to move seat fore and aft.

2. Height: Use knob to adjust height of the seat.

3. Suspension: Use the knob to adjust the suspension to the appropriate weight setting.

4. Backrest: Use knob to adjust backrest angle.

5. Seat Belt: Always fasten seat belt during operation. If required, a 76 mm (3 in) seat belt is available.

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Section 3 - Controls and Indicators Pneumatic Suspension Seat

4 1

5 3

2

OAM1710

1. Fore/Aft: Use handle to move seat fore and aft.

2. Suspension: Use the knob to adjust the suspension to the appropriate weight setting.

3. Weight: Displays current weight setting.

4. Backrest: Use lever to adjust backrest angle.

5. Seat Belt: Always fasten seat belt during operation. If required, a 76 mm (3 in) seat belt is available.

3-32

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Section 3 - Controls and Indicators Seat Belt

OH20912

Fasten seat belt as follows: 1. Grasp both free ends of the belt making certain that belt webbing is not twisted or entangled.

2. With back straight in the seat, couple the retractable end (male end) of the belt into the receptacle (buckle) end of the belt.

3. With belt buckle positioned as low on the body as possible, pull the retractable end of the belt away from the buckle until it is tight across the lap.

4. To release belt latch, depress red button on the buckle and pull free end from buckle.

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Section 3 - Controls and Indicators 3.6

BOOM INDICATORS 1 A

2 B

OAM1731

Boom Extension • The boom extension indicators (1) are located on the left side of the boom. Use these indicators to determine boom extension when using the load chart (see “Use of the Load Chart” on page 5-7).

Boom Angle (AUS) • The boom angle indicator (2) is located on the left side of the boom. Use this indicator to determine boom angle when using the load chart (see “Use of the Load Chart” on page 5-7).

3-34

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Section 4 - Operation

SECTION 4 - OPERATION 4.1

ENGINE

Note: Refer to Engine Operation & Maintenance Manual for additional information.

Starting the Engine This machine can be operated under normal conditions in temperatures of -20°C to 40°C (0°F to 104°F). Consult the local Caterpillar dealer for operation outside this range or under abnormal conditions.

1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Apply park brake.

2. If equipped for platform, pull the power/emergency stop switch up.

3. Turn ignition switch to position I. If active, enter anti theft code.

4. Turn ignition switch to position II. If the temperature is below 0° C (32° F), wait for engine preheat indicator on instrument panel to go out.

5. Turn ignition switch to position III to engage starting motor. Release key immediately when engine starts. If engine fails to start within 20 seconds, release key and allow starting motor to cool for a few minutes before trying again.

6. After engine starts, observe engine oil pressure indicator. If indicator remains on for more than five seconds, stop engine and determine cause before restarting engine.

7. Warm up engine at approximately 1/2 throttle.

Note: Engine will not start unless transmission control lever is in “Neutral” and park brake is applied.

WARNING UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control lever is in neutral and the service brake is applied before releasing park brake.

Releasing park brake in either forward or reverse could cause the machine to move abruptly.

WARNING ENGINE EXPLOSION. Do not spray ether into air intake for cold weather starting.

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4-1

Section 4 - Operation Battery Boosted Starting

OW0530

If battery-boost starting (jump-start) is necessary, proceed as follows: • Never allow vehicles to touch.

• Ensure boosting vehicle engine is running.

• Connect the positive (+) jumper cable to positive (+) post of discharged battery.

• Connect the opposite end of positive (+) jumper cable to positive (+) post of booster battery.

• Connect the negative (-) jumper cable to negative (-) post on booster battery.

• Connect opposite end of negative (-) jumper cable to ground point on machine away from discharged battery.

• Follow standard starting procedures.

• Remove cables in reverse order after machine has started.

WARNING BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery as it could explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging.

Wear safety glasses.

4-2

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Section 4 - Operation Normal Engine Operation • Observe instrument panel and display frequently to be sure all systems are functioning properly.

• Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform shut-down procedure. Report condition to your supervisor or local Caterpillar dealer.

• Avoid prolonged idling. If the engine is not being used, turn it off.

Shut-Down Procedure When parking the telehandler, park in a safe location on flat level ground and away from other equipment and/or traffic lanes.

1. Apply the park brake.

2. Shift the transmission to “Neutral.”

3. Lower forks or attachment to the ground.

4. Operate engine at low idle for 3 to 5 minutes. DO NOT over rev engine.

5. Shut off engine and remove ignition key.

6. If equipped for platform, push the power/emergency stop switch down.

7. Exit telehandler properly.

8. Turn off electrical master switch (if equipped).

9. Block wheels (if necessary).

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4-3

Section 4 - Operation 4.2

OPERATING WITH A NON-SUSPENDED LOAD

Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.

• Know the rated load capacities (refer to Section 5) of the telehandler to determine the operating range in which you can safely lift, transport and place a load.

Picking Up a Load • Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• Adjust spacing of forks so they engage the pallet or load at maximum width. See “Adjusting/Moving Forks” on page 5-25.

• Approach load slowly and squarely with fork tips straight and level. NEVER attempt to lift a load with just one fork.

• NEVER operate telehandler without a proper and legible load chart in the operator cab for the telehandler/attachment combination you are using.

4-4

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Section 4 - Operation Transporting a Load

OW0540

• After engaging the load and resting it against the backrest, tilt the load back to position it for travel. Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments and Hitches.

• If equipped, boom ride control mode (see page 3-23) is recommended for transport of a load over longer distances. When activated, the boom ride control system acts to cushion boom movement.

Leveling Procedure 1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL. 3. Observe level indicator(s) to determine whether machine must be leveled prior to lifting load. If equipped, level machine with frame level switch (see page 3-23) or outrigger controls (see page 3-19 or 3-21).

4. Move boom/attachment to 1,2 m (4 ft) off ground.

(AUS - Move boom so forks are no more than 300 mm (11.8 in) above ground surface.)

Important things to remember: • Never raise the boom/attachment more than 1,2 m (4 ft) above ground unless telehandler is level.

(AUS - Never raise the forks more than 300 mm (11.8 in) above ground surface unless telehandler is level.)

• The combination of frame leveling and load could cause the telehandler to tip over.

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4-5

Section 4 - Operation Placing a Load Before placing any load be sure that: • The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the load chart to determine safe boom extension range. See “Use of the Load Chart” on page 5-7.

• Align forks at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.

• Lower the boom until the load rests in position and the forks are free to retract.

Disengaging a Load Once the load has been placed safely at the landing point, proceed as follows: 1. With the forks free from the weight of the load, the boom can be retracted and/or the telehandler can be backed away from under the load if surface will not change level condition of telehandler.

2. Lower the carriage.

3. The telehandler can now be driven from the landing location to continue work.

4-6

31200368

Section 4 - Operation 4.3

OPERATING WITH A SUSPENDED LOAD

Lift Load Safely • You must know the weight and load center of every load you lift. If you are not sure of the weight and load center, check with your supervisor or with the supplier of the material.

WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.

• Know the rated load capacities (refer to Section 5) of the telehandler to determine the operating range in which you can safely lift, transport and place a load.

Picking Up a Suspended Load • Note the conditions of the terrain. Adjust travel speed and reduce amount of load if conditions warrant.

• Avoid lifting double-tiered loads.

• Make sure load is clear of any adjacent obstacles.

• NEVER operate telehandler without a proper and legible load chart in the operator cab for the telehandler/attachment combination you are using.

• Only use approved lifting devices rated for the lifting of the load.

• Identify the proper lifting points of the load, taking into consideration the center of gravity and load stability.

• Ensure to always properly tether loads to restrict movement.

• Refer to “Use of the Load Chart” on page 5-7 for proper lifting guidelines in addition to the appropriate load chart in the operator cab.

31200368

4-7

Section 4 - Operation Transporting a Suspended Load

OZ3160

OW0130

• Travel in accordance with the requirements set forth in Section 1 - General Safety Practices and Section 5 - Attachments and Hitches.

• For additional requirements, refer to the appropriate load chart in the operator cab.

Important things to remember: • Ensure the boom is fully retracted.

• Never raise the load more than 300 mm (11.8 in) above ground surface or the boom more than 45°.

• The combination of frame leveling and load could cause the telehandler to tip over.

• The guide persons and operator must remain in constant communication (verbal or hand) and be in visual contact with the operator at all times.

• Never place the guide persons between the suspended load and the telehandler.

• Only transport the load at walking speed, 0.4 m/s (0.9 mph), or less.

Leveling Procedure 1. Position machine in best location to lift or place load.

2. Apply parking brake and move transmission control lever to NEUTRAL. 3. Observe level indicator(s) to determine whether machine must be leveled prior to lifting load. If equipped, level machine with frame level switch (see page 3-23) or outrigger controls (see page 3-19 or 3-21).

4. Move boom so load is no more than 300 mm (11.8 in) above ground surface and boom/or boom is raised no more than 45°.

4-8

31200368

Section 4 - Operation Placing a Suspended Load Before placing any load be sure that: • The landing point can safely support the weight of the load.

• The landing point is level; front to back and side to side.

• Use the load chart to determine safe boom extension range. See “Use of the Load Chart” on page 5-7.

• Align load at the level load is to be placed, then position boom slowly until load is just above area where it is to be placed.

• Ensure that the guide persons and operator remain in constant communication (verbal or hand) when placing the load.

Disengaging a Suspended Load • Never place the guide persons between the suspended load and the telehandler.

• Once at the destination of the load, ensure to bring the telehandler to a complete stop and apply the park brake prior to disengagement of the lifting devices and tethers.

31200368

4-9

Section 4 - Operation 4.4

ROAD OPERATION (CE)

1. Preparation a. Remove load from attachment. b. Remove any large amounts of dirt from machine. c. Check lights and mirrors and adjust if necessary.

Note: Be sure to follow all local and federal/provincial traffic regulations.

2. Lower boom. Front edge of attachment should be approximately 30-40 cm (12-16 in) above the ground.

3. Fully tilt attachment back.

4. Place protective shield over front bucket edge: remove or reposition carriage forks toward the machine and secure to the carriage.

OZ2171

1

2

5. Depress button (2) to deactivate joystick function and disable all joystick controlled functions. Joystick function LED will go out.

6. Deactivating the joystick function automatically changes steer mode to front wheel steering (1). See “Steer Modes” on page 3-29 for details.

7. Machine is now ready for road operation.

4-10

31200368

Section 4 - Operation 4.5

LOADING AND SECURING FOR TRANSPORT

1001100957

OAM1750

Tiedown 1. If equipped, level the telehandler prior to loading.

2. Using a spotter, load the telehandler with boom as low as possible.

3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key.

4. Secure machine to deck by passing chains through the designated tiedown points as shown in the figure.

5. Do not tiedown front of boom.

Note: The user assumes all responsibility for choosing the proper method of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer and all local and federal/provincial laws are followed.

WARNING TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport, make sure deck, ramps and telehandler wheels are free of mud, snow and ice.

Failure to do so could cause telehandler to slide.

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4-11

Section 4 - Operation Lifting • When lifting machine, it is very important that the lifting device and equipment is attached only to designated lifting points. If machine is not equipped with lifting lugs contact JLG Product Safety for information.

• Make adjustments to the lifting device and equipment to ensure the machine will be level when elevated. The machine must remain level at all times while being lifted.

• Ensure that the lifting device and equipment is adequately rated and suitable for the intended purpose. See Section 9 - Specifications for machine weight or weigh machine.

• Remove all loose items from machine prior to lifting.

• Lift machine with smooth, even motion. Set machine down gently. Avoid quick or sudden motions that could cause shock loads to machine and/or lifting devices.

4-12

31200368

Section 5 - Attachments and Hitches

SECTION 5 - ATTACHMENTS AND HITCHES 5.1

APPROVED ATTACHMENTS

To determine if an attachment is approved for use on the specific telehandler you are using, perform the following prior to installation.

• The attachment type, weight, dimensions and load center must be equal to or less than the data shown on a load chart located in the operator cab.

• The model on the load chart must match the model telehandler being used.

• Hydraulically powered attachments must only be used on machines equipped with auxiliary hydraulics.

If any of the above conditions are not met, do not use the attachment. The telehandler may not be equipped with the proper load chart or the attachment may not be approved for the model telehandler being used. Contact JLG or the local Caterpillar dealer for further information.

5.2

UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons: • Range and capacity limitations for “will fit,” homemade, altered, or other non-approved attachments cannot be established.

• An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and/or those working nearby.

• The ability of a non-approved attachment to perform its intended function safely cannot be assured.

WARNING Use only approved attachments. Attachments which have not been approved for use with your telehandler could cause machine damage or an accident.

31200368

5-1

Section 5 - Attachments and Hitches 5.3

JLG SUPPLIED ATTACHMENTS

Note: All attachments listed are for use with the CAT quick coupler.

TH336, TH337, TH406 & TH407 Applicable Standard

Attachment Carriage, 1185 mm (47 in) Carriage, 1850 mm (72 in)

Part Number 326-2013

TH406 TH407

CE

CE

ANSI

X

X

X

X

X

X

351-2519 174-7731 301-9757

Carriage, 72 in

301-9758 222-6210

X X X X

X

X

351-2520

X

Side Shift Carriage, 48 in

314-8479

Rotate/Side Tilt Carriage, 1200 mm (47.2 in)

231-3229

Rotate/Side Tilt Carriage, 1850 mm (72 in)

227-5748

Rotate/Side Tilt Carriage, 50 in

309-4315

X

Rotate/Side Tilt Carriage, 72 in

309-4316

X

Swing Carriage, 100°

318-9222

X

Fork, Pallet 45x100x1070 mm (1.8x4x42 in)

252-1454

X

X

X

Fork, Pallet 50x100x1200 mm (2x4x47.2 in)

326-1997

X

X

X

Fork, Pallet 50x100x1525 mm (2x4x60 in)

252-1456

X

X

X

Fork, Pallet 50x120x1200 mm (2x4.7x47.2 in)

323-5635

X

X

X

Fork, Pallet 50x120x1200 mm (2x4.7x47.2 in)

*

X

X

X

Fork, Pallet 60x100x1200 mm

352-4117

Fork, Block 50x50x1220 mm (2x2x48 in)

252-1460

Fork, Pallet 2.36x4x48 in

301-9755

X

Fork, Pallet 2.36x6x60 in

301-9754

X

Fork, Pallet 1.75x7x60 in

301-9756

X

Fork, Block 2x2x48 in

301-9752

X

5-2

AUS X

351-2521

Carriage, 50 in

Side Shift Carriage, 1200 mm (47.2 in)

TH336 TH337

X X

X

X

X

X

X

351-2523

X

351-2522

X

X X

X

X

X

31200368

Section 5 - Attachments and Hitches Applicable Standard TH336 TH337

TH406 TH407

Attachment

Part Number

CE

CE

ANSI

Bucket, GP 1,0 m3 (1,3 yd3)

163-4261

X

X

X

Bucket, Light Material 1,5 m3 (1,9 yd3)

186-5838

X

X

X

Bucket, Light Material 2,0 m3 (2,6 yd3)

220-4759

X

X

X

3

3

220-4760

X

X

X

3

3

220-4761

X

X

X

Bucket, Light Material 2,5 m (3.3 yd ) Bucket, Light Material 3,0 m (3,9 yd ) Bucket, Multi-Purpose 1,0 m3 (1,3 yd3)

163-4265

X

X

X

Bucket, Grapple 0,8 m3 (1,0 yd3)

219-5515

X

X

X

Manure Fork

186-6054

X

X

X

Bale Handler

163-4263

X

X

X

Coupler Mounted Hook

169-6460

X

X

X

Truss Boom, 4 m (13.1 ft)

169-3945

X

X

X

Truss Boom, 2 m

354-2622

AUS

X

* Part number not available at publication.

31200368

5-3

Section 5 - Attachments and Hitches TH414, TH514 & TH417 Applicable Standard

Attachment

TH414

Part Number

CE

326-2013

X

351-2519

Carriage, 1185 mm (47 in)

AUS

TH514 CE

ANSI AUS

X X

X

X

X

X

X

X

X

X

X

X

X X

351-2521

Side Shift Carriage, 1200 mm (47.2 in)

222-6210

Rotate/Side Tilt Carriage, 1200 mm (47.2 in)

231-3229

Rotate/Side Tilt Carriage, 1850 mm (72 in)

227-5748

X X

351-2520

X

X X

351-2523

X

X X

351-2522

X X

X

X

X X

X

X

Fork, Pallet 45x100x1070 mm (1.8x4x42 in)

252-1454

X

X

Fork, Pallet 50x100x1200 mm (2x4x47.2 in)

326-1997

X

X

Fork, Pallet 50x100x1525 mm (2x4x60 in)

252-1456

X

X

Fork, Pallet 50x120x1200 mm (2x4.7x47.2 in)

323-5635

X

X

Fork, Pallet 50x120x1200 mm (2x4.7x47.2 in)

*

X

X

Fork, Pallet 60x100x1200 mm

352-4117

Fork, Pallet 60x100x1200 mm (2.4x4x47.2 in)

326-1998

Fork, Block 50x50x1220 mm (2x2x48 in)

252-1460

X

Bucket, GP 1,0 m3 (1,3 yd3)

163-4261

X

186-5838

X

163-4265

X

Bucket, Grapple 0,8 m3 (1,0 yd3)

219-5515

X

Bucket, Light Material 1,5 m

X

X X

X X

X

X

X

X

3

(1,9 yd3) Bucket, Multi-Purpose 1,0 m3 (1,3 yd3)

5-4

AUS X

X

351-2518 Carriage, 1850 mm (72 in)

CE X

215-4350 174-7731

TH417

Coupler Mounted Hook

169-6460

X

X

X

Truss Boom, 4 m (13.1 ft)

169-3945

X

X

X

Truss Boom, 2 m

354-2622

X

X X

X

31200368

Section 5 - Attachments and Hitches Applicable Standard

Attachment THP18s Platform THP45s Platform

TH414

Part Number

CE

343-7048

X

354-0474 343-7047 354-0475

AUS

TH514 CE

TH417

ANSI AUS

X X

X

AUS

X X

X X

CE

X X

X

X

* Part number not available at publication.

31200368

5-5

Section 5 - Attachments and Hitches 5.4

TELEHANDLER/ATTACHMENT/FORK CAPACITY

3 1 2

OZ0810

Prior to installing the attachment verify it is approved and the telehandler is equipped with the proper load chart. See “Approved Attachments” on page 5-1.

To determine the maximum capacity of the telehandler and attachment, use the smallest of the following capacities: • Capacity stamped on the attachment identification plate (1).

• Fork capacities and load centers are stamped on the side of each fork (2) (if equipped). This rating specifies the maximum load capacity that the individual fork can safely carry at the maximum load center (3). Total attachment capacity is multiplied by the number of forks on the attachment (if equipped), up to the maximum capacity of the attachment.

• Maximum capacity as indicated on the proper load chart. See “Approved Attachments” on page 5-1.

• When the load rating of the telehandler differs from the capacity of the forks or attachment, the lower value becomes the overall load capacity.

Use the proper load chart to determine maximum capacity at various machine configurations. Lifting and placing a load may require use of more than one load chart based on machine configuration.

Other than block forks, all forks should be used in matched pairs, block forks used in matched sets.

WARNING Never use an attachment without the appropriate JLG approved load chart installed on the telehandler.

5-6

31200368

Section 5 - Attachments and Hitches 5.5

USE OF THE LOAD CHART

To properly use the load chart (see page 5-8), the operator must first determine and/ or have the following: 1. An approved attachment. See “Approved Attachments” on page 5-1.

2. The proper Load Chart.

3. Weight of the load being lifted.

4. Load placement information: a. HEIGHT where the load is to be placed. b. DISTANCE from the front tires of the telehandler where the load is to be placed.

5. On the load chart, find the line for the height and follow it over to the distance.

6. The number in the load zone where the two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

The number in the load zone must be equal to or greater than the weight of the load to be lifted. Determine the limits of the load zone on the load chart and keep within these limits.

Capacity Indicator Locations

ATTACHMENT IDENTIFICATION PLATE

BOOM EXTENSION INDICATOR

A

BOOM ANGLE INDICATOR (AUS)

BOOM ANGLE INDICATOR (INSIDE CAB)

B

FORK WEIGHT STAMP OAM1761

31200368

5-7

Section 5 - Attachments and Hitches Sample Load Chart (CE & ANSI) This Load Chart may be used with this model ONLY. The telehandler model is indicated on the boom or chassis.

Model XXXX is used for demonstration purposes only.

XXXX

XXX xx - XXX xx

XXX xx MAX

75

XX

60

XX

50

XX

o

o

XXXX

o

D C

XX

40

XX

o

30

o

XXXX

XX

20

o

XX

10

o

XXXX

XX XX

A

Boom Extension Indicator (arc)

XXXX XXXX

XX

XXXX XXXX

XX

Boom Angle

B

XXXX

XX XX

Attachment type, weight and dimensions must be equal to or less than the data shown.

Load center must be equal to or less than value shown.

XX XX

0

o

XXX mm

XX XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XXXX XXXX OAM1801

Load zones indicate the maximum weight that may be safely lifted.

Note: This is a sample load chart only! DO NOT use this chart, use the one located in your operator cab.

WARNING TIP OVER HAZARD. All loads shown on rated load chart are based on machine being on firm ground with frame level (see page 4-5); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition.

5-8

31200368

Section 5 - Attachments and Hitches To identify the proper load chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the load chart.

• Use when lifting a load with outriggers up.

OAL1090

• Use when lifting a load with outriggers down.

OAL1100

31200368

5-9

Section 5 - Attachments and Hitches Sample Load Chart (AUS)

TRAVELING (PICK & CARRY)

REQUIRES FIRM SURFACE WITH LOAD ON FORKS. MAX TRAVEL WITH RATED LOAD XXKM/H. BOOM FULLY RETRACTED. XXXMM MAX

Traveling Traveling Information Information

X° MAX

XXXMM MAX

X° MAX

XXXMM MAX

X° MAX

LIFTING (STATIONARY)

REQUIRES FIRM SURFACE WITH LOAD ON FORKS.

Lifting Information

X° MAX

X° MAX

X° MAX

SPECIFICATIONS FOR SAFE USE 1. TYRE SIZES: - XX XX (XXXXX) XX PSI / XX BAR - XX XX (XXXXX) XX PSI / XX BAR - XX XX (XXXXX) XX PSI / XX BAR - XX XX (XXXXX) XX PSI / XX BAR 2. IN SERVICE WIND SPEED: - XXM/S (XXKM/H) 3. GROUND CONDITIONS: - FIRM SURFACES FOR BOTH LIFTING AND TRAVELING. - SLOPE AND LOAD LISTED ABOVE FOR BOTH CONFIGURATIONS. 4. STANDARD USED: XX XXXXXXXX

Specifications For Safe Use

This Load Chart may be used with this model ONLY. The telehandler model is indicated on the boom or chassis.

Model XXXX is used for demonstration purposes only.

XXXXXXXXXXX

XXXX

XXX xx - XXX xx

75

XX

60

XX

50

XX

XXXX

o

o

o

D C

XX

40

XX

o

30

XX

o

XXXX

20

o

XX

10

o

XXXX

XX

A

Boom Extension Indicator (arc)

XXXX XXXX

XX XX

XXXX XXXX

XX XX

B

XXXX

XX

Boom Angle

Attachment type, weight and dimensions must be equal to or less than the data shown.

XXX xx MAX

XX XX

Load zones indicate the maximum weight that may be safely lifted.

0

o

XXX mm

XX XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

Load center must be equal to or less than value shown.

XXXX XXXX

OAM2730

Note: This is a sample load chart only! DO NOT use this chart, use the one located in your operator cab.

5-10

31200368

Section 5 - Attachments and Hitches

WARNING TIP OVER HAZARD. All loads shown on rated load chart are based on machine being on firm ground with frame level (see page 4-5); the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the telehandler being in good operating condition.

To identify the proper load chart on telehandlers equipped with outriggers, refer to the following icons which may be located on the load chart.

• Use when lifting a load with outriggers up.

OAL1090

• Use when lifting a load with outriggers down.

OAL1100

31200368

5-11

Section 5 - Attachments and Hitches Example A contractor owns a model xxxx telehandler with a fork carriage. He knows this attachment may be used with his model since: • The attachment style, weight, dimensions and load center match the attachment data on the load chart.

• The load chart is clearly marked for model xxxx and corresponds with machine configuration being used.

Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted.

Load Weight

Distance

Height

OK to Lift

1250 kg (2755 lb)

4,0 m (13.1 ft)

3,5 m (11.5 ft)

Yes

2

750 kg (1653 lb)

6,0 m (19.7 ft)

9,0 m (29.5 ft)

NO

3

2500 kg (5512 lb)

2,0 m (6.6 ft)

6,5 m (21.3 ft)

Yes

4

3000 kg (6614 lb)

1,5 m (4.9 ft)

10,5 m (34.4 ft)

NO

1

XXXX

XXX mm - XXX mm

XXX kg MAX

75

14m

60

13m

50

12m

2000kg

o

o

o

D

40

10m

o

2500kg B

9m

20

4m 3m 2m

10

o

o

350kg

5m

500kg 750kg

7m 6m

Example 1

o

3700kg

1000kg 1500kg

30

8m

Example 2

Example 4

C

11m

A

Example 3

1m 0m

0

o

XXX mm

-1m 9m

XXXX XXXX

8m

7m

6m

5m

4m

3m

2m

1m

0m

OAM1921

Note: This is a sample load chart only! DO NOT use this chart, use the one located in your operator cab.

5-12

31200368

Section 5 - Attachments and Hitches 5.6

ATTACHMENT INSTALLATION

CAT Quick Coupler MECHANICAL

2

3

HYDRAULIC

1 3

6 4

5 6 4

OAM2051

1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Retainer Pin (mechanical coupler) 6. Quick Coupler (attachment tilt control in cab, see page 3-19 or 3-21)

WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and retainer pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

31200368

5-13

Section 5 - Attachments and Hitches Mechanical Quick Coupler This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

1. Tilt quick coupler forward to provide clearance.

Check to be sure lock pin and retainer pin is out.

OAM1860

2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in recess.

OAM1870

3. Tilt quick coupler back to engage attachment.

OAM1881

4. Insert lock pin and secure with retainer pin.

OAM1891

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-24.

5-14

31200368

Section 5 - Attachments and Hitches Hydraulic Quick Coupler This installation procedure is designed for one-person operation.

1. Tilt quick coupler forward to provide clearance.

Check to be sure lock pin is disengaged.

OAM2820

2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in recess.

OAM2830

3. Tilt quick coupler back to engage attachment.

OAM2840

2

4. Press and hold button (1) and at the same time push roller switch down (2) to engage lock pin or push roller switch up to disengage lock pin.

1 OAM1850

OAM1930

5. Raise boom to eye level and visually check that the lock pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

ENGAGED

DISENGAGED

6. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-24.

31200368

5-15

Section 5 - Attachments and Hitches JD Coupler

2

3

1

4

5

OAM2280

1. Attachment 2. Attachment Point Opening 3. Coupler Point 4. Lock Pin 5. JD Coupler (attachment tilt control in cab, see page 3-19 or 3-21)

WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

5-16

31200368

Section 5 - Attachments and Hitches This installation procedure is designed for one-person operation.

1. Tilt coupler forward to provide clearance. Check to be sure lock pin is disengaged.

OAM2290

2. Align coupler point with opening in attachment.

Raise boom slightly to engage coupler point in opening.

OAM2300

3. Tilt coupler back to engage attachment.

OAM2310

2

4. Press and hold button (1) and at the same time push roller switch down (2) to engage lock pin or push roller switch up to disengage lock pin.

1 OAM1850

5. Raise boom to eye level and visually check that the lock pin protrudes through the attachment hole. If the pin does not protrude through the attachment hole, place the attachment on the ground and return to step 2.

6. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-24.

31200368

5-17

Section 5 - Attachments and Hitches Manitou Coupler MECHANICAL

1

2

HYDRAULIC

3 3

4

5

6

4

6

OAM2621

1. Attachment 2. Attachment Pin 3. Attachment Pin Recess 4. Lock Pin 5. Retainer Pin (mechanical coupler) 6. Manitou Coupler (attachment tilt control in cab, see page 3-19 or 3-21)

WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

5-18

31200368

Section 5 - Attachments and Hitches Mechanical Coupler This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

1. Tilt coupler forward to provide clearance. Check to be sure lock pin and retainer pin is out.

OAM2780

2. Align attachment pin recess with attachment pin.

Raise boom slightly to engage attachment pin in recess.

