Blount 2748, 2948 Maintenance Manual

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Page 1

OPERATION AND MAINTENANCE MANUAL

FORWARDER 2748 PCL1 - Up

2948 PCH1 - Up

Page 2

i03933413

Important Safety Information

Most accidents basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the neces

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operat 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 heed

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

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

A non-exh on the product and in this publication.

that involve product operation, maintenance and repair are caused by failure to observe

sary training, skills and tools to perform these functions properly.

e or perform a ny lubrication, maintenance or repair on this product, until you have

ed, bodily injury or death could occur to you or to other persons.

! Become Alert! Your Safety is Involved.

austive list of operations that may cause product damage are identiﬁed by “NOTICE” labels

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warn 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 operat 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 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 av 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

ings in this publication and on the product are, therefore, not all inclusive. You must

ion of the product in the location of use, including site-speciﬁc rules and precautions

others. You should also ensure that the product will not be damaged or become unsafe by

ailable at the time that the publication was written. The speciﬁcations, torques, pressures,

any job. CAT dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using CAT

lacement parts or parts with equivalent spec-

rep iﬁcations including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or

ath.

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.

Page 3

SEBU8710 3

Table of Contents

Table of Co nte nts

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

Safety Section

Safety Messages .................................................... 6

Additional Messages ............................................. 13

General Hazard Information ................................. 16

Crushing Prevention and Cutting Prevention ........ 18

Burn Prevention .................................................... 19

Fire Prevention and Explosion Prevention ............ 19

Fire Extinguisher Location .................................... 23

Tire Information ..................................................... 23

Electrical Storm Injury Prevention ......................... 24

Before Starting Engine .......................................... 24

Engine Starting ..................................................... 24

Before Operation .................................................. 24

Visibility Information .............................................. 24

Operation ............................................ .................. 25

Machine Operat

Engine Starting ..................................................... 79

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

Transportat

Towing Information ................................................ 87

Engine Starting (Alternate Methods) ..................... 89

ion ............................................... 42

ion Information .................................... 83

Maintenance Section

Tire Inﬂati

Cooling System Speciﬁcations ............................. 92

Lubricant Viscosities and Reﬁll Capacities ........... 96

Maintena

Maintenance Support .......................................... 105

Maintenance Interval Schedule .......................... 107

on Information ....................................... 91

nce Access ........................................... 100

Reference Information Section

Referen

Index S

Index ................................................................... 167

ce Materials ............................................ 165

ection

Work Tools ............................................................ 26

Lifting Objects ............. .......................................... 26

Slope Operation .................................................... 26

Equipment Lowering with Engine Stopped ........... 27

Sound Information and Vibration Information ....... 27

Operator Station ................................................... 30

Guards (Operator Protection) ............................... 30

Engine Electronics ................................................ 31

Product Information Section

General Information .............................................. 33

Identiﬁcation Information ....................................... 36

Operation Section

Before Operation .................................................. 39

Page 4

4 SEBU8710 Foreword

Foreword

Literature Information

This manual sh compartment in the literature holder or seat back literature storage area.

This manual contains safety information, operation instructions, transportation information, lubrication informatio

Some photographs or illustrations in this publication show detail 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 wh Read, study and keep this manual with the machine.

Whenever or this publication, please consult your Caterpillar dealer for the latest available information.

Safety

ould be stored in the operator's

n and maintenance information.

s or attachments that can be different

ich are not included in this publication.

a question arises regarding your machine,

Maintenance

The maintenan care. The Maintenance Interval Schedule (MIS) lists the items to be maintained at a speciﬁcservice interval. Ite under the "When Required" service interval. The Maintenance Interval Schedule lists the page number for th accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or "one safe source

Maintenance Intervals

Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, e meter intervals if they provide more convenient servicing schedules and approximate the indicated service h should always be performed at the interval that occurs ﬁrst.

Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is speciﬁe be necessary.

d in the maintenance intervals chart might

ce section is a guide to equipment

ms without speciﬁc intervals are listed

e step-by-step instructions required to

" for all maintenance procedures.

tc.) can be used instead of service hour

our meter reading. Recommended service

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

Read and understand the basic precautions listed in the s lubrication, maintenance and repair on this machine.

ing signs and labels used on the machine.

afety section before operating or performing

Operation

The op operator and a refresher for the experienced operator. This section includes a discussion of gaug controls, transportation and towing information.

Phot 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 gai

eration section is a reference for the new

es, switches, machine controls, attachment

ographs and illustrations guide the operator

ns knowledge of the machine and its capabilities.

Perform requirement. For example, at every 500 service hours or 3 months, also service those items listed under e 10 service hours or daily.

service on items at multiples of the original

very 250 service hours or monthly and every

California Proposition 65 Warning

l engine exhaust and some of its constituents

Diese 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

r handling.

afte

iﬁed Engine Maintenance

Cert

Proper maintenance and repair is essential to keep

engine and machine systems operating correctly.

the As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required

ntenance listed in the Owner Manual, Operation

mai and Maintenance Manual, and Service Manual.

Page 5

SEBU8710 5

Foreword

It is prohibite business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoper element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 8 and engine such as the exhaust system, fuel system, electrical system, intake air system and cooling system may b altered unless approved by Caterpillar.

d for any person engaged in the

ative any emission related device or

9). Certain elements of the machine

e emission related and should not be

Machine Capacity

Additional machine design capacity which can adversely affect performance characteristics. Included would be stability steering, and rollover protective structures (ROPS). Contact your Caterpillar dealer for further information.

attachments or modiﬁcations may exceed

and system certiﬁcations such as brakes,

Caterpillar Product Identiﬁcation Number

ve First Quarter 2001 the Caterpillar Product

Effecti Identiﬁcation Number (PIN) has changed from 8 to 17 characters. In an effort to provide uniform equipment

cation, Caterpillar and other construction

identiﬁ equipment manufacturers are moving to comply with the latest version of the product identiﬁcation number deﬁned by ISO 10261. The new PIN format will apply to all Caterpillar machines and generator sets. The PIN pla character PIN. The new format will look like the following:

ing standard. Non-road machine PINs are

tes and frame marking will display the 17

3. Check Charac

4. Machine Indicator Section (MIS) or Product Sequence Numb previously referred to as the Serial Number.

Machines and 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 Numb

ter (character 9)

er (characters 10-17). These were

generator sets produced before First

er (S/N).

Illustration 1

Where:

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

2. Machine Descriptor (characters 4-8)

g00751314

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6 SEBU8710 Safety Section Safety Messages

Safety Section

i03916669

Safety Messages

SMCS Code: 7000

Illustration 2

g02150934

Page 7

SEBU8710 7

Safety Section

Safety Messages

Do Not Operate (1)

This warning is located in the headliner above the operator seat when the seat faces the engine compartment.

Illustration 3

g02151062

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. Please become familiarized with all safety messages.

Make sure that all of 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 legible. 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.

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

g0137090

Do not operate or work on this machine unless you have read and understand the instructions andwarningsintheOperationandMaintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your r esponsibility.

Distance From Cab (2)

This warning is located on the rear headliner above the operator seat.

g01814474

Warning! Crushing Hazard! The grapple or load

ay contact the cab which can cause serious in-

m jury or death. Keep the grapple and load away from cab.

Page 8

8 SEBU8710 Safety Section Safety Messages

Electrocution (3)

This danger label is located on the rear headliner above the operator seat.

g01412508

Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay cle length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Fai will cause serious injury or death

ar 3 m (10 ft) plus twice the line insulator

lure to follow the instructions and warnings

Swinging Bo om (4)

This warning is located on the rear headliner above the operator seat.

g01814475

Crushing Hazard! Stay clear of the boom when the machine is in operation. Failure to stay clear of the swinging boom could cause serious injury or death.

To avoid injury from a swinging boom and ﬂying debris, personnel should stay at least 20 m (70 ft) from the machine while the machine is operating. Falling trees or other debris can cause severe injury or death.

Distance (5)

This warning is located on each side of the boom.

g00947676

achine swings. Stay back. Crushing hazard

M could cause serious injury or death.

