Blount 2384D, 2484D OPERATOR’S MANUAL

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OPERATOR’S MANUAL

WHEEL FELLER

BUNCHER

OPERATOR’S MANUAL 2470 2570 2670

Knuckle Boom Loader 2384D & 2484D

Part No. SEBU9422

Oct. 2017 Rev. 02

KBF 1-Up KP5 1-Up KBR 1-Up KP7 1-Up

Part No. 30009235

Rev. No. 0503, 0904

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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, including human factors that can affect safety. 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 verify that you are authorized to perform this work, and 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.

A non-exhaustive list of 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. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. 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 you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, 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. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat replacement parts.

Failure to follow this warning may lead to premature failures, product damage, personal injury or death.

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

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Table of Contents

Foreword ........................................................... 4

Safety Section

Safety Messages (Knuckleboom Loader)......... 6

Additional Messages ....................................... 12

General Hazard Information............................ 18

General Hazard Information............................ 21

Crushing Prevention and Cutting Prevention.. 24

Burn Prevention............................................... 24

Fire Prevention and Explosion Prevention...... 25

Fire Prevention and Explosion Prevention...... 28

Tire Information ............................................... 31

Guards (Operator Protection) ......................... 40

Product Information Section

General Information ........................................ 41

Identification Information ................................. 47

Operation Section

Before Operation ............................................. 48

Machine Operation .......................................... 50

Controls ........................................................... 76

Engine Starting................................................ 80

Parking ............................................................ 81

Maintenance Section

Lubricant Viscosities and Refill Capacities ..... 83

Before Starting Engine .................................... 32

Engine Starting................................................ 33

Before Operation ............................................. 33

Operation......................................................... 33

Operation......................................................... 34

Engine Stopping .............................................. 34

High Pressure Fuel Lines................................ 35

Work Tools....................................................... 37

Lifting Objects.................................................. 37

Parking ............................................................ 37

Equipment Lowering with Engine Stopped ..... 38

Sound Information and Vibration Information . 38

Maintenance Support ...................................... 86

Maintenance Interval Schedule....................... 87

Reference Information Section

Reference Materials ...................................... 151

Index Section

Index.............................................................. 152

Accumulator Pressure Release ...................... 38

Operator Station .............................................. 40

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Foreword

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Foreword

Literature Information

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

This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information.

Some photographs or illustrations in this publication show details or attachments that can be different

from your machine. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. Read, study and keep this manual with the machine.

Whenever a question arises regarding your machine, or this publication, please consult your Cat dealer for the latest available information.

Safety

The safety section lists basic safety precautions. In addition, this section identifies the text and locations

of warning signs and labels used on the machine.

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

Operation

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

Maintenance Intervals

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

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

necessary.

Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed

under every 250 service hours or monthly and every 10 service hours or daily.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,

birth defects, and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands

after handling.

Certified Engine Maintenance

Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual.

Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities.

Maintenance

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

safe source" for all maintenance procedures.

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Foreword

It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 89). Certain elements of the machine and engine such as the exhaust system, fuel system, electrical system, intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar.

Machine Capacity

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

Cat Product Identification Number

Effective First Quarter 2001 the Cat Product Identification Number (PIN) has changed from 8 to 17

characters. In an effort to provide uniform equipment identification, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard. Non-road machine PINs are defined by ISO 10261. The new PIN format will apply to all Cat machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the

following:

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

format.

Components such as engines, transmissions, axles, etc. and work tools will continue to use an 8 character

Serial Number (S/N).

Illustration 1 g00751314

Where:

1. Caterpillar's World Manufacturing Code (characters 1-3)

2. Machine Descriptor (characters 4-8)

3. Check Character (character 9)

4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number.

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Safety Section Safety Messages

Safety Section

Safety Messages

(Knuckleboom Loader)

SMCS Code: 7000

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Safety Section

Knuckleboom Loader

Illustration 2 g06167665

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Safety Section Knuckleboom Loader

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Illustration 3 g03337559

There are several specific safety messages on this machine. The exact location of the hazards and the

description of the hazards are reviewed in this section. Become familiarized with all safety

messages.

Make sure that all the safety messages are legible. Clean the safety messages or replace the safety messages if you cannot read the words. Replace the illustrations if the illustrations are not visible. When

you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall.

Do Not Operate (1)

Safety Message (1) is located in the cab on the door of the machine.

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Illustration 4 g01055734

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed

the warnings could result in injury or death. Contact any Prentice dealer for replacement manuals. Proper care is your responsibility.

Safety Section

Knuckleboom Loader

Refer to Operation and Maintenance Manual“Specifications” for further information.

Improper Connections for Jump Start Cables (3)

Safety Message (3) is on the battery tie-down bracket inside the battery access cover.

Illustration 6 g01370909

Read and understand the operators manual before operating or performing maintenance on machine.

Electrocution (2)

This safety message (2) is located inside the cab on the door.

Illustration 5 g01506733

Electrocution Hazard! Keep the machine and attachments a safe distance from electrical

power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the

instructions and warnings will cause serious injury or death

Explosion Hazard! Improper jumper cable connections can cause an explosion resulting in serious injury or death. Batteries may be located in separate compartments. Refer to the Operation and Maintenance Manual for the correct jump starting procedure.

Refer to Operation and Maintenance Manual, “Engine Staring with Jump-Start Cables”.

Product Link (4) (If Equipped)

Safety Message (4) is on the cab door.

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Safety Section Knuckleboom Loader

Illustration 7 g01370917

This machine is equipped with a Cat Product Link communication device. Deactivate in or near a

blast site in compliance with applicable legal requirements. Failure to do so could cause interference with blasting operations resulting in serious injury or death.

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This machine has been certified to the standards that are listed on the certification plate.

Aerosol Starting Aid (6)

This safety message (6) is on the hood cross member above the cooling package access door near the Operator access platform.

Illustration 9 g01067463

Refer to Special Instruction, REHS1642, “Operation of the Product Link System” for additional information.

Do Not Weld On The FOPS (5)

Safety message (5) is on the inside front right-hand corner post of the cab.

Illustration 8 g01390454

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

Refer to Operation and Maintenance Manual, “Engine Starting” for further information.

Crush Point (7)

Safety Message (7) is on the left and right sides of the machine near the back plate. Film to be on sloped surface of side plates.

Structural damage, an overturn, modification, alteration, or improper repair can impair this structures protection capability thereby voiding this certification. Do not weld on or drill holes in the

structure. Consult a Prentice dealer to determine the structures limitations without voiding the

structures certification.

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Illustration 10 g01055930

Machine swings. Stay back. Crushing hazard could cause serious injury or death.

Crushing could cause serious injury or death. Turn off key to shutdown machine. Read the Operation and Maintenance Manual for further instruction.

Before operating or rotating machine, verify that all personnel are clear of the area. Do swing machine unless you have read and understand the correct operating procedure in the Operation and Maintenance Manual.

Crushing Hazard (8)

Safety Section

Knuckleboom Loader

Illustration 11 g01385579

A crushing hazard exists when the stick and boom are in motion and when the machine is

being used in object handling applications. Failure to stay clear of the stick and boom when the machine is in operation can result in personal injury or death. Stay clear of the stick and boom when the machine is in operation.

This safety message (8) is on both sides of the stick boom forward of the stick cylinder rod.

Verify that no personnel or objects are in the work path of the stick and boom when operating machine.

Do Not Step (9)

This safety message (9) is on the hood surface near the Operator access platform.

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Safety Section Additional Messages

Illustration 12 g00989364

Do not use this surface as a step or platform. This surface may not support additional weight or may be slippery. Serious injury or death could occur from a fall.

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Exceeding speeds of 50 MPH while transporting machine can cause tire malfunction. Refer to

Operation and Maintenance Manual, “Transportation”.

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Do not step on engine enclosure structure. The engine enclosure is not designed to support a persons weight and may be slippery.

Tire Malfunction (10) (Maximum Speed)

This safety message (if equipped) (10) is on each side of the carrier trailer.

Illustration 13 g03236217

Tire Malfunction could cause serious personal injury or death. Keep speed below 50 MPH when transporting. Read Operation and Maintenance Manual.

Additional Messages

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SMCS Code: 7000

Safety Section

Additional Messages

Illustration 14 g06243463

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Safety Section Additional Messages

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Illustration 15 g06164645

There are several specific messages on this

Diesel Fuel Requirements (1)

machine. The location of the messages and the description of the messages are reviewed in this section. Become familiarized with all messages.

This message is located next to the fuel filler cap in the fuel fill access compartment.

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

messages. Loose adhesive will allow the messages to fall.

Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, install a message on the replacement part. Any Prentice dealer can provide new messages.

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Safety Section

Additional Messages

Illustration 16 g02157153

NOTICE

Ultra Low Sulfur Diesel (ULSD) fuel will have ≤15 ppm (0.0015%) sulfur using the “ASTM D5453”, “ASTM D2622”, or “DIN 51400” test methods. Certain

applications and/or governments/localities MAY require the use of ULSD fuel. Emission controlled diesel engines and/or diesel engines equipped with exhaust aftertreatment devices MAY require the use of Ultra Low Sulfur Diesel (ULSD) fuel. Consult federal, state, and local authorities for guidance on fuel requirements for your area. Also, consult the specific engine Operation and Maintenance Manual for guidance.

Caterpillar does not mandate the across the board use of ULSD fuel in non-road and stationary applications, but does allow its use. When ULSD is used,

there are concerns with fuel viscosity, lubricity, and thermal stability. The fuel viscosity, lubricity, and thermal stability limits stated in the Caterpillar Specification for Distillate Diesel Fuel address these concerns.

In North America, diesel fuel that is identified as “ASTM D975 Grade No. 1-D S15” or “ASTM D975 Grade No. 2-D S15” and meet the “ASTM D975 Thermal Stability Guideline X2.10.2.2”, generally meet the

Caterpillar requirements for ULSD fuel.

Illustration 17 g01418953

The Product Link System is a satellite or cellular communication device that transmits information

regarding the machine back to Prentice dealers and customers. All logged events and diagnostic codes that are available to the Cat Electronic Technician

(ET) can be sent to satellite or cellular tower. Information can also be sent to the Product Link

System. The information is used to improve Cat products and Cat services.

Air Conditioner (3)

This message is on the left-hand front of the heater/ evaporator assembly.

2007 and newer mdoel lyear on-highway diesel engines are required to use fuel with 15 ppm or less sulfur.

Product Link (2)

Your machine is equipped with the Product Link System, this additional message is on the cab door.

Illustration 18 g03338001

This message for the air conditioner has the appropriate information for the following services: the air conditioner lubricant.

Follow instruction to avoid engine damage.

Reference: See Operation and Maintenance Manual, “Maintenance Interval Schedule” for all maintenance recommendations.

Alternate Exit (4)

This message is on the lower front corner of the righthand sliding window.

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Safety Section Additional Messages

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Illustration 19 g03337999

This message indicates the correct alternate exit path.

Window Cleaning (5)

This message is on the left-hand rear corner of the skylight.

Illustration 20 g00930685

Reference: For more information, refer to Operation and Maintenance Manual, “Windows - Clean”.

Fire Point (Engine) (6)

Illustration 21 g02095974

This message describes the fire point that is available on the engine compartment. Use the aperture to suppress fire hazard in the engine compartment.

Do not use an unsafe method to suppress fire hazard in the engine compartment.

Machine Hydraulic System (7)

The following message is on the hydraulic oil fill pump pipe support bracket.

Illustration 22 g02096113

This message is on the front engine enclosure door, over the Fire Extinguisher Access Hole.

This machine hydraulic system is filled with Cat HYDO Advanced oil.

Refer to Operation and Maintenance Manual, “Lubricant Viscosities” for more information about the

hydraulic oil.

Fuse Panel Identifier (8)

The following message is on the inside console door fuse/relay panel access.

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Safety Section

Additional Messages

This message is on the right-hand side of the hydraulic tank, level with the hydraulic oil sight

gauge.

Illustration 23 g06162900

The messages on the left-hand side of the film identify the function for each fuse and the amperage of each fuse. The messages on the right-hand side of the film identify the relay functions.

Joystick Control Functions (9)

This message is located in the cab on the lower rear surface of the door window.

Illustration 24 g03233117

Illustration 25 g06162901

This message identifies the hydraulic oil fill level information.

DEO-ULS Oil Information (11)

This message is located under the oil fill access cover on the bracket supporting the remote oil fill hose.

This message identifies what function each joystick movement will initiate. Films are applied according to factory settings.

Hydraulic Oil System (10)

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Safety Section General Hazard Information

Illustration 26 g03337954

This message identifies the proper oil required for engine.

Grease Identifier (12)

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This message is on the outside of the operator cab on the lower rear corner of the front left-hand side

panel. Located near the grease fittings on the operator access platform.

Illustration 27 g03337966

This message identifies the proper grease to use for remote grease fittings.

Power Wash Prohibited(13)

This message is on the inside of the Diesel Exhaust Fluid fill access panel.

Illustration 28 g06243353

Washing with high-pressure water is prohibited in this area. Manually clean with a wet cloth or sponge.

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General Hazard Information

SMCS Code: 7000

Illustration 29 g00104545

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Prentice dealer.

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Safety Section

General Hazard Information

Obey all local regulations for the disposal of liquids.

Operating the machine while distracted can result in the loss of machine control. Use extreme cau-

tion when using any device while operating the machine. Operating the machine while distracted can result in personal injury or death.

Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles.

Be aware of high voltage power lines and power cables that are buried. If the machine comes in

contact with these hazards, serious injury or death may occur from electrocution.

Use all cleaning solutions with care. Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.

When maintenance is performed above ground level, use appropriate devices such as ladders or man lift machines. If Equipped, use the machine anchorage points and use approved fall arrest harnesses and lanyards.

Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. The debris and/or hot water 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.

Illustration 30 g00702020

Wear a hard hat, protective glasses, and other protective equipment, as required.

Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment.

Make sure that all protective guards and all covers are secured in place on the equipment.

Keep the equipment free from foreign material. Remove debris, oil, tools, and other items from the

deck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools, and other items that are not a part of the equipment.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.

Do not smoke when you service an air conditioner. Also, do not smoke if refrigerant gas may be present. Inhaling the fumes that are released from a flame that contacts air conditioner refrigerant can cause bodily harm or death. Inhaling gas from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death.

Never put maintenance fluids into glass containers. Drain all liquids into a suitable container.

The maximum air pressure for cleaning purposes must be reduced to 448 kPa (65 psi) when the nozzle is deadheaded and the nozzle is used with an

effective chip deflector and personal protective equipment. The maximum water pressure for cleaning purposes must be below 448n kPa (65 psi).

Avoid direct spraying of water on electrical connectors, connections, and components. When using air for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when redeposited on hot surfaces.

Trapped Pressure

Pressure can be trapped in a hydraulic system. Accumulators in a hydraulic system will store pressure. Allow a sufficient amount of time for the pressure that is stored in the accumulators to be released. Releasing trapped pressure can cause sudden machine movement or attachment

movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip. High-pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and possible death.

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.

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Safety Section General Hazard Information

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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 Service Manual for any procedures that are required to relieve the hydraulic pressure.

Illustration 31 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 equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Tools and Shop Products Guide” for the following items:

• Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids and equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Inhalation

Illustration 32 g02159053

Exhaust

Use caution. Exhaust fumes can be hazardous to your health. If you operate the machine in an

enclosed area, adequate ventilation is necessary.

Asbestos Information

Prentice equipment and replacement parts that are shipped from Caterpillar are asbestos free. Prentice recommends the use of only genuine Prentice 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.

• Avoid brushing materials that contain asbestos.

• 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.

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• Use exhaust ventilation on permanent machining jobs.

• Wear an approved respirator if there is no other way to control the dust.

• Obey environmental regulations for the disposal of asbestos.

Safety Section

General Hazard Information

• Stay away from areas that might have asbestos particles in the air.

Dispose of Waste Properly

Illustration 33 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.

Illustration 34 g00104545

Typical example

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls. Attach the warning tag before you service the equipment or before you repair the equipment. Warning tag SEHS7332 is available from your Cat dealer.

Operating the machine while distracted can result in the loss of machine control. Use extreme cau-

tion when using any device while operating the machine. Operating the machine while distracted can result in personal injury or death.

Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles.

Be aware of high voltage power lines and power cables that are buried. If the machine comes in

contact with these hazards, serious injury or death may occur from electrocution.

General Hazard Information

SMCS Code: 7000

S/N: KP51–Up

i07046904

Illustration 35 g00702020

Wear a hard hat, protective glasses, and other protective equipment, as required.

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Safety Section General Hazard Information

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Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment.

Make sure that all protective guards and all covers are secured in place on the equipment.

Keep the equipment free from foreign material. Remove debris, oil, tools, and other items from the

deck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools, and other items that are not a part of the equipment.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.

Never put maintenance fluids into glass containers. Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Trapped Pressure

Pressure can be trapped in a hydraulic system. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use

caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip. High-pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and possible death.