OAM2790

3. Tilt coupler back to engage attachment.

OAM2800

4. Insert lock pin and secure with retainer pin.

OAM2810

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-24.

31200368

5-19

Section 5 - Attachments and Hitches Hydraulic Coupler This installation procedure is designed for one-person operation.

1. Tilt coupler forward to provide clearance. Check to be sure lock pin is disengaged.

OAM2630

2. Align attachment pin recess with attachment pin.

Raise boom slightly to engage attachment pin in recess.

OAM2640

3. Tilt coupler back to engage attachment.

OAM2650

2

4. Press and hold button (1) and at the same time push roller switch down (2) to engage lock pin or push roller switch up to disengage lock pin.

1 OAM1850

5. Raise boom to eye level and visually check that the lock pin protrudes through the attachment hole. If the pin does not protrude through the attachment hole, place the attachment on the ground and return to step 2.

6. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-24.

5-20

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Section 5 - Attachments and Hitches JCB Coupler 2 1

3

5

MECHANICAL

4

HYDRAULIC

3

6

7 6

7

OAM2661

1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Hook (mechanical coupler) 5. Lock Pin Handle (mechanical coupler) 6. Lock Pin 7. JCB Coupler (attachment tilt control in cab, see page 3-19 or 3-21)

WARNING CRUSH HAZARD. Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin. Failure to ensure proper installation could permit carriage/attachment/load to disengage.

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5-21

Section 5 - Attachments and Hitches Mechanical Coupler This installation procedure is designed for one-person operation. Prior to exiting cab, perform “Shut-Down Procedure” on page 4-3.

1. Tilt coupler forward to provide clearance.

Unhook lock pin handle and pull to disengage lock pin.

OAM2850

2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in recess.

OAM2860

3. Tilt coupler back to engage attachment.

OAM2870

4. Push lock pin handle to engage coupler lock pin and secure with hook.

OAM2870

5. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-24.

5-22

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Section 5 - Attachments and Hitches Hydraulic Coupler This installation procedure is designed for one-person operation.

1. Tilt coupler forward to provide clearance. Check to be sure lock pin is disengaged.

OAM2670

2. Align attachment pin with recess in attachment.

Raise boom slightly to engage attachment pin in recess.

OAM2680

3. Tilt coupler back to engage attachment.

OAM2690

2

4. Press and hold button (1) and at the same time push roller switch down (2) to engage lock pin or push roller switch up to disengage lock pin.

1 OAM1850

5. Raise boom to eye level and visually check that the lock pin protrudes through the attachment hole. If the pin does not protrude through the attachment hole, place the attachment on the ground and return to step 2.

6. If attachment is equipped, connect auxiliary hydraulic hoses. See “Hydraulic Operated Attachment” on page 5-24.

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5-23

Section 5 - Attachments and Hitches Hydraulic Operated Attachment

2 1

OAM1840

OAM1810

1. Install attachment (see page 5-13 or 5-16).

2. Lower attachment to ground.

3. Quickly depress and release continuous auxiliary hydraulics switch (1) twice.

Depress again and hold to relieve pressure at both auxiliary fittings (2).

Note: Depressing of auxiliary hydraulics switch three times must be accomplished within two seconds. If buzzer sounds or continuous auxiliary hydraulics indicator illuminates, repeat step 3.

4. Perform “Shut-Down Procedure” on page 4-3.

5. Connect attachment hoses to both auxiliary fittings.

5.7

PLATFORM ATTACHMENT (IF EQUIPPED)

3

OAM2591

1. Install platform (see page 5-13) and connect hydraulic lines (see above).

2. With the park brake applied and engine off, remove connector cover and connect electric cable (3) from the platform.

5-24

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Section 5 - Attachments and Hitches 5.8

ADJUSTING/MOVING FORKS

Carriages may have different locations where forks can be positioned. Two different methods can be used for repositioning, depending upon the carriage structure.

Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork bar.

To slide forks: 1. Ensure attachment is properly installed. See “Attachment Installation” on page 5-13.

2. Elevate attachment to approximately 1,5 m (5 ft) and tilt carriage forward until fork heel is free from attachment.

3. Stand at the side of the carriage. To slide fork toward the center of the carriage, push the fork near the fork eye. To slide fork toward the edge of the carriage, pull the fork near the fork eye. To avoid pinching, do not place fingers or thumb between the fork and carriage structure.

If removing fork bar is necessary: 1. Rest forks on ground.

2. Remove fork bar.

3. Reposition forks.

4. Reinstall the fork bar and fork bar retaining mechanism(s).

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5-25

Section 5 - Attachments and Hitches 5.9

ATTACHMENT OPERATION

• Capacities and range limits for the telehandler change depending on the attachment in use.

• Separate attachment instructions must be kept in Manual Holder in cab with this Operation & Maintenance Manual. An additional copy must be kept with the attachment if it is equipped with a manual holder.

Note: Operations described within this section reference the Lift joystick pattern.

Refer to page 3-20 if utilizing the Loader joystick pattern.

NOTICE EQUIPMENT DAMAGE. Some attachments may contact the front tires or machine structure when the boom is retracted and the attachment is rotated.

Improper use of attachment may result in attachment or machine structural damage.

NOTICE EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a load. Maintain clearance around boom structure and load. Failure to maintain clearance may result in attachment or machine structural damage.

5-26

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Section 5 - Attachments and Hitches Carriage w/Forks Use Carriage Attachment Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OZ0770

2 1

OAM1940

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

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5-27

Section 5 - Attachments and Hitches Side Shift Carriage Use Side Shift Carriage Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OAL1540

2 1

OAM1940

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

3

OAM1970

5-28

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Section 5 - Attachments and Hitches To Side Shift: The attachment auxiliary hydraulic roller switch (3) controls side shift.

• Push roller switch down to shift forks left.

• Push roller switch up to shift forks right.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

WARNING CRUSH HAZARD. Do not use side shift to push or pull objects or load. Failure to comply could cause object or load to fall.

Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

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5-29

Section 5 - Attachments and Hitches Rotate/Side Tilt Carriage Use Rotate/Side Tilt Carriage Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OAL1550

2 1

OAM1940

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls carriage tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

3

OAM2040

5-30

31200368

Section 5 - Attachments and Hitches To Rotate: The attachment auxiliary hydraulic roller switch (3) controls carriage rotation.

• Push roller switch down to rotate left.

• Push roller switch up to rotate right.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

WARNING CRUSH HAZARD. Do not use rotation to push or pull objects or load. Failure to comply could cause object or load to fall.

Equipment Damage Precautions: • Do not use forks as a lever to pry material. Excessive prying forces could damage forks or machine structure.

• Do not attempt to lift loads that are attached or connected to another object.

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5-31

Section 5 - Attachments and Hitches Bucket Use Appropriate Bucket Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OZ0730

2 1

OAM1980

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls bucket tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

5-32

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Section 5 - Attachments and Hitches Operation: • Raise or lower boom to appropriate height for loading material from stockpile.

• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.

• Tilt bucket up far enough to retain load and back away from pile.

• Travel in accordance with requirements set forth in Section 1 - General Safety Practices.

• Tilt bucket down to dump load.

Equipment Damage Precautions • Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations.

• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket load charts are for evenly distributed loads only.

• Do not use bucket as a lever to pry material. Excessive prying forces could damage bucket or machine structure.

• Do not attempt to load material which is hard or frozen. This could cause severe damage to quick coupler or machine structure.

• Do not use bucket for "back dragging." This could cause severe damage to quick coupler.

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5-33

Section 5 - Attachments and Hitches Multi-Purpose Bucket Use Multi-Purpose Bucket Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OZ2540

2 1

OAM1980

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls bucket tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

3

OAM1990

5-34

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Section 5 - Attachments and Hitches To open/close bucket: The attachment auxiliary hydraulic roller switch (3) controls open/close movement of the bucket.

• Push roller switch down to open bucket.

• Push roller switch up to close bucket.

Installation Procedure: Refer to “Attachment Installation” on page 5-13.

Operation: • Raise or lower boom to appropriate height and close bucket for loading material from stockpile.

• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.

• Tilt bucket up far enough to retain load and back away from pile.

• Travel in accordance with requirements set forth in Section 1 - General Safety Practices.

• Open bucket or tilt bucket down to dump load.

Equipment Damage Precautions • Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations.

• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket load charts are for evenly distributed loads only.

• Do not use bucket as a lever to pry material. Excessive prying forces could damage bucket or machine structure.

• Do not attempt to load material which is hard or frozen. This could cause severe damage to quick coupler or machine structure.

• Do not use bucket for "back dragging." This could cause severe damage to quick coupler.

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5-35

Section 5 - Attachments and Hitches Grapple Bucket Use Grapple Bucket Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OZ1450

2 1

OAM1980

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls bucket tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

3

OAM2000

5-36

31200368

Section 5 - Attachments and Hitches To open/close grapple: The attachment auxiliary hydraulic roller switch (3) controls open/close movement of the grapple.

• Push roller switch down to open grapple.

• Push roller switch up to close grapple.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

Operation: • Raise or lower boom to appropriate height and open grapple for loading material from stockpile.

• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load bucket.

• Tilt bucket up far enough to retain load, close grapple and back away from pile.

• Travel in accordance with requirements set forth in Section 1 - General Safety Practices.

• Open grapple and tilt bucket down to dump load.

Equipment Damage Precautions • Except for lifting or dumping a load, the boom must be fully retracted for all bucket operations.

• Do not corner-load bucket. Distribute material evenly within the bucket. Bucket load charts are for evenly distributed loads only.

• Do not use bucket as a lever to pry material. Excessive prying forces could damage bucket or machine structure.

• Do not attempt to load material which is hard or frozen. This could cause severe damage to quick coupler or machine structure.

• Do not use bucket for "back dragging." This could cause severe damage to quick coupler.

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5-37

Section 5 - Attachments and Hitches Manure Fork Use Manure Fork Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OAM2060

2 1

OAM2070

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls manure fork tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

3

OAM2080

5-38

31200368

Section 5 - Attachments and Hitches To open/close manure fork: The attachment auxiliary hydraulic roller switch (3) controls open/close movement of the manure fork attachment.

• Push roller switch down to open forks.

• Push roller switch up to close forks.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

Operation: • Raise or lower boom to appropriate height and open manure fork for loading material from stockpile.

• Align telehandler with face of stockpile and drive slowly and smoothly into pile to load manure fork.

• Tilt manure fork up far enough to retain load, close manure fork and back away from pile.

• Travel in accordance with requirements set forth in Section 1 - General Safety Practices.

• Open manure fork and tilt down to dump load.

Equipment Damage Precautions • Except for lifting or dumping a load, the boom must be fully retracted for all operations.

• Do not corner-load manure fork. Distribute material evenly within the manure fork. Manure fork load charts are for evenly distributed loads only.

• Do not use manure fork as a lever to pry material. Excessive prying forces could damage manure fork or machine structure.

• Do not attempt to load material which is hard or frozen. This could cause severe damage to quick coupler or machine structure.

• Do not use manure fork for "back dragging." This could cause severe damage to quick coupler.

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5-39

Section 5 - Attachments and Hitches Bale Handler Use Bale Handler Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OZ1870

2 1

OAM2020

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls bale handler tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

3

OAM2010

5-40

31200368

Section 5 - Attachments and Hitches To open/close grapple: The attachment auxiliary hydraulic roller switch (3) controls open/close movement of the bale handler.

• Push roller switch down to open bale handler.

• Push roller switch up to close bale handler.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

Operation: • Travel in accordance with requirements set forth in Section 1 - General Safety Practices.

Equipment Damage Precautions • Do not use bale handler as a lever to pry material. Excessive prying forces could damage the bale handler or machine structure.

• Do not attempt to load material which is hard or frozen. This could cause severe damage to quick coupler or machine structure.

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5-41

Section 5 - Attachments and Hitches Coupler Mounted Hook Use Coupler Mounted Hook Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OAL1510

Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices.

2 1

OAM2030

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls quick coupler mounted hook tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

Operation: • Weight of rigging must be included as part of total load being lifted.

5-42

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Section 5 - Attachments and Hitches Truss Boom Use Truss Boom Load Chart To determine maximum capacity, refer Attachment/Fork Capacity” on page 5-6.

to

“Telehandler/

OAM1960

Suspend loads in accordance with requirements set forth in Section 1 - General Safety Practices.

2 1

OAM1950

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls truss boom tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

Operation: • Weight of rigging must be included as part of total load being lifted.

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5-43

Section 5 - Attachments and Hitches Platform (CE & AUS) Use Platform Load Chart To determine maximum capacity, refer to capacity decal on platform.

OZ2870

2 1

OAM2560

The joystick (1) controls movement of the boom.

The attachment tilt roller switch (2) controls platform tilt.

• Push roller switch down to tilt up.

• Push roller switch up to tilt down.

Installation Procedure: • Refer to “Attachment Installation” on page 5-13.

Operation from Cab • The platform is to be only used on machines specifically designed to accept the platform. Refer to the THP18s & THP45s Platforms for TH414, TH514, TH417 Operation & Maintenance Manual.

• Machine travel is limited to first gear.

• Function speeds are reduced.

• Boom can only be raised up to 10 degrees.

5-44

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Section 5 - Attachments and Hitches 5.10 HITCHES (TH336, TH337, TH406 & TH407) Machines may be equipped with various types of hitches.

Maximum towing capacity shall be the smallest of the telehandler and hitch capacities. Refer to local governmental regulations for additional towing requirements and/or restrictions.

Note: Ensure hitch is in lowest position when towing trailer. Speed and/or load may need reduced if traveling on ground which is not level.

If not previously installed, secure hitch to machine with hardware supplied with installation.

Pin Hitch - CUNA C (Italy) Maximum combined weight of trailer and load ............................ 6000 kg (13 225 lb) Maximum vertical weight at hitch interface..................................... 1500 kg (3305 lb)

5 2 4 OAM2440

3

1

Connecting trailer for towing: 1. Remove safety pin (1) and pull pin (2) from hitch (3).

2. Align machine and tow eye of trailer.

3. Place pin through hitch and tow eye. Secure pin with safety pin.

4. If equipped, connect trailer harness to trailer plug.

Adjusting Hitch Height: 1. Pull lock pin (4) and lift handle (5) to release locking mechanism.

2. Move hitch to desired height.

3. Lower handle. When locking mechanism engages, lock pin will return to locked position

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5-45

Section 5 - Attachments and Hitches Pin Hitch - CUNA D2 (Italy) Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2000 kg (4400 lb)

5 2 4 OAM2450

3 1

Connecting trailer for towing: 1. Remove safety pin (1) and pull pin (2) from hitch (3).

2. Align machine and tow eye of trailer.

3. Place pin through hitch and tow eye. Secure pin with safety pin.

4. If equipped, connect trailer harness to trailer plug.

Adjusting Hitch Height: 1. Pull lock pin (4) and lift handle (5) to release locking mechanism.

2. Move hitch to desired height.

3. Lower handle. When locking mechanism engages, lock pin will return to locked position

5-46

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Section 5 - Attachments and Hitches Pin Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2500 kg (5500 lb)

5 2

OAM2460

4

3

1

Connecting trailer for towing: 1. Remove safety pin (1) and pull pin (2) from hitch (3).

2. Align machine and tow eye of trailer.

3. Place pin through hitch and tow eye. Secure pin with safety pin.

4. If equipped, connect trailer harness to trailer plug.

Adjusting Hitch Height: 1. Pull lock pin (4) and lift handle (5) to release locking mechanism.

2. Move hitch to desired height.

3. Lower handle. When locking mechanism engages, lock pin will return to locked position

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5-47

Section 5 - Attachments and Hitches Auto Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2500 kg (5500 lb)

7

1 3 OAM2470

6 5 4

2

Connecting trailer for towing: 1. Rotate lever (1) until pin (2) fully retracts.

2. Align hitch mouth (3) and tow eye of trailer.

3. Reverse machine toward trailer.

4. After the tow eye contacts trigger (4), the pin and lever will be released.

5. If equipped, connect trailer harness to trailer plug.

Note: Use lever (5) to lower pin (2) after disconnecting from trailer.

Adjusting Hitch Height: 1. Pull lock pin (6) and lift handle (7) to release locking mechanism.

2. Move hitch to desired height.

3. Lower handle. When locking mechanism engages, lock pin will return to locked position

5-48

31200368

Section 5 - Attachments and Hitches Piton Frame and Auto Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2500 kg (5500 lb) Note: See page 5-48 for Auto Hitch information.

1

2 3 OAM2480

Connecting trailer for towing: 1. Raise Auto Hitch (1) to highest position.

2. Remove safety pin (2) and lift locking latch (3).

3. Insert safety pin to hold locking latch in the up position.

4. Align machine and tow eye of trailer.

5. Remove safety pin and lower locking latch. Secure locking latch with safety pin.

6. If equipped, connect trailer harness to trailer plug.

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5-49

Section 5 - Attachments and Hitches Hydraulic Hitch Maximum combined weight of trailer and load ......................... 12 000 kg (26 450 lb) Maximum vertical weight at hitch interface..................................... 2000 kg (4400 lb)

1 7 6

4 5

3 OAM2490

2

Connecting trailer for towing: 1. Depress and hold right side of hydraulic hitch switch (1) to raise hitch safety posts (2) off safety hooks (3).

2. Pull safety hook release (4).

3. Depress and hold left side of hydraulic hitch switch to lower the hitch (5) to the required height.

4. Reverse machine until the hitch is under the center of the tow eye.

5. Depress and hold right side of hydraulic hitch switch to raise hitch until the safety hooks are engaged.

6. If equipped, connect trailer harness to trailer plug (6).

7. If equipped, connect trailer brake line to trailer coupling (7).

5-50

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Section 6 - Emergency Procedures

SECTION 6 - EMERGENCY PROCEDURES 6.1

TOWING A DISABLED PRODUCT

The following information assumes the telehandler cannot be moved under its own power.

• Before moving the telehandler, read all of the following information to understand options available. Then select the appropriate method.

• Machine mounted retrieval devices provide suitable means to attach a tow rope, chain or tow bar only in the event the telehandler becomes stuck or disabled.

Retrieval devices are not intended for trailer towing applications.

• The steering system permits manual steering if engine or power assist feature fails; however, steering will be slow and will require much greater force.

• DO NOT attempt to tow a telehandler that is loaded or the boom/attachment is raised above 1,2 m (4 ft).

Moving Short Distances • If it is only necessary to move telehandler a short distance, less than 30 m (100 ft), it is permissible to use a vehicle of sufficient capacity to tow the unit with no previous preparation.

Moving Longer Distance • See Service Manual for information.

Contact the local Caterpillar dealer for specific instructions if neither of these methods are applicable.

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6-1

Section 6 - Emergency Procedures 6.2

EMERGENCY LOWERING OF BOOM

In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis.

Contact the local Caterpillar dealer for specific instructions.

Secure the telehandler using the following procedures: 1. Clear the area around telehandler of all personnel.

2. Apply the parking brake. Place the transmission control lever in “NEUTRAL”.

3. Block all four wheels.

4. Section off a large area under the boom with string or tape to restrict any personnel from entering this area.

6-2

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Section 6 - Emergency Procedures 6.3

EMERGENCY LOWERING OF BOOM IF EQUIPPED FOR PLATFORM

Auxiliary Power System In case of an emergency or engine failure an auxiliary power system is available in the cab.

1

4 3

2

OAM2570

1. Verify the power/emergency stop switch (1) is not depressed and the ignition switch (2) is in position I. 2. Depress auxiliary power switch (3) and hold in place to engage auxiliary power system.

3. While holding the switch, operate the boom joystick (4) until the attachment is at ground level.

4. Release the auxiliary power switch and depress the emergency stop switch.

WARNING TIP OVER HAZARD. To be used for retracting then lowering. Only use the extend or lift functions if necessary and limit their duration. Extending/lifting could damage the equipment and/or cause tip over.

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6-3

Section 6 - Emergency Procedures 6.4

CAB EMERGENCY EXIT 1

OZ0240

• In an emergency the rear window can be used to exit the telehandler.

• Remove the latch pin (1). The window is then free to swing open.

6-4

31200368

Section 7 - Lubrication and Maintenance

SECTION 7 - LUBRICATION AND MAINTENANCE 7.1

INTRODUCTION

Service the product in accordance with the maintenance schedule on the following pages.

B

B

A

A

1

1

VIEW A-A (EARLY PRODUCTION ONLY)

OAM2121

VIEW B-B

The lubrication & maintenance decal (1) contains instructions that must be followed to keep this product in good operating condition. The Operation & Maintenance Manual and Service Manual contain more detailed service information with specific instructions.

Clothing and Safety Gear • Wear all the protective clothing and personal safety devices issued to you or called for by job conditions.

• DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts.

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7-1

Section 7 - Lubrication and Maintenance 7.2

GENERAL MAINTENANCE INSTRUCTIONS

Prior to performing any service or maintenance on the telehandler, follow the shut-down procedure on page 4-3 unless otherwise instructed. Ensure telehandler is level, for proper fluid readings.

• Clean lubrication fittings before lubricating.

• After greasing telehandler, cycle all functions several times to distribute lubricants. Perform this maintenance procedure without attachment installed.

• Apply a light coating of engine oil to all linkage pivot points.

• Intervals shown are for normal usage and conditions. Adjust intervals for abnormal usage and conditions.

• Drain engine and gear cases after operating when oil is hot.

• Check all lubricant levels when lubricant is cool. For ease of filling hydraulic reservoir, use a funnel with a hose or flexible tube for best results.

Note: (TH414 & TH417 only) Be certain to check boom chain and tension every 250 hours and adjust as required. Chain damage can occur if chain is not adjusted properly.

WARNING CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the machine with the engine running.

7-2

31200368

Section 7 - Lubrication and Maintenance 7.3

SERVICE AND MAINTENANCE SCHEDULES

10, 1st 50 & 50 Hour Maintenance Schedule

EVERY

10

Check Engine Oil Level

Check Fuel Level

Check Hydraulic Oil Level

Check Tire Condition & Pressure

Check Engine Coolant Level

Additional Checks Section 8

1st

50

LB/F T (N m)

Check Axle Differential Oil Level

Check Wheel End Oil Levels

Check Boom Chain & Tension (TH414 & TH417)

Check Wheel Lug Nut Torque

Lubrication Schedule

Check Battery

EVERY

50

Drain Fuel/ Water Separator

Air Precleaner (if equipped)

Check Washer Fluid Level (if equipped) OAM2132

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7-3

Section 7 - Lubrication and Maintenance 1st 150 & 250 Hour Maintenance Schedule

1st

150

Change Axle Differential Oil

Change Wheel End Oil

Clean Axle Breather

Clean Axle Magnetic Oil Plugs

EVERY

250

Check Axle Differential Oil Level

Check Wheel End Oil Levels

Check Boom Wear Pads

Check Boom Chain & Tension (TH414 & TH417)

Check Fan Belt

Clean Axle Breather OAM2143

7-4

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Section 7 - Lubrication and Maintenance 500 & 1000 Hour Maintenance Schedule

EVERY

500

LB/F T (N m)

Change Fuel Filters

Change Engine Oil and Filter

Change Air Filter Elements

Check Wheel Lug Nut Torque

Lubrication Schedule

Check LSI Calibration

EVERY

1000

Change Axle Differential Oil

Change Wheel End Oil

Clean Axle Breather

Clean Axle Magnetic Oil Plugs

Change Hydraulic Fluid & Filters OAM2155

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7-5

Section 7 - Lubrication and Maintenance 6000 & 12000 Hour Maintenance Schedule

EVERY

6000 or 3 Years

Add Engine Coolant Extender

EVERY

12000 or 6 Years

Change Engine Coolant OAM2970

Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine Operation & Maintenance Manual for additional information.

7-6

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Section 7 - Lubrication and Maintenance

This Page Intentionally Left Blank

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7-7

Section 7 - Lubrication and Maintenance 7.4

LUBRICATION SCHEDULES

50 Hour Lubrication Schedule TH336, TH337, TH406 & TH407

EVERY

50

A B

A

A

B

B

B

B B

B

A

A

A A

A

A

A A

A

OAM2411

7-8

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Section 7 - Lubrication and Maintenance TH414

EVERY

50

A B

A A

A

A

A

A

A

A

B

A

A

B

B

B

B

B

B

B

A A A A

A

A

A

A A

OAM2202

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7-9

Section 7 - Lubrication and Maintenance TH514

EVERY

50

A B

A

A

A

A

A

A

A

A A A

B

B

B B B

B

B

B

B

A

B

B

B A A

A

A

A

A

A A OAM2880

7-10

31200368

Section 7 - Lubrication and Maintenance TH417

EVERY

50

A B

A A

A

A

A

B

B

B

B

A

A

A

B

A A

B

B

A

A

B

A B

B

B

B

B

A

B

B

B B

B

B

A

B

B

B

A

B

A A

A

A

A

A

A A OAM2891

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7-11

Section 7 - Lubrication and Maintenance 500 Hour Lubrication Schedule TH336, TH337, TH406 & TH407

EVERY

500

C

C

C

OAM2421

7-12

31200368

Section 7 - Lubrication and Maintenance TH414, TH514 & TH417

EVERY

500

C

C

C

OAM2212

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7-13

Section 7 - Lubrication and Maintenance 7.5

OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

10

A. Fuel Level Check

OW0970

OW0990

1

2 OZ2081

OAM2260

1. Check fuel gauge (1) located on instrument panel in cab.

2. If fuel is low, proceed to fuel source and perform “Shut-Down Procedure” on page 4-3.

3. Turn fuel tank cap (2) to remove from filler neck.

4. Add diesel fuel as needed.

5. Replace fuel tank cap.

Note: Replenish diesel fuel at end of each work shift to minimize condensation.

NOTICE EQUIPMENT DAMAGE. Do not allow machine to run out of fuel during operation.

See Engine Operation & Maintenance Manual for details prior to servicing.

7-14

31200368

Section 7 - Lubrication and Maintenance

50

B. Drain Fuel/Water Separator

OW0980

OW1000

74.5 kW ENGINE

4

3

OAM2270

93.1 kW ENGINE

3

4 OAM2220

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.

3. Loosen drain cock (3) on underside of fuel filter (4) and allow all water to drain into a glass until clear fuel is visible. Tighten drain cock.

4. Close and secure engine cover.

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7-15

Section 7 - Lubrication and Maintenance Engine Oil

10

A. Engine Oil Level Check

OW0970

OW1020

4

AD

D

2 3 1

OZ0480

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.

3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick.

4. Replace dipstick.

5. If oil is low, remove oil fill cap (4) and add motor oil to bring oil up to the full mark in the crosshatch area.

6. Replace oil fill cap.

7. Close and secure engine cover.

7-16

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Section 7 - Lubrication and Maintenance Hydraulic Oil

A. Hydraulic Oil Level Check

10

OW0970

OW1030

8 6 7 5

OAM2250

1. If equipped, ensure outriggers are fully raised.

2. Perform “Shut-Down Procedure” on page 4-3.

3. If hydraulic oil is cold, check fluid level at the sight gauge (5) on the hydraulic tank (6). The oil level should be visible in the gauge window.

If hydraulic oil is warm, check fluid level at the sight gauge (7) on the hydraulic tank. The oil level should be visible in the gauge window.

4. If hydraulic oil is low, remove oil fill cap (8). Add hydraulic fluid to bring oil up to the center of the appropriate gauge window.

5. Replace hydraulic oil fill cap.

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7-17

Section 7 - Lubrication and Maintenance Tires

A. Tire Air Pressure Check

10

OW0970

OW1040

1. Perform “Shut-Down Procedure” on page 4-3.

2. Remove valve stem cap.

3. Check tire pressure.

4. Add air if required.

TH336, TH337, TH406 & TH407 15.5/80-24 TR01 ......................................................................4,1 bar (59 psi) 15.5/80-24 SGI.........................................................................4,0 bar (58 psi) 15.5-25 SGL.............................................................................4,0 bar (58 psi) 460/70 R24 ..............................................................................4,2 bar (61 psi) 500/70 R24 (TH337 & TH407 only) .........................................3,0 bar (44 psi) 400/80-24.................................................................................4,0 bar (58 psi) 440/80-24 (TH337 & TH407 only)............................................3,5 bar (51 psi) TH414 15.5/80-24 TR01 ......................................................................4,1 bar (59 psi) 15.5-25 SGL-2A .......................................................................4,0 bar (58 psi) 400/80-24.................................................................................4,5 bar (65 psi) 440/80-24.................................................................................4,0 bar (58 psi) TH514 & TH417 14-24 TG02............................................................................4,25 bar (61 psi) 14-24 SGG-2A .......................................................................5,25 bar (76 psi) 5. Replace valve stem cap.