Page 9

SEBU8710 9

Safety Section

Safety Messages

High Pressure Cylinder (6)

This warning is located on each accumulator in the front frame and the rear frame.

g01372252

Hydraulic accumulator c ontains gas and oil under high pressure. Improper removal or repair procedures could cause severe injury. To remove or repair, instructions in the service manual must be followed. Special equipment is required for testing and charging.

Crushhazard(7)

This warning is located on the main frame near the articulation lock.

g01371647

Crushing Hazard. There is no clearance for a person in this area when the machine turns. Severe injury or death from crushing could occur. Connect the steering frame lock between front and rear frames before lifting, transporting, or servicing the machine in the articulation area.

Disconnect the steering lock and secure before resuming operation.

Page 10

10 SEBU8710 Safety Section Safety Messages

Cab Tilting (8)

This warning is located on the frame near the cab tilt pump.

g01384815

Do not tilt the cab when occupied. Before tilting the cab remove all loose articles from the cab, secure all windows and emergency exits, and then close the cab and cab riser doors. Failure to do so can result in personal injury or damage to the machine.

ROPS/FOPS Structure (10)

This warning is located in the left storage area inside the cab.

g01869578

Structural damage, an overturn, modiﬁcation, alteration,orimproperrepaircanimpairthisstructure's protection capabil ity thereby voiding this certiﬁcation. Do not weld on or drill holes in the structure. This will void the certiﬁcation. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certiﬁcation.

No Clearance (9)

This warning is located on both sides of the cab front frame above the steering cylinders.

g01371644

rushing Hazard! Stay back a safe distance. There

C is no clearance for a person in this area when the machine turns. Failure to follow these instructions

ould cause serious injury or death.

This machine has been certiﬁed to the standards that arelistedonthecertiﬁcation plate. The maximum mass of the machine, which includes the operator and the attachments without a payload, should not exceed the mass on the certiﬁcation plate.

Refer to Operation and Maintenance Manual, “Guards (Operator Protection)” for more information.

Page 11

SEBU8710 11

Safety Section

Safety Messages

No Ether (11)

This warning is located on the air cleaner.

g01372254

Explosion hazard! Do not use ether! This machine is equipped with an air inlet heater. Using ether can create explosions or ﬁres that can cause personal injury or death. Read and follow the starting procedure in the Operation and Maintenance Manual.

Trip Point (13)

This warning is located on the platform plate at the top of the operator access ladder.

g01505713

Trip Point. When entering or exiting the cab, watch for protruding objects. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death.

Ladder (12)

This warning is located above the ladder on the left side radiator guard.

g01814477

Crushing Hazard! Stay clear of the ladder when the

perator is starting the machine and when the op-

o erator is stopping the machine. The ladder is automatically raised when the parking brake is disen-

aged. The ladder is automatically lowered when

g the parking brake is engaged. Failure to stay clear of the ladder when it is raised or lowered could cause serious injury or death.

Page 12

12 SEBU8710 Safety Section Safety Messages

Pressurized S ystem (14)

This warning is located near the expansion tank pressure cap toward the front of the engine compartment.

g0137164

Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.

Battery (15)

This warning is located on the right machine frame above the batteries.

g01370909

Explosion Hazard! Improper jumper cable connections can cause an explosion resulting in serious injury or death. Batteries may be located in separate compartments. When using jump start cables, always connect the positive (+) cable from the source to the positive (+) terminal of the battery that is connected to the starter s olenoid. Connect the negative (−) cable from the source to the negative (−) terminal of the starter. If the machine is not equipped with a starter negative terminal, connect the negative (−) cable to the engine block. Follow the procedure in the Operation and Maintenance Manual.

Page 13

SEBU8710 13

Safety Section

Additional Messages

Seat Belt (16)

This warning is located on the right side window.

g01370908

A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

i03932449

Additional Messages

SMCS Code: 7000

Air Conditioner (1)

Illustration 5

g00946380

Do not work on the air conditioning system until you have read the service manual and you understand the service manual.