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the machine 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.

When you perform maintenance above ground level, use appropriate devices such as ladders or man lift machines. If equipped, use the machine anchorage points and use approved fall arrest harnesses and lanyards.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. The debris and/or hot water 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 reduced to 205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used with an

effective chip deflector and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

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Illustration 36 g00687600

Containing Fluid Spillage

Safety Section

General Hazard Information

Obey all local regulations for the disposal of liquids.

Inhalation

Illustration 37 g02159053

Exhaust

Use caution. Exhaust fumes can be hazardous to your health. If you operate the machine in an

enclosed area, adequate ventilation is necessary.

Care must be taken in order to ensure that fluids are contained during performance of inspection,

maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “Cat dealer Service Tool Catalog” for the following items:

• Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids and equipment that is suitable for containing fluids

Asbestos Information

Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Cat 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 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.

• Avoid brushing materials that contain asbestos.

• 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.

Page 24

Safety Section Crushing Prevention and Cutting Prevention

SEBU9422-02

• Use exhaust ventilation on permanent machining jobs.

• Wear an approved respirator if there is no other way to control the dust.

• 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”. In Japan, use the requirements found in the “Ordinance on Prevention of Health Impairment due to Asbestos” in addition to the requirements of the Industrial Safety and Health Act.

• Obey environmental regulations for the disposal of asbestos.

• Stay away from areas that might have asbestos particles in the air.

Dispose of Waste Properly

Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks.

Do not work beneath the cab of the machine unless the cab is properly supported.

Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.

Never jump across the starter solenoid terminals in order to start the engine. Unexpected machine movement could result.

Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine. Stay clear of areas that may have a sudden change in clearance with machine movement or equipment

movement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is performed.

Illustration 38 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.

i01359664

Crushing Prevention and Cutting Prevention

SMCS Code: 7000

Keep objects away from moving fan blades. The fan blade will throw objects or cut objects.

Do not use a kinked wire cable or a frayed wire cable. Wear gloves when you handle wire cable.

When you strike a retainer pin with force, the retainer pin can fly out. The loose retainer pin can injure personnel. Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear protective glasses when you strike a retainer pin.

Chips or other debris can fly off an object when you strike the object. Make sure that no one can be injured by flying debris before striking any object.

i05294650

Burn Prevention

SMCS Code: 7000

S/N: KP51–Up

Do not touch any part of an operating engine system. The engine, the exhaust, and the engine aftertreatment system can reach temperatures as high as 650° C (1202° F) under normal operating conditions.

S/N: KP51–Up

Allow the engine system to cool before any maintenance is performed. Relieve all pressure in the air system, hydraulic system, lubrication system, fuel system, and the cooling system before the related items are disconnected.

Page 25

SEBU9422-02

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

After the engine has stopped, wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines.

Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before disconnecting any lines, fittings, or related items.

Induction System

Safety Section

Fire Prevention and Explosion Prevention

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

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

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.

i05185212

Sulfuric Acid Burn Hazard may cause serious personal injury or death.

The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sul-

fur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid

may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.

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.

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 that 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.

Fire Prevention and Explosion Prevention

SMCS Code: 7000

Illustration 39 g00704000

General

Much of the material found in forestry applications is highly flammable, including limbs, bark, leaves, saw dust, small wood chips and pine needles. When the forestry debris is soaked with fuel or lubricants, the risk of fire is greatly increased SEBD1901. Doing a daily inspection before every shift, or more often based on the work activity and build-up of debris, is the best way to prevent a machine fire. Frequent inspections and thorough machine cleaning are critical when engaged in forestry operations. Even minor leaks or electrical malfunctions should be

repaired as soon as possible. SEBD1901

All fuels, most lubricants, and some coolant mixtures are flammable.

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Safety Section Fire Prevention and Explosion Prevention

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To minimize the risk of fire or explosion, Prentice recommends the following actions.

Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists. Contact your Prentice dealer for service.

Understand the use of the primary exit and alternative exit on the machine. Refer to Operation and Maintenance Manual, “Alternative Exit”.

Do not operate a machine with a fluid leak. Repair leaks and clean up fluids before resuming machine operation. Fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. A fire may cause personal injury or death.

Remove flammable material such as leaves, twigs, papers, trash, and so on. These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine. Highly flammable debris such as leaves, twigs, saw dust, small wood chips and pine needles can collect on and in equipment used in forestry operations. If allowed to accumulate, the debris can rapidly become the fuel component of a machine fire. Clean all accumulations of forest debris in the engine compartment or around other hot areas and hot parts on the machine at eh completion of each work shift or more frequently when working in conditions where large amounts of forest debris are present.

Keep the access doors to major machine compartments closed and access doors in working condition in order to permit the use of fire suppression equipment, in case a fire should occur.

Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and flammable materials in protective containers. Do not smoke in areas that are used for

storing flammable materials.

Illustration 40 g00704059

Use caution when you are fueling a machine. Do not smoke while you are fueling a machine. Do not fuel a machine near open flames or sparks. Always stop the engine before fueling. Fill the fuel tank outdoors. Properly clean areas of spillage.

Clean all accumulations of flammable materials such as fuel, oil, and debris from the machine.

Do not operate the machine near any flame.

Keep shields in place. Exhaust shields (if equipped) protect hot exhaust components from oil spray or fuel spray in case of a break in a line, in a hose, or in a seal. Exhaust shields must be installed correctly.

Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material. Empty and

purge the lines and tanks. Then clean the lines and tanks with a nonflammable solvent prior to welding or flame cutting. Ensure that the components are properly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallic hoods or fenders may be flammable and/or explosive. Repair such components in a well ventilated area away from open flames or sparks. Use suitable Personal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration. Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. Tighten all connections to the recommended torque. Damage to the protective cover or insulation may provide fuel for fires.

Page 27

SEBU9422-02

Safety Section

Fire Prevention and Explosion Prevention

Never store flammable fluids in the operator compartment of the machine.

Battery and Battery Cables

Illustration 41 g02298225

• Cracking

• Discoloration

• Cuts on the insulation of the cable

• Fouling

• Corroded terminals, damaged terminals, and loose terminals

Replace damaged battery cable(s) and replace any related parts. Eliminate any fouling, which may have caused insulation failure or related component damage or wear. Ensure that all components are reinstalled correctly.

An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface. A battery cable short produces heat from the battery current, which may be a fire hazard.

An exposed wire on the ground cable between the battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes into contact with a grounded surface. This may result in an unsafe condition for servicing the machine. Repair components or replace components before servicing the machine.

Prentice recommends the following in order to minimize the risk of fire or an explosion related to the battery.

Do not operate a machine if battery cables or related parts show signs of wear or damage. Contact your Prentice dealer for service.

Follow safe procedures for engine starting with jumpstart cables. Improper jumper cable connections can cause an explosion that may result in injury. Refer to Operation and Maintenance Manual, “Engine Starting with Jump Start Cables” for specific instructions.

Do not charge a frozen battery. This may cause an explosion.

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 in order to check the battery charge.

Daily inspect battery cables that are in areas that are visible. Inspect cables, clips, straps, and other restraints for damage. Replace any damaged parts. Check for signs of the following, which can occur over time due to use and environmental factors:

• Fraying

• Abrasion

Fire on a machine can result in personal injury or death. Exposed battery cables that come into contact with a grounded connection can result in fires. Replace cables and related parts that show signs of wear or damage. Contact your Prentice dealer.

Wiring

Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine.

• Fraying

• Signs of abrasion or wear

• Cracking

• Discoloration

• Cuts on insulation

• Other damage

Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation.

Page 28

Safety Section Fire Prevention and Explosion Prevention

SEBU9422-02

Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should

be avoided.

Consult your Prentice dealer for repair or for replacement parts.

Keep wiring and electrical connections free of debris.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are bent or damaged. Use the appropriate backup wrenches in order to tighten all connections to the recommended torque.

Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, excessive heat, and failure of lines, tubes, and hoses.

Do not operate a machine when a fire hazard exists. Repair any lines that are corroded, loose, or damaged. Leaks may provide fuel for fires. Consult your Prentice dealer for repair or for replacement parts. Use genuine Prentice parts or the equivalent, for capabilities of both the pressure limit and temperature limit.

Ether

Ether (if equipped) is commonly used in cold-weather applications. Ether is flammable and poisonous.

Follow the correct cold engine starting procedures. Refer to the section in the Operation and Maintenance Manual with the label “Engine Starting”

Do not spray ether manually into an engine if the machine is equipped with a thermal starting aid for cold weather starting.

Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you

are using an ether spray.

Illustration 42 g00687600

Check lines, tubes, and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. 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.

Replace the affected 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 swelling or ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have exposed embedded armoring.

• End fittings are displaced.

Do not store ether cylinders in living areas or in the operator compartment of a machine. Do not store ether cylinders in direct sunlight or in temperatures above 49° C (120.2° 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.

Fire Extinguisher

As an additional safety measure, keep a fire extinguisher on the machine.

Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Follow the recommendations on the instruction plate.

Consider installation of an aftermarket Fire Suppression System, if the application and working

conditions warrant the installation.

i06180998

Fire Prevention and Explosion Prevention

SMCS Code: 7000

S/N: KP51–Up

Page 29

SEBU9422-02

Illustration 43 g00704000

General

All fuels, most lubricants, and some coolant mixtures are flammable.

To minimize the risk of fire or explosion, Caterpillar recommends the following actions.

Safety Section

Fire Prevention and Explosion Prevention

Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material. Empty and

Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and flammable materials in protective containers. Do not smoke in areas that are used for

storing flammable materials.

Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists. Contact your Cat dealer for service.

Understand the use of the primary exit and alternative exit on the machine. Refer to Operation and Maintenance Manual, “Alternative Exit”.

Remove flammable material such as leaves, twigs, papers, trash, and so on. These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine.

Keep the access doors to major machine compartments closed and access doors in working condition in order to permit the use of fire suppression equipment, in case a fire should occur.

Clean all accumulations of flammable materials such as fuel, oil, and debris from the machine.

Do not operate the machine near any flame.

Illustration 44 g03839130

Use caution when you are fueling a machine. Do not smoke while you are fueling a machine. Do not fuel a machine near open flames or sparks. Do not use cell phones or other electronic devices while you are refueling. Always stop the engine before fueling. Fill the fuel tank outdoors. Properly clean areas of spillage.

Page 30

Safety Section Fire Prevention and Explosion Prevention

SEBU9422-02

Avoid static electricity risk when fueling. Ultra low sulfur diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur content. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Never store flammable fluids in the operator compartment of the machine.

Battery and Battery Cables

• Fraying

• Abrasion

• Cracking

• Discoloration

• Cuts on the insulation of the cable

• Fouling

• Corroded terminals, damaged terminals, and loose terminals

Illustration 45 g03839133

Caterpillar recommends the following in order to minimize the risk of fire or an explosion related to the battery.

Do not operate a machine if battery cables or related parts show signs of wear or damage. Contact your Cat dealer for service.

Do not charge a frozen battery. This may cause an explosion.

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. Do not use cell phones or other electronic devices in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter in order to check the battery charge.

Wiring

Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine.

• Fraying

• Signs of abrasion or wear

• Cracking

• Discoloration

Page 31

SEBU9422-02

Safety Section

Tire Information

• Cuts on insulation

• Other damage

Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation.

Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should

be avoided.

Consult your Cat dealer for repair or for replacement parts.

Keep wiring and electrical connections free of debris.

Lines, Tubes, and Hoses

• Outer covers have exposed embedded armoring.

• End fittings are displaced.

Do not operate a machine when a fire hazard exists. Repair any lines that are corroded, loose, or damaged. Leaks may provide fuel for fires. Consult your Cat dealer for repair or for replacement parts. Use genuine Cat parts or the equivalent, for capabilities of both the pressure limit and temperature limit.

Ether

Ether (if equipped) is commonly used in cold-weather applications. Ether is flammable and poisonous.

Only use approved Ether canisters for the Ether dispensing system fitted to your machine, do not spray Ether manually into an engine, follow the correct cold engine starting procedures. Refer to the section in the Operation and Maintenance Manual with the label “Engine Starting” .

Illustration 46 g00687600

type of injury.

Replace the affected 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 swelling or ballooning.

• Flexible parts of the hoses are kinked.

Use ether in ventilated areas. Do not smoke while you are replacing an ether cylinder.

Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel.

Fire Extinguisher

As an additional safety measure, keep a fire extinguisher on the machine.

Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Follow the recommendations on the instruction plate.

Consider installation of an aftermarket Fire Suppression System, if the application and working

conditions warrant the installation.

i06164462

Tire Information

SMCS Code: 7000

S/N: KP51–Up

Page 32

Safety Section Before Starting Engine

SEBU9422-02

Explosions of air inflated tires have resulted from heat-induced gas combustion inside the tires. Explosions can be caused by heat that is generated by welding, by heating rim components, by external fire, or by excessive use of brakes.

A tire explosion is much more violent than a blowout. The explosion can propel the tire, the rim components, and the axle components from the machine. Stay out of the trajectory path. Both the force of the explosion and the flying debris can cause property damage, personal injury, or death.

Illustration 47 g02166933

Typical example of tire is shown

Do not approach a hot or an apparently damaged tire.

Caterpillar recommends against using water or calcium as a ballast for the tires except in machines designed for this additional mass. For those applicable machines, the maintenance section will contain instructions on the correct tire inflation and

filling procedures. Ballast, such as fluid in the tires, increases overall machine weight and may affect braking, steering, power train components, or the certification of the protective structure such as the ROPS. The use of tire/rim rust preventatives or other liquid additives is not required.

Proper nitrogen inflation equipment, and training in using the equipment, are necessary to avoid over inflation. A tire blowout or rim failure can re-

sult from improper or misused equipment and personal injury or death can occur.

A tire blowout and/or rim failure can occur if the inflation equipment is not used correctly, due to

the fact that a fully charged nitrogen cylinder's pressure is approximately 15000 kPa (2200 psi).

Dry nitrogen gas is recommended for inflation of tires. If the tires were originally inflated with air, nitrogen is still preferred for adjusting the pressure. Nitrogen mixes properly with air.

Nitrogen inflated tires reduce the potential of a tire explosion because nitrogen does not aid combustion. Nitrogen helps to prevent oxidation of the rubber, deterioration of rubber, and corrosion of rim

components.

To avoid overinflation, proper nitrogen inflation equipment and training in the usage of the equipment are necessary. A tire blowout or a rim failure can result from improper equipment or from misused equipment.

When you inflate a tire, stand behind the tread and use a self-attaching chuck.

Servicing tires and rims can be dangerous. Only trained personnel that use proper tools and proper procedures should perform this maintenance. If correct procedures are not used for servicing tires and rims, the assemblies could burst with explosive force. This explosive force can cause serious personal injury or death. Carefully obey the specific instructions from your tire dealer.

i05069109

Before Starting Engine

SMCS Code: 1000; 7000

S/N: KP51–Up

Start the engine only from the operator compartment. Never short across the starter terminals or across the

batteries. Shorting could bypass the engine neutral start system. Shorting could also damage the electrical system.

Inspect the condition of the seat belt and the condition of mounting hardware. Replace any damaged parts or worn parts. Regardless of appearance, replace the seat belt after 3 years of use. Do not use an extension for a seat belt on a

retractable seat belt.

Adjust the seat so that full pedal travel can be achieved. Make sure that the operator's back is against the back of the seat. Adjust the seat only when the controls are de-energized.

Make sure that the machine is equipped with a lighting system that is adequate for the job conditions. Ensure that all lights are in proper working condition.

Make sure that there are no personnel in the area before you start the engine. Make sure that there are no personnel in the area before you move the machine. Make sure that there are no personnel on the machine, underneath the machine, or around the

machine.

Check for worn wires or for frayed wires. Check for loose connections in the electrical system.

Page 33

SEBU9422-02

Safety Section

Engine Starting

i05069131

Engine Starting

SMCS Code: 1000; 7000

S/N: KP51–Up

Illustration 48 g00104545

Perform the walk-around inspection before starting the engine.

If a warning tag is attached to the start switch or to the controls, do not start the engine. Also, do not move any controls.

Adjust the rear view mirrors (if equipped) for the best vision of the area near the machine.

Ensure that the horn, the alarm (if equipped), and all other warning devices are working properly.

Fasten the seat belt securely.

i05278107

Operation

SMCS Code: 7000

S/N: KP51–Up

Know the maximum height and the maximum reach of your machine. Serious injury or death by electrocution can occur if the machine or the

work tools are not kept a safe distance from electrical power lines. Keep a distance of at least 3 m (10 feet) .

For safety, one of the following may require a greater distance:

• Local codes

• State codes

Ensure that all hydraulic controls are in the HOLD position before you start the engine.

Make sure that the hydraulic activation control lever is in the LOCKED position.

Ensure that the cab door is shut.