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Section 7 - Lubrication and Maintenance B. Tire Damage For pneumatic tires, when any cut, rip or tear is discovered that exposes sidewall or tread area cords in the tire, measures be taken to remove the product from service immediately. Arrangements must be made for replacement of the tire or tire assembly.

For polyurethane foam filled tires, when any of the following are discovered, measures must be taken to remove the product from service immediately.

Arrangements must be made for replacement of the tire or tire assembly.

• a smooth even cut through the cord piles which exceeds 7,5 cm (3 in) in total length.

• any tears or rips (ragged edges) in the cord plies which exceeds 2,5 cm (1 in) in any direction • any punctures which exceed 2,5 cm (1 in) in diameter.

If a tire is damaged but within the above noted criteria, the tire must be inspected daily to ensure the damage has not propagated beyond the allowable criteria.

C. Tire and Wheel Replacement It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, the replacement tires must have the following characteristics: • Equal or greater ply/load rating and size of original.

• Tire tread contact width equal or greater than original.

• Wheel diameter, width and offset dimensions equal to the original.

• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load).

Unless specifically approved by JLG, do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. Due to size variations between tire brands, when selecting and installing a replacement tire ensure both tires on the axle are the same.

The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability.

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7-19

Section 7 - Lubrication and Maintenance E. Wheel Installation Torque lug nuts after first 50 hours and after each wheel installation.

Note: If machine is equipped with directional tire assemblies, the wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.

1. Install wheel lug washers.

2. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

3. Tighten lug nuts in an alternating pattern as indicated in figure.

TH336, TH337, TH406, TH407 & TH414 ..................460 ±60 Nm (339 ±44 lb-ft) TH514 & TH417 ........................................................510 ±60 Nm (376 ±44 lb-ft)

3 5

1 8

7 2

6 4

OAH0990

WARNING TIP OVER HAZARD. Lug nuts must be installed and maintained at the proper torque to prevent loose wheels, broken studs and possible separation of wheel from the axle.

7-20

31200368

Section 7 - Lubrication and Maintenance Engine Cooling System

10

A. Engine Coolant Level Check

OW0970

OW1070

2

1

OAM1740

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.

3. Check coolant level in overflow bottle (1). When coolant is hot, bottle should be 1/2 to 3/4 full. When coolant is cool, bottle should be 1/4 to 1/2 full.

4. If coolant is low, remove overflow bottle cap (2) and add coolant as required.

5. Replace overflow bottle cap.

6. Close and secure engine cover.

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7-21

Section 7 - Lubrication and Maintenance Air Intake System

50

A. Air Filter Check

OW0980

OW1010

WITH PRECLEANER

2

4 6

7

5 1

3

OAM2240

WITHOUT PRECLEANER

2

OAM2230

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.

3. If equipped, locate precleaner bowl (1) on side of engine pod, remove cover from precleaner canister.

4. Remove dust from precleaner bowl.

5. Replace precleaner bowl and secure cover.

6. Locate air cleaner (2) and remove dust from vacuator valve (3) by squeezing bottom of valve to allow loose particles to fall out.

7. Close and secure engine cover.

Note: Only remove canister cover to service the elements as restriction indicator indicates. Excessive access to check an element can lead to premature element failure.

7-22

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Section 7 - Lubrication and Maintenance B. Element Change (as restriction indicator indicates) If Air Filter Restriction Indicator remains on after start up or illuminates while operating machine perform the following: 1. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner canister (5).

2. Remove outer primary element (6) and inspect for damage. Damaged elements should not be reused.

3. Thoroughly clean the interior of the air cleaner canister and vacuator valve.

4. Replace inner safety element (7) after every third primary element change. If replacing the inner safety element at this time, carefully slide the element out and replace with new element.

5. Slide the new primary element over the inner element making sure the sealing edge is flush with the base of the air cleaner.

6. Position air cleaner cover in place, turn clockwise and lock into position.

7. Close and secure engine cover.

Note: An inner safety element should never be washed or reused. Always install a new element.

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7-23

Section 7 - Lubrication and Maintenance Battery

50

A. Battery Check

OW0980

SINGLE BATTERY CONFIGURATION

OW1080

DUAL BATTERY CONFIGURATION

1 1

OAM1770

1. Perform “Shut-Down Procedure” on page 4-3.

2. Open engine cover.

3. Wearing eye protection, visually inspect the battery (1). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case.

4. Close and secure engine cover.

7-24

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Section 7 - Lubrication and Maintenance Windshield Washer System (if equipped)

50

A. Windshield Washer Fluid Level Check

OW0980

OAL2040

2

OAM2430

1. Perform “Shut-Down Procedure” on page 4-3.

2. The windshield washer fluid should be visible in the reservoir (2).

3. If washer fluid level is low, add fluid as needed.

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Section 7 - Lubrication and Maintenance

This Page Intentionally Left Blank

7-26

31200368

Section 8 - Additional Checks

SECTION 8 - ADDITIONAL CHECKS 8.1

GENERAL

If any of the following test results cannot be achieved, the system is not functioning properly and the machine must be removed from service and repaired before continued operation.

8.2

LOAD STABILITY INDICATOR SYSTEM (CE & AUS)

A. Load Stability Indicator System Test

10

OW0970

OZ0840

The Load Stability Indicator (LSI) is intended to continuously monitor the forward stability of the telehandler. To check this feature, perform the following: TH336 Before S/N TDE00335 excluding TDE00297-313, 328 & 332, TH337 Before S/N TDF00320 excluding TDF00297, 299-302 & 317, TH406 Before S/N TBX00454, TH407 Before S/N TBY01110 including TBY01121, 1122 & 1128, TH414 Before S/N TBZ00561, TH514 Before S/N TBW00201, TH417 Before S/N TBT00216 1. Fully retract and level boom, with no load. Do not raise the boom during this test.

2. Level frame using level in cab (if equipped).

3. Press the test button on the LSI display. This will cause all LEDs to flash on and an audible warning to sound. This indicates that the system is functioning properly.

TH336 S/N TDE00335 & After including TDE00297-313, 328 & 332, TH337 S/N TDF00320 & After including TDF00297, 299-302 & 317, TH406 S/N TBX00454 & After, TH407 S/N TBY01110 & After excluding TBY01121, 1122 & 1128, TH414 S/N TBZ00561 & After, TH514 S/N TBW00201 & After, TH417 S/N TBT00216 & After 1. Fully retract and level boom, with no load. Do not raise the boom during this test.

2. Level frame using level in cab (if equipped).

3. Press the system check button on the LSI display. This will cause all LEDs to flash on and an audible warning to sound. This indicates that the system is functioning properly.

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8-1

Section 8 - Additional Checks 8.3

BOOM INTERLOCK (TH414, TH514 & TH417)

A. Boom Interlock System Test

10

OW0970

Boom interlock system operates in two modes. With boom angle below 20 degrees, outrigger and frame level functions are operable. With boom raised above 20 degrees, outriggers and frame level are not operable. To check the system, perform the following: 1. Test system with machine on a level surface and no load.

2. Shift transmission to neutral and engage park brake.

3. Ensure outriggers and frame level functions are properly functioning. Lower then raise outriggers. Rotate frame in each direction.

4. Keep outriggers raised and level machine using level in cab.

5. Raise boom above 20 degrees.

6. Attempt to lower outriggers then rotate frame. Neither function should respond.

7. Lower boom fully.

8-2

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Section 8 - Additional Checks B. Boom Interlock System Test (if equipped with boom retracted switch)

10

OW0970

Boom interlock system (if equipped with boom retracted switch) operates in three modes. With boom at any extension and angle below 20 degrees, outrigger and frame level functions are operable. With boom fully retracted and raised between 20 and 55 degrees, outriggers and frame level are operable. With boom at any extension and raised above 55 degrees, outriggers and frame level are not operable. To check the system, perform the following: 1. Test system with machine on a level surface and no load.

2. Shift transmission to neutral and engage park brake.

3. Ensure outriggers and frame level functions are properly functioning. Lower then raise outriggers. Rotate frame in each direction.

4. Keep outriggers raised and level machine using level in cab.

5. Raise boom to between 20 and 55 degrees and extend approximately 1 m (39 in).

6. Attempt to lower outriggers then rotate frame. Neither function should respond.

7. Fully retract boom and raise above 55 degrees.

8. Attempt to lower outriggers then rotate frame. Neither function should respond.

9. Lower boom fully.

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8-3

Section 8 - Additional Checks 8.4

AUXILIARY POWER (IF EQUIPPED FOR PLATFORM)

A. Auxiliary Power System Test

10

OW0970

OZ2770

The auxiliary power system is available in case of an emergency or engine failure.

To check this feature, perform the following: 1. Test system with machine on a level surface and no load.

2. Lower attachment to ground and shut-off engine.

3. Verify the power/emergency stop switch is not depressed and the ignition switch is in position I. 4. Depress auxiliary power switch and hold in place to engage auxiliary power system.

5. While holding auxiliary power switch operate each boom joystick function briefly to ensure proper operation 6. Release auxiliary power switch, turn ignition switch to position 0 and depress the power/emergency stop switch.

8-4

31200368

Section 9 - Specifications

SECTION 9 - SPECIFICATIONS 9.1

PRODUCT SPECIFICATIONS

Fluids

Compartment or System

Engine Crankcase

Hydraulic System

Axle Differential* and Wheel End Cylinder, Boom Wear Pad and Axle Grease Engine Coolant Fuel Air Conditioning

Ambient Temperature Range Viscosities °F °C Min Max Min Max SAE 0W-20 -40 50 -40 10 SAE 0W-30 -40 86 -40 30 Cat DEO Multigrade SAE 0W-40 -40 104 -40 40 Cat DEO SYN SAE 5W-30 -22 86 -30 30 Cat Arctic DEO SYN SAE 5W-40 -22 122 -30 50 Cat ECF-1 SAE 10W-30 0 104 -18 40 API CG-4 Multigrade SAE 10W-40 0 122 -18 50 SAE 15W-40 15 122 -9.5 50 SAE 0W-20 -40 104 -40 40 SAE 0W-30 -40 104 -40 40 SAE 5W-30 -22 104 -30 40 Cat TDTO SAE 5W-40 -22 104 -30 40 Cat TDTO-TMS SAE 10W -4 104 -20 40 Cat Arctic TDTO SYN SAE 30 50 122 10 50 commercial TO-4 SAE 10W-30 -4 104 -20 40 SAE 15W-40 5 122 -15 50 Cat TDTO-TMS -4 122 -20 50 Type and Classification

Cat TDTO TO-4 Cat Multipurpose Grease

SAE 30

-4

104

-20

40

NLGI Grade 2

-22

104

-30

40

Cat Extended Life Coolant (ELC) #2 Diesel

Low Sulfur

Refrigerant R-134a

Tetrafluoroethane

50/50 Mix

Note: Friction Modifier (Cat Brake Oil Additive) required for front axle differential.

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9-1

Section 9 - Specifications Fluid Capacities Engine Crankcase Oil Capacity with Filter Change 74.5 kW (100 hp) .............................................................................. 8,4 L (8.9 qt) 93.1 kW (125 hp) .............................................................................. 8,5 L (9.0 qt) Fuel Tank Capacity..............................................................................................150 L (39.6 gal) Cooling System System Capacity................................................................................. 14,0 L (14.8 qt) Overflow Bottle Capacity ........................................................................ 2,4 L (2.5 qt) Hydraulic System System Capacity TH336, TH337, TH406 & TH407 ..................................................135 L (35.7 gal) TH414, TH514 & TH417 ...............................................................145 L (38.3 gal) Reservoir Capacity to Full Mark ...........................................................90 L (23.8 gal) Auxiliary Hydraulic Circuit Max Flow ..............................................90 lpm (23.8 gpm) Axles Differential Housing Capacity TH336, TH337, TH406 & TH407 Front Axle.................................................................................10,5 L (11.1 qt) Rear Axle .................................................................................11,5 L (12.2 qt) TH414, TH514 & TH417 Front & Rear Axle ....................................................................11,5 L (12.2 qt) Friction Modifier - Front Axle Differential ............................................ 0,35 L (0.37 qt) Wheel End Capacity TH336, TH337, TH406 & TH407 ...................................................... 0,8 L (0.8 qt) TH414 ............................................................................................... 0,9 L (1.0 qt) TH514 & TH417................................................................................ 1,5 L (1.6 qt) Air Conditioning System (if equipped) System Capacity....................................................................................1,1 kg (2.4 lb)

9-2

31200368

Section 9 - Specifications Tires TH336, TH337, TH406 & TH407 15.5-25 SGL Pneumatic................................................................................4,0 bar (58 psi) Foam (ANSI only) ........................................................Approx 264 kg (582 lb) 15.5/80-24 TR01............................................................................4,1 bar (59 psi) 15.5/80-24 SGI ..............................................................................4,0 bar (58 psi) 460/70 R24 ....................................................................................4,2 bar (61 psi) 500/70 R24 (TH337 & TH407 only) ...............................................3,0 bar (44 psi) 400/80-24 ......................................................................................4,0 bar (58 psi) 440/80-24 (TH337 & TH407 only) .................................................3,5 bar (51 psi) TH414 15.5/80-24 TR01............................................................................4,1 bar (59 psi) 15.5-25 SGL-2A.............................................................................4,0 bar (58 psi) 400/80-24 ......................................................................................4,5 bar (65 psi) 440/80-24 ......................................................................................4,0 bar (58 psi) TH514 & TH417 14-24 TG02 .................................................................................4,25 bar (61 psi) 14-24 SGG-2A.............................................................................5,25 bar (76 psi) Wheel Lug Nut Torque TH336, TH337, TH406, TH407 & TH414 ................... 460 ±60 Nm (339 ±44 lb-ft) TH514 & TH417.......................................................... 510 ±60 Nm (376 ±44 lb-ft)

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9-3

Section 9 - Specifications Performance Maximum Lift Capacity TH336 CE .......................................................................................3300 kg (7275 lb) AUS......................................................................................3000 kg (6614 lb) TH337 .......................................................................................3300 kg (7275 lb) TH406 CE .......................................................................................3700 kg (8157 lb) AUS......................................................................................3500 kg (7716 lb) ANSI.....................................................................................8150 lb (3697 kg) TH407 CE & AUS ............................................................................3700 kg (8157 lb) ANSI.....................................................................................8150 lb (3697 kg) TH414 CE .......................................................................................3700 kg (8157 lb) AUS Outriggers Engaged .......................................................3700 kg (8157 lb) Outriggers Not Engaged ................................................3300 kg (7275 lb) TH514 CE .................................................................................... 4999 kg (11,021 lb) AUS Outriggers Engaged .................................................... 5000 kg (11,023 lb) Outriggers Not Engaged .............................................4600 kg (10,141 lb) ANSI.................................................................................. 11,000 lb (4990 kg) TH417 CE & AUS ............................................................................4000 kg (8818 lb) Maximum Lift Height TH336 & TH406.............................................................................. 6,1 m (20.0 ft) TH337 & TH407.............................................................................. 7,3 m (24.0 ft) TH414 ........................................................................................... 13,7 m (44.9 ft) TH514 Outriggers Engaged................................................................ 13,7 m (44.9 ft) Outriggers Not Engaged ......................................................... 13,3 m (43.6 ft) TH417 Outriggers Engaged................................................................ 17,3 m (56.8 ft) Outriggers Not Engaged ......................................................... 15,2 m (49.9 ft) Capacity at Maximum Height TH336 CE .......................................................................................2400 kg (5291 lb) AUS......................................................................................2250 kg (4960 lb) TH337 .......................................................................................2000 kg (4409 lb) TH406 CE .......................................................................................2500 kg (5512 lb) AUS......................................................................................2000 kg (4409 lb) ANSI.....................................................................................5500 lb (2495 kg)

9-4

31200368

Section 9 - Specifications TH407 CE & AUS ............................................................................ 2000 kg (4409 lb) ANSI .................................................................................... 4000 lb (1814 kg) TH414 Outriggers Engaged............................................................. 3700 kg (8157 lb) Outriggers Not Engaged ...................................................... 2000 kg (4409 lb) TH514 Outriggers Engaged CE .................................................................................. 3500 kg (7716 lb) AUS................................................................................ 2000 kg (4409 lb) ANSI........................................................................................... 0 lb (0 kg) Outriggers Not Engaged CE .................................................................................. 1500 kg (3307 lb) AUS................................................................................ 1800 kg (3968 lb) ANSI............................................................................... 4000 lb (1814 kg) TH417 Outriggers Engaged............................................................. 3000 kg (6614 lb) Outriggers Not Engaged ...................................................... 1000 kg (2205 lb) Maximum Forward Reach TH336 & TH406...............................................................................3,1 m (10.2 ft) TH337 & TH407...............................................................................3,8 m (12.3 ft) TH414 & TH514...............................................................................9,2 m (30.3 ft) TH417............................................................................................12,7 m (41.7 ft) Capacity at Maximum Forward Reach TH336 CE ....................................................................................... 1000 kg (2205 lb) AUS ....................................................................................... 975 kg (2150 lb) TH337 ....................................................................................... 1000 kg (2205 lb) TH406 & TH407 CE ....................................................................................... 1500 kg (3307 lb) AUS ..................................................................................... 1300 kg (2866 lb) ANSI .................................................................................... 3300 lb (1497 kg) TH414 Outriggers Engaged CE .................................................................................. 1150 kg (2535 lb) AUS................................................................................ 1000 kg (2205 lb) Outriggers Not Engaged .......................................................... 350 kg (772 lb) TH514 Outriggers Engaged CE .................................................................................. 1600 kg (3572 lb) AUS................................................................................ 1200 kg (2646 lb) ANSI............................................................................... 3000 lb (1361 kg) Outriggers Not Engaged CE .................................................................................... 600 kg (1322 lb) AUS.................................................................................. 500 kg (1102 lb) ANSI................................................................................. 1000 lb (454 kg)

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9-5

Section 9 - Specifications TH417 Outriggers Engaged............................................................... 500 kg (1102 lb) Outriggers Not Engaged ..................................................................0 kg (0 lb) Reach at Maximum Height TH336 & TH406................................................................................ 0,8 m (2.6 ft) TH337 & TH407................................................................................ 0,7 m (2.3 ft) TH414 ............................................................................................... 0,5 m (1.6 ft) TH514 Outriggers Engaged.................................................................... 0,5 m (1.6 ft) Outriggers Not Engaged ............................................................. 1,8 m (5.9 ft) TH417 Outriggers Engaged.................................................................... 2,1 m (6.9 ft) Outriggers Not Engaged ........................................................... 6,0 m (19.7 ft) Maximum Travel Speed TH336, TH337, TH406 & TH407 4 Speed...............................................................................32 kph (19.9 mph) 5 Speed...............................................................................40 kph (24.9 mph) TH414, TH514 & TH417 ...........................................................32 kph (19.9 mph) Towing Capacity TH336, TH337, TH406 & TH407 .........................................12.000 kg (26,455 lb) TH414, TH514 & TH417 ........................................................................0 kg (0 lb) Frame Leveling TH336, TH337, TH406 & TH407 ...........................................................0 degrees TH414, TH514 & TH417 ......................................................................10 degrees Maximum Travel Grade (boom in travel position) Gradeability.....................................................................................................45% Side Slope ...................................................................................................8.75%

9-6

31200368

Section 9 - Specifications Dimensions Overall Height TH336 & TH406........................................................................2323 mm (91.5 in) TH337 & TH407........................................................................2385 mm (93.9 in) TH414.....................................................................................2592 mm (102.0 in) TH514.....................................................................................2630 mm (103.5 in) TH417.....................................................................................2630 mm (105.0 in) Overall Width TH336, TH337, TH406 & TH407 ..............................................2400 mm (94.5 in) TH414, TH514 & TH417...........................................................2449 mm (96.4 in) Track Width TH336, TH337, TH406 & TH407 ..............................................1988 mm (78.3 in) TH414, TH514 & TH417...........................................................2036 mm (80.2 in) Wheelbase TH336 & TH406...................................................................... 2950 mm (116.1 in) TH337 & TH407......................................................................3050 mm (120.1 in) TH414, TH514 & TH417.........................................................3200 mm (126.0 in) Length at Front Wheels TH336.....................................................................................4253 mm (167.4 in) TH337.....................................................................................4426 mm (174.3 in) TH406.....................................................................................4253 mm (167.4 in) TH407.....................................................................................4679 mm (184.2 in) TH414 & TH514......................................................................5091 mm (200.4 in) TH417.....................................................................................5135 mm (202.2 in) Overall Length (less Forks) TH336.....................................................................................4621 mm (181.9 in) TH337.....................................................................................4866 mm (191.6 in) TH406.....................................................................................4621 mm (181.9 in) TH407.....................................................................................5153 mm (202.9 in) TH414.....................................................................................6325 mm (249.0 in) TH514.....................................................................................6520 mm (256.7 in) TH417.....................................................................................6670 mm (262.6 in) Ground Clearance TH336, TH337, TH406 & TH407 ................................................430 mm (16.9 in) TH414 & TH514..........................................................................458 mm (18.0 in) TH417.........................................................................................468 mm (18.4 in) Turning Radius Over Tires TH336 & TH406......................................................................3700 mm (145.7 in) TH337 & TH407......................................................................3750 mm (147.6 in) TH414.....................................................................................3805 mm (149.8 in) TH514 & TH417......................................................................3920 mm (154.3 in)

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9-7

Section 9 - Specifications Outside Turning Radius TH336 & TH406......................................................................7270 mm (286.2 in) TH337 & TH407......................................................................7442 mm (293.0 in) TH414 & TH514......................................................................7636 mm (300.6 in) TH417 .....................................................................................7637 mm (300.7 in) Maximum Gross Vehicle Weight with Attachment TH336 .....................................................................................7830 kg (17,262 lb) TH337 .....................................................................................8330 kg (18,364 lb) TH406 .....................................................................................8460 kg (18,651 lb) TH407 .....................................................................................8960 kg (19,753 lb) TH414 CE .....................................................................................9910 kg (21,848 lb) AUS................................................................................10.100 kg (22,267 lb) TH514 CE & ANSI ..................................................................... 11.100 kg (24,471 lb) AUS................................................................................ 11.340 kg (25,000 lb) TH417 .................................................................................. 11.800 kg (26,015 lb) Maximum Front Axle Weight with Standard Carriage and Forks (boom level and fully retracted) TH336 ........................................................................................3310 kg (7297 lb) TH337 ........................................................................................3375 kg (7441 lb) TH406 ........................................................................................3575 kg (7882 lb) TH407 ........................................................................................3640 kg (8025 lb) TH414 CE .....................................................................................4840 kg (10,670 lb) AUS......................................................................................4310 kg (9502 lb) TH514 CE & ANSI ........................................................................ 5070 kg (11,177 lb) AUS...................................................................... Not Available at Publication TH417 .....................................................................................5960 kg (13,140 lb) Maximum Rear Axle Weight with Standard Carriage and Forks (boom level and fully retracted) TH336 ........................................................................................3255 kg (7176 lb) TH337 ........................................................................................3690 kg (8135 lb) TH406 ........................................................................................3625 kg (7992 lb) TH407 ........................................................................................4060 kg (8951 lb) TH414 CE ........................................................................................4520 kg (9965 lb) AUS...................................................................................5460 kg (12,037 lb) TH514 CE & ANSI ........................................................................6000 kg (13,228 lb) AUS...................................................................... Not Available at Publication TH417 .....................................................................................6170 kg (13,603 lb)

9-8

31200368

Section 9 - Specifications Maximum Ground Bearing Pressure TH336........................................................................ Not Available at Publication TH337........................................................................ Not Available at Publication TH406........................................................................ Not Available at Publication TH407........................................................................ Not Available at Publication TH414........................................................................ Not Available at Publication TH514........................................................................ Not Available at Publication TH417........................................................................ Not Available at Publication

31200368

9-9

Section 9 - Specifications Declaration of Vibration (CE) Average weighted whole body acceleration.

Mechanical Suspension Seat TH336 ....................................................................................... 0,5 m/s² (1.6 ft/s²) TH337 ....................................................................................... 0,5 m/s² (1.6 ft/s²) TH406 ....................................................................................... 0,5 m/s² (1.6 ft/s²) TH407 ....................................................................................... 0,5 m/s² (1.6 ft/s²) TH414 ....................................................................................... 0,7 m/s² (2.3 ft/s²) TH514 ....................................................................................... 0,7 m/s² (2.3 ft/s²) TH417 ....................................................................................... 0,7 m/s² (2.3 ft/s²) Pneumatic Suspension Seat TH336 ....................................................................................... 0,6 m/s² (2.0 ft/s²) TH337 ....................................................................................... 0,6 m/s² (2.0 ft/s²) TH406 ....................................................................................... 0,6 m/s² (2.0 ft/s²) TH407 ....................................................................................... 0,6 m/s² (2.0 ft/s²) TH414 ....................................................................................... 0,6 m/s² (2.0 ft/s²) TH514 ....................................................................................... 0,6 m/s² (2.0 ft/s²) TH417 ....................................................................................... 0,6 m/s² (2.0 ft/s²)

Noise Emission Level (CE) • The telehandler is approved under the applicable EC directives.

• The LWA sound power level is shown on the machine.

74.5 kW (100 hp) Engine ........................................................................... 106 dB 93.1 kW (125 hp) Engine ........................................................................... 107 dB • To avoid any increase in noise emission, after maintenance and repair work, all panels and other sound absorbing materials must be replaced in their original condition. Do not modify the machine in such a manner as to increase noise emissions.