Reference: For more information, refer to Service Publication, SENR5664, “Air Conditioning and Heating with R-134a”.

Alternate Exit (2)

18717

Illustration 6

g019

Illustration 4

g01918134

This message is located on the right side of the engine on the alternator support bracket.

Two messages are located above the latch on the right side window of the cab.

Illustration 7

Alternate exit

g01422244

Page 14

14 SEBU8710 Safety Section Additional Messages

Illustration 8

g00956057

Unlock the alternate exit during machine operation.

Window Cleaning (3)

8766

Illustration 9

g0191

This message is located on the rear right window of the cab.

Illustration 11

g02095974

This message describes the ﬁre points that are available on the engine compartments. Use the apertures in order to suppress ﬁre hazards in the engine compartment.

Illus

tration 12

g02154423

Thismessageislocatedontheleftsideoftheengine

artment.

comp

Illustration 10

g00930685

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

Fire Points (Engine)(4)

Illustration 13

his message is located on the right side of the

g01915575

engine compartment.

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

Page 15

SEBU8710 15

Safety Section

Additional Messages

“No weld/No dri

Illustration 14

ll” (5)

g01918794

Illustration 17

g02096140

This message is located on the rear facing frame of the machine. Tow the machine with this towing hitch, if necessary.

Tie-Downs (7)

Illustration 18

g00680110

Illustration 15

g00935231

This message is located on the left side compartment inside the cab. Do not weld or drill on the ROPS structural members. Read the “Operation and Maintenance Manual”.

Hitches (6)

02096016

Illustration 16

Illustration 19

Rear axle

g02096181

Illustration 20

Front axle

g02096177

Page 16

16 SEBU8710 Safety Section General Hazard Information

Also, two locat

ions on each of the front and rear axles are for tying down the machine or towing the machine. Do not use these tie-downs to lift the

machine.

Read “Towing the Machine” and “Lifting and TyingDownth

e Machine” in this manual for more

information.

i03559343

General Hazard Information

SMCS Code: 7

Illustration 21

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 Caterpillar dealer.

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.

000

g00104545

Illustration 22

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.

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.

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.

Page 17

SEBU8710 17

Safety Section

General Hazard Information

When you perfor use appropriate devices such as ladders or man lift machines. If equipped, use the machine anchorage points and use lanyards.

m maintenance above ground level

approved fall arrest harnesses and

Pressurized Air and Water

Pressurized and/or hot water to be blown out. This could result in personal injury.

When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and e goggles or a protective face shield.

The maximu must be reduced to 205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used with an effect equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

air and/or water can cause debris

ye protection. Eye protection includes

m air pressure for cleaning purposes

ivechipdeﬂector and personal protective

Trapped Pressure

Illustration 23

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.

g00687600

Containing Fluid Spillage

Pressure can be trapped in a hydraulic system. Releasing trapped pressure can cause sudden machine caution if you disconnect hydraulic lines or ﬁttings. High pressure oil that is released can cause a hose to whip. H to spray. Fluid penetration can cause serious injury and possible death.

movement or attachment movement. Use

igh pressure oil that is released can cause oil

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can

hydraulic ﬂuid or items such as pipe plugs to

cause escape rapidly if the pressure is not relieved correctly.

t remove any hydraulic components or parts

Do no until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic

onents or parts until pressure has been relieved

comp or personal injury may occur. Refer to the Service Manual for any procedures that are required to

ieve the hydraulic pressure.

rel

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, “Caterpillar 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

Obey all local regulations for the disposal of liquids.

Page 18

18 SEBU8710 Safety Section Crushing Prevention and Cutting Prevention

Asbestos Information

ion 24

Illustrat

Caterpillar equipment and replacement parts that are shipped f recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when you asbestos or when you handle asbestos debris.

Use caut generated when you handle components that contain asbestos ﬁbers. Inhaling this dust can be hazardous to your asbestos ﬁbers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbest boundinaresinorsealedinsomeway.Normal handling is not hazardous unless airborne dust that conta

If dust that may contain asbestos is present, there are se

rom Caterpillar are asbestos free. Caterpillar

handle any replacement parts that contain

ion. Avoid inhaling dust that might be

health. The components that may contain

os that is used in these components is usually

ins asbestos is generated.

veral guidelines that should be followed:

g00702022

Comply with app

•

for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requir can be found in “29 CFR 1910.1001”.