Diesel engine exhaust contains products of combustion which can be harmful to your health. Always operate the engine in a ventilated area. If you are in an enclosed area, vent the exhaust to the

outside.

i05069191

Before Operation

SMCS Code: 7000

S/N: KP51–Up

Clear all personnel from on the machine and from the area around the machine.

Clear all obstacles from the path of the machine. Beware of hazards such as wires, ditches, ravines,

cetera.

Make sure that all windows are clean. Secure the door in the shut position. Secure the windows in the

open position or in the shut position.

• Requirements of the job site

Machine Operating Temperature Range

The standard machine configuration is intended for use within an ambient temperature range of −40 °C (−40 °F) to 50 °C (122 °F). Special configurations for different ambient temperatures may be available. Consult your CAT dealer for additional information on special configurations of your machine.

Machine Operation

Only operate the machine while you are sitting in a seat. Only operate the controls while the engine is running.

While you operate the machine slowly in an open area, check for proper operation of all controls and all protective devices.

Before you move the machine, make sure that no one will be endangered.

Do not allow riders on the machine.

Note any needed repairs during machine operation. Report any needed repairs.

Do not operate close to the edge of a cliff, an excavation, or an overhang.

Page 34

Safety Section Operation

SEBU9422-02

Avoid any conditions that can lead to tipping the machine. The machine can tip when you work on hills, on banks and on slopes.

Maintain control of the machine. Do not overload the machine beyond the machine capacity.

Make sure that the hitches and the towing devices are adequate. Only connect trailing equipment to a drawbar or to a hitch.

Never straddle a wire cable. Never allow other personnel to straddle a wire cable.

Know the maximum dimensions of your machine.

i06952586

Operation

SMCS Code: 7000

Know the maximum height and the maximum reach of your machine. Serious injury or death by electrocution can occur if the machine or the

work tools are not kept a safe distance from electrical power lines. Keep a distance of at least 3 m (10 feet) .

Do not allow riders on the machine.

Note any needed repairs during machine operation. Report any needed repairs.

Do not operate close to the edge of a cliff, an excavation, or an overhang.

Avoid any conditions that can lead to tipping the machine. The machine can tip when you work on hills, on banks and on slopes.

Maintain control of the machine. Do not overload the machine beyond the machine capacity.

Make sure that the hitches and the towing devices are adequate. Only connect trailing equipment to a drawbar or to a hitch.

Never straddle a wire cable. Never allow other personnel to straddle a wire cable.

Know the maximum dimensions of your machine.

i06843037

Engine Stopping

SMCS Code: 1000; 7000

S/N: KP51–Up

For safety, one of the following may require a greater distance:

• Local codes

• State codes

• Requirements of the job site

Machine Operating Temperature Range

The standard machine configuration is intended for use within an ambient temperature range of −40 °C (−40 °F) to 50 °C (122 °F). Special configurations for different ambient temperatures may be available. Consult your Prentice dealer for additional information on special configurations of your machine.

Machine Operation

Only operate the machine while you are sitting in a seat. Only operate the controls while the engine is running.

While you operate the machine slowly in an open area, check for proper operation of all controls and all protective devices.

Stopping the engine immediately after it has been

NOTICE

working under load can result in overheating and accelerated wear of engine components.

Refer to the following procedure to allow the engine to cool and to prevent excessive temperatures in the turbocharger housing, which could cause oil coking problems.

1. Stop the machine and run the engine at low idle for 5 minutes.

2. Turn the engine start switch to the OFF position and remove the engine start switch key.

NOTICE

Never turn the battery disconnect switch to the OFF position while the engine is running. Serious damage to the electrical system may result.

Before you move the machine, make sure that no one will be endangered.

Page 35

SEBU9422-02

Safety Section

High Pressure Fuel Lines

Illustration 49 g06138431

3. There is an emergency kill switch(1) located in the

platform of the knuckleboom loader. Activate this switch in emergency situations only.

i06858015

High Pressure Fuel Lines

SMCS Code: 1000; 1252; 1274; 7000

S/N: KP51–Up

Page 36

Safety Section High Pressure Fuel Lines

SEBU9422-02

Illustration 50 g03452057

(1) High-pressure line (2) High-pressure line (3) High-pressure line

The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the highpressure fuel manifold and the fuel lines that are

(4) High-pressure line (5) High-pressure fuel manifold (rail) (6) High-pressure supply line

Do not loosen the high-pressure fuel lines to remove air from the fuel system. This procedure is not required.

(7) High-pressure supply line

between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel

systems.

Visually inspect the high-pressure fuel lines before the engine is started. This inspection should be each day.

This difference is because of the following items:

If you inspect the engine in operation, always use the

• The high-pressure fuel lines are constantly charged with high pressure.

proper inspection procedure to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.

• The internal pressures of the high-pressure fuel lines are higher than other types of fuel system.

• Inspect the high-pressure fuel lines for damage, deformation, a nick, a cut, a crease, or a dent.

• The high-pressure fuel lines are formed to shape and then strengthened by a special process.

• Do not operate the engine with a fuel leak. If there is a leak, do not tighten the connection to stop the

Do not step on the high-pressure fuel lines. Do not deflect the high-pressure fuel lines. Do not bend or strike the high-pressure fuel lines. Deformation or damage of the high-pressure fuel lines may cause a point of weakness and potential failure.

Do not check the high-pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped, allow 90 seconds to pass to

leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines - Remove and Fuel injection lines - Install”.

• If the high-pressure fuel lines are torqued correctly and the high-pressure fuel lines are leaking, the high-pressure fuel lines must be replaced.

allow the pressure to be purged before any service or repair is performed on the engine fuel lines.

Page 37

SEBU9422-02

Safety Section

Work Tools

• Ensure that all clips on the high-pressure fuel lines are in place. Do not operate the engine with clips that are damaged, missing, or loose.

• Do not attach any other item to the high-pressure fuel lines.

• Loosened high-pressure fuel lines must be replaced. Also removed high-pressure fuel lines must be replaced. Refer to Disassembly and assembly manual, “Fuel Injection Lines - Install”.

NOTICE

The low-pressure fuel system can be pressurized for a time period after the engine has stopped operating. The operating pressure of the low-pressure fuel system can be 500 kPa (73 psi). The secondary fuel filters should be drained before any maintenance of the low-pressure fuel system is carried out.

i06952588

Work Tools

SMCS Code: 6700

Only use work tools that are recommended by Prentice for use on Prentice machines.

Use of work tools, including buckets, which are outside of Prentice recommendations or

specifications for weight, dimensions, flows, pressures, and so on. may result in less-than-optimal vehicle performance, including but not limited to reductions in production, stability, reliability, and component durability. Prentice recommends appropriate work tools for Prentice machines to maximize the valuePrentice customers receive

fromPrentice products. Prentice understands that special circumstances may lead a customer to use tools outside of Prentice specifications. In these cases, customers must be aware that such choices

can reduce vehicle performance. Affecting the customers ability to claim warranty in the event of what a customer may perceive as a premature failure.

Work tools and work tool control systems, that are compatible with your Prentice machine, are required for safe machine operation and/or reliable machine operation. If you are in doubt about the compatibility of a particular work tool with your machine, consult your Prentice dealer.

Make sure that all necessary guarding is in place on the host machine and on the work tool.

Always wear protective glasses. Always wear the protective equipment that is recommended in the operation manual for the work tool. Wear any other protective equipment that is required for the operating environment.

To prevent personnel from being struck by flying objects, ensure that all personnel are out of the work

area.

While you are performing any maintenance, any testing, or any adjustments to the work tool stay clear of the following areas: cutting edges, pinching surfaces, and crushing surfaces.

Never use the work tool for a work platform.

i02273818

Lifting Objects

SMCS Code: 7000

S/N: KP51–Up

There may be some local regulations and/or government regulations that govern the use of machines which lift heavy objects. Obey those regulations.

If this machine is used to lift objects within an area that is controlled by the European Directive “89/392/ EEC”, the machine must be equipped with a boom lowering control valve and an overload warning device.

i06919099

Parking

SMCS Code: 7000

1. Park the carrier on a level surface. If you must park

the carrier on a downgrade, block the tires or chock the tracks of the carrier.

2. Lower all work tools to the ground. Make sure that

all work tools are in the recommended servicing position before servicing the machine.

3. Move the hydraulic lockout control to the LOCKED

position. This pressure should decrease in a short time (approximately 1 minute). While the hydraulic system maintains a charge, the machine controls remain functional.

Keep all windows and doors closed on the host machine. A polycarbonate shield must be used when the host machine is not equipped with windows and when a work tool could throw debris.

Do not exceed the maximum operating weight that is listed on the machine certification.

Page 38

Safety Section Equipment Lowering with Engine Stopped

Deactivation of the hydraulic controls does not prevent the blade, boom swing, or auxiliary circuit functions from moving under gravity or other external forces. Gravity or other external forces can move the blade, boom swing, or auxiliary circuit functions suddenly if a hydraulic control lever is moved.

Personal injury or death may occur from sudden machine movement.

4. Turn the engine start switch to the OFF position

and remove the key.

5. Turn the battery disconnect switch to the OFF position. If the machine will not be operated for an extended time period, remove the key to avoid battery discharge that may be caused by a battery short circuit, by the current draw via certain components, or by vandalism.

SEBU9422-02

The operator sound exposure Leq (equivalent sound pressure level) that is measured according to the work cycle procedures specified in “ISO 5131” is __ dB(A). Measurement is for the cab that is offered by Cat, when the cab is properly installed, maintained and tested with the doors and windows closed.

The operator sound pressure level measured according to the procedures specified in “ISO 5131” is __ dB(A). During this test, the machine was in high idle and the operator fan was in the midrange position. Measurement is for the cab that is offered by Cat , when properly installed, maintained and tested with the doors and windows closed and with

the machine in middle gear range and moving.

The exterior sound pressure level for the standard machine measured at a distance of 15 m (49.2 ft) according to the test procedures specified in “ISO 6393”, with the machine in middle gear range and moving, is __ dB(A).

i06843541

Note: Do not conduct any service procedures until the DEF purge indicator lamp in not illuminated. The indicator lamp may remain illuminated for several minutes even thought eh battery disconnect switch is OFF and the engine start switch is OFF. When the indicator lamp is on the DEF system is still powered.

i01329161

Equipment Lowering with Engine Stopped

SMCS Code: 7000

S/N: KP51–Up

Before lowering any equipment with the engine stopped, clear the area around the equipment of all personnel. The procedure to use will vary with the type of equipment to be lowered. Keep in mind most systems use a high pressure fluid or air to raise or lower equipment. The procedure will cause high pressure air, hydraulic, or some other media to be released in order to lower the equipment. Wear appropriate personal protective equipment and follow the established procedure in the Operation and Maintenance Manual, “Equipment Lowering with Engine Stopped” in the Operation Section of the manual.

Accumulator Pressure Release

SMCS Code: 5077; 5077-553-ZJ

Delimber Blade Safety

Charged accumulator can close delimber blades resulting in sever personal injury or death. DO NOT enter the delimber area without closing delimber blades, shutting engine down, discharging accumulator and blocking out tilting delimber base frame.

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine can cause injury or death to persons on or near the machine.

To prevent injury or death, make sure that the area around the machine is clear of all personnel and obstructions before you test the machine.

Sound Information and Vibration Information

SMCS Code: 7000

S/N: KP51–Up

i04887388

Page 39

SEBU9422-02

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components

or lines.

The accumulator cylinder contains a bladder. Accumulator pressure is set by pumping nitrogen gas into the bladder through the nitrogen charge and check port.

Discharging the Accumulator

Safety Section

Accumulator Pressure Release

Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, mainte-

nance, 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.

Refer to Special Publication, NENG2500, “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat

products.

Dispose of all fluids according to local regulations and mandates.

Delimbers mounted on a loader or trailer have hydraulic oil pressure that must be bled from the

accumulator before performing any maintenance or disconnecting any hydraulic lines.

Verify that machine engine is OFF.

Open purge valve in the accumulator box by turning the purge valve handle counterclockwise.

Illustration 51 g03321206

Give the accumulator 45 seconds to purge off pressure.

Note: In a quiet area, the purge off will be audible.

The accumulator purge valve must be closed for operation.

Discharging the Pilot Accumulator

Always use a board or cardboard when checking for a leak.

Care must be taken to ensure that fluids are contained during performance of inspection, mainte-

nance, 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.

Refer to Special Publication, NENG2500, “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat

NOTICE

products.

Dispose of all fluids according to local regulations and mandates.

Discharge pilot hydraulic circuit by turning the engine OFF.

Page 40

Safety Section Operator Station

SEBU9422-02

Lower the left-hand arm rest to enable the hydraulic circuit.

Turn the key switch to the on position.

Verify that engine is OFF.

Verify that the pilot enable button is enabled.

Cycle both joysticks in all directions at least 4 times each.

i03634321

Operator Station

SMCS Code: 7000

S/N: KP51–Up

Any modifications to the inside of the operator station should not project into the operator space or into the space for the companion seat (if equipped). The addition of a radio, fire extinguisher, and other equipment must be installed so that the defined operator space and the space for the companion seat (if equipped) is maintained. Any item that is brought into the cab should not project into the defined operator space or the space for the companion seat (if equipped). A lunch box or other loose items must be secured. Objects must not pose an impact hazard in rough terrain or in the event of a rollover.

Other Guards (If Equipped)

Protection from flying objects and/or falling objects is required for special applications. Logging applications and demolition applications are two examples that require special protection.

A front guard should be installed when a work tool that creates flying objects is used. Mesh front guards that are approved by Cat or polycarbonate front guards that are approved by Cat are available for machines with a cab. On machines that are equipped with cabs, the window should also be closed. Safety glasses are recommended when flying hazards exist for machines with cabs and machines with open canopies.

If the work material extends above the cab, top guards and front guards should be used. Typical examples of this type of application are listed below:

• Demolition applications

• Rock quarries

• Forestry products

Additional guards may be required for specific applications or work tools. The Operation and Maintenance Manual for your machine or your work tool will provide specific requirements for the guards. Consult your Cat dealer for additional information.

i05142050

Guards

(Operator Protection)

SMCS Code: 7000

S/N: KP51–Up

S/N: KP71–Up

S/N: KBF1–Up

There are different types of guards that are used to protect the operator. The machine and the machine application determines the type of guard that should be used.

A daily inspection of the guards is required in order to check for structures that are bent, cracked, or loose.

Never operate a machine with a damaged structure.

The operator becomes exposed to a hazardous situation if the machine is used improperly or if poor operating techniques are used. This situation can occur even though a machine is equipped with an appropriate protective guard. Follow the established operating procedures that are recommended for your machine.

Page 41

SEBU9422-02

Product Information Section

General Information

Product Information Section

General Information

Specifications

SMCS Code: 7000

Basic machine specifications are listed in the following tables.

Table 1

Knuckleboom Loader 2384D

Operating Weight - Loader Only (approximate)

Engine

Engine RPM

15500 kg (34100 lb)

C 4.4

1800

i06952595

(Table 2, contd)

Knuckleboom Loader 2484D

Engine RPM

Hydraulic System System Pressure Swing Pressure Swing Speed

Capacities Fuel Capacity Hydraulic Capacity Swing Drive Capacity

Counterweight 653.2 kg (1440 lb)

Tail Swing (with counterweight) 2750 (108.2)

Knuckleboom Length 12.5 m (41.0 ft)

1800

24993 kpa (3625 psi) 25855 kpa (3750 psi) 9 RPM

378.5 L (100 gal)

302.8 L (80 gal)

5.9 L (1.56 gal)

Hydraulic System System Pressure Swing Pressure Swing Speed

Capacities Fuel Capacity Hydraulic Capacity Swing Drive Capacity

Counterweight

Tail Swing 2692 (106)

Knuckleboom Length 12.5 m (41.0 ft)

Table 2

24993 kpa (3625 psi) 25855 kpa (3750 psi) 11 RPM

378.5 L (100 gal)

302.8 L (80 gal) 4 L (1.06 gal)

Knuckleboom Loader 2484D

Operating Weight - Loader Only (approximate)

Engine

16582 kg (36480 lb)

C 4.4

(continued)

Page 42

Product Information Section Specifications

Trailer Dimensions (w/Suspension) 2384D 2484D Option

SEBU9422-02

Illustration 52 g03247996

(A) 11.2 m (36.8 ft).

(B) 3.4 m (11.3 ft).

(D) 1.3 m (4.1 ft).

(E) 0.46 m (1.5 ft).

(F) 2.8 m (9.3 ft).

Page 43

SEBU9422-02

(G) 15.85 m (52 ft).

Trailer Dimensions (wo/Suspension) 2384D Standard

Product Information Section

Lifting Capacities

Illustration 53 g03247996

(A) 11.2 m (36.8 ft).

(B) 3.4 m (11.3 ft).

(G) 15.3 m (50 ft).

i07103672

Lifting Capacities

(D) 1.2 m (3.8 ft).

(E) 0.46 m (1.5 ft).

(F) 2.8 m (9.3 ft).