9-10

31200368

Index

Index A

D

Accessory Control Lever ................ 3-25

Decals TH336, TH337, TH406 & TH407 (CE & AUS)......................2-3 TH406 & TH407 (ANSI)...............2-6 TH414, TH514 & TH417 (CE & AUS) .................................2-8 TH514 (ANSI) ............................2-11

Additional Checks............................. 8-1 Adjusting/Moving Forks .................. 5-25 Air Filter .......................................... 7-22 Anti Theft ........................................ 3-28 Attachment Installation CAT Quick Coupler................... 5-13 JCB Coupler.............................. 5-21 JD Coupler ................................ 5-16 Manitou Coupler........................ 5-18 Attachment Operation .................... 5-26 Attachments Approved..................................... 5-1 JLG Supplied .............................. 5-2 Unapproved ................................ 5-1

Dimensions .......................................9-7 Disengaging a Load ..........................4-6 Disengaging a Suspended Load.......4-9 Display Screen..................................3-6 Driving Hazards on Slopes ...............1-9

E Electrical Hazards .............................1-2

Auto Hitch....................................... 5-48

Emergency Lowering of Boom..........6-2

Auxiliary Power System.................... 6-3 Test ............................................. 8-4

Emergency Procedures ....................6-1

Axles................................................. 9-2

Engine Normal Operation ........................4-3 Starting ........................................4-1

B

Engine Crankcase Oil .......................9-2

Bale Handler................................... 5-40

Engine Oil Level..............................7-16

Battery ............................................ 7-24 Battery Boosted Starting .................. 4-2 Boom Indicator Angle......................................... 3-34 Extension .................................. 3-34

F Fall Hazard......................................1-12 Fluid Capacities ................................9-2 Fluids ................................................9-1

Boom Interlock Test ......................... 8-2

Front Console Switches ..................3-22

Bucket ............................................ 5-32

Fuel Level .......................................7-14

C Cab Emergency Exit......................... 6-4

Fuel Tank ..........................................9-2 Fuel/Water Separator......................7-15

Capacity ........................................... 5-6

G

Capacity Indicator Locations ............ 5-7

General Maintenance........................7-2

Carriage w/Forks ............................ 5-27

Grapple Bucket ...............................5-36

Chemical Hazards .......................... 1-13 Controls ............................................ 3-2 Coolant Level ................................. 7-21 Cooling System ................................ 9-2 Coupler Mounted Hook .................. 5-42

31200368

1

Index H

N

Hazard Classification System........... 1-1

Noise Emission ...............................9-10

Hitches............................................ 5-45 Horn................................................ 3-13

O

Hydraulic Hitch ............................... 5-50

Operating with a Non-Suspended Load ..................................................4-4

Hydraulic Oil Level.......................... 7-17

Operating with a Suspended Load....4-7

Hydraulic Operated Attachment ..... 5-24

Operational Check ..........................2-16

Hydraulic System.............................. 9-2

Operator Cab ..................................2-17

I

Operator Maintenance Instructions......................................7-14

Ignition ............................................ 3-10 Instrument Panel .............................. 3-4

J Joystick Lift Pattern................................. 3-18 Loader Pattern .......................... 3-20

K Keypad ............................................. 3-8

Operator Seat..................................3-31

P Park Brake ......................................3-11 Parking Procedure ..........................3-11 Performance......................................9-4 Picking Up a Load .............................4-4 Picking Up a Suspended Load..........4-7 Pin Hitch..........................................5-47

L

Pin Hitch - CUNA C.........................5-45

Leveling Procedure.................... 4-5, 4-8

Pin Hitch - CUNA D2.......................5-46

Lifting Personnel............................... 1-8

Pinch Points and Crush Hazards ....1-10

Load Chart Example .................................... 5-12 Sample (AUS) ........................... 5-10 Sample (CE & ANSI)................... 5-8

Piton Hitch.......................................5-49

Load Falling Hazard ......................... 1-7 LSI .................................................. 3-14 Test ............................................. 8-1

Placing a Load ..................................4-6 Placing a Suspended Load ...............4-9 Pre-Operation Check and Inspection..........................................2-1

R

Lubrication and Maintenance ........... 7-1

Reversing Fan.................................3-26

Lubrication Schedule 50 Hour ....................................... 7-8 500 Hour ................................... 7-12

Right Console Switches ..................3-23

M Manure Fork ................................... 5-38 Multi-Purpose Bucket ..................... 5-34

Rotate/Side Tilt Carriage.................5-30

S Safety Decals ....................................2-3 Safety Practices ................................1-1 Safety Signal Words..........................1-1 Seat Belt..........................................3-33

2

31200368

Index Service and Maintenance Schedule 10 Hour ....................................... 7-3 1000 Hour ................................... 7-5 12000 Hour ................................. 7-6 1st 150 Hour ............................... 7-4 1st 50 Hour ................................. 7-3 250 Hour ..................................... 7-4 50 Hour ....................................... 7-3 500 Hour ..................................... 7-5 6000 Hour ................................... 7-6

W Walk-Around Inspection..................2-14 Warm-Up Check .............................2-16 Wheel Installation............................7-20 Wheel Lug Nut ..................................9-3 Wheel Replacement........................7-19 Windshield Washer Fluid Level.......7-25

Shut-Down Procedure ...................... 4-3 Side Shift Carriage ......................... 5-28 Specifications ................................... 9-1 Steering Alignment Mode All Wheel Assisted .................... 3-30 Manual ...................................... 3-29 Steering Column Adjuster .............. 3-17

T Tip Over Hazard ............................... 1-3 Tires ........................................ 7-18, 9-3 Air Pressure .............................. 7-18 Damage .................................... 7-19 Replacement............................. 7-19 Towing.............................................. 6-1 Transmission Control Lever Direction of Travel..................... 3-12 Gear Selection .......................... 3-13 Transport Lifting ........................................ 4-12 Tiedown .................................... 4-11 Transporting a Load ......................... 4-5 Transporting a Suspended Load ...... 4-8 Travel Hazard................................... 1-6 Truss Boom .................................... 5-43

V Vibration ......................................... 9-10

31200368

3

Index

4

31200368

Inspection, Maintenance and Repair Log

Inspection, Maintenance and Repair Log Serial Number ______________________________

Date

Comments

Inspection, Maintenance and Repair Log Date

Comments

TRANSFER OF OWNERSHIP An Oshkosh Corporation Company

To Product Owner: If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary.

Please use this form to provide JLG with updated information with regard to the current ownership of JLG products. Please return completed form to the JLG Product Safety & Reliability Department via facsimile or mail to address as specified below.

Thank You, Product Safety & Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA Telephone: +1-717-485-6591 Fax: +1-301-745-3713 NOTE: Leased or rented units should not be included on this form.

Mfg. Model: _______________________________________________________________ Serial Number: ____________________________________________________________ Previous Owner: ___________________________________________________________ Address: _________________________________________________________________ _________________________________________________________________________ Country: _________________________ Telephone: (_______) ____________________ Date of Transfer: _________________________________ Current Owner: ____________________________________________________________ Address: _________________________________________________________________ _________________________________________________________________________ Country: _________________________ Telephone: (_______) ____________________

Who in your organization should we notify?

Name: ___________________________________________________________________ Title: _____________________________________________________________________

Hand Signals

OY1090

EMERGENCY STOP - With both arms extended laterally, hands open downward, move arms back and forth.

OY1120

RAISE BOOM - With either arm extended horizontally, fingers closed, point thumb upward.

OY1150

EXTEND BOOM - With both hands clenched, point thumbs outward.

OY1180

TILT FORKS UP - With one arm held at side, extend other arm upward at about 45 degrees.

OY1100

STOP - With either arm extended laterally, hand open downward, move arm back and forth.

OY1130

LOWER BOOM - With either arm extended horizontally, fingers closed, point thumb downward.

OY1160

RETRACT BOOM - With both hands clenched, point thumbs inward.

OY1110

STOP ENGINE - Draw thumb or forefinger across throat.

OY1140

MOVE SLOWLY - Place one hand motionless in front of hand giving motion signal. (Raise load slowly shown)

OY1170

THIS FAR TO GO - With hands raised and open inward, move hands laterally, indicating distance to go.

OY1190

TILT FORKS DOWN - With one arm held at side, extend other arm downward at about 45 degrees.

Special Signals - When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in advance by the operator and signalman.

31200368

Operation & Maintenance Manual Original Instructions Keep this manual with machine at all times.

Load Management Indicator System 31200648 SEBU9287-03 Revised July 18, 2014

Revision Log Revision Log

REVISION LOG August 13, 2009 - A - Original Issue of Manual November 16, 2009 - B - Revised cover.

March 13, 2014 - C - Revised pages 1-13, 2-1, 2-2, 2-3, 2-4, 3-2, 3-3 & 3-4.

July 18, 2014 - D - Revised cover.

31200648

a

Read This First Read This First

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

Operator Qualifications The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. Operation within the U.S.A. requires training per OSHA 1910.178.

Operators of this equipment must possess a valid, applicable driver’s license, be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.

In addition, the operator must read, understand and comply with instructions contained in the following material furnished with the material handler: • This Operation & Maintenance Manual • Telehandler Safety Manual (ANSI only) • All instructional decals and plates • Any optional equipment instructions furnished The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and regulations.

Modifications Any modification to this machine must be approved by JLG.

b

31200648

Read This First This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local Caterpillar dealer representative for information regarding safety-related bulletins which may have been issued for this product.

JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.

JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product.

FOR: • Accident Reporting and Product Safety Publications • Current Owner Updates • Questions Regarding Product Applications and Safety • Standards and Regulations Compliance Information • Questions Regarding Product Modifications

CONTACT: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA In USA: Toll Free:

1-877-JLG-SAFE (1-877-554-7233)

Outside USA: Phone: +1-717-485-6591 E-mail: ProductSafety@JLG.com

31200648

c

Read This First Other Publications Available For detailed machine operation procedures and safety information, please refer to the appropriate machine Operation & Maintenance Manual.

Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard.

d

31200648

Table of Contents

Table of Contents

TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ................................................................................. b Modifications ................................................................................................... b Other Publications Available........................................................................ d

Table of Contents Section 1 - General Safety Practices 1.1 1.2 1.3

Hazard Classification System .......................................................................... 1-1 Safety Alert System and Safety Signal Words...................................... 1-1 General Precautions.......................................................................................... 1-1 Operation Safety................................................................................................ 1-2 Electrical Hazards ........................................................................................ 1-2 Tip Over Hazard ........................................................................................... 1-3 Travel Hazard ............................................................................................... 1-6 Load Falling Hazard.................................................................................... 1-7 Lifting Personnel ......................................................................................... 1-8 Driving Hazards on Slopes........................................................................ 1-9 Pinch Points and Crush Hazards............................................................ 1-10 Fall Hazard .................................................................................................. 1-12 Chemical Hazards...................................................................................... 1-13

Section 2 - System Operation 2.1 2.2 2.3

2.4

General ................................................................................................................. 2-1 Control Panel ...................................................................................................... 2-1 Display ........................................................................................................... 2-2 Operation............................................................................................................. 2-4 System Start Up ........................................................................................... 2-4 Attachment Selection ................................................................................ 2-5 Lifting Conditions and Alarms ................................................................. 2-6 Diagnostic Data.................................................................................................. 2-7 Alarms and Warnings................................................................................. 2-7 LMI Values..................................................................................................... 2-7 Pressure Values............................................................................................ 2-8 Angle and Length Transducers................................................................ 2-8 LMI Status ..................................................................................................... 2-9

Section 3 - Service and Maintenance 3.1

31200648

Auto-Diagnostic System .................................................................................. 3-1 Alarm Codes ................................................................................................. 3-2

i

Table of Contents

ii

31200648

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES 1.1

HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

OW0010

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

OW0021

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

OW0031

CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury.

1.2

GENERAL PRECAUTIONS

WARNING Before operation, read & understand this manual. Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.

31200648

1-1

Section 1 - General Safety Practices 1.3

OPERATION SAFETY

Electrical Hazards

10 FT (3 M)

OW0040

• This machine is not insulated and does not provide protection from contact or being near electrical current.

• NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.

• Always check for power lines before raising the boom.

• Follow employer, local and governmental regulations for clearance from powerlines.

1-2

31200648

Section 1 - General Safety Practices Tip Over Hazard General • For additional load requirements, refer to the appropriate load chart.

OW0050

• Never use an attachment without the appropriate JLG approved load chart installed on the telehandler.

• Understand how to properly use the load charts located in cab.

• DO NOT exceed rated lift capacity.

• Be sure that the ground conditions are able to support the machine.

OW0080

• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on load chart.

4 FT (1,2 M)

OW0100

• DO NOT level machine with boom/attachment above 1,2 m (4 ft).

(AUS - DO NOT level machine with load more than 300 mm (11.8 in) above ground surface.)

31200648

1-3

Section 1 - General Safety Practices

OH2291

• MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.

• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast.

OH20911

• Always wear the seat belt.

• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.

OH2221

If the telehandler starts to tip over: • DO NOT JUMP • BRACE YOURSELF and STAY WITH THE MACHINE • KEEP YOUR SEAT BELT FASTENED • HOLD ON FIRMLY • LEAN AWAY FROM THE POINT OF IMPACT

1-4

31200648

Section 1 - General Safety Practices Suspended Load

OW0150

• Tether suspended loads to restrict movement.

• Weight of all rigging (slings, etc.) must be included as part of load.

• Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads even with tag lines.

• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

When driving with a suspended load: • Start, travel, turn and stop slowly to prevent load from swinging.

• DO NOT extend boom.

• DO NOT raise the load more than 300 mm (11.8 in) above ground surface or the boom more than 45°.

• DO NOT exceed walking speed.

31200648

1-5

Section 1 - General Safety Practices Travel Hazard 2-Wheel Front Steer

4-Wheel Circle Steer

4-Wheel Crab Steer

OAL2030

• Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated.

• DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary.

• Visually verify proper wheel alignment after each steer mode change.

• Ensure that adequate clearance is provided for both rear tail swing and front fork swing.

• Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view.

• Before moving be sure of a clear path and sound horn.

• When driving, retract boom and keep boom/attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel.

• Always look in the direction of travel.

• Always check boom clearances carefully before driving underneath overhead obstructions.

Position attachment/load to clear obstacles.

• When driving in high speed, use only front wheel steer (if steering modes are selectable).

1-6

31200648

Section 1 - General Safety Practices Load Falling Hazard

OW0130

• Never suspend load from forks or other parts of carriage.

• DO NOT burn or drill holes in fork(s).

• Forks must be centered under load and spaced apart as far as possible.

31200648

1-7

Section 1 - General Safety Practices Lifting Personnel

OW0170

• When lifting personnel, USE ONLY a JLG approved personnel work platform, with proper load chart displayed in the cab.

OW0190

• DO NOT drive machine from cab when personnel are in platform.

1-8

31200648

Section 1 - General Safety Practices Driving Hazards on Slopes

OW0200

To maintain sufficient traction and braking capabilities, travel on slopes as follows: • When unloaded, the rear of the machine is the “heavy end.” Drive with forks pointed downhill.

• When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill.

• For additional travel requirements, refer to the appropriate load chart.

• To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances.

• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.

• DO NOT park on a slope.

31200648

1-9

Section 1 - General Safety Practices Pinch Points and Crush Hazards Stay clear of pinch points and rotating parts on the telehandler.

OW0210

• Stay clear of moving parts while engine is running.

OW0220

• Keep clear of steering tires and frame or other objects.

OW0230

• Keep clear from under boom.

1-10

31200648

Section 1 - General Safety Practices

OW0240

• Keep clear of boom holes.

OW0250

• Keep arms and hands clear of attachment tilt cylinder.

OW0260

• Keep hands and fingers clear of carriage and forks.

OW0960

• Keep others away while operating.

31200648

1-11

Section 1 - General Safety Practices Fall Hazard

OW0280

• Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine.

• DO NOT get off the machine until the shutdown procedure has been performed.

OW0290

• DO NOT carry riders. Riders could fall off machine causing death or serious injury.

1-12

31200648

Section 1 - General Safety Practices Chemical Hazards Exhaust Fumes • DO NOT operate machine in an enclosed area without proper ventilation.

• DO NOT operate the machine in hazardous environments unless approved for that purpose

by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.

Flammable Fuel

OW0300

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.

Hydraulic Fluid

OW0950

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure.

• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.

31200648

1-13

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14

31200648

Section 2 - System Operation

SECTION 2 - SYSTEM OPERATION 2.1

GENERAL

The LMIS provides visual indication of stability limitations by monitoring suspended loads compared to predetermined load charts.

Note: When using non-suspended load type attachments, load charts located in the operator cab must be used. Refer to the machine Operation & Maintenance Manual for details.

2.2

CONTROL PANEL

The control panel displays information and allows for the selection of different attachments.

4

3

2

5

1

6 +

OZ3091

1. UP Button - Depress to scroll up inside a menu.

2. DOWN Button - Depress to scroll down inside a menu.

3. Display - Shows working data. See page 2-2.

4. Status Lights - Progressively illuminate (two green, yellow then red) to indicate lifting conditions. See page 2-6.

5. ENT Button - Depress to confirm an action.

6. ESC Button - Depress to return to previous menu.

31200648

2-1

Section 2 - System Operation Display b

a

1

2

3

4

5

OFF

6

0

c

0.0 m

d

0.0 m 0.0 d

e

0.0 m

f

OZ3132

0.0

t

7 8

max

0.0

t

XXXXX XXXXX

9 10 11

1. Attachment - Current attachment selection (see page 2-5). a. OFF - Select when lifting a non-suspended load. Minimal information shown on display.

Load charts located in the operator cab must be used. b. Coupler Mounted Hook attachment selected. c. Truss Boom attachment selected. d. Fork and Carriage attachment selected.

2. Operating Mode e. Outriggers fully engaged. f. Outriggers not engaged.

3. Boom Length - Displays boom length in meters or feet.

4. Bargraph - Displays approximate percentage of rated capacity.

5. Boom Height - Displays boom height in meters or feet.

6. Load Percentage - Displays approximate load percentage of the rated capacity.

7. Load - Displays approximate load in metric ton or k-pounds. Load includes object being lifted and all rigging (slings, etc).

8. Boom Angle - Displays boom angle in degrees.

9. Rated Capacity - Displays rated capacity in metric ton or k-pounds.

10. Reach - Displays boom reach from front of tires in meters or feet.

11. Message Display Window - Displays general system information, alarms and warnings.

2-2

31200648

Section 2 - System Operation Note: To change display brightness, depress ESC for 2-3 seconds. As the display cycles through various levels of brightness, depress ENT when the desired brightness is reached.

31200648

2-3

Section 2 - System Operation 2.3

OPERATION

System Start Up

0 0.0 m

0.0 m 0.0 d 0.0 m

OZ3440

0.0 max

0.0

t

t

2 1

ST02 Date XXXXXXX

1. When the machine is started the system automatically switches on, performs a self-test and briefly shows the machine model (1) and LMIS software version (2) (dd.mm.yy = software date of development).

0

4 5

0.0 m

0.0 m 0.0 d 0.0 m

0.0 max

0.0

t

t

OZ3180

2. The display shows the last used attachment icon (4) and current operating mode (5).

2-4

31200648

Section 2 - System Operation Attachment Selection The machine can operate with various attachments, but the appropriate load chart must be selected by the operator. When an attachment is changed, the LMIS must be manually set to the corresponding attachment load chart.

1. Escape out of all menus.

2. Press the UP button.

0

2 3

0.0 m

0.0 m 0.0 d 0.0 m

OZ3190

0.0 max

0.0

XXXXXXXXXXA XXXX XXXX

t

t

1

3. Press the UP or DOWN button until the part number of the attachment load chart being used is displayed (1).

Note: DO NOT install suspended load type attachments that do not have correct load charts available on the LMIS. 4. Confirm the selection by pressing the ENT button.

5. The correct attachment icon (2) should now be displayed.

Note: Before lifting a load, check that the correct operating mode (3) is displayed. The system should automatically select the correct operating mode.

WARNING Never use a suspended load type attachment without the appropriate JLG supplied load chart installed on the LMIS.

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2-5

Section 2 - System Operation Lifting Conditions and Alarms The control panel and external audible beacon tower (if equipped) display machine operating conditions.

1

2

3

4

3

0 0.0 m

0.0 m 0.0 d 0.0 m

+

0.0 max

0.0

2

t

1

t

-

OAM2900

VIEW OF EXTERNAL AUDIBLE BEACON TOWER (IF EQUIPPED)

1. Green Light - Illuminates when load is less than rated capacity.

2. Yellow Light - Illuminates and intermittent alarm sounds when load is approaching rated capacity.

3. Red Light - Illuminates and constant alarm sounds when automatic function cut-out is activated. Certain functions are disabled (i.e. boom lift, extend, etc). Retract boom to re-enable functions.

4. Bargraph - See page 2-2.

5. Automatic Function Cut-Out Override (not illustrated) - Momentarily disables the automatic function cut-out. Indicator flashes while activated.

Switch/button and indicator locations vary by model. Refer to the machine Operation & Maintenance Manual for location details.

Note: Override will only function for 30 seconds. After 30 seconds, boom functions will cease and the switch/button will need released and depressed again.

WARNING TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the equipment and/or cause tip over.

2-6

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Section 2 - System Operation 2.4

DIAGNOSTIC DATA

By pressing ENT, the display shows sub-menus. To enter a sub-menu, wait 2-3 seconds on the selected menu.

Alarms and Warnings The first menu displays the Alarm and Warning Codes.

P01 : Alarms

In this menu, the Alarm code and Warning codes are shown.

Alarms :

XXXX

Warning : XXXX

LMI Values The second menu displays the LMI Values.

P02 : Lmi Values

In this menu the following values are shown: • P - Differential Pressure (bar).

• W - Weight Lifted (ton).

• M - Max Load (ton).

• Ac - Boom Angle (degree).

• L - Boom Length (meter).

• R - Boom Radius (meter).

P XXX W XXX M XXX Ac XXX L XXX R XXX

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2-7

Section 2 - System Operation Pressure Values The third menu displays Pressure Values.

P03 : Pressures

In this menu the following values are shown: • P - Differential pressure of the Lift cylinder (bar).

• L - Pressure in the piston side of the Lift cylinder (bar).

• H - Pressure in the rod side of the Lift cylinder (bar).

• p - Differential pressure in the Compensation cylinder (bar).

• l - Pressure in the piston side of Compensation cylinder (bar).

• h - Pressure in rod side of the Compensation cylinder (bar).

P XXX L XXX H XXX p XXX l XXX h XXX

Angle and Length Transducers The fourth menu displays information from the cable reel.

P04 : Act 1A

In this menu the following values are shown: • A - Angle Reading from angle sensor.

• L - Length Reading from length sensor.

• E - Error reading from cable reel.

Act1A E : XX

2-8

A : XXX L : XXX

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Section 2 - System Operation LMI Status The fifth menu displays information relative to LMI status.

P17 : Lmi Status

P17 : Lmi Status I

0 : OFF

1. Press ESC to enter the sub-menu. * X

I : value

2. Press ESC to move the (*).

3. Press DOWN to decrease the item selected.

4. Press UP to increase the item selected.

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2-9

Section 2 - System Operation

This Page Intentionally Left Blank

2-10

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Section 3 - Service and Maintenance

SECTION 3 - SERVICE AND MAINTENANCE 3.1

AUTO-DIAGNOSTIC SYSTEM

The system is equipped with an auto-diagnostic system which is able to detect faulty pressure transducers, boom angle/length sensors, broken cables or internal electronic faults.

When the alarm sounds, the display shows an alarm message. If an alarm code sounds apply the park brake, shift the transmission into “Neutral”, lower forks or attachment to the ground and shut off the engine. Restart the engine.

If the alarm code persists, refer to “Alarm Codes” on page 3-2. For troubleshooting information, refer to the appropriate machine service manual.

For additional information, contact the local Caterpillar dealer.

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3-1

Section 3 - Service and Maintenance Alarm Codes Alarm Code

3-2

Description

What To Do

1

Memory Data Not Reliable.

• Switch the system off and on.

• Re-enter data and save again it.

• If the alarm persists, please, contact Technical Assistance

2

Angle Sensor 1 reading lower than minimum value.

• Verify that the wiring and the connectors are not in short circuit.

• Verify the angle sensor integrity.

• If the alarm persists, please, contact Technical Assistance

3

Angle Sensor 1 reading higher than maximum value.

• Verify that the cable or the connector wiring is not open.

• Verify the angle sensor integrity.

• If the alarm persists, please, contact Technical Assistance

4

Reading of boom length sensor 1 lower than minimum value.

• Verify that the wiring and the connectors are not in short circuit.

• Verify the length transducer integrity.

• If the alarm persists, please, contact Technical Assistance

5

Reading of boom length sensor 1 higher than maximum value.

• Verify that the cable or the connector wiring is not broken.

• Verify the length transducer integrity.

• If the alarm persists, please, contact Technical Assistance

10

Reading pressure of Lift cylinder (bottom side) lower than minimum value.

• Verify that the cable or the connector wiring are not in short circuit.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

11

Reading pressure of the Lift cylinder (bottom side) higher than maximum value.

• Verify that the cable or the connector wiring are not open.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

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Section 3 - Service and Maintenance Alarm Code

Description

What To Do

12

Reading pressure of the Lift cylinder (rod side) lower than minimum value.

• Verify that the cable or the connector wiring are not in short circuit.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

13

Reading pressure of the Lift cylinder (rod side) higher than maximum value.

• Verify that the cable or the connector wiring are not open.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

14

Reading pressure of the Compensation cylinder (bottom side) lower than minimum value.

• Verify that the cable or the connector wiring are not in short circuit.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

15

Reading pressure of the Compensation cylinder (bottom side) higher than maximum value.

• Verify that the cable or the connector wiring are not open.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

16

Reading pressure of the Compensation cylinder (rod side) lower than minimum value.

• Verify that the cable or the connector wiring are not in short circuit.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

17

Reading pressure of the Compensation cylinder (rod side) higher than maximum value.

• Verify that the cable or the connector wiring are not open.

• Verify the pressure transducer integrity.

• If the alarm persists, please, contact Technical Assistance

50

ByPass LMIS active.

• Advise that the external BYPASS of LMIS it's active.

60

Redundance alarm output shut-off LMIS.

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of

the

• Verify connection.

• Verify CLS integrity.

• If the alarm persists, please, contact Technical Assistance

3-3

Section 3 - Service and Maintenance Alarm Code

3-4

Description

What To Do

62

Redundance alarm output WDO relay.

of

the

• Verify connection.

• Verify CLS integrity.

• If the alarm persists, please, contact Technical Assistance

120

Canbus time-out from cable reel.

• Verify the canbus connection.

121

Internal error from cable reel.

• Verify the canbus connection.

• Verify cable reel integrity

130

Canbus timeout from external canbus joystick.

• If joystick reading option is active, verify the canbus connection between joystick and CLS.

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31200648

SEBU8327 May 2007

Operation and Maintenance Manual C4.4 (Mech) Industrial Engine 4461-Up (Engine)

i01658146

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 identified 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.

Operations that may cause product damage are identified 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. If a tool, procedure, work method or operating technique that is not specifically 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 be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, 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. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications 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.

SEBU8327

Table of Contents

3 Table of Contents

Reference Information Section Engine Ratings ..................................................... 74

Foreword ................................................................. 4

Safety Section Safety Messages .................................................... 6 General Hazard Information ................................... 7 Burn Prevention .................................................... 10 Fire Prevention and Explosion Prevention ............ 10 Crushing Prevention and Cutting Prevention ........ 12 Mounting and Dismounting ................................... 13 Before Starting Engine .......................................... 13 Engine Starting ..................................................... 13 Engine Stopping ................................................... 14 Electrical System .................................................. 14

Product Information Section Model Views ......................................................... 15 Product Identification Information ........................ 19

Operation Section Lifting and Storage ................................................ 22 Gauges and Indicators .......................................... 23 Features and Controls .......................................... 24 Engine Starting ..................................................... 25 Engine Operation .................................................. 28 Engine Stopping ................................................... 30 Cold Weather Operation ....................................... 31

Maintenance Section Refill Capacities .................................................... 33 Maintenance Interval Schedule ............................ 40

Warranty Section Warranty Information ............................................ 73

Customer Service ................................................. 76 Reference Materials .............................................. 78

Index Section Index ..................................................................... 82

4 Foreword

Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information.

English is the primary language for all Caterpillar publications. The English used facilitates translation and consistency in electronic media delivery.

Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Caterpillar dealer for the latest available information.

Safety This safety section lists basic safety precautions.

In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.

Operation Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.

The operation section is a reference for operators.

Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

Maintenance The maintenance section is a guide to engine care.

The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.

SEBU8327

Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.

Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder.

We also recommend that a maintenance record be maintained as part of the engine’s permanent record.

See the section in the Operation and Maintenance Manual, “Maintenance Records” for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Caterpillar dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval.

Major repairs are best left to trained personnel or an authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available from your Caterpillar dealer. Consult with your dealer for information regarding these options.

SEBU8327

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.

5 Foreword

6 Safety Section Safety Messages

SEBU8327

Safety Section

The Universal Warning label (2) is located on the rear end of the valve mechanism cover. Refer to illustration 2. i02690461

Safety Messages SMCS Code: 1000; 7405 There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened could drop off of the engine.

Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Caterpillar dealer or your distributor can provide new warning signs.

(1) Universal Warning

Do not operate or work on this equipment 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 serious injury or death.

Illustration 1 Typical example

g01154807

SEBU8327

7 Safety Section General Hazard Information

g01353108

Illustration 2 (1) Ether Warning Label

(2) Universal warning

(2) Ether

i02705981

General Hazard Information Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

SMCS Code: 1000; 7405

Illustration 4

Illustration 3

g01154809

Typical example

The ether warning label (1) is located on the inlet manifold cover. Refer to illustration 2.

g00104545

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls.

8 Safety Section General Hazard Information

SEBU8327

Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.

• Use all cleaning solutions with care.

Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside.

Unless other instructions are provided, perform the maintenance under the following conditions:

Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.

• Disconnect the batteries when maintenance

• Filler caps

• Report all necessary repairs.

• The engine is stopped. Ensure that the engine cannot be started.

is performed or when the electrical system is serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not understood.

• Grease fittings

Use the proper tools. Replace any equipment that is damaged or repair the equipment.

• Pressure taps

Pressurized Air and Water

• Breathers • Drain plugs Use caution when cover plates are removed.

Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.

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

The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.

Illustration 5

g00702020

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

• When work is performed around an engine that is

operating, wear protective devices for ears in order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are secured in place on the engine.

• Never put maintenance fluids into glass containers.

Glass containers can break.

Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.

SEBU8327

9 Safety Section General Hazard Information

Asbestos Information

Illustration 6

g00687600

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid 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 fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “Dealer Service Tool Catalog” for the following items:

• Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids

Illustration 7

g00702022

Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.

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

• Never use compressed air for cleaning.