Obey environ

•

of asbestos.

Stay away fr

•

particles in the air.

licable rules and regulations

ements. These OSHA requirements

mental regulations for the disposal

om areas that might have asbestos

Dispose of Waste Properly

Illustration 25

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.

g00706404

Never use compressed air for cleaning.

•

Avoid brushing materials that contain asbestos.

•

d grinding materials that contain asbestos.

Avoi

•

Useawetmethodinordertocleanupasbestos

•

erials.

mat

A vacuum cleaner that is equipped with a high

•

ciency particulate air ﬁlter (HEPA) can also be

efﬁ used.

e exhaust ventilation on permanent machining

•

jobs.

ar an approved respirator if there is no other

•

way to control the dust.

i01359664

Crushing Prevention and Cutting Prevention

SMCS Code: 7000

port the equipment properly before you perform

Sup any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold

the equipment. Equipment can fall if a control is

up moved, or if a hydraulic line breaks.

not work beneath the cab of the machine unless

Do the cab is properly supported.

nless you are instructed otherwise, never attempt

U adjustments while the machine is moving or while the engine is running.

Page 19

SEBU8710 19

Safety Section

Burn Prevention

Never jump acro 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 t 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 maintenan

Keep objects away from moving fan blades. The fan blade will

Do not use a kinked wire cable or a frayed wire cable. Wear glov

When you strike a retainer pin with force, the retainer pin can ﬂy personnel. Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eye a retainer pin.

throw objects or cut objects.

s, wear protective glasses when you strike

ss the starter solenoid terminals

he equipment or the machine. Stay

ce is performed.

es when you handle wire cable.

out. The loose retainer pin can injure

Ensure that the ﬁller cap. The ﬁller cap must be cool enough to touch with a bare hand. Remove the ﬁller cap slowly in order to relie

Cooling system conditioner contains alkali. Alkali can cause person the skin, the eyes, or the mouth.

ﬁller cap is cool before removing the

ve pressure.

al injury. Do not allow alkali to contact

Oils

Hot oil and h injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.

Remove the hydraulic tank ﬁller cap only after the engine has been stopped. The ﬁller cap must be cool enoug standard procedure in this manual in order to remove the hydraulic tank ﬁller cap.

ot components can cause personal

h to touch with a bare hand. Follow the

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

. Always wear protective glasses for servicing

Chips or strike the object. Make sure that no one can be injured by ﬂying debris before striking any object.

other debris can ﬂy off an object when you

i01329099

Burn Prevention

SMCS Code: 7000

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the oil system, in the lubrication system, in the fuel system, or in the cooling system before any lines, ﬁttings or related items are disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

i03863998

Fire Prevention and Explosion Prevention

SMCS Code: 7000

0704000

Illustration 26

Check the coolant level only after the engine has been stopped.

Page 20

20 SEBU8710 Safety Section Fire Prevention and Explosion Prevention

General

Much of the material that is found in forestry applications is highly ﬂammable. This includes the following pieces: limbs, bark, leaves, sawdust, small wood chips, and pine tree's needles. When this debris from forestry applications is soaked with fuel or lubricants, the risk of ﬁre is greatly increased. Perform a daily inspection before every shift or more often when the amount of work output and buildup of debris is the best way to prevent a machine ﬁre. Frequent inspections and thorough cleanings of the machine are critical when the machine is engaged in forestry applications. Even minor leaks or electrical malfunctions should be repaired as soon as possible.

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

To m i ni mi z e t h e r is k of ﬁre or explosion, Caterpillar 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 Caterpillar dealer for service.

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

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 ﬂui

ds 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 cutt

ing. 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 o

pen ﬂames or sparks. Use suitable

Personal Protection Equipment (PPE).