SMCS Code: 7000

Failure to comply to the rated load can cause possible personal injury or property damage. This includes the risk of unintended boom lower-

ing. Review the rated load of a particular work tool before performing any operation. Make adjustments to the rated load as necessary for nonstandard configurations.

There may be local regulations and/or government regulations that govern the use of knuckleboom loaders which lift heavy objects. Obey all local and government regulations.

Page 44

Product Information Section Lifting Capacities

Lifting capacities should be used as a guide. Work tools, uneven ground conditions, soft ground conditions, or poor ground conditions have effects on lifting capacities. The operator is responsible for being aware of these effects.

Lifting capacities will vary with different work tools and attachments. The weight of a work tool attachment must be subtracted from the lift capacity. Consult your Prentice dealer regarding the lifting capacities for specific work tools and attachments.

2384D

Table 3

All lifting capacities are in kilograms and pounds.

L O A D R A D I U S

HEIGHT

10.6 m

35.0 ft

9.1 m

30.0 ft

7.6 m

25.0 ft

6.0 m

20.0 ft

4.5 m

15.0 ft

3.0 m

10.0 ft

3 m

10 ft

6586 5729 5729

8462 7362 7362

9997 8697 8697

4.5 m 15 ft

22039 19174 19174

14519 12631 12631

18655 16230 16230

6.0 m 20 ft

6222 5413 5413

6606 5747 5747

6770 5889 5889

7247 6305 6305

8176 7113 7113

13717 11934 11934

14564 12671 12671

14925 12984 12984

15977 13900 13900

18025 15682 15682

5555 4833 4833

6116 5321 5273

6300 5481 5182

6809 5924 5041

7.6 m 25 ft

12246 10654 10654

13483 11730 11625

13889 12084 11425

15011 13060

11114

5099 4436 3707

5444 4736 3653

9.1 m 30 ft

11242

9780 8172

12002 10442

8053

MAXIMUM

REACH

3967 3542 3275

SEBU9422-02

100%

Over

End

Over

Side

100%

Over

End

Over

Side

100%

Over

End

Over

Side

100%

Over End

Over Side

100%

Over

End

Over

Side

8746 7809 7220

100%

Over

End

(continued)

Page 45

SEBU9422-02

(Table 3, contd)

1.5 m

5.0 ft

Line

−1.5 m

−5.0 ft

10359

9012 9012

9843 8563 8563

22837 19868 19868

21700 18879 18879

All lifting capacities are in kilograms and pounds.

L O A D R A D I U S

11524 10026 10026

11889 10343 10343

10932

9511 9511

25407 22104 22104

26210 22803 22803

24101 20968 20968

8700 7569 7244

8755 7617 6982

8008 6967 6840

19181 16687 15971

19302 16792 15393

17655 15360 15079

6942 6040 4889

6729 5854 4766

5849 5089 4709

15305 13315 10778

14835 12906 10508

12895 11219 10381

5270 4585 3590

4720 4107 3550

Product Information Section

Lifting Capacities

11618 10108

7915

10406

9054 7826

4026 3502 3242

8875 7721 7147

Over

Side

100%

Over

End

Over

Side

100%

Over

End

Over

Side

100%

Over

End

Over Side

2484D

Table 4

HEIGHT

10.6 m

35.0 ft

9.1 m

30.0 ft

7.6 m

25.0 ft

6.0 m

20.0 ft

3 m

10 ft

All lifting capacities are in kilograms and pounds.

L O A D R A D I U S

4.5 m 15 ft

7555 6573 6573

16656 14490 14490

7142 6214 6214

7855 6843 6843

8053 7006 7006

6.0 m 20 ft

15746 13699 13699

17318 15067 15067

17754 15446 15446

6385 5555 5555

7314 6363 5893

7.6 m 25 ft

14076 12246 12246

16125 14029 12992

9.1 m 30 ft

MAXIMUM

REACH

100%

Over

End

Over

Side

100%

Over

End

Over

Side

100%

Over

End

Over

Side

100%

(continued)

Page 46

Product Information Section Lifting Capacities

(Table 4, contd)

4.5 m

15.0 ft

3.0 m

10.0 ft

1.5 m

5.0 ft

Line

−1.5 m

−5.0 ft

12902

11225 11225

12266 10672 10672

28444 24746 24746

27042 23527 23527

All lifting capacities are in kilograms and pounds.

L O A D R A D I U S

19007

9995 8695 8695

11705 10184 10184

13708 11926 11926

14178 12335 12335

13082 11381 11381

22035 19170 19170

25806 22452 22452

30222 26293 26293

31258 27195 27195

28840 25091 25091

10385

10473

8621 7501 7501

9743 8476 8442

9035 8100

9112 7825

9614 8364 7676

16536 16536

21479 18687 18612

22896 19919 17857

23090 20089 17251

21195 18440 16923

7539 6559 5798

8148 7089 5649

8320 7032 5361

8083 7032 5361

7061 6143 5302

16620 14460 12782

17964 15628 12455

18342 15957 12103

17821 15504 11820

15567 13544 11688

5868 5105 4173

6555 5703 4117

6358 5532 4051

5670 4933 4009

12937 11255

9199

14452 12573

9076

14018 12196

8931

12501 10876

8838

4583 3987 3699

4649 4045 3665

SEBU9422-02

Over End

Over Side

100%

Over

End

Over

Side

100%

10103

8790 8156

10249

8917 8080

Over

End

Over

Side

100%

Over

End

Over

Side

100%

Over

End

Over

Side

100%

Over

End

Over

Side

Page 47

SEBU9422-02

Product Information Section

Identification Information

i06952597

Plate Locations and Film Locations

SMCS Code: 1000; 7000

The Product Identification Number (PIN) is used to identify a powered machine that is designed for an operator to ride.

Prentice products such as engines, transmissions, and major attachments that are not designed for an operator to ride are identified by Serial Numbers.

For quick reference, record the identification numbers in the spaces that are provided below the illustration.

i06952607

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Note: This information is pertinent in the United

States, Canada, and Europe.

Consult your Prentice dealer for Emission Control Warranty Statement.

Illustration 54 g03299878

Machine PIN

Engine Serial Number

i04019095

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

S/N: KP51–Up

Note: This information is pertinent in the United

States, in Canada and in Europe.

Consult your Cat dealer for an Emission Control Warranty Statement.

This label is located on the engine.

Illustration 55 g03320827

The certification label (if equipped) is used to verify an engine conformance to the emissions requirements of the EPA.

This label is on the engine.

Page 48

Operation Section Before Operation

SEBU9422-02

Operation Section

Before Operation

Mounting and Dismounting

SMCS Code: 7000

S/N: KP51–Up

i05278197

Machine Access System Specifications

The machine access system has been designed to meet the intent of the technical requirements in “ISO 2867 Earth-moving Machinery – Access Systems”. The access system provides for operator access to the operator station and to conduct the maintenance procedures described in the maintenance section.

Alternate Exit

Machines that are equipped with cabs have alternate exits. For additional information, see Operation and Maintenance Manual, “Alternate Exit”.

i05278203

Daily Inspection

SMCS Code: 1000; 7000

S/N: KP51–Up

For a maximum service life of the machine, complete a thorough daily inspection before you mount the machine and before you start the engine.

Illustration 56 g00037860

Typical example

Mount the machine and dismount the machine only at locations that have steps and/or handholds. Before you mount the machine, clean the steps and the handholds. Inspect the steps and handholds. Make all necessary repairs.

Face the machine whenever you get on the machine and whenever you get off the machine.

Maintain a three-point contact with the steps and with the handholds.

Note: Three-point contact can be 2 feet and one hand. Three-point contact can also be 1 foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Ensure that the work tool is fully lowered to the ground and the brake is applied. Ensure that the Left Hand Joystick Control (if equipped) is tilted up and out of the way before you enter or exit the cab. Never jump off the machine. Do not carry tools or supplies when you try to mount the machine or when you try to dismount the machine. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the operator compartment or when you exit the operator compartment.

• Daily, perform the maintenance requirements that are applicable to your machine.

Reference: For more information on the daily maintenance requirements, refer to Operation and Maintenance Manual, “Maintenance Interval Schedule”.

• Inspect the area around the machine and under the machine. Look for loose bolts, trash buildup, oil, fluid leakage, broken parts, or worn parts.

• Watch closely for leaks. If you observe a leak, find the source of the leak and correct the leak. Replace hoses, as needed. If you suspect a leak or you observe a leak, check the fluid levels more frequently.

• Inspect the engine compartment. Remove any debris buildup from the engine compartment. Inspect the engine for any obvious component damage.

• Inspect the hydraulic system for leaks. Check the hydraulic tank, all hoses, and all tubes. Inspect plugs, seals, couplings, and fittings. Fix any leaks and replace hoses, as needed.

• Inspect all attachments and the linkages for wear and for damage.

• Make sure that all access doors, all access covers and all guards are secured. Inspect the access doors, the access covers and the guards for damage.

Page 49

SEBU9422-02

• Inspect the tires for damage. Replace any missing valve caps.

• Inspect the steps, the walkways, and the handholds. Remove any debris. Repair any damage or replace any damaged parts.

• Inspect the lights. Replace any broken bulbs and any broken lenses.

• Inspect the cab structure for obvious damage. Consult your authorized dealer for repairs.

• Inspect the operator compartment. Remove any trash buildup. Keep the operator compartment clean. Inspect the dash panel for broken gauges and for broken indicator lights. Replace any broken parts.

• Inspect the windows. Make sure that the operators vision is not impaired by dust, by mud, or by other foreign materials. Clean the windows, if necessary. For more information, refer to Operation and Maintenance Manual, “Windows Clean”.

Operation Section

Daily Inspection

• Make all necessary repairs before you operate the machine.

Page 50

Operation Section Machine Operation

Machine Operation

Alternate Exit

SMCS Code: 7310

S/N: KP51–Up

SEBU9422-02

i05278251

Illustration 57 g03319904

Front right-hand window.

The right-hand cab window can be used as an alternate exit. The window can be opened from the inside of the cab. There is a latch that holds the righthand window in place. Release latch in order to free the window. Slide window rearward in the track as far

as possible.

i06843137

Seat

SMCS Code: 7312

S/N: KP51–Up

Put the hydraulic lockout control in the LOCKED position. For further details on this procedure, refer to Operation and Maintenance Manual, “Hydraulic Lockout Control”. Do this procedure before you adjust the seat and the console. This will prevent any possibility of unexpected movement of the machine.

Adjust the seat at the beginning of each work period and adjust the seat when you change operators.

The seat should be adjusted so that full pedal travel is allowed.

Illustration 58 g00101115

Illustration 59 g03319863

The operator can adjust the seat position forward or backward. Pull up on the adjustment lever (1) and slide the seat forward and backward to the desired

seat position. Select the desired position to allow full pedal travel and full lever travel.

The seat position can be adjusted up and down. Pull up on the height adjustment lever (2) to raise or lower the seat to the desired position.

The firmness of the seat cushion can be adjusted. Turn firmness adjustment knob (3) clockwise for a softer seat, counterclockwise for a firmer seat.

Page 51

SEBU9422-02

Operation Section

Seat

Illustration 60 g03319865

The operator may also adjust the seat back lumbar support. Use the knob (4) on the right-hand side of the seat to select the firmness of the seat back

lumbar support.

Illustration 61 g03319867

The right console and the left arm rest console (5) can be adjusted horizontally.

There is an adjustment knob underneath the arm rest to adjust vertical positioning.

The seat and the consoles can also slide as one unit.

Page 52

Operation Section Operator Controls

SEBU9422-02

i07176359

Operator Controls

SMCS Code: 5705; 6461; 6700; 7000; 7008; 7220;

7300; 7301; 7451; 7490

Display Monitor (1)

Refer to Monitoring System in the Operation section of the Operation and Maintenance Manual.

Radio (2)

Note: The radio can be used only when the battery

disconnect switch and the engine start switch are in the ON position.

Power Switch – Push the power switch to turn on the radio. Push the power switch again to turn off the radio.

AM/FM Band Selector – After you push the AM/FM band selector, the selected radio band appears on display panel .

Preset Buttons – The circuitry in the memory system allows you to preset six radio stations.

Tone Control – Music is optimized by pressing the tone control so that display will show “MUSIC” .

Scan and Auto Memory – Press button for less than

0.5 seconds to listen to 5 seconds of each preset radio station. Press button at least 1.5 seconds to

store the radio stations with the six strongest signals.

Illustration 62 g06055325

Operator Console

(1) Display Monitor (2) Radio (3) Wiper Switch (4) Light Switch (5) Fan Switch (6) Heater Air Conditioner Switch (7) Key Switch (8) Switch Panel (Stabilizer Select, Throttle, Pilot)

““Tune”” Buttons – Push the “tune” buttons to select a radio station. Pressing “tune” button will decrease the

frequency. Pressing “tune” button will increase the frequency. Pressing the “tune” button for less than

0.5 seconds changes the radio station one at a time. Pressing the “tune” buttons for more than 0.5 seconds will change the frequency automatically until a radio station is found.

Volume Control – Turn volume control knob clockwise to increase the sound level and turn knob counterclockwise to decrease the sound level.

Page 53

SEBU9422-02

Wiper and Washer Switch (3)

Window Washer – Push the switch to activate the window washer. When the

switch is depressed, the indicator light will come on and washer fluid will spray from the nozzle. The window wiper will also operate when the switch is depressed. After the switch is released for approximately 3 seconds, the window wiper will stop.

Working Light Switch (4)

Light Switch – This a three position

switch. Depressing the switch once will

turn on the work lights. Depress the switch fully to turn on all machine lights

Operation Section Operator Controls

Heater and Air Conditioner Switch (6)

Fan Switch (5)

Illustration 63 g03321226

Fan Speed Switch – Fan speed switch

(A) controls the speed of the blower fan

motor for the heating and air conditioning system.

Illustration 64 g03320629

The control switch for the heating and air conditioning system are on the console of the operator cab.

On/Off Switch

Selector Switch (A) allows the selection between Heater or Air Conditioner on and off.

Page 54

Operation Section Operator Controls

SEBU9422-02

Temperature Control

Illustration 65 g03320650

The temperature control knob is on the unit behind the operator seat.

Cooling – Turn knob (B)

counterclockwise to decrease the

temperature in the cab.

Heating – Turn knob (B) clockwise to

increase the temperature in the cab.

Engine Start Switch (7)

OFF – When you insert the engine start

switch key and when you remove the

engine start switch key, the engine start switch must be in the OFF position. To disconnect the power to the electrical circuits in the cab, turn the engine start switch to the OFF position. Also, turn the engine start switch to the OFF position to stop the engine.

Note: If the engine fails to start, return the engine

start switch to the OFF position. Action must be taken before you attempt to start the engine again.

Switch Panel (8)

Illustration 66 g03320667

Note: Hydraulic arming control refers to the System Controllers and Joysticks. The Main Hydraulic System will still be pressurized.

The hydraulic arming control (A) is used to turn the machine hydraulic system (implement and steering) on and off. The hydraulic control arming control is on the operator console of the machine.

When the hydraulic arming control is in the LOCKED position, the machine control hydraulic system is not

on.

When the hydraulic arming control is in the UNLOCKED position, the machine hydraulic system is on.

ON – To activate the electrical circuits in

the cab, turn the engine start switch key

clockwise to the ON position.

START – To start the engine, turn the

engine start switch clockwise to the

START position. When the engine start switch key is released, the engine start switch will return to the ON position.

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Operation Section

Diesel Particulate Filter Regeneration

Note: The left-hand arm console must be lowered to arm the hydraulics.

Throttle Up Speed Control

Illustration 67 g03320684

The switch (A) controls the engine speed by regulating the signal pressure to the engine ECM.

Depress switch to increase engine speed.

Throttle Down Speed Control

Depress switch to decrease engine speed.

Stabilizer Switches

Illustration 68 g03356091

These switches select which stabilizer function will be active.

The left-hand switches (A) control the up and down functions of the left-hand stabilizers.

The right-hand switches (B) control the up and down functions of the right-hand stabilizers.

This switch (B) controls the engine speed by regulating the signal pressure to the engine ECM.

The switch in the center (C) controls the selection of the front and rear stabilizers.

Note: The center switch also controls the trailer stabilizer legs if equipped.

i06952618

Diesel Particulate Filter Regeneration

SMCS Code: 108F

Reduction of Particulate Emissions

The Diesel Particulate Filter (DPF) will reduce particulate emissions. The DPF collects the soot and any ash that is produced by the combustion in the engine. During regeneration, the soot is converted into a gas which is released into the atmosphere. The Ash remains in the DPF.

The temperature of the DPF must be above a particular value in order for regeneration to occur. The exhaust gas provides heat for the regeneration

process.

Page 56

Operation Section Diesel Particulate Filter Regeneration

SEBU9422-02

Passive Regeneration The engine provides sufficient exhaust gas temperature for regeneration.

Engine Operation and a DPF

During normal engine operation, the operator of the engine may notice the lack of black smoke from the exhaust system.