• Tools that are suitable for containing fluids and equipment that is suitable for containing fluids

• Avoid brushing materials that contain asbestos.

Obey all local regulations for the disposal of liquids.

• 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

efficiency particulate air filter (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.

10 Safety Section Burn Prevention

SEBU8327

• Comply with applicable rules and regulations

for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal of asbestos.

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

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

Check the coolant level after the engine has stopped and the engine has been allowed to cool.

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

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

Dispose of Waste Properly

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

Batteries

Illustration 8

g00706404

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.

Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. i01372254

Fire Prevention and Explosion Prevention SMCS Code: 1000; 7405

i01480768

Burn Prevention SMCS Code: 1000; 7405 Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings or related items are 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 the heaters or to the engine contain hot coolant.

Illustration 9

g00704000

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

SEBU8327

Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage.

A flash fire may result if the covers for the engine crankcase are removed within fifteen minutes after an emergency shutdown.

Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result.

11 Safety Section Fire Prevention and Explosion Prevention

Inspect all lines and hoses for wear or for deterioration. The hoses must be properly routed.

The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.

The filter housings must be tightened to the proper torque.

If the application involves the presence of combustible gases, consult your Caterpillar dealer for additional information about suitable protection devices.

Remove all flammable materials such as fuel, oil, and debris from the engine. Do not allow any flammable materials to accumulate on the engine.

Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly.

Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting.

Illustration 10

g00704059

Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.

Wiring must be kept in good condition. All electrical wires must be properly routed and securely attached.

Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.

Illustration 11

g00704135

12 Safety Section Crushing Prevention and Cutting Prevention

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

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.

Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.

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

The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.

Fire Extinguisher Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

Ether Ether is flammable and poisonous.

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

Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 °F). Keep ether cylinders away from open flames or sparks.

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

Do not spray ether into an engine if the engine is equipped with a thermal starting aid for cold weather starting.

Lines, Tubes and Hoses Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged.

Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Caterpillar dealer for repair or for replacement parts.

SEBU8327

Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.

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

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat. i01359666

Crushing Prevention and Cutting Prevention SMCS Code: 1000; 7405 Support the component properly when work beneath the component is performed.

Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards.

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

When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.

SEBU8327

13 Safety Section Mounting and Dismounting

i01372247

Mounting and Dismounting SMCS Code: 1000; 7405 Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies. i02704618

Before Starting Engine SMCS Code: 1000 NOTICE For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Overspeed shutdown should occur automatically.

If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.

If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped.

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.

See the Service Manual for repairs and for adjustments. i02707603

Engine Starting SMCS Code: 1000

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Start the engine from the operator’s compartment or from the engine start switch.

Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components.

Knowing the procedure will also help to prevent personal injury.

To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge and/or the oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.

14 Safety Section Engine Stopping

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Note: The engine is equipped with a device for cold starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.

These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting. i02707233

Engine Stopping SMCS Code: 1000 Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. This may be accomplished by shutting off the fuel supply to the engine and/or shutting off the air supply to the engine. i02176668

Electrical System SMCS Code: 1000; 1400 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” jump start cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the jump start cable to the engine block.

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions.

Grounding Practices Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.

To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine ground to the frame.

All grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle the full charging current of the alternator.

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15 Product Information Section Model Views

Product Information Section Model Views i02707217

Model View Illustrations SMCS Code: 1000

16 Product Information Section Model Views

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Engine Model Views

g01351713

Illustration 12 Typical example (1) (2) (3) (4)

Pulley Alternator Front Lifting Eye Water Outlet

(5) (6) (7) (8)

Valve Mechanism Cover Rear Lifting Eye Air Intake Secondary Fuel Filter

(9) Fuel Injection Pump (10) Oil Filter (11) Crankshaft Pulley (12) Water Pump

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17 Product Information Section Model Views

Illustration 13

g01352705

(13) (14) (15) (16)

Flywheel Flywheel Housing Oil Filler Cap Exhaust Manifold

(17) (18) (19) (20)

(21) Oil Drain Plug (22) Primary Fuel Filter

Turbocharger Oil Gauge Oil Pan Starting motor

i02708021

• Naturally aspirated

Engine Description

• Turbocharged

SMCS Code: 1000

• Turbocharged aftercooled

The Caterpillar C4.4 engines are available in the following types of aspiration:

18 Product Information Section Model Views

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Engine Specifications Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder.

The engine lubricating oil is supplied by a gear type pump. The engine lubricating oil is cooled and the engine lubricating oil is filtered. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high. Bypass valves can also provide unrestricted flow of lubrication oil to the engine parts if the oil cooler should become plugged or if the oil filter element should become plugged.

Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to proper operation and maintenance recommendations.

Engine performance and efficiency also depend on the use of recommended fuels, lubrication oils, and coolants. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information on maintenance items.

Engine Service Life g00984281

Illustration 14 A typical example of the layout of the valves (A) Inlet valves (B) Exhaust valves Table 1

C-4.4 Industrial Engine Specifications Number of Cylinders

4 In-Line

Bore

105 mm (4.134 inch)

Stroke Aspiration

127 mm (5.0 inch) Naturally aspirated Turbocharged Turbocharged aftercooled

Compression Ratio Displacement

NA 19.3:1 T, TA 18.2:1 4.4 L (268 in 3)

Firing Order Rotation (flywheel end)

1 3 4 2 Counterclockwise

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.45 mm (0.018 inch)

Engine Cooling and Lubrication The cooling system consists of the following components:

• Gear-driven centrifugal water pump • Water temperature regulator which regulates the engine coolant temperature

• Gear-driven oil pump (gear type) • Oil cooler

Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. In addition, use recommended fuels, coolants and lubricants. Use the Operation and Maintenance Manual as a guide for required engine maintenance.

Expected engine life is generally predicted by the average power that is demanded. The average power that is demanded is based on fuel consumption of the engine over a period of time. Reduced hours of operation at full throttle and/or operating at reduced throttle settings result in a lower average power demand. Reduced hours of operation will increase the length of operating time before an engine overhaul is required.

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19 Product Information Section Product Identification Information

Product Identification Information i02711140

Plate Locations and Film Locations SMCS Code: 1000

Illustration 16

g01258789

Serial number plate

i02708605

Reference Numbers SMCS Code: 1000 Information for the following items may be needed to order parts. Locate the information for your engine.

Record the information in the appropriate space.

Make a copy of this list for a record. Keep the information for future reference.

Record for Reference Illustration 15

g01360892

Location of the serial number plate

Serial Number Plate (1) The engine serial number plate is located on the left side of the cylinder block to the rear of the engine.

Caterpiller dealers need all of these numbers in order to determine the components that were included with the engine. This permits accurate identification of replacement part numbers.

Engine Model _______________________________________________ Engine Serial number _____________________________________ Engine Low Idle rpm ______________________________________ Engine Full Load rpm _____________________________________ Primary Fuel Filter _________________________________________ Water Separator Element ________________________________ Secondary Fuel Filter Element __________________________ Lubrication Oil Filter Element ___________________________ Auxiliary Oil Filter Element _______________________________ Total Lubrication System Capacity _____________________ Total Cooling System Capacity _________________________ Air Cleaner Element _______________________________________ Fan Drive Belt ______________________________________________ Alternator Belt ______________________________________________

20 Product Information Section Product Identification Information

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i02711190

Emissions Certification Film SMCS Code: 1000; 7405

Illustration 17 Typical example

g01360989

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21 Product Information Section Product Identification Information

Illustration 18

g01361347

Typical locations of the Emission Certification Film

22 Operation Section Lifting and Storage

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Operation Section

i02068367

Product Storage

Lifting and Storage

SMCS Code: 1000; 1404; 7002

i02708018

Product Lifting SMCS Code: 1000; 1404; 7002

If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder liner surface. Rust on the cylinder liner surface will cause increased engine wear and a reduction in engine service life.

To help prevent excessive engine wear, use the following guidelines:

• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

• If freezing temperatures are expected, check the

cooling system for adequate protection against freezing. See this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

Illustration 19

g00103219

NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.

When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

Some removals require lifting the fixtures in order to obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that are on the engine.

Lifting eyes are designed and installed for the specific engine arrangement. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your Caterpillar dealer for information regarding fixtures for proper engine lifting.

If an engine is out of operation and if use of the engine is not planned, special precautions should be made.

If the engine will be stored for more than one month, a complete protection procedure is recommended.

For more detailed information on engine storage, see Special Instruction, SEHS9031, “Storage Procedure For Caterpillar Products”.

Your Caterpillar dealer can assist in preparing the engine for extended storage periods.

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23 Operation Section Gauges and Indicators

Gauges and Indicators

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks. i02704606

Gauges and Indicators SMCS Code: 1900; 7450 Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the OEM information.

Gauges provide indications of engine performance.

Ensure that the gauges are in good working order.

Determine the normal operating range by observing the gauges over a period of time.

Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications.

Determine and correct the cause of any significant change in the readings. Consult your Caterpillar dealer for assistance.

NOTICE If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.

Engine Oil Pressure – The oil pressure should be greatest after a cold engine is started. The typical engine oil pressure with SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated rpm.

A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure: 1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature – Typical temperature range is 71 to 96°C (160 to 205°F). The maximum allowable temperature with the pressurized cooling system at 48 kPa (7 psi) is 103°C (217°F). Higher temperatures may occur under certain conditions. The water temperature reading may vary according to load. The reading should never exceed the boiling point for the pressurized system that is being used.

If the engine is operating above the normal range and steam becomes apparent, perform the following procedure:

3. Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load.

Tachometer – This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load.

NOTICE To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at high idle without damage, but should never be allowed to exceed high idle rpm.

Note: The high idle rpm and the full load rpm are stamped on the Information Plate.

Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the indicator should be to the right side of “0”(zero).

Fuel Level – This gauge indicates the fuel level in the fuel tank. The electrically operated fuel level gauge only operates when the “START/STOP” switch is “ON”.

Service Hour Meter – This gauge indicates operating time of the engine.

24 Operation Section Features and Controls

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Features and Controls

Engines may be equipped with alarms in order to alert the operator when undesirable operating conditions occur. i02704608

Engine Shutoffs and Engine Alarms SMCS Code: 1900; 7400; 7418

Shutoffs Shutoffs and alarms are electrically operated or mechanically operated. The operation of all electric shutoffs and alarms utilize components which actuate switches in a sensing unit.

Shutoffs are set at critical levels for the following items: operating temperature, operating pressure, operating level, and operating rpm. The particular shutoff may need to be reset before the engine will start.

NOTICE Always determine the cause of the engine shutdown.

Make necessary repairs before attempting to restart the engine.

Be familiar with the following items:

• Types and locations of shutoff • Conditions which cause each shutoff to function

NOTICE When an alarm is activated, corrective measures must be taken before the situation becomes an emergency in order to avoid possible engine damage.

If corrective measures are not taken within a reasonable time, engine damage could result. The alarm will continue until the condition is corrected.

The alarm may need to be reset.

A switch may be installed in the alarm while the engine is stopped for repairs. Before the engine is started, ensure that the switch is moved to the ON position and that the warning lights are flashing. The engine will not be protected if the switch is left in the OFF position.

Testing the Shutoff and Alarm System Most control panels are equipped with a lamp test switch. Turn the switch to the ON position in order to check the indicator lights for proper operation.

Replace worn bulbs immediately.

NOTICE During testing, abnormal operating conditions must be simulated. Perform the tests correctly in order to help prevent possible engine damage.

• The resetting procedure that is required to restart the engine

Alarms Alarms consist of a switch and a contactor. The switches are wired to the contactors. The contactors activate alarm circuits in an annunciator panel. Your engine may be equipped with the following switches: Engine oil pressure – The engine oil pressure switch indicates when oil pressure drops below rated system pressure.

Coolant level – The low coolant level switch indicates when the coolant level is low.

Coolant temperature – The coolant temperature switch indicates high jacket water coolant temperature.

Note: The sensing element of the coolant temperature switch must be submerged in coolant in order to operate.

Refer to the Service Manual for more information on testing procedures or consult your Caterpillar dealer. i02704607

Fuel Shutoff SMCS Code: 1259; 1704 The fuel shutoff solenoid is located on the fuel injection pump.

When the fuel shutoff solenoid is activated, the solenoid moves to the “Open” position.

When the fuel shutoff solenoid is deactivated, the solenoid moves to the “Closed” position.

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25 Operation Section Engine Starting

Engine Starting

• Do not start the engine or move any of the controls i02704617

Before Starting Engine SMCS Code: 1000; 1400; 1450 Perform the required daily maintenance and other periodic maintenance before the engine is started.

Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information.

• For the maximum service life of the engine, make

a thorough inspection before the engine is started.

Look for the following items: oil leaks, coolant leaks, loose bolts, and trash buildup. Remove trash buildup and arrange for repairs, as needed.

• Inspect the cooling system hoses for cracks and for loose clamps.

• Inspect the alternator and accessory drive belts for cracks, breaks, and other damage.

• Inspect the wiring for loose connections and for worn wires or frayed wires.

• Check the fuel supply. Drain water from the water

separator (if equipped). Open the fuel supply valve (if equipped).

NOTICE All valves in the fuel return line must be open before and during engine operation to help prevent high fuel pressure. High fuel pressure may cause filter housing failure or other damage.

If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have entered the filter housing. Also, when fuel filters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on priming the fuel system.

Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.

if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.

• Ensure that the areas around the rotating parts are clear.

• All of the guards must be put in place. Check for damaged guards or for missing guards. Repair any damaged guards. Replace damaged guards and/or missing guards.

• Disconnect any battery chargers that are not

protected against the high current drain that is created when the electric starting motor (if equipped) is engaged. Check electrical cables and check the battery for poor connections and for corrosion.

• Reset all of the shutoffs or alarm components (if equipped).

• Check the engine lubrication oil level. Maintain the oil level between the “MIN” mark and the “MAX” mark on the oil level gauge.

• Check the coolant level. Observe the coolant level

in the coolant recovery tank (if equipped). Maintain the coolant level to the “FULL” mark on the coolant recovery tank.

• If the engine is not equipped with a coolant

recovery tank maintain the coolant level within 13 mm (0.5 inch) of the bottom of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant level in the sight glass.

• Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the yellow diaphragm enters the red zone, or when the red piston locks in the visible position.

• Ensure that any driven equipment has been

disengaged. Minimize electrical loads or remove any electrical loads.

26 Operation Section Engine Starting

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i02710653

Starting the Engine SMCS Code: 1000; 1450

When Group 2 diesel fuel is used, the following items provide a means of minimizing starting problems and fuel problems in cold weather: engine oil pan heaters, jacket water heaters, fuel heaters, and fuel line insulation.

Use the procedure that follows for cold weather starting.

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

Refer to the OMM for your type of controls. Use the following procedure to start the engine.

1. If equipped, move the throttle lever to the full throttle position before you start the engine.

NOTICE Do not crank the engine for more than 30 seconds.

Allow the electric starting motor to cool for two minutes before cranking the engine again.

2. Turn the engine start switch to the START position.

Hold the engine start switch in the START position and crank the engine.

3. When the engine starts, release the engine start switch.

4. If equipped, slowly move the throttle lever to the low idle position and allow the engine to idle. Refer to the Operation and Maintenance Manual, “After Starting Engine” topic.

1. If equipped, move the throttle lever to the full throttle position before you start the engine.

2. If equipped, turn the engine start switch to the HEAT position. Hold the engine start switch in the HEAT position for 6 seconds until the glow plug indicator light illuminates. This will activate the glow plugs and aid in the starting of the engine.

NOTICE Do not crank the engine for more than 30 seconds.

Allow the electric starting motor to cool for two minutes before cranking the engine again.

3. While the glow plug indicator light is illuminated, turn the engine start switch to the START position and crank the engine.

Note: If the glow plug indicator light illuminates rapidly for 2 to 3 seconds, or if the glow plug indicator light fails to illuminate, a malfunction exists in the cold start system. Do not use ether or other starting fluids to start the engine.

4. When the engine starts, release the engine start switch key.

5. If the engine does not start, release the engine start switch and allow the electric starting motor to cool. Then, repeat steps 2 through step 4.

5. If the engine does not start, release the engine start switch and allow the starting motor to cool.

Then, repeat steps 2 through step 4.

6. Turn the engine start switch to the OFF position in order to stop the engine.

6. If the engine is equipped with a throttle allow the engine to idle for three to five minutes, or allow the engine to idle until the water temperature indicator begins to rise. The engine should run at low idle smoothly until speed is gradually increased to high idle. Allow the white smoke to disperse before proceeding with normal operation.

i02710719

Cold Weather Starting SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

Startability will be improved at temperatures below −18 °C (0 °F) from the use of a jacket water heater or extra battery capacity.

7. Operate the engine at low load until all systems reach operating temperature. Check the gauges during the warm-up period.

8. Turn the engine start switch to the OFF position in order to stop the engine.

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27 Operation Section Engine Starting

i02344933

Starting with Jump Start Cables SMCS Code: 1000; 1401; 1402; 1900

Improper jump start cable connections can cause an explosion resulting in personal injury.

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

If the installation is not equipped with a backup battery system, it may be necessary to start the engine from an external electrical source.

For information on troubleshooting the charging system, refer to Special Instruction, REHS0354, “Charging System Troubleshooting”.

Many batteries which are considered unusable are still rechargeable. After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. The batteries must be charged to the proper voltage with a battery charger.

For information on testing and charging, refer to the Special Instruction, SEHS7633, “Battery Test Procedure”.

NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system.

Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove first.

When using an external electrical source to start the engine, turn the generator set control switch to the “OFF” position. Turn all electrical accessories OFF before attaching the jump start cables.

Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started.

1. Turn the start switch on the stalled engine to the OFF position. Turn off all the engine’s accessories.

2. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.

3. Connect one negative end of the jump start cable to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cable to the engine block or to the chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that are produced by some batteries.

4. Start the engine.

5. Immediately after the engine is started, disconnect the jump start cables in reverse order.

After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged.

The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”.

Refer to the Electrical Schematic for your engine.

Consult your Caterpillar dealer for more information. i02710753

After Starting Engine SMCS Code: 1000 Note: In temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately three minutes. In temperatures below 0°C (32°F), additional warm-up time may be required.

When the engine idles during warm-up, observe the following conditions:

• Check for any fluid or for any air leaks at idle rpm

and at one-half full rpm (no load on the engine) before operating the engine under load. This is not possible in some applications.

• Operate the engine at low idle until all systems

achieve operating temperatures. Check all gauges during the warm-up period.

Note: Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated.

28 Operation Section Engine Operation

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Engine Operation

i01646335

i02708025

Engine Operation

Engaging the Driven Equipment SMCS Code: 1000

SMCS Code: 1000 Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be minimized and engine service life can be maximized.

The time that is needed for the engine to reach normal operating temperature can be less than the time taken for a walk-around inspection of the engine.

The engine can be operated at the rated rpm after the engine is started and after the engine reaches operating temperature. The engine will reach normal operating temperature sooner during a low engine speed (rpm) and during a low power demand. This procedure is more effective than idling the engine at no load. The engine should reach operating temperature in a few minutes.

Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge.

Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated. i02707215

Engine Warm-up SMCS Code: 1000 1. Run the engine at low idle for three to five minutes, or run the engine at low idle until the jacket water coolant temperature starts to rise.

More time may be necessary when the temperature is below −18°C (0°F).

2. Check all of the gauges during the warm-up period.

3. Perform a walk-around inspection. Check the engine for fluid leaks and air leaks.

4. Increase the rpm to the rated rpm. Check for fluid leaks and air leaks. The engine may be operated at full rated rpm and at full load when the temperature of the water jacket reaches 60°C (140°F).

1. Operate the engine at one-half of the rated rpm, when possible.

2. Engage the driven equipment without a load on the equipment, when possible.

Interrupted starts put excessive stress on the drive train. Interrupted starts also waste fuel. To get the driven equipment in motion, engage the clutch smoothly with no load on the equipment. This method should produce a start that is smooth and easy. The engine rpm should not increase and the clutch should not slip.

3. Ensure that the ranges of the gauges are normal when the engine is operating at one-half of the rated rpm. Ensure that all gauges operate properly.

4. Increase the engine rpm to the rated rpm. Always increase the engine rpm to the rated rpm before the load is applied.

5. Apply the load. Begin operating the engine at low load. Check the gauges and equipment for proper operation. After normal oil pressure is reached and the temperature gauge begins to move, the engine may be operated at full load. Check the gauges and equipment frequently when the engine is operated under load.

Extended operation at low idle or at reduced load may cause increased oil consumption and carbon buildup in the cylinders. This carbon buildup results in a loss of power and/or poor performance.

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i02707216

Fuel Conservation Practices SMCS Code: 1000; 1250 The efficiency of the engine can affect the fuel economy. Caterpillar’s design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed.

• Be aware of the properties of the different fuels.

Use only the recommended fuels. Refer to the Operations and Maintenance Manual, “Fuel Recommendations”for further information.

• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods of time.

• Observe the service indicator frequently. Keep the air cleaner elements clean.

• Ensure that the turbocharger is operating correctly

so that the proper air/fuel ratio is maintained. Clean exhaust indicates proper functioning.

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator.

This will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. The belts should be in good condition. Refer to the Specifications manual for further information.

• Ensure that all of the connections of the hoses are tight. The connections should not leak.

• Ensure that the driven equipment is in good working order.

• Cold engines consume excess fuel. Utilize heat from the jacket water system and the exhaust system, when possible. Keep cooling system components clean and keep cooling system components in good repair. Never operate the engine without water temperature regulators.

All of these items will help maintain operating temperatures.

30 Operation Section Engine Stopping

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Engine Stopping

i02704619

After Stopping Engine i02710650

Stopping the Engine

SMCS Code: 1000 Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan.

SMCS Code: 1000; 7000 NOTICE Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components.

If the engine has been operating at high rpm and/or high loads, run at low idle for at least three minutes to reduce and stabilize internal engine temperature before stopping the engine.

Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.

Prior to stopping an engine that is being operated at low loads, operate the engine at low idle for 30 seconds before stopping. If the engine has been operating at highway speeds and/or at high loads, operate the engine at low idle for at least three minutes. This procedure will cause the internal engine temperature to be reduced and stabilized.

Ensure that the engine stopping procedure is understood. Stop the engine according to the shutoff system on the engine or refer to the instructions that are provided by the OEM.

• To stop the engine, turn the keyswitch to the OFF position.

• Check the crankcase oil level. Maintain the oil level between the “MIN” mark and the “MAX” mark on the oil level dipstick.

• If necessary, perform minor adjustments. Repair any leaks and tighten any loose bolts.

• Note the required service interval. Perform

the maintenance that is in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

• Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not overfill the fuel tank.

NOTICE Only use antifreeze/coolant mixtures recommended in the Refill Capacities and Recommendations topic that is in this Operation and Maintenance Manual. Failure to do so can cause engine damage.

• Allow the engine to cool. Check the coolant level.

• If freezing temperatures are expected, check the

coolant for the correct antifreeze protection. The cooling system must be protected against freezing to the lowest expected outside temperature. Add the correct coolant/water mixture, if necessary.

i01903586

Emergency Stopping SMCS Code: 1000; 7418 NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

The OEM may have equipped the application with an emergency stop button. For more information about the emergency stop button, refer to the OEM information.

Ensure that any components for the external system that support the engine operation are secured after the engine is stopped.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in the instructions from the OEM.

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31 Operation Section Cold Weather Operation

Cold Weather Operation i02708046

Radiator Restrictions SMCS Code: 1353; 1396 Caterpillar discourages the use of air flow restriction devices that are mounted in front of radiators. Air flow restriction can cause the following conditions:

• Special Fuels Caterpillar prefer only Group 1 and Group 2 fuels for use in this series of engines.

Group 1 fuels are the preferred Group of Fuels for general use by Caterpillar. Group 1 fuels maximize engine life and engine performance. Group 1 fuels are usually less available than Group 2 fuels.

Frequently, Group 1 fuels are not available in colder climates during the winter.

Note: Group 2 fuels must have a maximum wear scar of 650 micrometers (HFRR to ISO 12156-1).

• High exhaust temperatures • Power loss

Group 2 fuels are considered acceptable for issues of warranty. This group of fuels may reduce the life of the engine, the engine’s maximum power, and the engine’s fuel efficiency.

• Excessive fan usage • Reduction in fuel economy If an air flow restriction device must be used, the device should have a permanent opening directly in line with the fan hub. The device must have a minimum opening dimension of at least 770 cm2 (120 in2).

A centered opening that is directly in line with the fan hub is specified in order to prevent an interrupted air flow on the fan blades. Interrupted air flow on the fan blades could cause a fan failure.

Caterpillar recommends a warning device for the inlet manifold temperature and/or the installation of an inlet air temperature gauge. The warning device for the inlet manifold temperature should be set at 75 °C (167 °F). The inlet manifold air temperature should not exceed 75 °C (167 °F). Temperatures that exceed this limit can cause power loss and potential engine damage. i02704604

When Group 2 diesel fuels are used the following components provide a means of minimizing problems in cold weather:

• Glow plugs (if equipped) • Engine coolant heaters, which may be an OEM option

• Fuel heaters, which may be an OEM option • Fuel line insulation, which may be an OEM option There are three major differences between Group 1 fuels and Group 2 fuels. Group 1 fuels have the following different characteristics to Group 2 fuels.

• A lower cloud point • A lower pour point • A higher energy per unit volume of fuel

Fuel and the Effect from Cold Weather

Note: Group 3 fuels reduce the life of the engine. The use of Group 3 fuels is not covered by the Caterpillar warranty.

SMCS Code: 1000; 1250

Group 3 fuels include Low Temperature Fuels and Aviation Kerosene Fuels.

Note: Only use grades of fuel that are recommended

by Caterpillar. Refer to this Operation and Maintenance Manual, “Fluid Recommendations”.

The following fuels can be used in this series of engine.

• Group 1 • Group 2 • Group 3

Special fuels include Biofuel.

The cloud point is a temperature that allows wax crystals to form in the fuel. These crystals can cause the fuel filters to plug.

The pour point is the temperature when diesel fuel will thicken. The diesel fuel becomes more resistant to flow through fuel lines, fuel filters,and fuel pumps.

32 Operation Section Cold Weather Operation

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Be aware of these facts when diesel fuel is purchased. Consider the average ambient air temperature for the engine’s application. Engines that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result due to changes in temperature.

Before troubleshooting for low power or for poor performance in the winter, check the fuel for waxing.

Low temperature fuels may be available for engine operation at temperatures below 0 °C (32 °F). These fuels limit the formation of wax in the fuel at low temperatures.

For more information on cold weather operation, refer to the Operation and Maintenance Manual, “Cold Weather Operation and Fuel Related Components in Cold Weather”. i02705983

Fuel Related Components in Cold Weather SMCS Code: 1000; 1250

Fuel Tanks Condensation can form in partially filled fuel tanks.

Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.

Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe.

Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important.

Drain the water and sediment from any fuel storage tank at the following intervals: weekly, oil changes, and refueling of the fuel tank. This will help prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank.

Fuel Filters It is possible that a primary fuel filter is installed between the fuel tank and the engine fuel inlet. After you change the fuel filter, always prime the fuel system in order to remove air bubbles from the fuel system. Refer to the Operation and Maintenance Manual in the Maintenance Section for more information on priming the fuel system.

The micron rating and the location of a primary fuel filter is important in cold weather operation. The primary fuel filter and the fuel supply line are the most common components that are affected by cold fuel.

Fuel Heaters Fuel heaters help to prevent fuel filters from plugging in cold weather due to waxing. A fuel heater should be installed in the fuel system before the primary fuel filter.

The following fuel heaters are recommended for Caterpillar engines:

• 7C-3557 Fuel Heater Group • 7C-3558 Heater Kit For further information on fuel heaters, consult your Caterpillar dealer.

Disconnect the fuel heater in warm weather.

Note: Fuel heaters that are controlled by the water temperature regulator or self-regulating fuel heaters should be used with this engine. Fuel heaters that are not controlled by the water temperature regulator can heat the fuel in excess of 65°C (149°F). A loss of engine power can occur if the fuel supply temperature exceeds 37°C (100°F).

Note: Heat exchanger type fuel heaters should have a bypass provision in order to prevent overheating of the fuel in warm weather operation.