Passive regeneration is the process that is used by the DPF to remove soot from the DPF. In some

applications, the engine idle speed will automatically be increased to allow passive regeneration to occur.

Regeneration

Regeneration is to increase the exhaust temperature for a given time. The Caterpillar Regeneration System (CRS) is used to remove soot from the DPF, and warmup the Selective Catalyst Reduction (SCR) system. The DPF traps both soot and ash. The ash is removed through a manual cleaning process. Refer to Operation and Maintenance Manual, “Diesel Particulate Filter - Clean” for more information on the

service of the DPF.

Regeneration Indicators

Regeneration Active – When

illuminated, this indicator shows that

the system is active. This indicator shows that elevated emission temperatures are possible. This indicator will turn off when regeneration is complete.

DPF – This indicator will illuminate to

show that regeneration is required. This

indicator will illuminate when ““Time to Regen”” is less than a pre-determined amount of time.

Regeneration Disabled – This indicator

will illuminate to show that regeneration

has been disabled.

Regeneration Switch

Note: When engine start switch key is cycled or the

“Force Regeneration” switch is pressed for longer than 2 seconds the system will no longer be disabled. When the “Force Regeneration” switch is pressed and “Time to Regen” is less than 8 hours, regeneration will begin if the machine is at low idle and is parked.

Note: If the engine start switch key is cycled while the regeneration system is disabled via the “Disable Regeneration” switch., Press and hold the “Disable Regeneration” switch for 2 seconds to reinitiate.

Modes of Regeneration

Automatic: The Electronic Control Module (ECM)

uses multiple inputs from the engine and the machine to determine the best time to perform automatic regeneration. Automatic regenerations can take place throughout the operating cycle of the engine. The regeneration active indicator will be illuminated when regeneration is being performed. Interruptions of the regeneration are acceptable. If regeneration is in progress and needs to be stopped, it is permissible to press the “Disable Regeneration” switch.

Note: Automatic adjustments of engine speed may be noticed during regenerations. If regeneration is taking place and the engine is taken to low idle, the engine speed may remain elevated to maintain the regeneration.

Note: If the machine returns to work while automatic regeneration is active, the regeneration may be stopped. The ECM will continue to monitor inputs to determine the best time to restart the regeneration.

Manual: Manual regeneration is initiated by pressing the “Force Regeneration” switch. Manual regeneration will only be allowed if the “Time to Regen” is less than 8 hours. If the “Force Regeneration” switch is pressed before “Time to Regen” is less than 8 hours, then “Regen not Required” will be displayed. The machine must be stationary, the parking brake must be applied, and the engine must be at low idle to perform manual regeneration.

Force Regeneration – Press in the top

switch for 2 seconds to begin

regeneration.

Disable Regeneration – Press in the

bottom switch for 2 seconds to disable

regeneration.

Note: If equipped with a rocker style switch, the

MIDDLE position of the regeneration switch is the default position for automatic regeneration.

Disabled: When the regeneration system is in disabled mode, automatic regenerations will not be performed. The DPF indicator will illuminate if manual regeneration is required. The “Time to Regen” displayed on the performance screen will indicate that the time until the next regeneration will be required. However, the DPF indicator may illuminate with time remaining on the display. When the DPF indicator illuminates, the operator must perform manual regeneration.

Regeneration Triggers

Regeneration may be required for the following reasons:

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SEBU9422-02

Soot: The DPF will collect soot produced by the engine. Automatic regeneration will become active to reduce soot level.

Start-Up Regeneration: Start-up regeneration is initiated by the ECM after a cold engine start. This regeneration is performed to heat the system to a required temperature for Diesel Exhaust Fluid (DEF) dosing to begin.

SCR Maintenance: Regeneration is performed to maintain the SCR system.

ARD Maintenance: Regeneration is performed to maintain the CRS system.

Regeneration System Warning Indicators

Operation Section

Diesel Particulate Filter Regeneration

Illustration 71 g03676115

Once the amount of soot collected in the DPF has reached a threshold or “Time to Regen” has been at

0 hours for a pre-determined time, the DPF indicator and an action indicator will be illuminated and an

audible alarm will sound.

10 minutes after the illumination of the DPF indicator, action indicator, and audible alarm, the engine will

shutdown. The engine can be restarted by cycling the engine start switch key. The engine will return to the previous derate state before shutdown.

Once the amount of soot collected reaches a threshold level or 6.4 hours of run time has passed

since the action indictor was illuminated without successful regeneration, the engine will have a 100%

derate.

Illustration 69 g02117258

The DPF Indicator will illuminate when regeneration is required. Regeneration should be performed as soon as possible.

Note: In some situations, the DPF indicator may stay illuminated after regeneration ends. The illuminated DPF indicator indicates that complete regeneration has not been performed. Complete regeneration is when the soot has been depleted or all the criteria for one of the other regeneration types have been met. If the DPF indicator stays illuminated, perform regeneration without interruption. The DPF indicator will shut off when regeneration is complete.

Illustration 70 g02117259

If the soot load is above a threshold or “Time to Regen” is 0 hours, then regeneration is required. The

DPF indicator and an action indicator will be illuminated. Engine power will be slightly derated. If

the machine continues to operate without regeneration, derate will eventually reach 100%. Stop the machine and apply the parking brake. With the engine at low idle, initiate manual regeneration.

Page 58

Operation Section Operator Station

Once the amount of soot collected reaches a critical threshold level, the regeneration will be locked out.

Now, regeneration can only be done through Cat Electronic Technician (ET), by an authorized dealer. The engine may be restarted, but will only run for 30 seconds before shutting down again.

i05085870

Operator Station

SMCS Code: 7300; 7451

S/N: KP51–Up

SEBU9422-02

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Operation Section

Operator Station

Illustration 72 g03304176

(1) Swing Control (2) Hydraulic Lockout Control (3) Joystick for Boom Control and Open/

Close Function for the Grapple

(4) Joystick Control for Stick Control and

Grapple Rotate (5) Monitor System (6) Engine Start Switch

(7) Increase Engine Speed Switch (8) Decrease Engine Speed Switch (9) Stabilizer Select Switch (Front, Rear,

Trailer) (10) Raise Right-hand Stabilizer Switch (11) Raise Left-hand Stabilizer Switch (12) Lower Right-hand Stabilizer Switch (13) Lower Left-hand Stabilizer Switch

(14) Heater/Air Conditioner Fan Switch (15) Wiper/Washer Switch (16) Working Lights Switch (17) Heater/Air Conditioner Select Switch (18) Satellite Radio (19) 12V Power Receptacles

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Operation Section Battery Disconnect Switch

SEBU9422-02

Battery Disconnect Switch

SMCS Code: 1411

S/N: KP51–Up

i06635486

The battery disconnect switch operates differently than the engine start switch. When the battery disconnect switch is in the OFF position, the electrical system is disabled. When the engine start switch is turned to the OFF position and the battery disconnect switch is turned to the ON position, the battery remains connected to the entire electrical system.

Turn the battery disconnect switch to the OFF position. Remove the disconnect switch key when you service the electrical system or other components on the machine.

Turn the battery disconnect switch to the OFF position. Remove the disconnect switch key if you do not operate the machine for an extended period of a month or more. This will prevent drainage of the battery.

NOTICE

Never move the battery disconnect switch to the OFF position when the engine is operating. Serious damage to the electrical system could result.

i06635588

Illustration 73 g06055316

The battery disconnect switch (1) is in the engine compartment, accessible from the platform of the knuckleboom loader.

NOTICE

Never move the battery disconnect switch to the OFF position when the Indicator light (2) is illuminated. Serious damage to the electrical system could result.

ON – To activate the electrical system, turn the battery disconnect switch (1)

clockwise. The battery disconnect switch must be turned to the ON position before you start the engine.

OFF – To deactivate the electrical

system, turn the battery disconnect

switch (1)counterclockwise to the OFF position.

Monitoring System

SMCS Code: 1900; 5258; 7000; 7400; 7402; 7450;

7451; 7490; 7600; 7601; 7603

S/N: KP51–Up

NOTICE

When the monitor provides a warning, immediately check the monitor and perform the required action or maintenance as indicated by the monitor.

The monitor indicator does not guarantee that the machine is in a good condition. Do not use the monitor panel as the only method of inspection. Maintenance and inspection of the machine must be performed on a regular basis. See the Maintenance Section of this Operation and Maintenance Manual.

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Operation Section

Monitoring System

Engine Coolant Temperature – The gauge represents the coolant

temperature of 45 °C (113 °F) to 122 °C (252 °F). If the pointer enters the red zone, the coolant temperature is 107 °C (225 °F). Increased temperatures will sound the warning alarm. Machine operation during the sounding of the alarm may damage the engine. Also, machine operation with the pointer in the red zone may damage the engine. Stop the machine in a safe place and investigate the cause.

DEF Level – The gauge represents the

level of the DEF If the pointer enters the

red zone, the DEF is low. Increased temperatures will sound the warning alarm. Machine operation during the sounding of the alarm may damage the engine. Also, machine operation with the pointer in the red zone may damage the engine. Stop the machine in a safe place and investigate the cause.

Illustration 74 g06056649

(1) Gauge area. (2) Alert indicator. (3) Status indicators. (4) Graphical display area. (5) Menu navigation buttons.

Note: For more information refer to Systems Operation Troubleshooting, Testing and Adjusting 559D and 579D Knuckleboom Loader Machine Monitoring System, UENR0395.

Gauges (1)

Fuel Level – The fuel level gauge indicates the amount of fuel that is left in

the fuel tank. The fuel level gauge indicates a percentage from 5% to 95%. The red zone indicates 15%.

Hydraulic Oil Temperature – The gauge

indicates the temperature of the

hydraulic oil in the hydraulic sump for the implement circuit. The gauge represents the hydraulic oil temperature of 45 °C (113 °F) to 120 °C (248 °F). If the pointer enters the red zone, the hydraulic oil temperature is 80 °C (176 °F). If necessary, reduce the load that is on the machine until the hydraulic oil temperature decreases.

Alert Indicator (2)

The alert indicator will flash amber and the action alarm will sound to indicate a level 2 warning. A level

2 warning indicates that a failure has occurred and that the machine operation will be changed.

The alert indicator will flash red and the action alarm will sound to indicate a level 3 warning. A level 3

warning requires an immediate safe shutdown.

Status Indicators (3)

The indicators will illuminate or flash when any function or level of warning is active.

Lights – Indicator will illuminate when working lights are turned on.

Economy Mode – Indicator will illuminate when the machine is set to operate in the economy mode.

Operator Alert – Indicator will illuminate when there has been a system error detected.

Parking Brake – This indicator illuminates when the parking brake is engaged. The indicator should flash

during start-up.

Hydraulic Lockout – This indicator is illuminated when the hydraulic oil pressure is locked out.

Fuel Temperature – Indicator will illuminate/flash when fuel temperature is above recommended temperature.

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Operation Section Monitoring System

SEBU9422-02

Engine Emission Temperature –

Indicator will illuminate/flash when DEF

is above recommended temperature.

Engine Emission System Filter –

Indicator will illuminate/flash when a

restriction is detected in the emission filter.

Hydraulic System Failure – The

hydraulic filter is restricted. Restriction

of the filter will cause hydraulic components to malfunction. Turn the engine start switch to the OFF position and then turn the engine start switch to the ON position. If the warning disappears, the filter is good. Operate the machine on flat ground for at least 10 minutes. If the warning reappears, replace the filter.

Auto Kick Down – Indicator will

illuminate when the engine RPM needs

to decelerate.

Engine Emission Failure – Stop the

engine and contact your authorized

dealer.

The display module is used to change the customer preferences and operation parameters. Allowing an extra means for the operator to increase machine efficiency.

Menu Navigation Buttons (5)

Engine System Warning – Indicator will

illuminate/flash when the engine system

needs attention.

Hydraulic System Filter – The hydraulic

filter is restricted. Restriction of the filter

will cause hydraulic components to malfunction. Turn the engine start switch to the OFF position and then turn the engine start switch to the ON position. If the warning disappears, the filter is good. Operate the machine on flat ground for at least 10 minutes. If the warning reappears, replace the filter.

Hydraulic System Warning – Indicator

will illuminate/flash when a restriction in

the hydraulic system is detected.

Transmission Engage – Indicator will

illuminate when the transmission is

engaged.

Graphical Display Area (4)

The LCD screen provides readouts for the display module. The LCD screen displays the following items: machine operations, diagnostic events, and modes of operation.

If a fault indication occurs, the message will override any screen that was displayed on the monitoring system display.

Illustration 75 g06056671

Navigation Buttons

The navigation buttons (1 & 2) are used to navigate the menu.

Up – Depress the up arrow

Down – Depress the down arrow

• Navigating a menu list in the upward direction

• Scrolling a highlighted letter in a letter entry screen

• Scrolling a highlighted number in a number entry screen

• Navigating to the previous performance page

Down

• Navigating a list in the downward direction

• Scrolling a highlighted letter in an entry screen

• Scrolling a highlighted number in an entry screen

Note: You may snooze the fault display from the screen by pushing the OK button or the back button.

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Operation Section

Monitoring System

OK/Select Button

The OK/Select button (3) is used for the following functions:

• Selecting the highlighted entry in a list

• Opening the configuration screen for a highlighted performance page quadrant

• Selecting a highlighted item

• Confirming an action when a popup is visible

• Snooze a warning or information popup

Back/Previous Button

The back/previous button (3) is used for the following functions:

• Navigating to the previous screen

• Cancel an action when a popup is visible

Operator Select Button

The operator select button (4) is used for the following functions:

If the engine is started during the fluid level check, the monitor will cancel these checks.

Machine Warnings

The Cat Monitoring System provides three warning categories. The first category requires only operator awareness. The second and 2S warning categories require an operator response. The third warning category requires immediate shutdown of the machine.

• Navigate to main menu screen from anywhere in the menu structure

• If the main menu is visible, the menu button will return to performance pages

Information Button

The information button (5) is used to obtain menu information.

Prestart Monitoring Function

Turn the engine start switch to the ON position.

The coolant temperature, the hydraulic oil temperature, the fuel level, and the position of the engine speed dial are now indicated.

The monitoring system checks the level of the engine coolant, the engine oil, and the hydraulic oil before the engine starts.

If the fluid level check detects a low fluid level, the appropriate message will be displayed. A pictograph

will be shown to indicate the fluid level that is low.

Note: The machine cannot perform an accurate fluid level check when the machine is on a slope. Perform the fluid level check on level ground.

Page 64

Operation Section Monitoring System

Table 5

Warning Indications

SEBU9422-02

WARNING OPERATION

(1)

Warning

Category

1 No immediate action is required. The sys-

2 X X Change machine operation or perform

2S X X X

3 X X X

(1)

The active warning indications are marked with an X.

(2)

This is the possible result if the operator takes no action.

(3)

A steady alarm sounds.

(4)

A pulsating action alarm sounds.

Flashing Alert

Indicator

The monitoring system has the following three warning levels for events:

Warning Level 1 – Warning level 1 does not alert the operator that a warning has occurred and does not affect the operation of the machine. Warning level 1 is recorded. This warning may be viewed from the “Diagnostics” menu of the display. Warning level 1 may also be viewed with Cat

Flashing

Action

Lamp

Electronic Technician

Action

Alarm

(3)

(4)

Action

tem needs attention soon.

maintenance to the system.

Change machine operation or perform maintenance to the system.

Immediately perform a safe engine shutdown.

If the monitoring system detects an abnormal operating condition, the operator will be notified.

If multiple warnings are present in the system, the most important problem is shown first. Press the right key or press the left key to view all the warnings that are present in the machine. If no keys are pressed within 5 seconds, the display will return to the most important problem.

(Cat ET) Service Tool.

Note: The menu is still functional by pressing the

Warning Level 2 – Warning level 2 requires

changing the operation of the machine or performing a maintenance procedure. Failure to correct the problem that causes this warning may result in damage to the involved components or system of the machine.

Warning Level 2S – Warning level 2S requires changing the operation of the machine or performing

menu key.

Main Menu

The “Main Menu” allows the operator to view information concerning the machine. This menu also allows the operator to change information concerning the machine.

a maintenance procedure. Failure to correct the problem that causes this warning may result in damage to the involved components or system of the

Operator Parameters

machine. A steady alarm sounds when Warning Level 2S is active.

Possible Result

No damage will occur to the machine. Minor reductions in machine performance may occur.

Severe damage to components can occur.

Injury to the operator or severe damage to components can occur.

(2)

Warning Level 3 – Warning level 3 requires an

immediate safe shutdown of the machine to avoid damage to the machine or injury to personnel around

the machine. The problem that caused the event must be corrected before machine operation can

resume.

Note: Certain conditions will allow the machine to be operated in the partial limp home mode.

Table 5 indicates the status of the alarm and “Check Monitor” indicator for each warning level.

Illustration 76 g03881117

The “Information” (1) allows the operator to view information concerning the machine. This menu also allows the operator to change information concerning the machine.

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SEBU9422-02

Operation Section

Radio

Operator Parameters can be set by selecting the Information Button.

Illustration 77 g06056686

From the main menu, select Machine (2). Depress the OK button (3).

When driving, always keep your eyes on the road and hands on the steering wheel, paying careful attention to normal driving tasks. As always, the driver is responsible for safe vehicle operation. Not keeping your eyes on the road and hands on the wheel while driving could result in injury to you or others.

Stereo Receivers

Illustration 79 g03566500

MP3/USB/iPod/Aux/Bluetooth Receiver

Illustration 78 g06056692

The list of Operator Parameters will be displayed.

The operator will be able to select and set the parameters listed. Select the function to be adjusted select the OK button, adjust to preferred settings.

i06204660

Radio

(Entertainment If Equipped)

SMCS Code: 7338

Illustration 80 g03566527

MP3/USB/iPod/Aux/Bluetooth/CD Receiver

Illustration 81 g03566571

MP3/USB/iPod/Aux/Bluetooth/CD/SAT Receiver

Radio Pin out

Radio pinout is shown below

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Operation Section Entertainment If Equipped

SEBU9422-02

General Radio Receiver Functions

Illustration 82 g03566584

Illustration 83 g03566592

(1) Phone (2) Knob (3) SRC/PWR (Source/Power) (4) Next (5) Eject (6) Play/Pause (7) Browse (8) Clock/Alarm (9) RPT (Repeat) (10) RDM (Random) (11) ESC (Escape) (12) DISP (Display) (13) SCAN/ASCN (Scan/Autoscan) (14) PREV (Previous)

Options

• An AM band with 6 AM presets

• Three FM bands with a total of 18 FM presets

• One weather band with six WX presets

Phone (if equipped)

Press the Phone button for more than 3 seconds to show the Bluetooth Menu. When Bluetooth is enabled, press the button to display the Dial Menu or

to accept an Incoming Call (if a Phone is paired). During a call press the button for more than 3 seconds to transfer the call from the radio to the

Phone.

VOLUME KNOB/OK

Press for less than 3 seconds to display Audio Control Menu. Press for more than 3 seconds to

show the user menu. Rotate to increase/decrease volume or during a menu for navigation. Press while

in a menu to confirm the selected action.

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Operation Section

Entertainment If Equipped

SRC/PWR (Source/Power)

Press to switch to FM -> AM -> WX -> SXM -> CD -> USB/iPod ->AUX -> Bluetooth Audio (if equipped)

and to turn Radio ON. Press and hold to turn radio OFF.

NEXT (Next/Forward)

Press to select next track or station. Press and hold for FF or Tune Up

EJECT

Press to eject the CD

PLAY/PAUSE

Press to pause / unpause current Media.

BROWSE

Press to navigate on the device and select a specific song or play context (Applicable to USB sticks, CD MP3 discs and iPod).

CLOCK/ALARM

Press during Alarm activation to cancel the Alarm.

RPT (Repeat)

Press to repeat current track. Press again to stop repeat. Look for the RPT icon in the radio display to turn this feature ON or OFF.

RDM (Random)

Press to play the tracks randomly. Press again to stop random mode. Look for the RDM icon to turn on in the radio display.

ESC (ESCAPE)

Press to exit one Menu Level.

DISP (DISPLAY)

If vehicle ignition is ON: Press to change source display

SCAN/ASCAN

Scans stations/CD tracks/MP3/WMA files and folder and in tuner, stores stations to presets

PREV (Previous/Reverse)

Press to select previous track or station. Press and hold for FR or Tune Down

Change the Frequency Band

The following instruction provides information on how to correctly set the frequency band on the radios installed on Caterpillar machines. Once in the frequency then you will have the correct increments.

NOTICE

If the radio is set to the Saudi Arabia frequency band, the radio CANNOT be reset to any other country.

Illustration 84 g03812356

1. Radio OFF, ignition on

2. Press preset 5 (RDM 10) and volume knob (2) at

the same time for 6 seconds.

3. Display will show USA number 1/6

4. Turn knob clockwise to select Frequency:

Table 6

USA 1/6

EUROPE 2/6

JAPAN 3/6

LATAM (Latin America) 4/6

CHINA 5/6

SAUDI 6/6

5. Push knob to select zone.

6. Turn on radio to verify frequency.

To return to USA, follow same procedure.

Setting the Presets

The six numbered pushbuttons allow you to preset 6 of your favorite stations per band and easily return with the touch of a button. To set the presets:

(1) Turn on the receiver.

(2) Select the band.

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Operation Section Entertainment If Equipped

SEBU9422-02

(3) Tune to the desired station.

(4) Press and hold one of the six numbered buttons for more than 2 seconds to store the selected station.

When the station has been set to the preset number you chose, you will hear a beep and the preset number will be visible.

(5) Repeat steps 1-4 for each pushbutton.

Note: Pressing a preset button in the future will tune the radio to the station you set on the band to which you are listening.

CD Receiver

Illustration 85 g03566527

Compact Disc Player (If Equipped)

Note: On newer machines there is an internal battery

backup in the radio to retain time when using the machine battery disconnect switch.

TUNE/SEEK

Press (5) button to forward to the next track. The track number and elapsed time will appear.

TUNE/SEEK

Press (6) button to go to the beginning of the track being played. Press this button within the first 8 seconds of the track to go to the beginning of the previous track. The track number and elapsed time will appear.

PAUSE

Press the (9) button to pause a CD. PAU will appear on the display and the audio will be muted. Press the button again to resume play of the CD.

RDM

Press the RDM (10) button to activate random track selection. RDM will appear on the display and the tracks on the loaded disc will play in random order. Press the RDM (10) button to turn off random play.

Your integral CD player plays full size compact discs.

NOTICE

Never insert anything other than a CD into your CD player. Doing so could damage your CD player, result in unnecessary repairs and/or void the unit's warrant.

Playing a Compact Disc

(1) Turn on the ignition and receiver.

(2) Insert a disc partway into the slot, label-side up. The player will automatically pull the disc in once disc has been partially inserted. The CD icon and LOADING will appear on the display followed by the track number and elapsed time. Then, the disc will begin to play.

(3) If you are listening to AM/FM/WX radio, press the AUX (2) button to play a CD that has been loaded into the player. If no CD has been loaded, the display will show "NO CD" for 5 seconds and return to the

default display. If a CD has been loaded, the track number and the elapsed time will be displayed.

Note: If a CD is ejected and not removed within 16 seconds, the CD will reload but will not start playing until the AUX (2) button is pressed.

RPT

Press the RPT (11) button to repeat the track you are playing. RPT will appear on the display and the track you are playing will be repeated until you press the RPT (11) button again.

Press and hold the FF (13) button to fast-forward through a track. When you release the button, play will resume at normal speed. The track number and elapsed time will appear for 5 seconds before the default display reappears.

REV

Press and hold the REV (11) button to fast REVERSE. When you release the button, play will resume at normal speed. The track number and elapsed time will appear for 5 seconds before the default display reappears.

TRACK SCAN

Press SCAN/PSCAN (17) to scan all tracks on the CD. After playing 10 seconds of the current track, the player will automatically go to the next track. To end track scan, press SCAN/PSCAN (17) again.

DSPL/TIME

Press DSPL/TIME to toggle between the track number/elapsed time and time of day. To change the display, see the Display section of this manual.

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Operation Section

Entertainment If Equipped

EJECT

Press the Eject (18) button to eject a CD.

MP3/USB/iPod/Aux/Bluetooth/CD/ SAT

Illustration 86 g03566571

Mode Display

When you are playing MP3 or WMA files, press the "i Title/Menu" button to toggle between different displays views

(1) Track Number

(2) Artist Name

(3) Song Name ("Song Title" for iPod)

(3) Album Name

(5) Folder/PLST Name (excluding iPod)

AUX Input Display

When you are using an external device connected through the auxiliary inputs, pressing the "i Title/ Menu" button will have no effect.

When a device is connected via the aux input, the radio will display FRONT AUX as long as radio is kept in this mode. AUX is selected by pressing the SRC button and no device is connected, the radio will

select the rear auxiliary input, and display REAR AUX as long as REAR AUX is kept in this mode.

Hands Free Display (Bluetooth®)

Bluetooth Hands Free section) with the radio and an incoming call is received, the radio will pause/mute. The display will show the phone name on the first line and the phone number on the second line. The << characters indicate an incoming call. Note: If the phone is in normal mode, the radio will emit a ring tone. If the phone is in silent mode, there will not be a ring tone.

When a cell phone has been previously paired and connected (see Using the Bluetooth Hands Free section) with the radio. A call is placed from the radio or the cell phone, the radio will pause/mute and the display will show the phone name on the first line and the phone number on the second line. The characters >> indicate an outgoing call.

Phone Disconnection

If the cell phone ends the Bluetooth connection, the phone turns off or the phone signal weakens, the radio will terminate the connection, and the radio will

display PHONE DISCONNECTED for 3 seconds.

Use the DISCONNECT (see Using the Bluetooth Hands Free section) option from the Hands Free menu and the radio will attempt to disconnect with the current cell phone device.

Phone Reconnection

If a previously connected cell phone reactivates the connection with the radio, the cell phone is turned on or the phone re-establishes signal, the radio will display PHONE CONNECTED for 3 seconds.

Use the CONNECT (see Using the Bluetooth Hands Free section) option from the Hands Free menu to reconnect with a previously paired cell phone device.

Using an iPod®

The radio is capable of controlling and playing music from an iPhone/iPod.

Playing an iPod

Insert the iPod USB cable connector into the radio USB connector (the other end connected to your

iPod). iPod READING will appear on the display. After all the connections have been made and the

radio has finished reading the iPod, the iPod will begin playing. The elapsed time and the track number will be displayed. Play begins from current track played on iPod and continues sequentially through all tracks from the iPod's last selected mode. After playing the last track of the iPod's last selected mode, play stops and the radio will display the iPod Menu.

Files supported on USB sticks: MP1, MP2, MP3 (VBR) and WMA (ver. 9 and VBR).

Your MP3 player is able to read and play a maximum of 50 folders and playlists. Long files, folders, or a combination can reduce the number of files and

folders that can be played. If you want to play many files or folders, minimize the length of the files and folders. You can also play an MP3/WMA recorded without file folders. The system can support up to 11 levels of folder nesting. If a disc contains more than 50 folders or 11 folder levels, your player will only let you access and navigate the maximum number and will ignore additional items.

Page 70

Operation Section Entertainment If Equipped

SEBU9422-02

The WX band is for the Governmental weather radio services frequencies; the radio can tune the seven

weather channels following the steps in Tuning, Presets, and SCAN sections.

SXM (If Equipped)

Vehicles with a valid SiriusXM® satellite radio subscription can receive SiriusXM programming.

SiriusXM satellite radio has a wide variety of programming and commercial-free music, coast to coast, and in digital-quality sound.

SiriusXM®

SXM Display

When SiriusXM is active, the channel number, channel name, artist name/content info, song title, or

category name could be displayed on the screen. SiriusXM may update the information at any time.

To change the current display view, short press the DISP button.

When a new channel is selected, a song change occurs, SXM source is selected (from power up or source change) or the information is updated, all the elements will be displayed using paging; the paging can be stopped by short pressing the DISP button

Category mode Enable/Disabled

Category Search Mode Enabled means that only channels in the current Category are searched. When enabled, the CATEGORY icon is turned on.

Category Search Mode Disabled means that all channels are searched. When disabled, the

CATEGORY icon is turned off.

To enable/disable the category browse mode follow the steps in the User Menu section

The default after a power up is Category Disabled.

SXM Channel Selection

Presets and SCAN functions work the same as defined in the SCAN subsection of AM-FM-WX Radio.

NEXT button

While in SXM the radio will scroll to the next channel available in numerical order.

PREV button

While in SXM the radio will scroll to the previous channel available in numerical order

Note: If the SXM service is not activated, only the free-to-air channels will be present.

Display labels

To recognize the displayed text the radio uses the following convention :

• Channel Number: CH

• Channel Name: CH

• Artist Name: ART

• Content Info: INFO

• Song Title: SONG

• Category name: CAT

SXM Categories

SiriusXM stations are organized in categories.

The category list for SXM is in the following webpage: “http://www.siriusxm.com/sxm/pdf/sirius/ channelguide.pdf”

To change the current category long press the NEXT/ PREV button and the radio will tune the first channel

on next or previous category.

SXM Radio ID

If tuned to channel 0, "RADIO ID" label alternates with the SXM radio eight-digit code. This code is

needed to activate the service.

DISP button does not work in channel 0. Channel 0 is not available in category mode enabled.

SXM Messages

SXM BUSY – The audio system is acquiring and/or

processing audio and/or text data. No action is needed.

ART UNAVAIL – There is not Artist Name related with the current song.

SONG UNAVAIL – There is not Song Title related with the current song.

CHAN UNAVAIL – There is no Channel Name related with the current channel.

CHECK ANTENNA – SXM antenna or antenna cable is not connected to the radio or the antenna is shorted.

NO SIGNAL – SXM tuner module reports the No Signal condition. Under this condition only Channel 0 will work as stated in this manual.

CHAN UNSUB – Active channel has become unsubscribed or the requested channel is not

unsubscribed.

Page 71

SEBU9422-02

Operation Section

Engine Start Switch

SUBSCRIPTION UPDATED - PRESS OK TO CONTINUE – The subscription of the radio was

updated. To remove the message and return to the previous state pres "OK" (Knob).

CH UNAVAIL – Requested channel is reported unavailable for a newly selected channel or the currently selected channel. Unavailable channels are those that are in the legal channel range but are not currently available for display or subscription as a broadcast service. After 3 seconds the previous channel (if available) or channel 1 will be tuned.

OPTIONAL EQUIPMENT

Infrared Remote Control

Your receiver is compatible with an optional handheld remote control available from your dealer. The remote control will:

CD – Press this button to turn on your integrated CD player.

VOL – Press this button to adjust the volume

1-6 – Press this button to advance through the

presets in the selected band.

i06635590

Engine Start Switch

SMCS Code: 1416

S/N: KP51–Up

Illustration 87 g03566682

(1) Select a band (2) Turn your receiver on and off (3) Select the next or previous track/ Seek up and down (4) Mute/Pause (5) Select AUX inputs 1 or 2, iPod/USB (6) Play a CD (7) Adjust volume (8) Select a preset station

Button Functions

BAND – Press this button to select FM1, FM2, AM or

WX.

PWR – Press this button to turn the receiver on/off.

SEEK – Press these buttons to move to the next

available radio station or to go to the next track.

II: – Press this button to reduce volume to a minimum. The radio display will read

MUTE – To deactivate mute, press this button again. The audio source will continue to play while the volume is at a minimum

AUX – Press this button to select Front Auxiliary, Rear Auxiliary, iPod/USB, or Bluetooth® Audio

Illustration 88 g03300457

NOTICE

Key must be in the ON position with engine running to maintain electrical and hydraulic functions and prevent serious machine damage.

OFF (1) – Insert the engine start switch key only when the engine start switch is

in the OFF position. Also, remove the engine start switch key only when the engine start switch is in the OFF position. Turn the engine start switch to the OFF position before you attempt to restart the engine. Turn the engine start switch to the OFF position to stop the engine.

ON (2) – The engine start switch will

return to the ON position when the

engine start switch key is released from the START position.

Page 72

Operation Section Light Switches

START (3) – Turn the engine start switch to the START position to crank the engine. Release the engine start switch

key when the engine starts.

Note: Return the key to the OFF position if the

engine does not start. This must be done before another starting attempt is made.

Note: If the engine does not start after 30 seconds, return the engine start switch to the OFF position. Wait for 2 minutes before you turn the engine start switch to the START position again.

To start the engine, the battery disconnect switch must be in the ON position. Also, the hydraulic activation control lever must be in the LOCKED

position.

i06635592

Light Switches

SMCS Code: 1429-ZS; 7451

S/N: KP51–Up

SEBU9422-02

Illustration 90 g03304537

The interior light is on the upper left side of the cab. The switch for the interior light is located inside the light.

Illustration 89 g03304458

Working Lights Switch

Move the Light Switch to center position to turn on the front work lights.

Move the Light Switch to bottom position to turn on all machine lights.

Illustration 91 g03304520

Press the right-hand side of the lens to turn on the light.

Page 73

SEBU9422-02

Operation Section

Window Wiper and Washer Control

Illustration 92 g03304498

Press the left-hand side of the lens to turn off the light.

Illustration 93 g06055339

The engine compartment light switch is on the same bracket as the battery disconnect switch. The switch is inside the platform engine access door.

Flip the toggle switch to turn the engine compartment light on and off.

i05147649

Window Wiper and Washer Control

SMCS Code: 7305; 7306

S/N: KP51–Up

Page 74

Operation Section Heating and Air Conditioning Control

SEBU9422-02

Illustration 94 g03304656

The control switch for the window wiper and the window washer is located on the left-hand console of

the cab.