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33 Maintenance Section Refill Capacities

Maintenance Section

Table 2

API Classifications

Refill Capacities

Obsolete

CH-4(1) CI-4

CE, CC, CD

-

i02501519

Refill Capacities and Recommendations

Current

CD-2

(2)

(1)

API CH-4 and CI-4 oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification-1) are met. CH-4 and CI-4 oils that have not met the requirements of Caterpillar’s ECF-1 Specification may cause reduced engine life.

(2) The oil CD-2 is for a two-cycle diesel engine. Caterpillar does not sell engines that utilize CD-2 oil.

SMCS Code: 1348; 1395; 7560

Engine Oil NOTICE These recommendations are subject to change without notice. Contact your local Caterpillar dealer for the most up to date recommendations.

API Oils

Note: When oil meets more than one API classification, the applicable footnote is determined by the highest API classification that is met.

Example – An oil meets both the API CH-4 and the API CF oil classifications. In this case, the API CH-4 applies.

Cat DEO (Diesel Engine Oil)

The Engine Oil Licensing and Certification System by the American Petroleum Institute (API) is recognized

by Caterpillar. For detailed information about this system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized by API.

Caterpillar Oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Caterpillar Engines. Caterpillar Oils are currently used to fill diesel engines at the factory. These oils are offered

by Caterpillar dealers for continued use when the engine oil is changed. Consult your Caterpillar dealer for more information on these oils.

Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations:

• Cat DEO (Diesel Engine Oil) (10W-30) • Cat DEO (Diesel Engine Oil) (15W-40)

Illustration 20

g00546535

Typical API symbol

Diesel engine oils CC, CD, CD-2, and CE have not been API authorized classifications since 1 January 1996.

Caterpillar multigrade DEO is formulated with the correct amounts of detergents, dispersants, and alkalinity in order to provide superior performance in Caterpillar Diesel Engines.

Caterpillar multigrade DEO is available in various viscosity grades that include SAE 10W-30 and SAE 15W-40. To choose the correct viscosity grade for the ambient temperature, see Table 3. Multigrade oils provide the correct viscosity for a broad range of operating temperatures.

Multigrade oils are effective in maintaining low oil consumption and low levels of piston deposits.

34 Maintenance Section Refill Capacities

Caterpillar multigrade DEO can be used in other diesel engines and in gasoline engines. See the engine manufacturer’s guide for the recommended specifications. Compare the specifications to the specifications of Caterpillar multigrade DEO. The current industry standards for Caterpillar DEO are listed on the product label and on the data sheets for the product.

Consult your Caterpillar dealer for part numbers and for available sizes of containers.

Note: Caterpillar SAE 15W-40 multigrade DEO exceeds the performance requirements for the following API classifications: CI-4, CH-4, CG-4, CF-4, and CF. The Caterpillar multigrade DEO exceeds the requirements of the Caterpillar specification that is ECF-1 (Engine Crankcase Fluid-1). The Caterpillar SAE 15W-40 multigrade DEO passes the following proprietary tests: sticking of the piston ring, oil control tests, wear tests, and soot tests. Proprietary tests help ensure that Caterpillar multigrade oil provides superior performance in Caterpillar Diesel Engines.

In addition, Caterpillar multigrade oil exceeds many of the performance requirements of other manufacturers of diesel engines. Therefore, this oil is an excellent choice for many mixed fleets. True high performance oil is produced with a combination of the following factors: industry standard tests, proprietary tests, field tests, and prior experience with similar formulations. The design and the development of Caterpillar lubricants that are both high performance and high quality are based on these factors.

Note: Non-Caterpillar commercial oils are second choice oils.

Commercial Oils Note: If Caterpillar Multigrade DEO is not used, use only commercial oils that meet the following classifications.

• API CH-4 multigrade oils and API CI-4 multigrade

oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification-1) are met. CH-4 oils and CI-4 oils that have not met the requirements of Caterpillar’s ECF-1 Specification may cause reduced engine life.

• API CF-4 multigrade oils are not recommended for this series of diesel engines. For all other smaller commercial diesel engines, the oil drain interval should not exceed 50 percent of the standard oil drain interval for your engine.

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NOTICE In selecting oil for any engine application, both the oil viscosity and oil performance classification/specification as specified by the engine manufacturer must be defined and satisfied. Using only one of these parameters will not sufficiently define oil for an engine application.

In order to make the proper choice of a commercial oil, refer to the following explanations: API CI-4 – API CI-4 oils were developed in order to meet the requirements of high performance diesel engines that use cooled Exhaust Gas Recirculation (EGR). API CI-4 oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification-1) are met.

API CH-4 – API CH-4 oils were developed in order to protect low emissions diesel engines that use a 0.05 percent level of fuel sulfur. However, API CH-4 oils may be used with higher sulfur fuels. API CH-4 oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification-1) are met.

Note: CH-4 oils and CI-4 oils that have not met the requirements of Caterpillar’s ECF-1 Specification may cause reduced engine life.

NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.

Note: Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for additional information that relates to lubrication for your engine.

Lubricant Viscosity Recommendations The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.

Refer to Table 3 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Refer to Table 3 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.

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35 Maintenance Section Refill Capacities

If ambient temperature conditions at engine start-up require the use of multigrade SAE 0W oil, SAE 0W-40 viscosity grade is preferred over SAE 0W-20 or SAE 0W-30.

Table 3

Engine Oil Viscosities for Ambient Temperatures Ambient Temperature Viscosity Grade

Minimum

Maximum

SAE 0W-20

−40 °C (−40 °F)

10 °C (50 °F)

SAE 0W-30

−40 °C (−40 °F)

30 °C (86 °F)

SAE 0W-40

−40 °C (−40 °F)

40 °C (104 °F)

SAE 5W-30

−30 °C (−22 °F)

30 °C (86 °F)

SAE 5W-40

−30 °C (−22 °F)

50 °C (122 °F)

SAE 10W-30

−18 °C (0 °F)

40 °C (104 °F)

SAE 10W-40

−18 °C (0 °F)

50 °C (122 °F)

SAE 15W-40

−9.5 °C (15 °F)

50 °C (122 °F)

Note: Supplemental heat is recommended below the minimum recommended ambient temperature.

S·O·S Oil Analysis Caterpillar has developed a tool for maintenance management that evaluates oil degradation and the tool also detects the early signs of wear on internal components. The Caterpillar tool for oil analysis is called S·O·S Oil Analysis and the tool is part of the S·O·S Services program. S·O·S Oil Analysis divides oil analysis into three categories:

• Wear Analysis • Oil condition • Additional tests The wear analysis monitors metal particles, some oil additives, and some contaminants.

Oil condition uses infrared (IR) analysis to evaluate the chemistry of the oil. Infrared analysis is also used to detect certain types of contamination.

Additional tests are used to measure contamination levels from water, fuel, or coolant. Oil viscosity and corrosion protection can be evaluated, as needed.

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” or contact your local Caterpillar dealer for additional information concerning the S·O·S Oil Analysis program.

Refill Capacities for the Lubrication System The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter.

Table 4

Engine Refill Capacities Compartment or System Crankcase Oil Sump(1) (1)

Minimum

Maximum

5 L (5.2834 qt)

7 L (7.3968 qt)

These values are the approximate capacities for the crankcase oil sump (aluminum) which includes the standard factory installed oil filters. Engines with auxiliary oil filters will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter.

Lubricating Grease Caterpillar provides a range of moderate greases to extremely high performance greases in order to service the entire line of Caterpillar products that operate throughout the wide variety of climates.

From this variety of Caterpillar grease products, you will find at least one of the Caterpillar greases that will satisfy the performance requirements for any machine or equipment application.

Before selecting a grease for any application, the performance requirements must be determined.

Consult the grease recommendations that are made by the OEM for the equipment when the equipment is operated in the expected conditions. Then, consult with your Caterpillar dealer for a list of greases and the following related characteristics.

• Performance specifications • Available sizes of containers • Part numbers Always choose a grease that satisfies the recommendations that are specified by the equipment manufacturer for the application.

Note: If it is necessary to choose a single grease to use for all of the equipment at one site, always choose a grease that satisfies the requirements of the most demanding application.

Do not use the cost per pound as the only factor when you choose a grease. Use the grease that yields the lowest total cost of operation. The cost analysis should include the following factors:

36 Maintenance Section Refill Capacities

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• Parts

General Coolant Information

• Labor

NOTICE These recommendations are subject to change without notice. Contact your local Caterpillar dealer for the most up to date fluids recommendations.

• Downtime • Cost of the grease Greases that barely meet the minimum performance requirements can be expected to barely produce the minimum life of the parts.

Note: Take care when you change the type of grease.

Take care when you change to a different supplier of grease. Some greases are not chemically compatible.

Some brands of grease can not be interchanged. If you are in doubt about the compatibility of the old grease and the new grease, purge all of the old grease from the joint. Consult your supplier in order to determine if the greases are compatible.

Note: All Caterpillar brand of greases are compatible with each other.

Note: Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for additional information that relates to lubrication for your engine.

General Fuel Information Diesel fuels that meet the Caterpillar Specification for Distillate Diesel Fuel are recommended. These fuels will help to provide maximum engine service life and performance. In North America, diesel fuel that is identified as No. 1-D or No. 2-D in “ASTM D975” generally meet the specifications. Diesel fuels from other sources could exhibit detrimental properties that are not defined or controlled by this specification.

NOTICE Operating with fuels that do not meet Caterpillar’s recommendations can cause the following effects: starting difficulty, poor combustion, deposits in the fuel injectors, reduced service life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine.

Note: Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for the Caterpillar Specification for distillate fuel and for additional information that relates to fuel for your engine.

Refill Capacities for the Fuel System Refer to the Operation and Maintenance Manual that is provided by the OEM for capacities of the fuel system.

NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first.

NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely to prevent damage.

NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

• Contamination of the cooling system • Overheating of the engine • Foaming of the coolant Note: Air pockets can form in the cooling system if the cooling system is filled at a rate that is greater than 5 L (1.3 US gal) per minute.

After you drain the cooling system and after you refill the cooling system, operate the engine. Operate the engine without the filler cap until the coolant reaches normal operating temperature and the coolant level stabilizes. Ensure that the coolant is maintained to the proper level.

NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators.

Refer to Special Instruction, SEBD0518, “Know Your Cooling System” and Special Instruction, SEBD0970, “Coolant and Your Engine” for more detailed information.

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37 Maintenance Section Refill Capacities

Many engine failures are related to the cooling system. The following problems are related to cooling system failures: overheating, leakage of the water pump, plugged radiators or heat exchangers, and pitting of the cylinder liners.

• Agricultural agent

These failures can be avoided with proper cooling system maintenance. Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system. Quality of the coolant is as important as the quality of the fuel and the lubricating oil.

Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufficient amounts of additives enable the following conditions to occur:

Coolant is normally composed of three elements: water, additives, and glycol.

• Formation of mineral deposits

• Independent laboratory Additives

• Corrosion

• Rust

Water

• Scale

NOTICE Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water alone is corrosive at engine operating temperatures.

Water alone does not provide adequate protection against boiling or freezing.

Water is used in the cooling system in order to transfer heat.

Distilled water or deionized water is recommended for use in engine cooling systems.

• Pitting and erosion from cavitation of the cylinder liner

• Foaming of the coolant Many additives are depleted during engine operation.

These additives must be replaced periodically.

This can be done by adding Supplemental Coolant Additives (SCA) to Diesel Engine Antifreeze/Coolant (DEAC) or by adding ELC Extender to Extended Life Coolant (ELC).

DO NOT use the following types of water in cooling systems: hard water, softened water that has been conditioned with salt, and sea water.

Additives must be added at the proper concentration.

Overconcentration of additives can cause the inhibitors to drop out-of-solution. The deposits can enable the following problems to occur:

If distilled water or deionized water is not available, use water with the properties that are listed in Table 5.

• Formation of gel compounds • Reduction of heat transfer

Table 5

Caterpillar Minimum Acceptable Water Requirements

• Leakage of the water pump seal

Property

Maximum Limit

ASTM Test

Chloride (Cl)

40 mg/L (2.4 grains/US gal)

“D512”, “D4327”

Sulfate (SO4)

100 mg/L (5.9 grains/US gal)

“D516”

Total Hardness

170 mg/L (10 grains/US gal)

“D1126”

Total Solids

340 mg/L (20 grain/US gal)

“D1888”

• Freezing

Acidity

pH of 5.5 to 9.0

“D1293”

• Cavitation of the water pump and the cylinder liner

• Plugging of radiators, coolers, and small passages Glycol Glycol in the coolant helps to provide protection against the following conditions:

• Boiling

For a water analysis, consult one of the following sources:

For optimum performance, Caterpillar recommends a 1:1 mixture of a water/glycol solution.

• Caterpillar dealer

Note: Use a mixture that will provide protection against the lowest ambient temperature.

• Local water utility company

38 Maintenance Section Refill Capacities

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Note: 100 percent pure glycol will freeze at a temperature of −23 °C (−9 °F).

Most conventional heavy-duty antifreezes use ethylene glycol. Propylene glycol may also be used.

In a 1:1 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boiling. See Tables 6 and 7.

Table 6

Ethylene Glycol Concentration

Freeze Protection

Boil Protection

50 Percent

−36 °C (−33 °F)

106 °C (223 °F)

60 Percent

−51 °C (−60 °F)

111 °C (232 °F)

Caterpillar recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a antifreeze.

Note: Caterpillar DEAC does not require a treatment with an SCA at the initial fill. A commercial heavy-duty antifreeze that meets “ASTM D4985” or “ASTM D6210” specifications MAY require a treatment with an SCA at the initial fill. These coolants WILL require a treatment with an SCA on a maintenance basis.

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for additional information that relates to coolant.

S·O·S Coolant Analysis Table 8

NOTICE Do not use propylene glycol in concentrations that exceed 50 percent glycol because of propylene glycol’s reduced heat transfer capability. Use ethylene glycol in conditions that require additional protection against boiling or freezing.

Recommended Interval Type of Coolant

Level 1

Level 2

DEAC

Every 250 Hours

Yearly(1)

ELC

Not Required

Yearly

(1)

Table 7

Propylene Glycol

The Level 2 Coolant Analysis should be performed sooner if a problem is identified by a Level 1 Coolant Analysis.

S·O·S Coolant Analysis (Level 1)

Concentration

Freeze Protection

Anti-Boil Protection

50 Percent

−29 °C (−20 °F)

106 °C (223 °F)

A coolant analysis (Level 1) is a test of the properties of the coolant.

The following properties of the coolant are tested:

To check the concentration of glycol, use the 1U-7298 Coolant/Battery Tester (Degrees Celsius) or use the 1U-7297 Coolant/Battery Tester (Degrees Fahrenheit). The testers give readings that are immediate and accurate. The testers can be used with ethylene or propylene glycol.

Coolant Recommendations NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 specification. This type of coolant/antifreeze is made for light duty automotive applications.

The following two coolants are used in Caterpillar diesel engines: Preferred – Caterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that meets the Caterpillar EC-1 specification Acceptable – Caterpillar Diesel Engine Antifreeze (DEAC) or a commercial heavy-duty antifreeze that meets “ASTM D4985”, or “ASTM D6210” specifications

• Glycol concentration for freeze protection and boil protection

• Ability to protect from erosion and corrosion • pH • Conductivity • Visual analysis • Odor analysis The results are reported, and appropriate recommendations are made.

Refer to the Maintenance Interval Schedule in this Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” for a sampling location and the maintenance interval for collecting the coolant samples.

S·O·S Coolant Analysis (Level 2)

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A coolant analysis (Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system.

The S·O·S Coolant Analysis has the following features:

• Full coolant analysis (Level 1) • Identification of the source of metal corrosion and of contaminants

• Water hardness • Identification of buildup of the impurities that cause corrosion

• Identification of buildup of the impurities that cause scaling

The results are reported, and appropriate recommendations are made.

Refer to the Maintenance Interval Schedule in this Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 2) - Obtain” for a sampling location and the maintenance interval for collecting the coolant samples.

Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and from corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and from freezing. The S·O·S Coolant Analysis can be done at your Caterpillar dealer. Caterpillar S·O·S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system.

S·O·S Coolant Analysis is a program that is based on periodic samples.

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for additional information.

Refill Capacity of the Cooling System To maintain the cooling system, the Total Cooling System capacity must be known. The approximate capacity for the “Engine Only” cooling system is listed. External System capacities will vary among applications. Refer to the OEM specifications for the External System capacity. This capacity information will be needed in order to determine the amount of antifreeze that is required for the Total Cooling System.

39 Maintenance Section Refill Capacities

Table 9

Engine Refill Capacities Compartment or System Engine Only External System Per (1)

Liters 7 L (7.3968 qt)

OEM(1)

The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specifications. Enter the value for the capacity of the External System in this row.

40 Maintenance Section Maintenance Interval Schedule

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i02711636

Every 1000 Service Hours

Maintenance Interval Schedule

Engine Valve Lash - Inspect/Adjust ...................... 59

SMCS Code: 1000; 7500

Every 2000 Service Hours

When Required

Alternator - Inspect ...............................................

Starting Motor - Inspect ........................................

Turbocharger - Inspect ..........................................

Water Pump - Inspect ...........................................

Battery - Replace ..................................................

Battery or Battery Cable - Disconnect ..................

Engine - Clean ......................................................

Engine Air Cleaner Element (Dual Element) Clean/Replace ....................................................

Engine Air Cleaner Element (Single Element) Inspect/Replace ..................................................

Fuel System - Prime .............................................

Severe Service Application - Check .....................

41 42 51 51 54 60 68

Daily Alternator Belt - Inspect/Adjust/Replace ...............

Cooling System Coolant Level - Check ................

Driven Equipment - Check ....................................

Engine Air Cleaner Service Indicator - Inspect .....

Engine Air Precleaner - Check/Clean ...................

Engine Oil Level - Check ......................................

Fuel System Primary Filter/Water Separator Drain ...................................................................

V-Belts - Inspect/Adjust/Replace ..........................

Walk-Around Inspection ........................................

41 46 50 54 55 55 61 70 71

Every 2000 Service Hours or 1 Year Engine Mounts - Inspect ....................................... 55

Every Year Cooling System Coolant Sample (Level 2) Obtain ................................................................. 48

Every 3000 Service Hours Alternator Belt - Inspect/Adjust/Replace ............... 41 Fuel Injection Nozzles - Test/Exchange ................ 59

Every 3000 Service Hours or 2 Years Cooling System Coolant (DEAC) - Change .......... 43 Cooling System Water Temperature Regulator Replace ............................................................... 49

Every 12 000 Service Hours or 6 Years

Every 50 Service Hours or Weekly Fuel Tank Water and Sediment - Drain ................. 63

Cooling System Coolant (ELC) - Change ............. 45

Overhaul

Every 250 Service Hours Cooling System Coolant Sample (Level 1) Obtain ................................................................. 47 Engine Oil Sample - Obtain .................................. 56

Every 500 Service Hours V-Belts - Inspect/Adjust/Replace .......................... 70

Every 500 Service Hours or 6 Months Engine Protective Devices - Check ...................... 58

Every 500 Service Hours or 1 Year Battery Electrolyte Level - Check ..........................

Cooling System Supplemental Coolant Additive (SCA) - Test/Add .................................................

Crankcase Breather (Canister) - Replace .............

Engine Air Cleaner Element (Dual Element) Clean/Replace ....................................................

Engine Oil and Filter - Change .............................

Fuel System Secondary Filter - Replace ..............

Hoses and Clamps - Inspect/Replace ..................

Radiator - Clean ....................................................

41 69 69 72

42 48 50 51 56 61 64 68

Overhaul Considerations ...................................... 65

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41 Maintenance Section Alternator - Inspect

i02704667

Alternator - Inspect SMCS Code: 1405-040 Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required.

Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm.

When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge. i02491869

Alternator Belt Inspect/Adjust/Replace (Poly V-Belt)

Illustration 21

g01251375

Typical example

Adjustment This type of belt has an automatic belt tensioner.

Replace Refer to Disassembly and Assembly manual, “Alternator Belt - Remove and Install”.

SMCS Code: 1357-036; 1357-510 i02322315

Inspection

Battery - Replace

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

SMCS Code: 1401-510

• If the belt (1) has more than four cracks per

25.4000 mm (1 inch) the belt must be replaced.

• Check the belt of cracks, splits, glazing, grease, and splitting.

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.

Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.

42 Maintenance Section Battery Electrolyte Level - Check

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The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

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.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

1. Remove the filler caps. Maintain the electrolyte level to the “FULL” mark on the battery.

1. Switch the engine to the OFF position. Remove all electrical loads.

2. Turn off any battery chargers. Disconnect any battery chargers.

3. The NEGATIVE “-” cable connects the NEGATIVE “-” battery terminal to the NEGATIVE “-” terminal on the starting motor. Disconnect the cable from the NEGATIVE “-” battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE “+” battery terminal to the POSITIVE “+” terminal on the starting motor. Disconnect the cable from the POSITIVE “+” battery terminal.

Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate recycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that the engine start switch is OFF. 7. Connect the cable from the starting motor to the POSITIVE “+” battery terminal.

8. Connect the NEGATIVE “-” cable to the NEGATIVE “-” battery terminal. i02710765

Battery Electrolyte Level Check SMCS Code: 1401-535 When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are properly charged, ammeter reading should be very near zero, when the engine is in operation.

If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water.

2. Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the following cleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and 1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit properly.

Coat the clamps and the terminals with 5N-5561 Silicone Lubricant, petroleum jelly or MPGM. i02323088

Battery or Battery Cable Disconnect SMCS Code: 1402-029

The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

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43 Maintenance Section Cooling System Coolant (DEAC) - Change

1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.

2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection must be disconnected.

Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary.

Drain

3. Remove the positive connection.

4. Clean all disconnected connection and battery terminals.

5. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly.

6. Tape the cable connections in order to help prevent accidental starting.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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.

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

7. Proceed with necessary system repairs.

8. In order to connect the battery, connect the positive connection before the negative connector. i02710742

Cooling System Coolant (DEAC) - Change SMCS Code: 1350-070; 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the coolant is contaminated.

• The fuel has entered the cooling system and the coolant is contaminated.

NOTICE Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.

Illustration 22

g01003928

2. Open the cooling system drain valve (if equipped).

If the cooling system is not equipped with a drain valve, remove the drain plug (1).

Allow the coolant to drain.

NOTICE Dispose of used engine coolant properly or recycle.

Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant.

For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Dealer Service Tools Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL

44 Maintenance Section Cooling System Coolant (DEAC) - Change

Flush 1. Flush the cooling system with clean water in order to remove any debris.

2. Close the drain valve (if equipped). Clean the drain plug (1). Install the drain plug. Refer to Torque Specifications, SENR3130 for more information on the correct torques.

NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

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2. Close the drain valve (if equipped). Clean the drain plug (1). Install the drain plug. Refer to Torque Specifications, SENR3130 for more information on the correct torques.

NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the cooling system filler cap.

3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Install the cooling system filler cap.

4. Start and run the engine at low idle for a minimum of 90 minutes. The coolant temperature should be at least 82 °C (180 °F).

4. Start and run the engine at low idle for a minimum of 30 minutes. The coolant temperature should be at least 82 °C (180 °F).

NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.

NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.

To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

5. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain valve (if equipped) or remove the cooling system drain plug (1). Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plug. Install the drain plug. Refer to Torque Specifications, SENR3130 for more information on the correct torques.

Cooling Systems with Heavy Deposits or Plugging Note: For the following procedure to be effective, there must be some active flow through the cooling system components.

1. Flush the cooling system with clean water in order to remove any debris.

5. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain valve (if equipped) or remove the cooling system drain plug (1). Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plug. Install the drain plug. Refer to Torque Specifications, SENR3130 for more information on the correct torques.

Fill NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

1. Fill the cooling system with coolant or antifreeze.

Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section) for more information on cooling system specifications. Do not install the cooling system filler cap.

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45 Maintenance Section Cooling System Coolant (ELC) - Change

2. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within 13 mm (0.5 inch) to the proper level on the sight glass (if equipped).

4. Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap.

If the gasket that is on the cooling system filler cap is not damaged, perform a pressure test. A 9S-8140 Pressurizing Pump is used to perform the pressure test. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, obtain a new cooling system filler cap. Install the cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for the correct operating temperature.

Drain

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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.

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

2. Open the cooling system drain valve (if equipped).

If the cooling system is not equipped with a drain valve, remove the cooling system drain plugs.

Allow the coolant to drain.

NOTICE Dispose of used engine coolant properly or recycle.

Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant.

i02242512

Cooling System Coolant (ELC) - Change SMCS Code: 1350-070; 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the coolant is contaminated.

• The fuel has entered the cooling system and the coolant is contaminated.

Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.

Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary.

For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Dealer Service Tools: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL

Flush 1. Flush the cooling system with clean water in order to remove any debris.

2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to Torque Specifications, SENR3130 for more information on the correct torques.

NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

3. Fill the cooling system with clean water. Install the cooling system filler cap.

4. Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F).

46 Maintenance Section Cooling System Coolant Level - Check

5. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain valve (if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to Torque Specifications, SENR3130 for more information on the correct torques.

Fill NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

1. Fill the cooling system with Extended Life Coolant (ELC). Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section) for more information on cooling system specifications. Do not install the cooling system filler cap.

2. Start and run the engine at low idle. Increase the engine rpm to high idle. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within 13 mm (0.5 inch) to the proper level on the sight glass (if equipped).

4. Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket that is on the cooling system filler cap is not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system filler cap. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap.

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i02480380

Cooling System Coolant Level - Check SMCS Code: 1395-082

Engines With a Coolant Recovery Tank Note: The cooling system may not have been provided by Caterpillar. The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures.

Check the coolant level when the engine is stopped and cool.

1. Observe the coolant level in the coolant recovery tank. Maintain the coolant level to “COLD FULL” mark on the coolant recovery tank.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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.

2. Loosen filler cap slowly in order to relieve any pressure. Remove the filler cap.

3. Pour the correct coolant mixture into the tank.

Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” for information on the correct mixture and type of coolant. Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” for the cooling system capacity. Do not fill the coolant recovery tank above “COLD FULL” mark.

5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

Illustration 23

g00103639

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47 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain

4. Clean filler cap and the receptacle. Reinstall the filler cap and inspect the cooling system for leaks.

Note: The coolant will expand as the coolant heats up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool, the coolant will return to the engine.

Engines Without a Coolant Recovery Tank Check the coolant level when the engine is stopped and cool.

i02603581

Cooling System Coolant Sample (Level 1) - Obtain SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is filled with Cat ELC (Extended Life Coolant). Cooling systems that are filled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant instead of Cat ELC. This includes the following types of coolants:

• Commercial long life coolants that meet the Caterpillar Engine Coolant Specification -1 (Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant) • Commercial heavy-duty coolant/antifreeze Table 10

Recommended Interval Illustration 24

g00285520

Type of Coolant

Level 1

Level 2

Cat DEAC

Every 250 Hours(1)

Yearly(1)(2)

Cat ELC

Optional(2)

Yearly(2)

Cooling system filler cap

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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.

1. Remove the cooling system filler cap slowly in order to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant level to the correct level in the sight glass.

3. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure is stamped on the face of the filler cap. If the filler cap does not retain the correct pressure, install a new filler cap.

4. Inspect the cooling system for leaks.

(1)

This is the recommended interval for coolant samples for all conventional heavy-duty coolant/antifreeze. This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC-1 specification for engine coolant.

(2) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified.

NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

Note: Level 1 results may indicate a need for Level 2 Analysis.

48 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain

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Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced.

Supplies for collecting samples can be obtained from your Caterpillar dealer.

Submit the sample for Level 2 analysis.

Use the following guidelines for proper sampling of the coolant:

Cooling System Supplemental Coolant Additive (SCA) Test/Add

• Complete the information on the label for the sampling bottle before you begin to take the samples.

For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids Recommendations” or consult your Caterpillar dealer. i02456600

SMCS Code: 1352-045; 1395-081

• Keep the unused sampling bottles stored in plastic bags.

• Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.

• Keep the lids on empty sampling bottles until you are ready to collect the sample.

• Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” or consult your Caterpillar dealer. i01987714

Cooling System Coolant Sample (Level 2) - Obtain SMCS Code: 1350-008; 1395-008; 1395-554; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” for the guidelines for proper sampling of the coolant.

Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with the skin and the eyes. Do not drink cooling system coolant additive.

Note: Test the concentration of the Supplemental Coolant Additive (SCA) or test the SCA concentration as part of an S·O·S Coolant Analysis.

Test for SCA Concentration Coolant and SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration.