Depress top of the control switch in order to activate the window wipers. Depress top switch again to increase speed of wiper.

Depress and hold the control switch in order to activate the window washer.

i05281414

Heating and Air Conditioning Control

SMCS Code: 7304; 7320; 7337

S/N: KP51–Up

Illustration 95 g03320387

Heater and Air Conditioner Controls

Switch (1) controls the heater fan and the air conditioning fan. Depress the upper switch in order to activate fan.

Switch (2) toggles between the heater and the air conditioning. Depress the upper switch in order to activate the heater. Push the lower in order to

activate the air conditioner.

Page 75

SEBU9422-02

Operation Section

Defroster Fan Control

The fan uses a three-position switch. The middle position is the OFF position. The remaining switch positions are LOW and HIGH.

Illustration 96 g03320388

Temperature Control Dial

Turn the temperature control dial (3) located behind the operator seat on the temperature control in order to change the temperature setting. Turn the dial to the left in order to lower the temperature. Turn the dial to the right in order to raise the temperature.

i05162657

Defroster Fan Control

SMCS Code: 7316

S/N: KP51–Up

Illustration 97 g03316891

Fan Switch

Page 76

Operation Section Controls

Controls

i06843192

Hydraulic Lockout Control

SMCS Code: 5258

S/N: KP51–Up

The hydraulic lock is used to turn the machine pilot hydraulic system on and off. The hydraulic system will lock when the left-hand joystick control console is raised .

SEBU9422-02

Illustration 99 g03321116

Hydraulic Lock/Unlock Button

To UNLOCK the control/function hydraulic system, depress the Hydraulic Lock/Unlock Button.

Illustration 98 g03356610

Note: Verify that left-hand arm console is lowered to activate the hydraulic system.

When the hydraulic system lock is in the LOCKED position, the machine pilot hydraulic system is charged. The control/function hydraulic system is not charged.

Note: Always place the left-hand joystick control console in the LOCKED (RAISED) position when you exit the operator compartment.

Page 77

SEBU9422-02

Operation Section

Swing Control (Foot Pedal)

SMCS Code: 5059

i06923798

i07167426

Stabilizer Control

SMCS Code: 5258; 7222-ZS

Illustration 100 g03317678

Press the left swing control foot pedal toward the floor in order to swing the machine platform to the left. Release pressure on the left swing control foot pedal in order to decrease the swing speed of the platform. If you completely release pressure from the pedal, the platform will stop.

Press the right swing control foot pedal toward the floor in order to swing the machine platform to the right. Release pressure on the right swing control foot pedal in order to decrease the swing speed of the platform. If you completely release pressure from the pedal, the platform will stop.

Illustration 101 g06169545

(1) Left Stabilizer Raise Control Switch.

(2) Left Stabilizer Lower Control Switch.

Illustration 102 g06169547

(3) Right Stabilizer Raise Control Switch.

(4) Right Stabilizer Lower Control Switch.

Page 78

Operation Section Machine Operation Information

Note: There are 4 different stabilizer modes that can be selected. Front and rear, front, rear, or trailer. Front and rear enable the operator to move all four front and rear stabilizers simultaneously. The alarm will sound once per second when any of the stabilizers are being actuated.

SEBU9422-02

Illustration 103 g06169549

(5) Trailer Stabilizer Control Switch (If equipped)

The stabilizer control switches are on the left-hand console. Use the corresponding stabilizer control

switches to raise each stabilizer arm and lower each stabilizer arm.

The stabilizer control switch selected will be displayed on the monitor screen. The stabilizer

control selected will also be illuminated above the control panel switch.

Illustration 104 g06241505

Note: If the trailer stabs are selected and not actuated for more than 1 minute, then the stabilizer selection will automatically transition to “front and rear” selection.

i06925260

Machine Operation Information

SMCS Code: 7000

Operating the machine while personnel are working on or near the machine can cause personal injury or death.

Before operating the machine, make sure all personnel are clear of the machine and are outside

of the machine operation area. The machine operation area consists of the length of the boom, stick, and grapple when fully extended, as well as the length of the load being carried.

Page 79

SEBU9422-02

Operation Section

Machine Operation Information

Note: Raise machine slowly until trailer tires are completely off the ground.

5. Raise the boom to a height that is sufficient to

provide clearance of the trailer.

6. Adjust the engine speed control switch to increase

the engine speed (RPM) to the desired speed.

7. Apply pressure to either side of the boom swing

pedal to swing the machine.

Note: If the machine does not operate correctly or if the machine does not swing smoothly, consult your authorized dealer.

Illustration 105 g00488011

Operation Area of Loader

1. Adjust the operator seat.

2. Depress hydraulic unlock button (1).

Illustration 106 g03316925

3. Use the engine speed increase button to adjust the

engine speed to the operating range. Depress the decrease (turtle) (2) button to decrease engine speed. Depress the increase (rabbit) (3) order to increase the engine speed.

4. Lower the four stabilizers to the ground so that the

machine is supported by the stabilizers.

Page 80

Operation Section Engine Starting

SEBU9422-02

Engine Starting

SMCS Code: 1000; 7000

S/N: KP51–Up

If the display monitor does not display properly, inspect the machine for the trouble. Repair all problems before operating the machine.

i06635598

NOTICE

Rotate the grapple at least 20 complete revolutions every 10 hours, allowing hydraulic oil to completely flow through all lines.

3. Cycle all controls to allow warm oil to circulate

through all the lines and the cylinders. Observe the following recommendations during the warmup period for the engine:

• In temperatures above 0°C (32°F), the warmup

period is 15 minutes.

• In temperatures below 0°C (32°F), the warmup

period is 30 minutes or a longer time period.

• In temperatures below −18°C (0°F), more time is

required if the hydraulic controls are sluggish.

Illustration 107 g03319977

1. Turn the engine start switch (1) to the START

position to start the engine. Release the engine start switch key after the engine starts.

Do not crank the engine for more than 30 seconds. Allow the starter to cool for two minutes before crank-

ing again. Turbocharger damage can result if the engine rpm is not kept low until the oil gauge display verifies that the oil pressure is sufficient.

NOTICE

i07161651

Engine and Machine Warm-Up

SMCS Code: 1000; 7000

1. Allow a cold engine to warmup at LOW IDLE for at

least 5 minutes.

2. Look at the display monitor and the indicator lights

frequently during operation.

If low engine oil pressure fails to register, inspect the machine for the cause of the trouble.

Page 81

SEBU9422-02

Parking

i06843219

Equipment Lowering with Engine Stopped

SMCS Code: 7000

S/N: KP51–Up

To relieve pressure on hydraulic cylinders other than boom hydraulic cylinders, turn off the engine, leaving the key switch on and the hydraulic system armed. Cycle the joysticks to relieve pressure. Turn key switch OFF.

Note: The pressure can be relieved within 60 seconds after turning off the engine if the accumulator is charged. After 60 seconds, the hydraulic electronic control module will shut off and the joysticks will be disabled.

Operation Section

Parking

Illustration 108 g03701382

Machine With a Boom Lowering Control Valve (If Equipped)

Boom load may cause cylinder oil pressure to reach relief pressure of the boom lowering control device when the boom is supported by one cylinder. Boom can lower suddenly, causing possible injury or death.

To avoid possible injury or death, be sure no one is under or near the work tool before manually lowering the boom.

Keep all personnel away from the boom drop area when lowering the boom with the engine stopped.

If the engine is stopped or the hydraulic system is disabled, the operator can still lower the boom. Use the following procedure if the machine is equipped with a boom lowering control valve.

The boom lowering control valve (1) (if equipped) is installed on the main valve bank. The boom lowering control valve allows the operator to manually lower the boom if the engine is stopped.

1. Loosen valve by turning counter-clockwise.

2. Slowly lower boom to the ground.

3. Make sure that the work tool has been lowered

onto the ground. Tighten valve by turning

clockwise.

4. Before you put the machine into operation, make

any necessary repairs.

For additional information, consult your authorized dealer.

i06635606

Leaving the Machine

SMCS Code: 7000

S/N: KP51–Up

Page 82

Operation Section Leaving the Machine

SEBU9422-02

Illustration 109 g06055354

1. Turn the battery disconnect switch to the OFF

position.

Note: Do not turn the battery disconnect OFF until after the light has gone out.

2. Inspect all engine compartments for debris. Clean

out any debris to avoid a fire.

Illustration 110 g03321070

3. Use the steps and the handholds when you get off

the machine. Make sure that the steps are clear of

debris before you dismount.

4. Turn the battery disconnect switch to the OFF

position.

Note: Do not turn the battery disconnect OFF until after the light has gone out.

5. Install all vandalism protection locks and all

vandalism covers.

Page 83

SEBU9422-02

Maintenance Section

Lubricant Viscosities and Refill Capacities

Maintenance Section

Lubricant Viscosities and Refill Capacities

i06952631

Lubricant Viscosities

SMCS Code: 7581

General Information for Lubricants

When you are operating the machine in temperatures below −20°C (−4°F), refer to Special Publication, SEBU5898, “Cold Weather Recommendations”. This

publication is available from your Prentice dealer.

Refer to the “Lubricant Information” section in the latest revision of the Special Publication, SEBU6250,

“Caterpillar Machine Fluids Recommendations” for a list of Cat engine oils and for detailed information. This manual may be found on the Web at Safety.Cat.

com.

The footnotes are a key part of the tables. Read ALL footnotes that pertain to the machine compartment in question.

Cat oils have been developed and tested to provide the full performance and life that has been designed and built into Cat engines.

Cat DEO-ULS or oils that meet the Cat ECF-3 specification and the API CJ-4 are required for use in

the applications listed below. Cat DEO-ULS and oils meeting Cat ECF-3 specification and the API CJ-4 and ACEA E9 oil categories have been developed with limited sulfated ash, phosphorus, and sulfur. These chemical limits are designed to maintain the expected aftertreatment devices life, performance, and service interval. If oils meeting the Cat ECF-3 specification and the API CJ-4 specifications are not available, oils meeting ACEA E9 may be used. ACEA E9 oils meet the chemical limits designed to maintain aftertreatment device life. ACEA E9 oils are validated

using some but not all ECF-3 and API CJ-4 standard engine performance tests. Consult your oil supplier when considering use of an oil that is not Cat ECF-3 or API CJ-4 qualified.

Failure to meet the listed requirements will damage aftertreatment-equipped engines and can negatively impact the performance of the aftertreatment devices. The Diesel Particulate Filter (DPF) if equipped, will plug sooner and require more frequent DPF ash service intervals.

Typical aftertreatment systems may include the following:

Selecting the Viscosity

To select the proper oil for each machine compartment, refer to the “Lubricant Viscosity for Ambient Temperature” table. Use the oil type AND oil viscosity for the specific compartment at the proper ambient temperature.

The proper oil viscosity grade is determined by the minimum ambient temperature (the air in the immediate vicinity of the machine). Measure the temperature when the machine is started and while the machine is operated. To determine the proper oil viscosity grade, refer to the “Min” column in the table. This information reflects the coldest ambient

temperature condition for starting a cold machine and for operating a cold machine. Refer to the “Max” column in the table for operating the machine at the highest temperature that is anticipated. Unless specified otherwise in the “Lubricant Viscosities for Ambient Temperatures” tables, use the highest oil viscosity that is allowed for the ambient temperature.

Engine Oil

Machines that are operated continuously should use oils that have the higher oil viscosity in the final drives and in the differentials. The oils that have the higher oil viscosity will maintain the highest possible oil film thickness. Refer to “General Information for

Lubricants” article, “Lubricant Viscosities” tables, and any associated footnotes. Consult your Cat dealer if

additional information is needed.

• Diesel Particulate Filters (DPF)

• Diesel Oxidation Catalysts (DOC)

• Selective Catalytic Reduction (SCR)

• Lean NOx Traps (LNT)

Other systems may apply.

Page 84

Maintenance Section Lubricant Viscosities

Table 7

SEBU9422-02

Lubricant Viscosities for Ambient Temperatures

Compartment or System

Oil Type and Performance

Requirements

Oil Viscosities

°C °F

Min Max Min Max

Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104

Engine Crankcase for all Machines

Cat DEO-ULS SYN SAE 5W-40 −30 50 −22 122

Cat DEO-ULS

SAE 10W-30 −18 40 0 104

SAE 15W-40 −9.5 50 15 122

Table 8

Lubricant Viscosities for Ambient Temperatures

Compartment or System Oil Type and Classification

Oil Viscosities

°C °F

Min Max Min Max

SAE 0W-20 −40 40 −40 104

SAE 0W-30 −40 40 −40 104

Cat HYDO

Cat DEO Cat MTO

Cat TDTO

Cat TDTO-TMS

Hydraulic Systems

Cat Arctic TDTO SYN

Cat ECF-1

Cat BIO HYDO (HEES)

API CG-4

API CF commercial TO-4 commercial BF-1

Transmission Gearbox

Swing Drive Gearbox

Grease Points

(1)

Commercial biodegradable hydraulic oil (HEES) must meet the Caterpillar BF-1 specification. The listed ambient temperature range is for the current Cat BIO HYDO (HEES), not for commercial BF-1 oil.

(2)

Refer to the machine Operation and Maintenance Manual or contact your local Caterpillar dealer before using Cat BIO HYDO (HEES) or commercial BF-1 oil in Caterpillar Hydraulic Excavators.

(3)

Cat TDTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the TO-4M multigrade specification requirements).

(4)

Preferred gear oil in the transmission gearbox only.

(5)

Extreme Pressure - EP Gear Oil SAE 80 or API GL-4 gear oil

(6)

4.0 L (1.0 US gal) (0.9 Imp gal) capacity in small swing drive; 5.9 L (1.5 US gal) (1.3 Imp gal) in large swing drive; fill at angled inlet port IP

(7)

If CAT GO or CAT Synthetic GO cannot be used, select a commercial oil that meets the API GL-5 specification. Non-Caterpillar commercial “API GL-5” gear oils are as a group second choice oils.

(8)

If MPGM is not available, use multipurpose type grease which contains 3 to 5 percent molybdenum.

(6)

(8)

API GL-4 gear oil

API GL-5 gear oil

CAT GO (Gear Oil)

Caterpillar MPGM 3% Moly

(4)

(7)

SAE 5W-30 −30 40 −22 104

SAE 5W-40 −30 40 −22 104

SAE 10W −20 40 −4 104

SAE 30 10 50 50 122

SAE 10W-30 −20 40 −4 104

SAE 15W-40 −15 50 5 122

Cat MTO −25 40 −13 104

Cat BIO HYDO (HEES)

(1)(2)

Cat TDTO-TMS

(5)

SAE 80

−40 43 −40 110

(3)

−20 50 −4 122

-20 40 -4 104

SAE 80W90 -20 40 -4 104

SAE 85W-140 -10 50 14 122

-20 40 -4 104

Page 85

SEBU9422-02

i05195838

S·O·S Information

SMCS Code: 1348; 1350; 5050; 7542

S·O·S Services is a highly recommended process for Prentice customers to use in order to minimize

owning and operating cost. Customers provide oil samples, coolant samples, and other machine information. The dealer uses the data in order to

provide the customer with recommendations for management of the equipment. In addition, S·O·S

product problem.

Refer to Special Publication, SEBU6250, “Caterpillar Machine Fluid Recommendations” for detailed

information concerning S·O·S Services.

Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for a specific sampling location and a service hour maintenance interval.

Maintenance Section

S·O·S Information

Consult your Prentice dealer for complete information and assistance in establishing an S·O·S program for your equipment.

Page 86

Maintenance Section Maintenance Support

SEBU9422-02

Maintenance Support

i06858501

Welding on Machines and Engines with Electronic Controls

SMCS Code: 1000; 6461; 6640; 6700-KH; 6700;

7000; 7220

S/N: KP51–Up

Do not weld on any protective structure. If it is necessary to repair a protective structure, contact your authorized dealer.

Proper welding procedures are necessary to avoid damage to the electronic controls and to the bearings. When possible, remove the component that must be welded from the machine or the engine and then weld the component. If you must weld near an electronic control on the machine or the engine, temporarily remove the electronic control to prevent heat-related damage. The following steps should be followed to weld on a machine or an engine with electronic controls.

• Engine ECM Module - On the engine

• Control Module - Located in the cab

• Machine ECM Module - Located in the cab

• Product Link Module - Located under the hydraulic tank

5. Protect any wiring harnesses and components

from the debris and the spatter which is created from welding.

6. Use standard welding procedures to weld the

materials together.

1. Turn off the engine. Place the engine start switch

in the OFF position.

2. Turn the battery disconnect switch to the OFF

position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure to reduce the possibility of damage to the following components:

• Bearings of the drive train

• Hydraulic components

• Electrical components (Engine ECM, and the Product Link Module.