Use the 8T-5296 Coolant Conditioner Test Kit or use the 4C-9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA. Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” for more information.

Water and SCA NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Refer to the Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for more information.

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49 Maintenance Section Cooling System Water Temperature Regulator - Replace

S·O·S Coolant Analysis S·O·S coolant samples can be analyzed at your Caterpillar dealer. S·O·S Coolant Analysis is a program that is based on periodic samples.

Level 1 Level 1 is a basic analysis of the coolant. The following items are tested:

• Glycol Concentration • Concentration of SCA • pH • Conductivity The results are reported, and recommendations are made according to the results. Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S·O·S Coolant Analysis.

Level 2 This level coolant analysis is recommended when the engine is overhauled. Refer to this Operations and Maintenance Manual, “Overhaul Considerations” for further information.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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.

1. Slowly loosen the cooling system filler cap in order to relieve the pressure. Remove the cooling system filler cap.

Note: Always discard drained fluids according to local regulations.

2. If necessary, drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA. 3. Add the proper amount of SCA. Refer to the Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids Recommendations” for more information on SCA requirements.

4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling system filler cap with a new cooling system filler cap. Install the cooling system filler cap.

Add the SCA, If Necessary NOTICE Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine’s heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal wear. Never use both liquid supplemental coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could result in supplemental coolant additive concentration exceeding the recommended maximum.

i02623972

Cooling System Water Temperature Regulator Replace SMCS Code: 1355-510 Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice.

Replacing the water temperature regulator reduces the chances for unscheduled downtime.

A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine.

A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in cracking of the cylinder head or piston seizure problems.

50 Maintenance Section Crankcase Breather (Canister) - Replace

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A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner.

NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage.

Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed.

If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that the water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket or cylinder head surface.

Illustration 25

g01350307

Typical example

1. Place a container under the canister (1).

2. Clean the outside of the canister. Remove the canister with a 1U-8760 Chain Wrench.

3. Lubricate the O ring seal (2) on the new canister (3) with clean engine lubricating oil. Install the new canister. Tighten the canister to 12 N·m (8 lb ft).

Do not overtighten the canister.

Refer to two articles in the Disassembly and Assembly Manual, “Water Temperature Regulators - Remove and Water Temperature Regulators Install” for the replacement procedure of the water temperature regulator, or consult your Caterpillar dealer.

4. Remove the container. Dispose of the old canister and any split oil in a safe place.

Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing.

SMCS Code: 3279-535

i02711635

Crankcase Breather (Canister) - Replace SMCS Code: 1317-510 NOTICE Ensure that the engine is stopped before any servicing or repair is performed.

Note: This breather assembly is not installed on all engines.

i00174798

Driven Equipment - Check Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment:

• Inspection • Adjustment • Lubrication • Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM.

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51 Maintenance Section Engine - Clean

i02708606

Engine - Clean SMCS Code: 1000-070

i02708051

Engine Air Cleaner Element (Dual Element) - Clean/Replace SMCS Code: 1054-037; 1054-510

Personal injury or death can result from high voltage.

Moisture can create paths of electrical conductivity.

Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO NOT OPERATE”.

NOTICE Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine.

NOTICE Failure to protect some engine components from washing may make your engine warranty invalid.

Allow the engine to cool for one hour before washing the engine.

Periodic cleaning of the engine is recommended.

Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following benefits:

• Easy detection of fluid leaks • Maximum heat transfer characteristics • Ease of maintenance Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when the engine is cleaned. When a pressure washer or steam cleaner is used to clean the engine, a minimum distance of 300 mm (12 inch) must be maintained between the components of the engine and the jet nozzle of the pressure washer or steam cleaner. Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of cables into the rear of the connectors. Avoid electrical components such as the alternator and the starter. Protect the fuel injection pump from fluids in order to wash the engine.

NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.

NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements Note: The air filter system may not have been provided by Catapillar. The procedure that follows is for a typical air filter system. Refer to the OEM information for the correct procedure.

If the air cleaner element becomes plugged, the air can split the material of the air cleaner element.

Unfiltered air will drastically accelerate internal engine wear. Refer to the OEM information for the correct air cleaner elements for your application.

• Check the precleaner (if equipped) and the dust bowl daily for accumulation of dirt and debris.

Remove any dirt and debris, as needed.

• Operating in dirty conditions may require more frequent service of the air cleaner element.

• The air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

Replace the dirty air cleaner elements with clean air cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears and/or holes in the filter material. Inspect the gasket or the seal of the air cleaner element for damage.

Maintain a supply of suitable air cleaner elements for replacement purposes.

Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element.

52 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace

The primary air cleaner element can be used up to six times if the element is properly cleaned and properly inspected. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

The secondary air cleaner element is not serviceable.

Refer to the OEM information for instructions in order to replace the secondary air cleaner element.

When the engine is operating in environments that are dusty or dirty, air cleaner elements may require more frequent replacement.

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Cleaning the Primary Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning services that are available at Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove the dust from the filter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air flow up the pleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damage to the pleats.

Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components.

Illustration 26 (1) (2) (3) (4)

g00736431

Cover Primary air cleaner element Secondary air cleaner element Air inlet

1. Remove the cover. Remove the primary air cleaner element.

2. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air Cleaner Elements”.

3. Cover the air inlet with tape in order to keep dirt out.

4. Clean the inside of the air cleaner cover and body with a clean, dry cloth.

5. Remove the tape for the air inlet. Install the secondary air cleaner element. Install a primary air cleaner element that is new or cleaned.

The primary air cleaner element can be used up to six times if the element is properly cleaned and properly inspected. When the primary air cleaner element is cleaned, check for rips or tears in the filter material.

The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirty elements are being cleaned.

NOTICE Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result.

Visually inspect the primary air cleaner elements before cleaning. Inspect the air cleaner elements for damage to the seal, the gaskets, and the outer cover.

Discard any damaged air cleaner elements.

6. Install the air cleaner cover.

There are two common methods that are used to clean primary air cleaner elements:

7. Reset the air cleaner service indicator.

• Pressurized air • Vacuum cleaning

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53 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace

Pressurized Air

Note: Refer to “Inspecting the Primary Air Cleaner Elements”.

Personal injury can result from air pressure.

Inspecting the Primary Air Cleaner Elements

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than three times. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi). Pressurized air will not remove deposits of carbon and oil.

Illustration 28

g00281693

Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air cleaner element. Rotate the primary air cleaner element.

Inspect the primary air cleaner element for tears and/or holes. Inspect the primary air cleaner element for light that may show through the filter material. If it is necessary in order to confirm the result, compare the primary air cleaner element to a new primary air cleaner element that has the same part number.

Illustration 27

g00281692

Note: When the primary air cleaner elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside).

Aim the air hose so that air flows along the length of the filter. Follow the direction of the paper pleats in order to prevent damage to the pleats. Do not aim the air directly at the face of the paper pleats.

Do not use a primary air cleaner element that has any tears and/or holes in the filter material. Do not use a primary air cleaner element with damaged pleats, gaskets or seals. Discard damaged primary air cleaner elements.

Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used, the primary air cleaner element can be stored for future use.

Note: Refer to “Inspecting the Primary Air Cleaner Elements”.

Vacuum Cleaning Vacuum cleaning is a good method for removing accumulated dirt from the dirty side (outside) of a primary air cleaner element. Vacuum cleaning is especially useful for cleaning primary air cleaner elements which require daily cleaning because of a dry, dusty environment.

Cleaning from the clean side (inside) with pressurized air is recommended prior to vacuum cleaning the dirty side (outside) of a primary air cleaner element.

Illustration 29

g00281694

54 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace

Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An air flow restriction may result. To protect against dirt and damage, wrap the primary air cleaner elements in Volatile Corrosion Inhibited (VCI) paper.

Place the primary air cleaner element into a box for storage. For identification, mark the outside of the box and mark the primary air cleaner element.

Include the following information:

• Date of cleaning

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Some engines are equipped with a differential gauge for inlet air pressure. The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty, the pressure differential rises. If your engine is equipped with a different type of service indicator, follow the OEM recommendations in order to service the air cleaner service indicator.

The service indicator may be mounted on the air cleaner element or in a remote location.

• Number of cleanings Store the box in a dry location. i02708042

Engine Air Cleaner Element (Single Element) Inspect/Replace SMCS Code: 1054-040; 1054-510 Refer to Operation and Maintenance Manual, “Engine Air Cleaner Service Indicator-Inspect”.

NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.

Illustration 30

g00103777

Typical service indicator

Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

Test the Service Indicator

A wide variety of air cleaners may be installed for use with this engine. Consult the OEM information for the correct procedure to replace the air cleaner.

• Check for ease of resetting. The service indicator

Service indicators are important instruments. should reset in less than three pushes.

• Check the movement of the yellow core when i02708041

Engine Air Cleaner Service Indicator - Inspect SMCS Code: 7452-040 Some engines may be equipped with a different service indicator.

the engine is accelerated to the engine rated speed. The yellow core should latch at the greatest vacuum that is attained.

If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indicator will not reset, the hole for the service indicator may be restricted.

The service indicator may need to be replaced frequently in environments that are severely dusty.

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55 Maintenance Section Engine Air Precleaner - Check/Clean

i02708039

Engine Air Precleaner Check/Clean

i02708019

Engine Oil Level - Check SMCS Code: 1348-535-FLV

SMCS Code: 1055-070; 1055-535 Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Illustration 31

g00287039

Typical precleaner (1) Wing nut (2) Cover (3) Body

Remove wing nut (1) and cover (2). Check for an accumulation of dirt and debris in body (3). Clean the body, if necessary.

After cleaning the precleaner, install cover (2) and wing nut (1).

Note: When the engine is operated in dusty applications, more frequent cleaning is required. i02456872

Engine Mounts - Inspect SMCS Code: 1152-040 Inspect the engine mounts for deterioration and for proper bolt torque. Engine vibration can be caused by the following conditions:

• Improper mounting of the engine • Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced. Refer to Special Publication, SENR3130, “Torque Specifications” for the recommended torques. Refer to the OEM recommendations for more information.

Illustration 32

g01165836

(Y) “Min” mark. (X) “Max” mark.

NOTICE Perform this maintenance with the engine stopped.

Note: Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication.

Note: After the engine has been switched OFF, wait for ten minutes in order to allow the engine oil to drain to the oil pan before checking the oil level.

1. Maintain the oil level between the “MIN” mark (Y) and the “MAX” mark (X) on the engine oil dipstick.

Do not fill the crankcase above the “MAX” mark (X).

NOTICE Operating your engine when the oil level is above the “FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil’s lubricating characteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.

Clean the oil filler cap. Install the oil filler cap.

56 Maintenance Section Engine Oil Sample - Obtain

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i01935337

Engine Oil Sample - Obtain SMCS Code: 1000-008; 1348-554-SM; 7542-554-OC, SM In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump.

For instructions, see Special Publication, PEHP6001, “How To Take A Good Oil Sample”. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your engine. i02712378

Before you take the oil sample, complete the Label, PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, provide the following information:

Engine Oil and Filter - Change SMCS Code: 1318-510; 1348-044

• Engine model • Service hours on the engine • The number of hours that have accumulated since the last oil change

• The amount of oil that has been added since the last oil change

To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample.

To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.

Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The fluid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided.

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with the draining cold oil. Drain the crankcase with the engine stopped. Drain the crankcase with the oil warm. This draining method allows the waste particles that are suspended in the oil to be drained properly.

Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil.

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57 Maintenance Section Engine Oil and Filter - Change

Drain the Engine Oil

1. Remove the oil filter with a 1U-8760 Chain Wrench.

Note: The following actions can be carried out as part of the preventive maintenance program.

2. Cut the oil filter open with a 175-7546 Oil Filter Cutter Gp. Break apart the pleats and inspect the oil filter for metal debris. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure.

Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element. Ferrous metals may indicate wear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on the aluminum parts, brass parts or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, turbocharger bearings, and cylinder heads.

Illustration 33

g01356033

Oil drain plug

After the engine has been run at the normal operating temperature, stop the engine. Use one of the following methods to drain the engine crankcase oil:

Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter.

• If the engine is equipped with a drain valve, turn the drain valve knob counterclockwise in order to drain the oil. After the oil has drained, turn the drain valve knob clockwise in order to close the drain valve.

• If the engine is not equipped with a drain valve,

remove the oil drain plug (1) in order to allow the oil to drain. If the engine is equipped with a shallow sump, remove the bottom oil drain plugs from both ends of the oil pan.

After the oil has drained, the oil drain plugs should be cleaned and installed. If necessary, renew the O ring seal on the drain plug.

Some types of oil pans have oil drain plugs that are on both sides of the oil pan, because of the shape of the pan. This type of oil pan requires the engine oil to be drained from both plugs.

Replace the Spin-on Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Caterpillar.

Illustration 34

g01356034

(2) Filter head (3) O ring seal (4) Union

3. Clean the sealing surface of the oil filter head (2). Ensure that the union (4) in the filter head is secure.

4. Clean the sealing surface of the oil filter head (2). Ensure that the union (4) in the filter head is secure.

58 Maintenance Section Engine Protective Devices - Check

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NOTICE Do not fill the oil filters with oil before installing them.

This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to engine components.

5. Install the oil filter. Tighten the oil filter by hand according to the instructions that are shown on the oil filter. Do not overtighten the oil filter.

2. Start the engine and run the engine at “LOW IDLE” for two minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil leaks.

3. Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes.

Note: Some oil filters may be installed vertically.

Refer to illustration 35. Start at step (1) in order to remove the oil filter and install the oil filter.

Illustration 36

g01165836

(Y) “MIN” mark. (X) “MAX” mark.

4. Remove the oil level gauge in order to check the oil level. Maintain the oil level between the “MIN” and “MAX” marks on the oil level gauge. i00626013

Engine Protective Devices Check Illustration 35

g01356074

Typical example

Fill the Engine Crankcase 1. Remove the oil filler cap. Refer to the Operation and Maintenance Manual for more information on lubricant specifications. Fill the crankcase with the proper amount of oil. Refer to the Operation and Maintenance Manual for more information on refill capacities.

NOTICE If equipped with an auxiliary oil filter system or a remote oil filter system, follow the OEM or filter manufacturer’s recommendations. Under filling or overfilling the crankcase with oil can cause engine damage.

NOTICE To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will fill the oil filters before starting the engine. Do not crank the engine for more than 30 seconds.

SMCS Code: 7400-535 Alarms and shutoffs must function properly. Alarms provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation.

Malfunctions must be simulated in order to test the engine protective devices.

A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. Ensure that the engine protective devices are functioning properly.

NOTICE During testing, abnormal operating conditions must be simulated.

The tests must be performed correctly in order to prevent possible damage to the engine.

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59 Maintenance Section Engine Valve Lash - Inspect/Adjust

To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests.

Visual Inspection

i02707243

Fuel Injection Nozzles Test/Exchange SMCS Code: 1254-013; 1254-081

Visually check the condition of all gauges, sensors and wiring. Look for wiring and components that are loose, broken, or damaged. Damaged wiring or components should be repaired or replaced immediately. i02707257

Engine Valve Lash Inspect/Adjust SMCS Code: 1102-025 This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life.

NOTICE Only qualified service personnel should perform this maintenance. Refer to the Systems Operation/Testing and Adjusting Manual, “Valve Lash and Valve Bridge Adjustment”article or consult your Caterpillar dealer for the complete valve lash adjustment procedure.

Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

Ensure that the engine can not be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring the valve lash. To obtain an accurate measurement, allow the valves to cool before this maintenance is performed.

Refer to the Service Manual for more information.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

Fuel injection nozzles are subject to tip wear. Tip wear is a result of fuel contamination. Tip wear can cause the following problems:

• Increased fuel consumption • Black smoke • Misfire • Rough running Fuel Injection nozzles should be cleaned, inspected, tested, and replaced, if necessary. Refer to Special Instruction, SEHS7292 for using the 8S-2245 Injector Cleaning Tool Gp. Consult your Caterpillar dealer about cleaning the fuel injection nozzle and testing the fuel injection nozzle.

NOTICE Never wire brush or scrape a fuel injection nozzle.

Wire brushing or scraping a fuel injection nozzle will damage the finely machine orifice. Proper tools for cleaning and testing the fuel injection nozzles can be obtained from Caterpillar dealers.

The following items are symptoms of a malfunction of the fuel injection nozzle:

• Abnormal engine operation • Smoke emission • Engine knock Each fuel injection nozzle must be isolated one at a time in order to determine the malfunctioning fuel injection nozzle.

1. Start the engine.

60 Maintenance Section Fuel System - Prime

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2. Loosen each fuel line nut one at a time at the fuel injection pump. A cloth or similar material must be used in order to prevent fuel from spraying on the hot exhaust components. Tighten each nut before loosening the next nut.

3. Turn the ignition key to the OFF position.

3. Worn fuel injection nozzles or faulty fuel injection nozzles may be identified when a fuel line nut is loosened and the following conditions are present:

• The exhaust smoke is partially eliminated or the exhaust smoke is completely eliminated.

• Engine performance is not affected.

A fuel injection nozzle that is suspected of being worn and/or faulty should be removed. A new fuel injection nozzle should be installed in the cylinder in order to determine if the removed fuel injection nozzle is worn and/or faulty.

Removal and Installation of the Fuel Injection Nozzles For the removal and the installation of fuel injection nozzles, special tooling is required. Refer to the Service Manual for more information. Consult your Caterpillar dealer for assistance. i02677377

Fuel System - Prime

Illustration 37

g01003929

Injector nuts

Note: Damage to the fuel injection pump, to the battery, and to the starting motor can occur if the starting motor is used excessively to purge the air from the fuel system.

4. Loosen the flare nuts (1) for the high pressure fuel lines on all of the fuel injectors.

NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

SMCS Code: 1258-548

5. Observe the connection at the flare nut. Operate the starting motor and crank the engine until the fuel is free of air.

If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur:

6. Tighten the flare nuts (1) to a torque of 30 N·m (22 lb ft).

• The fuel tank is empty or the fuel tank has been partially drained.

• The low pressure fuel lines are disconnected.

• A leak exists in the low pressure fuel system.

• The fuel filter is replaced.

• A new injection pump is installed.

Use the following procedure in order to remove air from the fuel system: 1. Remove the cover for the fuel injectors. Refer to the Disassembly and Assembly Manual.

2. Turn the ignition key to the RUN position. Leave the ignition key in the RUN position for three minutes.

7. The engine is now ready to start. Operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system.

Note: Running the engine for this period of time will help ensure that the pump is completely free of air.

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61 Maintenance Section Fuel System Primary Filter/Water Separator - Drain

i02699081

Fuel System Primary Filter/Water Separator - Drain SMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.

Clean up fuel spills immediately.

NOTICE The water separator is not a filter. The water separator separates water from the fuel. The engine should never be allowed to run with the water separator more than half full. Engine damage may result.

NOTICE The water separator is under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system.

Illustration 38 (1) (2) (3) (4) (5) (6)

g01353878

Screw Element Bowl Bottom cover Drain Sensor connection

1. Place a suitable container below the water separator.

2. Open the drain (5). Allow the fluid to drain into the container.

3. When clean fuel drains from the water separator close the drain (5). Tighten the drain by hand pressure only. Dispose of the drained fluid correctly. i02699073

Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.

Clean up fuel spills immediately.

62 Maintenance Section Fuel System Secondary Filter - Replace

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NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

Element filter Turn the valves for the fuel lines (if equipped) to the OFF position before performing this maintenance.

Place a tray under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel immediately.

Illustration 40

g01353857

(3) Filter head (4) Element (5) O ring seal

3. Remove the filter bowl (1) from the filter head (3). Press on the element (4). Rotate the element counterclockwise in order to release the element for the filter bowl and remove the element from the bowl. Discard the used element.

4. Remove the O ring (5) from the filter bowl and clean the filter bowl. Check that the threads of the filter bowl are not damaged.

Illustration 39

g01353856

(1) Filter bowl (2) Drain

1. Close the valves for the fuel lines (if equipped).

2. Clean the outside of the fuel filter assembly. Open the fuel drain (2) and drain the fuel into a suitable container.

5. Install a new O ring seal (5) to the filter bowl (1).

6. Locate a new filter element (4) into the filter bowl (1). Press on the element and rotate the element clockwise in order to lock the element into the filter bowl.

7. Install the filter bowl (1) into the top of the filter head (3).

8. Tighten the filter bowl by hand until the filter bowl contacts the filter head. Rotate the filter bowl through 90 degrees.

Note: Do not use a tool to tighten the filter bowl.

9. Open the valves for the fuel lines (if equipped).

Spin-on filter Turn the valves for the fuel lines (if equipped) to the OFF position before performing this maintenance.

Place a tray under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel immediately.

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63 Maintenance Section Fuel Tank Water and Sediment - Drain

Illustration 42

g01353860

(4) O ring seal

4. Lubricate the sealing ring (4) with clean fuel oil.

Illustration 41

g01353858

(1) Filter Head (2) Spin-on filter (3) Drain

1. Clean the outside of the fuel filter assembly. Open the fuel drain (3) and drain the fuel into a suitable container.

2. Use a suitable tool in order to remove the spin-on filter (2) from the filter head (1).

3. Ensure that the fuel drain (3) on the new spin-on filter is closed.

5. Install the spin-on filter (2) into the top of the filter head (1).

6. Tighten the spin-on filter by hand until the sealing ring contacts the filter head. Rotate the spin-on filter through 90 degrees.

7. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”. i02702048

Fuel Tank Water and Sediment - Drain SMCS Code: 1273-543-M&S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.

Fuel Tank Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system.

64 Maintenance Section Hoses and Clamps - Inspect/Replace

Water can be introduced into the fuel tank when the fuel tank is being filled.

Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.

Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks.

Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve.

Check the fuel daily. Allow five minutes after the fuel tank has been filled before draining water and sediment from the fuel tank.

Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank may overflow.

Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important.

Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank at the following intervals:

• Weekly • Service intervals • Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank.

If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to settle before filling the engine fuel tank. Internal baffles in the bulk storage tank will also help trap sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel.

When possible, water separators should be used.

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i02705980

Hoses and Clamps Inspect/Replace SMCS Code: 7554-040; 7554-510 Inspect all hoses for leaks that are caused by the following conditions:

• Cracking • Softness • Loose clamps Replace hoses that are cracked or soft. Tighten any loose clamps.

NOTICE Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking • Outer covering that is chafed or cut • Exposed wire that is used for reinforcement • Outer covering that is ballooning locally • Flexible part of the hose that is kinked or crushed • Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp.

Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen.

This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.

Each installation application can be different. The differences depend on the following factors:

• Type of hose • Type of fitting material • Anticipated expansion and contraction of the hose

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65 Maintenance Section Overhaul Considerations

• Anticipated expansion and contraction of the

The need for an overhaul is generally indicated by increased fuel consumption and by reduced power.

Replace the Hoses and the Clamps

The following factors are important when a decision is being made on the proper time for an engine overhaul:

fittings

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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.

1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

Note: Drain the coolant into a suitable, clean container. The coolant can be reused.

3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: Refer to the Specifications, SENR3130, “Torque Specifications” in order to locate the proper torques.

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect the cooling system filler cap’s gaskets. Replace the cooling system filler cap if the gaskets are damaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system for leaks. i02708037

Overhaul Considerations SMCS Code: 7595-043 Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval.

• The need for preventive maintenance • The quality of the fuel that is being used • The operating conditions • The results of the S·O·S analysis

Oil Consumption as an Overhaul Indicator Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.

Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.

The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.

When an engine’s oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled.

There may be a corresponding increase in blowby and a slight increase in fuel consumption.

Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to the standards for reusable parts.

• The engine’s service life can be extended without the risk of a major catastrophe due to engine failure.

66 Maintenance Section Overhaul Considerations

• The best cost/value relationship per hour of extended life can be attained.

After Failure Overhaul If a major engine failure occurs and the engine must be removed, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaft is repairable, the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core.

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• Salvaging • Repairing • Replacing Using out-of-spec parts can result in the following problems:

• Unscheduled downtime • Costly repairs • Damage to other engine parts

This lower cost can be attributed to three aspects:

• Reduced engine efficiency

• Specially designed Caterpillar engine features

• Increased fuel consumption

• Caterpillar dealer exchange components

Reduced engine efficiency and increased fuel consumption translates into higher operating costs.

Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.

• Caterpillar Inc. remanufactured exchange components

Overhaul Recommendation

Inspection and/or Replacement

To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. This will provide you with the best cost/value relationship.

Crankshaft Bearings and Crankshaft Seals

Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life.

• Thrust bearings

The following components may not last until the second overhaul.

• Main bearings • Rod bearings • Crankshaft seals

If an overhaul is performed without overhaul service from your Caterpillar dealer, be aware of the following maintenance recommendations.

Caterpillar Inc. recommends the installation of new parts at each overhaul period.

Rebuild or Exchange

Inspect these parts while the engine is disassembled for an overhaul.

Cylinder Head Assembly, Oil Pump, and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications. The Special Publication, SEBF8029 lists the reusability publications that are needed for inspecting the engine parts.

If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline, the parts should be reused.

Parts that are not within the established inspection specifications should be dealt with in one of the following manners:

Inspect the crankshaft for any of the following conditions:

• Deflection • Damage to the journals • Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:

• Rod bearing

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67 Maintenance Section Overhaul Considerations

• Main bearings Inspect the camshaft for damage to the journals and to the lobes.

4. Use steam to clean the oil cooler core. This removes any remaining residue from the cleaner.

Flush the fins of the oil cooler core. Remove any other trapped debris.

Note: If the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the camshaft.

5. Wash the oil cooler core with hot, soapy water.

Rinse the oil cooler core thoroughly with clean water.

Inspect the following components for signs of wear or for signs of scuffing: Personal injury can result from air pressure.

• Camshaft bearings • Lifters Caterpillar Inc. recommends replacing the crankshaft vibration damper.

Oil Cooler Core During an overhaul, Caterpillar Inc. recommends the removal of the oil cooler core. Clean the oil cooler core. Then, pressure test the oil cooler core.

NOTICE Do not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of the core and cause leakage.

Note: Use this cleaning procedure to clean the oil cooler core.

1. Remove the oil cooler core.

2. Remove any debris from the oil cooler core. To remove debris from the oil cooler core, turn the oil cooler core onto one end.

3. Flush the oil cooler core internally with cleaner in order to loosen foreign substances. This will also help to remove oil from the oil cooler core.

Note: Caterpillar Inc. recommends the use of Hydrosolv Liquid Cleaners. Table 11 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer.

Table 11

Hydrosolv Liquid Cleaners Part Number

Description

Size

1U-5490

Hydrosolv4165

19 L (5 US gal)

1U-5492

Hydrosolv100

19 L (5 US gallon)

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

6. Dry the oil cooler core with compressed air. Direct the air in the reverse direction of the normal flow.

7. Inspect the components in order to ensure cleanliness. The oil cooler core should be pressure tested. Repair the oil cooler core, if necessary. Install the oil cooler core.

For more information about cleaning the cores, consult your Caterpillar dealer.

Obtain Coolant Analysis The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits or with S·O·S Coolant Analysis (Level 1). Further coolant analysis is recommended when the engine is overhauled.

For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals that were deposited on the engine over time.

A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis.

Caterpillar Inc. recommends an S·O·S Coolant Analysis (Level 2).

68 Maintenance Section Radiator - Clean

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S·O·S Coolant Analysis (Level 2) An S·O·S Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. An S·O·S Coolant Analysis (Level 2) provides the following information:

• Complete S·O·S Coolant Analysis (Level 1) • Visual inspection of properties • Identification of metal corrosion • Identification of contaminants • Identification of built up impurities (corrosion and scale)

S·O·S Coolant Analysis (Level 2) provides a report of the results of both the analysis and the maintenance recommendations.

For more information about coolant analysis, see your Caterpillar dealer. i02708040

Radiator - Clean SMCS Code: 1353-070 The radiator is not usually supplied by Caterpillar. The following text describes a typical cleaning procedure for the radiator. Refer to OEM information for further information on cleaning the radiator.

Note: Adjust the frequency of cleaning according to the effects of the operating environment.

Inspect the radiator for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.

Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the fan’s air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the fins. Slowly move the air nozzle in a direction that is parallel with the tubes.

This will remove debris that is between the tubes.

Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides.

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine.

Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be opened with a “comb”. Inspect these items for good condition: welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning and inspection, refer to Special Publication, SEBD0518, “Know Your Cooling System”. i00151038

Severe Service Application Check SMCS Code: 1000-535 Severe service is an application of an engine that exceeds current published standards for that engine.

Caterpillar maintains standards for the following engine parameters:

Personal injury can result from air pressure.

• Performance (power range, speed range, and fuel

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

• Fuel quality

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

consumption)

• Altitude range • Maintenance intervals • Oil selection and maintenance • Coolant selection and maintenance • Environmental qualities

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69 Maintenance Section Starting Motor - Inspect

• Installation

Improper Maintenance Procedures

Refer to the standards for the engine or consult with your Caterpillar dealer in order to determine if the engine is operating within the defined parameters.

• Extending the maintenance intervals

Severe service operation can accelerate component wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life.

Due to individual applications, it is not possible to identify all of the factors which can contribute to severe service operation. Consult your Caterpillar dealer for the unique maintenance that is necessary for the engine.

The operating environment, improper operating procedures and improper maintenance procedures can be factors which contribute to severe service conditions.

Environmental Factors Ambient temperatures – The engine may be exposed to extended operation in extremely cold environments or hot environments. Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures. Extremely hot inlet air reduces engine performance.

Air Quality – The engine may be exposed to extended operation in an environment that is dirty or dusty, unless the equipment is cleaned regularly.

Mud, dirt and dust can encase components.

Maintenance can be very difficult. The buildup can contain corrosive chemicals.

Buildup – Compounds, elements, corrosive chemicals and salt can damage some components.

Altitude – Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be made.

Improper Operating Procedures • Extended operation at low idle • Frequent hot shutdowns • Operating at excessive loads • Operating at excessive speeds • Operating outside the intended application

• Failure to use recommended fuel, lubricants and coolant/antifreeze

i02348493

Starting Motor - Inspect SMCS Code: 1451-040; 1453-040 Caterpillar recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not start in an emergency situation.

Check the starting motor for correct operation. Check the electrical connections and clean the electrical connections. Refer to the Systems Operation, Testing and Adjusting Manual, “Electric Starting System Test” for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance. i02710646

Turbocharger - Inspect SMCS Code: 1052-040; 1052 A regular visual inspection of the turbocharger is recommended. Any fumes from the crankcase are filtered through the air inlet system. Therefore, by-products from oil and from combustion can collect in the turbocharger compressor housing. Over time, this buildup can contribute to loss of engine power, increased black smoke and overall loss of engine efficiency.

If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head.

70 Maintenance Section V-Belts - Inspect/Adjust/Replace

NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems.

Loss of engine lubricant can result in serious engine damage.

Minor leakage of oil into a turbocharger under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occured.

When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is renewed.

A visual inspection of the turbocharger can minimize unscheduled downtime. A visual inspection of the turbocharger can also reduce the chance for potential damage to other engine parts.

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The presence of oil may be the result of extended engine operation at low idle. The presence of oil may also be the result of a restriction of the line for the intake air (clogged air filters), which causes the turbocharger to slobber.

3. Inspect the bore of the housing of the turbine outlet for corrosion.

4. Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing. i02517672

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

Inspection

Removal and Installation Note: The turbochargers that are supplied are nonserviceable.

For options regarding the removal, installation, and replacement, consult your Carerpillar dealer or your Carerpillar distributor. Refer to the Disassembly and Assembly Manual, “Turbocharger - Remove and Turbocharger - Install” for further information.

Inspecting NOTICE The compressor housing for the turbocharger must not be removed from the turbocharger for cleaning.

The actuator linkage is connected to the compressor housing. If the actuator linkage is moved or disturbed the engine may not comply with emmissions legislation.

1. Remove the pipe from the turbocharger exhaust outlet and remove the air intake pipe to the turbocharger. Visually inspect the piping for the presence of oil. Clean the interior of the pipes in order to prevent dirt from entering during reassembly.

2. Check for the presence of oil. If oil is leaking from the back side of the compressor wheel, there is a possibility of a failed turbocharger oil seal.

Illustration 43

g01249073

Arrangement for the V-belts

To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged.

For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched.

The additional load on the new belt could cause the new belt to break.

If the belts are too loose, vibration causes unnecessary wear on the belts and pulleys. Loose belts may slip enough to cause overheating.

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71 Maintenance Section Walk-Around Inspection

To accurately check the belt tension, install 144-0235 Belt Tension Gauge.

i02457734

Walk-Around Inspection SMCS Code: 1000-040

Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.

Illustration 44

g01003936

Typical example (1) Gauge

For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:

• The guards must be in the correct place. Repair

Fit the gauge (1) at the center of the longest free length and check the tension. The correct tension is 400 N (90 lb). If the tension of the belt is below 250 N (56 lb) adjust the belt to 400 N (90 lb).

If twin belts are installed, check and adjust the tension on both belts.

Adjustment

damaged guards or replace missing guards.

• Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system contamination.

NOTICE For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.

NOTICE Accumulated grease and/or oil on an engine is a fire hazard. Remove the accumulated grease and oil. Refer to this Operation and Maintenance Manual, “Engine - Clean” for more information.

• Ensure that the cooling system hoses are correctly Illustration 45

g01003939

1. Loosen The alternator pivot bolt (2) and the bolt (3).

2. Move the alternator in order to increase or decrease the belt tension. Tighten the alternator pivot bolt and the link bolt to 22 N·m (16 lb ft).(1).

Replace Refer to Disassembly and Assembly manual for more information.

clamped and that the cooling system hoses are tight. Check for leaks. Check the condition of all pipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract.

Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of the water pump and the installation of water pump and/or seal, refer to the Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more information or consult your Caterpillar dealer.

72 Maintenance Section Water Pump - Inspect

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• Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the rocker cover.

• Inspect the fuel system for leaks. Look for loose fuel line clamps and/or tie-wraps.

• Inspect the piping for the air intake system and the elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc.

• Inspect the alternator belts and any accessory drive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced.

The older belts are stretched. The additional load on the new belt could cause the belt to break.

• Drain the water and the sediment from the fuel

tank on a daily basis in order to ensure that only clean fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed wires.

• Inspect the ground strap for a good connection and for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery.

• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that can not be calibrated. i02457735

Water Pump - Inspect SMCS Code: 1361-040; 1361 A failed water pump may cause severe engine overheating problems that could result in the following conditions:

• Cracks in the cylinder head • A piston seizure • Other potential damage to the engine

Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract.

Visually inspect the water pump for leaks. Renew the water pump seal or the water pump if there is an excessive leakage of coolant. Refer to Disassembly and Assembly, “Water Pump - Remove” for the disassembly procedure and then refer to Disassembly and Assembly, “Water Pump - Install” for the assembly procedure.

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73 Warranty Section Warranty Information

Warranty Section Warranty Information i01087950

Emissions Warranty Information SMCS Code: 1000 This engine may be certified to comply with exhaust emission standards and gaseous emission standards that are prescribed by law at the time of manufacture, and this engine may be covered by an Emissions Warranty. A detailed explanation of the Emissions Warranty that is applicable to emissions certified engines is found in Supplement, SEBU6981, “Federal Emissions Control Warranty Information”. Consult your authorized Caterpillar dealer to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.

74 Reference Information Section Engine Ratings

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Reference Information Section

i00819749

Engine Rating Definitions SMCS Code: 1000

Engine Ratings i00727327

Engine Rating Conditions SMCS Code: 1000 All engine ratings are in compliance with the following standard ambient air conditions of “SAE J1349”:

• 99 kPa (29.3 inches of Hg) • 30 percent relative humidity • A temperature of 25 °C (77 °F) Ratings relate to the standard conditions of “ISO8665”, of “ISO3046/1”, of “DIN6271”, and of “BS5514”.

The engine ratings are based on the following fuel specifications:

• Low heat value (LHV) of the fuel of 42 780 kJ/kg (18,390 Btu/lb) at 29 °C (84 °F)

• Gravity (API) of 35 degrees at 15 °C (60 °F) • Specific gravity of .849 at 15 °C (60 °F) • Density of 850 kg/m3 (7.085 lb/US gal) The engine ratings are gross output ratings.

Gross Output Ratings – The total output capability of the engine that is equipped with standard accessories.

Standard accessories include the following components:

• Oil pumps • Fuel pumps • Water pumps Subtract the power that is required to drive auxiliary components from the gross output. This will produce the net power that is available for the external load (flywheel).

It is important to know the use of the engine so that the rating will match the operating profile. The proper rating selection is also important so that the customer’s perception of price and value is realized.

In selecting a rating for a specific application, the most important consideration is the time that is spent at full throttle. These rating definitions identify the percent of time at full throttle. The definitions also identify the corresponding times below rated rpm.

Note: The examples of the applications are only for reference. For an exact determination of the appropriate rating, follow the OEM specifications or consult your Caterpillar dealer.

A Rating – This rating is used for heavy-duty applications that are operated at rated load and at rated rpm up to 100 percent. This rating is used for engines that operate without interruption of load cycling. Typical applications include the following examples: pipeline pumping and ventilation.

B Rating – This rating is used when power and/or rpm are cyclic. The engine should be run at full load.

The engine should not exceed 80 percent of the duty cycle. Typical applications include the following examples: irrigation, operation where normal pump demand is 85 percent of the engine rating, oil pumping/drilling, field mechanical pumping/drilling, and stationary/plant air compressors.

C Rating – This rating is used when power and/or rpm are cyclic. The horsepower and the rpm of the engine can be utilized continuously for one hour. This is followed by one hour of operation at the A rating or below the A rating. The engine should be run at full load. The engine should not exceed 50 percent of the duty cycle. Typical applications include the following examples: agricultural tractors, harvesters and combines, off-highway trucks, fire pumps, blast hole drills, rock curshers, wood chippers with high torque rise, and oil field hoisting.

D Rating – This rating is used when rated power is required for periodic overloads. The maximum horsepower and the rpm of the engine can be utilized continuously for a maximum of 30 minutes. This is followed by one hour of operation at the C rating. The engine should be run at full load. The engine should not exceed 10 percent of the duty cycle. Typical applications include the following examples: offshore cranes, runway snow blowers, water well drills, portable air compressors, and fire pump certification power.

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E Rating – This rating is used when rated power is required for a short time for initial starting or for sudden overload. The rating is also used for emergency service when standard power is not available. The horsepower and the rpm of the engine can be utilized continuously for a maximum of 15 minutes. This is followed by one hour of operation at the C rating or by the duration of the emergency.

The engine should be run at full load. The engine should not exceed 5 percent of the duty cycle. Typical applications include the following examples: standby centrifugal water pumps, oil field well servicing, crash trucks, portable air compressors, and gas turbine starting motors.

NOTICE Operating engines above the rating definitions can result in shorter service life before overhaul.

75 Reference Information Section Engine Ratings

76 Reference Information Section Customer Service

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Customer Service i02097871

Customer Assistance SMCS Code: 1000

USA and Canada When a problem arises concerning the operation of an engine or concerning the service of an engine, the problem will normally be managed by the dealer in your area.

Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that has not been handled to your complete satisfaction, follow these steps: 1. Discuss your problem with a manager from the dealership.

2. If your problem cannot be resolved at the dealer level without additional assistance, use the phone number that is listed below to talk with a Field Service Coordinator: 1-800-447-4986 The normal hours are from 8:00 to 4:30 Monday through Friday Central Standard Time.

3. If your needs have not been met still, submit the matter in writing to the following address: Caterpillar Inc. Manager, Customer Service, Engine Division Mossville Bldg AC P.O. Box 610 Mossville, Illinois 61552-0610 Please keep in mind: probably, your problem will ultimately be solved at the dealership, using the dealership’s facilities, equipment, and personnel.

Therefore, follow the steps in sequence when a problem is experienced.

Outside of the USA and of Canada If a problem arises outside the USA and outside Canada, and if the problem cannot be resolved at the dealer level, consult the appropriate Caterpillar office.

Latin America, Mexico, Carribean Caterpillar Americas Co. 701 Waterford Way, Suite 200 Miami, FL 33126-4670 USA Phone: 305-476-6800 Fax: 305-476-6801 Europe, Africa, and Middle East Caterpillar Overseas S.A. 76 Route de Frontenex P.O. Box 6000 CH-1211 Geneva 6 Switzerland Phone: 22-849-4444 Fax: 22-849-4544 Far East Caterpillar Asia Pte. Ltd. 7 Tractor Road Jurong, Singapore 627968 Republic of Singapore Phone: 65-662-8333 Fax: 65-662-8302 China Caterpillar China Ltd. 37/F., The Lee Gardens 33 Hysan Avenue Causeway Bay G.P.O. Box 3069 Hong Kong Phone: 852-2848-0333 Fax: 852-2848-0440 Japan Shin Caterpillar Mitsubishi Ltd. SBS Tower 10-1, Yoga 4-Chome Setagaya-Ku, Tokyo 158-8530 Japan Phone: 81-3-5717-1150 Fax: 81-3-5717-1177 Japan Caterpillar Power Systems, Inc. SBS Tower (14th floor) 4-10-1, Yoga Setagaya-Ku, Tokyo 158-0097 Phone: 81-3-5797-4300 Fax: 81-3-5797-4359 Australia and New Zealand Caterpillar of Australia Ltd. 1 Caterpillar Drive Private Mail Bag 4 Tullamarine, Victoria 3043 Australia Phone: 03-9953-9333 Fax: 03-9335-3366

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77 Reference Information Section Customer Service

i01028392

Ordering Replacement Parts SMCS Code: 7567

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications 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.

Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world.

Caterpillar dealers’ parts inventories are up-to-date.

The parts stocks include all of the parts that are normally needed to protect your Caterpillar engine investment.

When you order parts, please specify the following information:

• Part number • Part name • Quantity If there is a question concerning the part number, please provide your dealer with a complete description of the needed item.

When a Caterpillar engine requires maintenance and/or repair, provide the dealer with all the information that is stamped on the Information Plate.

This information is described in this Operation and Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the dealer about the conditions of the problem and the nature of the problem. Inform the dealer about when the problem occurs. This will help the dealer in troubleshooting the problem and solving the problem faster.

78 Reference Information Section Reference Materials

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Reference Materials

• Special Publication, SEBD0970, “Coolant and Your Engine”

i02708607

Reference Material SMCS Code: 1000

• Label, PEEP5027, “Extended Life Coolant/ Antifreeze”

Miscellaneous

The following literature can be obtained through any Caterpillar dealer.

• Service Manual, REG1139F, “Service Manual

Lubricants

• Service Manual, KENR6217, “C4.4 Industrial

• Special Publication, PEHP8038, “Data Sheet -

• Systems Operation, Testing and Adjusting,

Caterpillar Diesel Engine Oils (DEO) (CH-4) (North America)”

• Special Publication, PEHP9536, “Data Sheet - Caterpillar Diesel Engine Oil (DEO) (CF-4) (International only)”

• Special Publication, NEDG6022, “Cat Lubricating Grease”

• Special Publication, PEHP0002, “Data Sheet Molybdenum (MPGM) Grease”

• Special Publication, NEHP6015, “Data Sheet Caterpillar Special Purpose Grease (SPG)”

• Special Publication, SEBD0640, “Oil and Your Engine”

• Operation and Maintenance Manual, SEBU5898, “Cold Weather Recommendations”

• Operation and Maintenance Manual, SEBU6251,

Contents Microfiche” Engines”

RENR9965, “C4.4 Industrial Engines”

• Specifications, RENR9961, “C4.4 Industrial Engines.”

• Disassembly and Assembly, KENR6216, “C4.4 Industrial Engines”

• Specifications, SENR3130, “Torque Specifications” • Special Publication, PECP9067, “One Safe Source” English language for use in NACD

• Special Publication, LEDM5615, “Caterpillar

Marine Parts and Service Locations Directory”

• Special Publication, SEBF8029, “Index to

Guidelines for Reusable Parts and Salvage Operations”

• Special Publication, SEBF8062, “Procedure to Inspect and Clean Air Filters”

“Caterpillar Commercial Diesel Engine Fluids Recomendations”

• Special Instruction, SEHS9031, “Storage

• Special Publication, PEHP6001, “How To Take A

• Special Publication, NEHS0526, “Service

Good Oil Sample”

Fuels • Special Publication, SEBD0717, “Diesel Fuels and Your Engine”

Coolants • Special Publication, PEHP4036, “Data Sheet Extended Life Coolant”

• Special Publication, PEHP7057, “Data Sheet S·O·S Coolant Analysis”

• Special Publication, SEBD0518, “Know Your Cooling System”

Procedure for Caterpillar Products” Technician Application Guide”

• Special Publication, SEBU6251, “Caterpillar

Commercial Diesel Engine Fluids Recomendations”

• Special Instruction, SEHS7633, “Battery Test Procedure”

• Label, SEHS7332, “Danger Do Not Operate”

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79 Reference Information Section Reference Materials

Emissions Warranty This engine may be Certified and this engine may be covered by an Emissions Warranty. A detailed explanation of the Emissions Warranty that is applicable to Certified engines is found in Supplement, SMBU6981, “Emissions Control Warranty Information”. The engine is Certified if the engine has a special label that verifies the certification. A Caterpillar dealer can also inform you if the engine is certified. i01775229

Additional Reference Material SMCS Code: 1000 The “Engine Fluids Data Book” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult EMA at the following address: Engine Manufacturers Association Two North LaSalle Street, Suite 2200 Chicago, Illinois, USA 60602 E-mail: ema@enginemanufacturers.org (312) 827-8700 Facsimile: (312) 827-8737 The “Society of Automotive Engineers (SAE) Specifications” can be found in your SAE handbook.

This publication can also be obtained from the following locations: local technological society, local library, and local college. If necessary, consult SAE at the following address: SAE International 400 Commonwealth Drive Warrendale, PA, USA 15096-0001 Telephone: (724) 776-4841 The “American Petroleum Institute Publication No. 1509” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult API at the following address: American Petroleum Institute 1220 L St. N.W. Washington, DC, USA 20005 Telephone: (202) 682-8000 The International Organization for Standardization (ISO) offers information and customer service regarding international standards and standardizing activities. ISO can also supply information on the following subjects that are not controlled by ISO: national standards, regional standards, regulations, certification, and related activities. Consult the member of ISO in your country.

International Organization for Standardization (ISO) 1, rue de Varembé Case postale 56 CH-1211 Genève 20 Switzerland Telephone: +41 22 749 01 11 Facsimile: +41 22 733 34 30 E-mail: central@iso.ch Web site: http://www.iso.ch European classifications are established by the Counseil International Des Machines a Combustion (CIMAC) (International Council on Combustion Engines).

CIMAC Central Secretariat Lyoner Strasse 18 60528 Frankfurt Germany Telephone: +49 69 6603 1567 Facsimile: +49 69 6603 1566 i02707212

Maintenance Records SMCS Code: 1000 Caterpillar Inc. recommends the retention of accurate maintenance records. Accurate maintenance records can be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other engines that are operated in the same environment.

• Show compliance with the required maintenance practices and maintenance intervals.

Maintenance records can be used for a variety of other business decisions that are related to engine maintenance.

Maintenance records are a key element of a maintenance program that is well managed. Accurate maintenance records can help your Caterpillar dealer to fine tune the recommended maintenance intervals in order to meet the specific operating situation. This should result in a lower engine operating cost.

Records should be kept for the following items: Fuel Consumption – A record of fuel consumption is essential in order to determine when the load sensitive components should be inspected or repaired. Fuel consumption also determines overhaul intervals.

80 Reference Information Section Reference Materials

Service Hours – A record of service hours is essential to determine when the speed sensitive components should be inspected or repaired.

Documents – A record of all documents should be obtained, and all documents should be kept in the engine history file. All of the documents should show this information: date, service hours, fuel consumption, unit number, and engine serial number.

The following types of documents should be kept as proof of maintenance or repair for warranty: Keep the following types of documents as proof of maintenance for warranty. Also, keep these types of documents as proof of repair for warranty:

• Dealer work orders and itemized bills • Owner’s repair costs • Owner’s receipts • Maintenance log

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81 Reference Information Section Reference Materials

i02705982

Maintenance Log SMCS Code: 1000 Table 12

Engine Model

Customer Identifier

Serial Number

Arrangement Number

Service Hours

Quantity Of Fuel

Service Item

Date

Authorization

82 Index Section

SEBU8327

Index Customer Service .................................................. 76

A Additional Reference Material ...............................

After Starting Engine .............................................

After Stopping Engine............................................

Alternator - Inspect ................................................

Alternator Belt - Inspect/Adjust/Replace (Poly V-Belt)..................................................................

Adjustment .........................................................

Inspection...........................................................

Replace..............................................................

79 27 30 41 41 41 41 41

B Battery - Replace................................................... 41 Battery Electrolyte Level - Check .......................... 42 Battery or Battery Cable - Disconnect ................... 42 Before Starting Engine .................................... 13, 25 Burn Prevention..................................................... 10 Batteries............................................................. 10 Coolant............................................................... 10 Oils..................................................................... 10 C Cold Weather Operation........................................

Cold Weather Starting ...........................................

Cooling System Coolant (DEAC) - Change...........

Cooling Systems with Heavy Deposits or Plugging ...........................................................

Drain ..................................................................

Fill ......................................................................

Flush ..................................................................

Cooling System Coolant (ELC) - Change..............

Drain ..................................................................

Fill ......................................................................

Flush ..................................................................

Cooling System Coolant Level - Check .................

Engines With a Coolant Recovery Tank.............

Engines Without a Coolant Recovery Tank........

Cooling System Coolant Sample (Level 1) Obtain ..................................................................

Cooling System Coolant Sample (Level 2) Obtain ..................................................................

Cooling System Supplemental Coolant Additive (SCA) - Test/Add..................................................

Add the SCA, If Necessary ................................

S·O·S Coolant Analysis......................................

Test for SCA Concentration ...............................

Cooling System Water Temperature Regulator Replace................................................................

Crankcase Breather (Canister) - Replace .............

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

Customer Assistance.............................................

Outside of the USA and of Canada....................

USA and Canada ...............................................

31 26 43 44 43 44 44 45 45 46 45 46 46 47 47 48 48 49 49 48 49 50 12 76 76 76

D Driven Equipment - Check..................................... 50 E Electrical System ................................................... 14 Grounding Practices .......................................... 14 Emergency Stopping ............................................. 30 Emissions Certification Film .................................. 20 Emissions Warranty Information............................ 73 Engaging the Driven Equipment............................ 28 Engine - Clean....................................................... 51 Engine Air Cleaner Element (Dual Element) Clean/Replace ..................................................... 51 Cleaning the Primary Air Cleaner Elements ...... 52 Servicing the Air Cleaner Elements ................... 51 Engine Air Cleaner Element (Single Element) Inspect/Replace ................................................... 54 Engine Air Cleaner Service Indicator - Inspect...... 54 Test the Service Indicator................................... 54 Engine Air Precleaner - Check/Clean.................... 55 Engine Description ................................................ 17 Engine Cooling and Lubrication ......................... 18 Engine Service Life ............................................ 18 Engine Specifications......................................... 18 Engine Mounts - Inspect........................................ 55 Engine Oil and Filter - Change .............................. 56 Drain the Engine Oil........................................... 57 Fill the Engine Crankcase .................................. 58 Replace the Spin-on Oil Filter ........................... 57 Engine Oil Level - Check ....................................... 55 Engine Oil Sample - Obtain ................................... 56 Obtain the Sample and the Analysis.................. 56 Engine Operation................................................... 28 Engine Protective Devices - Check ....................... 58 Visual Inspection................................................ 59 Engine Rating Conditions ...................................... 74 Engine Rating Definitions ...................................... 74 Engine Ratings ...................................................... 74 Engine Shutoffs and Engine Alarms...................... 24 Alarms................................................................ 24 Shutoffs.............................................................. 24 Testing the Shutoff and Alarm System............... 24 Engine Starting ................................................ 13, 25 Engine Stopping .............................................. 14, 30 Engine Valve Lash - Inspect/Adjust ....................... 59 Engine Warm-up.................................................... 28 F Features and Controls ........................................... 24

SEBU8327

Fire Prevention and Explosion Prevention ............ 10 Ether .................................................................. 12 Fire Extinguisher ................................................ 12 Lines, Tubes and Hoses .................................... 12 Foreword ................................................................. 5 California Proposition 65 Warning ....................... 5 Literature Information........................................... 4 Maintenance ........................................................ 4 Maintenance Intervals.......................................... 4 Operation ............................................................. 4 Overhaul .............................................................. 4 Safety................................................................... 4 Fuel and the Effect from Cold Weather ................. 31 Fuel Conservation Practices.................................. 29 Fuel Injection Nozzles - Test/Exchange................. 59 Removal and Installation of the Fuel Injection Nozzles ............................................................ 60 Fuel Related Components in Cold Weather .......... 32 Fuel Filters ......................................................... 32 Fuel Heaters ...................................................... 32 Fuel Tanks.......................................................... 32 Fuel Shutoff ........................................................... 24 Fuel System - Prime .............................................. 60 Fuel System Primary Filter/Water Separator Drain .................................................................... 61 Fuel System Secondary Filter - Replace ............... 61 Element filter ...................................................... 62 Spin-on filter....................................................... 62 Fuel Tank Water and Sediment - Drain ................. 63 Drain the Water and the Sediment..................... 64 Fuel Storage Tanks ............................................ 64 Fuel Tank ........................................................... 63

83 Index Section

M Maintenance Interval Schedule .............................

Maintenance Log ...................................................

Maintenance Records............................................

Maintenance Section .............................................

Model View Illustrations.........................................

Engine Model Views ..........................................

Model Views ..........................................................

Mounting and Dismounting....................................

40 81 79 33 16 16 15 13

O Operation Section..................................................

Ordering Replacement Parts .................................

Overhaul Considerations .......................................

Oil Consumption as an Overhaul Indicator ........

Overhaul Recommendation ...............................

22 77 65 65 66

P Plate Locations and Film Locations.......................

Serial Number Plate (1) .....................................

Product Identification Information ..........................

Product Information Section ..................................

Product Lifting........................................................

Product Storage.....................................................

19 19 19 15 22 22

R

Important Safety Information ................................... 2

Radiator - Clean ....................................................

Radiator Restrictions .............................................

Reference Information Section ..............................

Reference Material ................................................

Coolants.............................................................

Emissions Warranty ...........................................

Fuels ..................................................................

Lubricants ..........................................................

Miscellaneous ....................................................

Reference Materials ..............................................

Reference Numbers ..............................................

Record for Reference.........................................

Refill Capacities.....................................................

Refill Capacities and Recommendations...............

Coolant Recommendations................................

Engine Oil ..........................................................

General Coolant Information..............................

General Fuel Information ...................................

Lubricating Grease.............................................

Refill Capacity of the Cooling System................

S·O·S Coolant Analysis......................................

L

S

Lifting and Storage ................................................ 22

Safety Messages ..................................................... 6 (1) Universal Warning .......................................... 6 (2) Ether ............................................................... 7

G Gauges and Indicators .......................................... 23 General Hazard Information .................................... 7 Asbestos Information ........................................... 9 Containing Fluid Spillage ..................................... 9 Dispose of Waste Properly ................................ 10 Fluid Penetration.................................................. 8 Pressurized Air and Water ................................... 8 H Hoses and Clamps - Inspect/Replace ................... 64 Replace the Hoses and the Clamps .................. 65 I

68 31 74 78 78 79 78 78 78 78 19 19 33 33 38 33 36 36 35 39 38

84 Index Section

SEBU8327

Safety Section ......................................................... 6 Severe Service Application - Check ...................... 68 Environmental Factors ....................................... 69 Improper Maintenance Procedures.................... 69 Improper Operating Procedures ........................ 69 Starting Motor - Inspect ......................................... 69 Starting the Engine ................................................ 26 Starting with Jump Start Cables ............................ 27 Stopping the Engine .............................................. 30 T Table of Contents..................................................... 3 Turbocharger - Inspect .......................................... 69 Inspecting........................................................... 70 Removal and Installation.................................... 70 V V-Belts - Inspect/Adjust/Replace ...........................

Adjustment .........................................................

Inspection...........................................................

Replace..............................................................

70 71 70 71

W Walk-Around Inspection ........................................

Inspect the Engine for Leaks and for Loose Connections .....................................................

Warranty Information .............................................

Warranty Section ...................................................

Water Pump - Inspect............................................

71 71 73 73 72

Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual.

Delivery Date:

Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:

Dealer Information Name:

Branch:

Address:

Dealer Contact Sales: Parts: Service:

Phone Number

Hours

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