NOTICE

• Other components of the machine

4. Disconnect power source to or remove the

following components

Page 87

SEBU9422-02

Maintenance Section

Maintenance Interval Schedule

i06952723

Maintenance Interval Schedule

SMCS Code: 7000

When Required

“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 89

“ Cab Air Filter - Clean/Replace” . . . . . . . . . . . . . . . 93

“ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . . 93

“ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . . 94

“ Fuel System Primary Filter (Water Separator) -

Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

“ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 143

“ Window Washer Reservoir - Fill” . . . . . . . . . . . . 149

“ Window Wiper - Inspect/Replace” . . . . . . . . . . . 149

“ DEF Filler Screen - Clean” . . . . . . . . . . . . . . . . . 100

“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . 102

Every 10 Service Hours or Daily

“ Boom and Stick Linkage - Lubricate” . . . . . . . . . . 92

“ Differential Pinion - Lubricate”. . . . . . . . . . . . . . . 103

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 116

“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 118

Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)

“Cooling System Coolant Sample (Level 2) -

Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Every 500 Service Hours

“ Fuel Filter (In-Line) - Replace” . . . . . . . . . . . . . . 122

“ Hydraulic System Oil Filter (Case Drain) -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

“ Hydraulic System Oil Filter (Pilot) - Replace” . . . 136

“ Hydraulic System Oil Filter (Return) -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

“ Hydraulic System Oil Sample - Obtain” . . . . . . . 142

“Cooling System Coolant Sample (Level 1) -

Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

“ Engine Crankcase Breather - Clean” . . . . . . . . . 109

“ Fuel Tank Cap and Strainer - Clean” . . . . . . . . . 127

“ Hydraulic System Oil Filter - Replace” . . . . . . . . 133

Every 1000 Service Hours

“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . 102

“ Grapple Head - Lubricate” . . . . . . . . . . . . . . . . . . 128

“ Stabilizer and Cylinder Bearings - Lubricate”. . . 144

“ Swing Bearing - Lubricate” . . . . . . . . . . . . . . . . . 146

Every Week

“ Hoses and Clamps - Inspect/Replace” . . . . . . . . 129

Every 50 Service Hours or Weekly

“ Fuel Tank Water and Sediment - Drain” . . . . . . . 127

Every 250 Service Hours or Monthly

“ Battery - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

“ Battery Hold-Down - Tighten” . . . . . . . . . . . . . . . . 90

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 91

“ Battery or Battery Cable - Inspect/Replace”. . . . . 90

“ Fuel System Primary Filter (Water Separator)

Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 124

“ Fuel System Secondary Filter Number One -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

“ Swing Drive Oil - Change” . . . . . . . . . . . . . . . . . . 147

Every 1500 Service Hours

“Engine Crankcase Breather Element -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Every 2000 Service Hours or 1 Year

“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 130

“ Swing Drive Oil Level - Check” . . . . . . . . . . . . . . 148

Page 88

Maintenance Section Maintenance Interval Schedule

“ Receiver Dryer (Refrigerant) - Replace”. . . . . . . 143

Every Year

“Cooling System Coolant Sample (Level 2) -

Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Every 3000 Service Hours or 2 Years

“ Cooling System Coolant Extender (ELC) -

Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Every 6000 Service Hours or 4 Years

“ Cooling System Coolant (ELC) - Change” . . . . . . 94

SEBU9422-02

Page 89

SEBU9422-02

Battery - Clean

SMCS Code: 1401-070

S/N: KP51–Up

Maintenance Section

Battery - Clean

i05164804

Illustration 111 g03320832

Remove the access panel (1) in order to expose the batteries.

Illustration 112 g03320835

Clean the battery terminals (2) and the surfaces of the batteries with a clean cloth. Coat the battery terminals with petroleum jelly. Make sure that the battery cables are installed securely.

i02039199

Battery - Recycle

SMCS Code: 1401-561

S/N: KP51–Up

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

• A battery supplier

• An authorized battery collection facility

• A recycling facility

Page 90

Maintenance Section Battery Hold-Down - Tighten

i06932694

Battery Hold-Down - Tighten

SMCS Code: 7257-527

SEBU9422-02

Illustration 113 g06173045

The batteries are located in the platform of the machine. The access door (1) for the batteries is located in the center of the platform of the machine.

Remove the two bolts from the battery access door to access the battery compartment.

Illustration 114 g06173057

Over time, the vibration of an operating machine can cause the battery hold-down to loosen. To help prevent loose batteries and the possibility of loose cable connections, tighten all fastening hardware (2).

i06635612

Battery or Battery Cable Inspect/Replace

SMCS Code: 1401-040; 1401-510; 1402-510; 1402-

040

S/N: KP51–Up

1. Turn the engine start switch and all cab switches to

the OFF position.

Page 91

SEBU9422-02

Maintenance Section

Belts - Inspect/Adjust/Replace

4. Disconnect all battery cables.

5. Perform the necessary repairs. Replace the

battery cable or the battery, as needed.

6. Turn the battery disconnect switch (2) clockwise

into the ON position.

7. Install access plate (1).

i05164815

Belts - Inspect/Adjust/Replace

SMCS Code: 1357-040; 1357-510; 1357-025

S/N: KP51–Up

Serpentine Belt

Illustration 115 g06173045

2. Remove access plate (1) to gain access to the

batteries. The batteries are located in the platform of the machine.

Illustration 117 g03317751

1. Stop the engine. Open the engine access doors

that are located on the platform or on the rear of the machine.

2. Inspect the condition of the serpentine belt (1). If

the belt is cracked or frayed, replace the belt.

Illustration 116 g06055373

3. Turn the battery disconnect switch (2)

counterclockwise into the OFF position.

Page 92

Maintenance Section Boom and Stick Linkage - Lubricate

3. Cat engines are equipped with a belt tensioner.

Refer to the Perkins Engine OMM for maintenance procedures.

i06635616

Boom and Stick Linkage Lubricate

SMCS Code: 6501-086-KL; 6502-086-KL

S/N: KP51–Up

SEBU9422-02

When performing maintenance above ground level,

NOTICE

always use appropriate devices such as ladders and man lift machines.

Illustration 119 g06055401

Center Joint Lubrication - Main Boom Rod End, Stick Boom Base End

Illustration 118 g06056553

Main Boom Base End Lubrication Point

Illustration 120 g06173080

Stick Cylinder Rod End

1. Wipe excess grease and dirt off all grease fittings.

2. Lubricate all fittings.

Use ADV 3 Moly Grease.

Page 93

SEBU9422-02

Maintenance Section

Cab Air Filter - Clean/Replace

Illustration 121 g03321410

Note: Be sure to lubricate the link between the grapple and the stick.

i05164839

Cab Air Filter - Clean/Replace

SMCS Code: 7342-510; 7342-070

S/N: KP51–Up

Note: Clean the cab air filters more often if the

machine is being operated in dusty conditions.

NOTICE

When performing maintenance above ground level, use appropriate devices such as ladders or man lift machines.

Illustration 122 g03317774

1. Using a ladder or man machine lift the access door

on the right-hand side of the cab. Remove the filter element.

2. Remove the two retaining bolts (1) to access the

filter.

3. Clean the filter element with pressure air or wash

the filter element in warm water with a nonsudsing household detergent.

4. If water and detergent are used to clean the filter

element, rinse the filter element in clean water. Allow the filter element to air dry thoroughly.

Note: If the filter element is damaged, install a new filter element.

5. Install the filter element. Refasten the access door.

i06843259

Circuit Breakers - Reset

SMCS Code: 1420-529

Circuit Breaker Reset – Depress the button to reset the circuit breakers. If

the circuit is functioning properly, the button will remain depressed. If the button will not remain depressed, check the appropriate electrical circuit.

Page 94

Maintenance Section Circuit Breakers - Reset

Illustration 123 g06173552

The circuit breakers are located near the hydraulic filters on the right-hand rear of the machine.

i06865173

Circuit Breakers - Reset

SMCS Code: 1420-529

SEBU9422-02

Illustration 124 g06146602

Main circuit breaker(1) Glow plug circuit breaker (2) DEF ECM circuit breaker (3) Engine ECM circuit breaker (4)

The circuit breakers are on the rear right-hand side of the machine.

i06843263

Cooling System Coolant (ELC)

- Change

SMCS Code: 1350-044-NL

S/N: KP51–Up

Circuit Breaker Reset – Depress the button to reset the circuit breakers. If

the circuit is functioning properly, the button will remain depressed. If the button will not remain depressed, check the appropriate electrical circuit.

S/N: KP51–Up

Engine hood and engine hood parts can be hot while engine is running or immediately after engine shutdown. Hot parts or hot components can cause burns or personal injury. Do not allow these parts to contact your skin, when engine is running or immediately after engine shutdown. Use protective clothing or protective equipment to protect your skin.

Page 95

SEBU9422-02

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

Maintenance Section

Cooling System Coolant (ELC) - Change

Do not change the coolant until you read and under-

NOTICE

stand the cooling system information in Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.

Failure to do so could result in damage to the cooling system components.

NOTICE

Mixing ELC with other products will reduce the effectiveness of the coolant.

This could result in damage to cooling system components.

If Caterpillar products are not available and commercial products must be used, make sure they have passed the Caterpillar EC-1 specification for premixed or concentrate coolants and Caterpillar Extender.

Note: This machine was filled at the factory with Cat Extended Life Coolant.

If the coolant in the machine is changed to Extended Life Coolant from another type of coolant, see Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.

1. Open the cooling system access door.

Illustration 125 g06146673

2. Slowly loosen the pressure cap (1) that is on the

coolant reservoir to release pressure from the cooling system.

3. Remove the pressure cap.

4. Inspect the o-ring of the cooling system pressure

cap. If the o-ring is damaged, replace the pressure cap.

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information that pertains to containing fluid spillage.

5. Open the cooling system access door on the left

side of the machine.

6. Open the draincock valve and allow the coolant to

drain into a suitable container. The draincock valve is on the bottom of the radiator.

7. Flush the cooling system. Follow Step 7.a through

Step 7.h to flush the cooling system.

a. Close the drain valve.

b. Fill the cooling system with clean water.

c. Install the pressure cap.

d. Start the engine and run the engine until the

engine reaches operating temperature.

e. Stop the engine and allow the engine to cool.

f. Loosen the pressure cap slowly to relieve any

pressure in the cooling system.

Page 96

Maintenance Section Cooling System Coolant Extender (ELC) - Add

g. Open the drain valve that is on the bottom of the

radiator and allow the coolant to drain into a suitable container.

h. Flush the radiator with clean water until the

draining water is transparent.

8. Close the drain valve.

9. Add the Extended Life Coolant. Refer to the

following topics:

• Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”

SEBU9422-02

• Operation and Maintenance Manual, “Capacities (Refill)”

10. After the cooling system has been filled, perform

the following procedures during initial start-up:

a. Start the engine without the filler cap.

b. Run the engine at low idle for 10 minutes.

c. Then, increase the engine speed to a high idle

until the water temperature regulator is open and the coolant level is stabilized.

d. Maintain the coolant at the proper level as the

water temperature regulator opens, and the air is purged from the system. Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check”.

11. Install the cooling system pressure cap.

12. Stop the engine.

13. Check the coolant reservoir. Maintain the coolant

level between “FULL” mark and “LOW” mark .

14. If more coolant is necessary, remove the

pressure cap and add the appropriate coolant solution.

15. Install the pressure cap.

16. Close the cooling system access door and latch

the cooling system access door.

i05096733

Cooling System Coolant Extender (ELC) - Add

SMCS Code: 1352-544-NL

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

Use Cat Extended Life Coolant (ELC) when you add coolant to the cooling system. See Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” for all cooling system requirements.

Use a Coolant Conditioner Test Kit in order to check the concentration of the coolant.

NOTICE

Mixing ELC with other products will reduce the effectiveness of the coolant.

This could result in damage to cooling system components.

Note: This machine was filled at the factory with Cat Extended Life Coolant.

S/N: KP51–Up

1. Park the machine on level ground.

2. Stop the engine.

Page 97

SEBU9422-02

Maintenance Section

Cooling System Coolant Extender (ELC) - Add

3. Unlatch the cooling system access door and raise

the cooling system access door .

Illustration 126 g02930019

4. Make sure that the cooling system has cooled

down. Loosen the cooling system pressure cap slowly in order to relieve system pressure. Remove the pressure cap.

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage.

5. It may be necessary to drain some coolant from

the radiator so that Cat Extender can be added to the cooling system.

Note: Always discard drained fluids according to local regulations.

6. Add Cat Extended Life Coolant (ELC) to the

cooling system. Refer to the following topics for the proper amount of Caterpillar Extender:

• Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”

• Operation and Maintenance Manual, “Capacities (Refill)”

7. Inspect the o-ring of the cooling system pressure

cap. If the o-ring is damaged, replace the pressure cap.

8. Install the cooling system pressure cap.

9. Close the cooling system access door and latch

the cooling system access door .

i06869593

Cooling System Coolant Extender (ELC) - Add

SMCS Code: 1352-544-NL

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

Use a Coolant Conditioner Test Kit to check the concentration of the coolant.

NOTICE

Mixing ELC with other products will reduce the effectiveness of the coolant.

This could result in damage to cooling system components.

Page 98

Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain

SEBU9422-02

Note: This machine was filled at the factory with Cat Extended Life Coolant.

1. Park the machine on level ground.

2. Stop the engine.

3. Unlatch the cooling system access door and raise

the cooling system access door .

7. Inspect the o-ring of the cooling system pressure

cap. If the o-ring is damaged, replace the pressure cap.

8. Install the cooling system pressure cap.

9. Close the cooling system access door and latch

the cooling system access door .

i06952651

Cooling System Coolant Sample (Level 1) - Obtain

SMCS Code: 1350-008; 1395-008; 7542

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

Illustration 127 g06146673

4. Make sure that the cooling system has cooled

down. Loosen the cooling system pressure cap (1) slowly to relieve system pressure. Remove the pressure cap.

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage.

5. It may be necessary to drain some coolant from

the radiator so that Cat Extender can be added to the cooling system.

Note: Always discard drained fluids according to local regulations.

6. Add Cat Extended Life Coolant (ELC) to the

cooling system. Refer to the following topics for the proper amount of Caterpillar Extender:

• Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”

• Operation and Maintenance Manual, “Capacities (Refill)”

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

Note: It is not necessary to obtain a Coolant Sample (Level 1) 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) obtained. Refer to the recommended interval as 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. Including the following types of

coolants.

• Commercial long life coolants that meet the Caterpillar Engine Coolant Specification -1 (Caterpillar EC-1)

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commercial heavy-duty coolant/antifreeze

Page 99

SEBU9422-02

Maintenance Section

Cooling System Coolant Sample (Level 2) - Obtain

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.

Care must be taken to ensure that fluids are contained during performance of inspection, mainte-

nance, 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.

Refer to Special Publication, NENG2500, “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat

Dispose of all fluids according to local regulations and mandates.

Note: Level 1 results may indicate a need for Level 2 Analysis.

Obtain the sample of the coolant as close as possible to the recommended sampling interval. To receive the full effect of S·O·S analysis, establish a consistent trend of data. To establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your authorized dealer.

1. Use the following guidelines for proper sampling of

the coolant:

• Complete the information on the label for the sampling bottle before you begin to take the samples.

NOTICE

products.

2. Submit the sample for Level 1 analysis.

Reference: For additional information about coolant

analysis, refer to Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” or consult your Prentice dealer.

i06933221

Cooling System Coolant Sample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 7542

NOTICE

1. Obtain the sample of the coolant as close as

possible to the recommended sampling interval. Supplies for collecting samples can be obtained from your authorized dealer.

Reference: Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) Obtain” for the guidelines for proper sampling of the coolant.

2. Submit the sample for Level 2 analysis.

Reference: For additional information about coolant

analysis, refer to Special Publication, SEBU6250, “Machine Fluids Recommendations”.

i05698174

• 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 to avoid contamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

DEF Filler Screen - Clean

SMCS Code: 108K-070-Z3

S/N: KP51–Up

NOTICE

Ensure that the engine is stopped before any servicing or repair is performed.

Page 100

100

Maintenance Section DEF Filler Screen - Clean

SEBU9422-02

Care must be taken to ensure that fluids are con-

NOTICE

tained 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.

Refer to Special Publication, NENG2500, “Cat Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.

The filler neck adapter filter screen in the diesel exhaust fluid tank will need to be cleaned or replaced if contaminated.

i06870469

DEF Filler Screen - Clean

SMCS Code: 108K-070-Z3

NOTICE

Ensure that the engine is stopped before any servicing or repair is performed.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, mainte-

nance, 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.

The filler neck adapter filter screen in the diesel exhaust fluid tank will need to be cleaned or replaced if contaminated.

Illustration 128 g03618438

1. Use a screwdriver or pick to press the tabs (1).

2. Pull the screen assembly (2) upward from both

sides and remove from the fill neck adapter

3. Use water or compressed air to clean out the filter

screen (3). If there is any debris inside, let dry and remove the debris by turning the screen upside down and dumping debris out. If the debris cannot be removed or the filter screen is damaged, replace the filler neck adapter filter screen.