Inspect al

l lines and hoses for wear or deterioration. Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. T

ighten all connections to the recommended torque. Damage to the protective cover or insulation may provide fuel for ﬁres.

Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rag

sandﬂammable materials in protective containers. Do not smoke in areas that are used for storing ﬂammable materials.

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.

Keep the access doors to major machine compartments closed and access doors in working conditioninordertopermittheuseofﬁre suppression equipment, in case a ﬁre should occur.

Highly ﬂammable debris can collect on equipment and in equipment that is used in forestry applications. This debris includes the following pieces: leaves, twigs, sawdust, small wood chips, , and pine tree's needles. If the debris is allowed to accumulate, the debris can rapidly become the fuel agent 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 the completion of each work shift. Perform this activity more frequently when working in conditions with large amounts of forest debris are present.

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

Do not operate the machine near any ﬂame.

Illustration 27

g00704059

Usecautionwhenyouarefuelingamachine.Donot 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.

Page 21

SEBU8710 21

Safety Section

Fire Prevention and Explosion Prevention

Follow practic in the “Operation” section of the Operation and Maintenance Manual section and follow local regulations. operator compartment of the machine.

es for safe fueling that are described

Never store ﬂammable ﬂuids in the

Battery and Battery Cables

Fraying

•

Abrasion

•

Cracking

•

Discolorati

•

Cuts on the insulation of the cable

•

Fouling

•

Corroded te

•

terminals

Replace da any related parts. Eliminate any fouling, which may have caused insulation failure or related component damage or w reinstalled correctly.

An expose a short to ground if the exposed area comes into contact with a grounded surface. A battery cable short pro may be a ﬁre hazard.

rminals, damaged terminals, and loose

maged battery cable(s) and replace

ear. Ensure that all components are

d wire on the battery cable may cause

duces heat from the battery current, which

Illustration 28

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 Caterpillar dealer for service.

Follow safe procedures for engine starting with jump start 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.

g00704135

An expos battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes in may result in an unsafe condition for servicing the machine. Repair components or replace components before

Fire on a machine can result in personal injury or death. Exposed battery cables that come into cont ﬁres. Replace cables and related parts that show signs of wear or damage. Contac t your Caterpillar deal

Wiri

Check electrical wires daily. If any of the following con the machine.

•

Signs of abrasion or wear

•

ed wire on the ground cable between the

to contact with a grounded surface. This

servicing the machine.

act with a grounded connection can result in

er.

ditions exist, replace parts before you operate

aying

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:

Cracking

•

scoloration

•

Cuts on insulation

•

Page 22

22 SEBU8710 Safety Section Fire Prevention and Explosion Prevention

Other damage

•

Make sure that all clamps, guards, clips, and straps are reinstall 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 Caterpillar dealer for repair or for replacemen

Keep wiring and electrical connections free of debris.

ed correctly. This will help to prevent

tparts.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. order to tighten all connections to the recommended torque.

Use the appropriate backup wrenches in

Flexible parts

•

Outer covers have exposed embedded armoring.

•

End ﬁttings are displaced.

•

Make sure tha are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, exce hoses.

Do not opera exists. Repair any lines that are corroded, loose or damaged. Leaks may provide fuel for ﬁres. Consult yo replacement parts. Use genuine Caterpillar parts or the equivalent, for capabilities of both the pressure limit and t

of the hoses are kinked.

t all clamps, guards, and heat shields

ssive heat, and failure of lines, tubes and

te a machine when a ﬁre hazard

ur Caterpillar dealer for repair or for

emperature limit.

Ether

Ether (if equipped) is commonly used in cold weather applicat

Follow the correct cold engine starting procedures. Refer to Manual with the label “Engine Starting”.

ions. Ether is ﬂammable and poisonous.

the section in the Operation and Maintenance

stration 29

Illu

Check lines, tubes and hoses carefully. Wear

onal Protection Equipment (PPE) in order to

Pers check for leaks. Always use a board or cardboard when you check for a leak. Leaking ﬂuid that is under

ssure can penetrate body tissue. Fluid penetration

pre can cause serious injury and possible death. A pin hole leak can cause severe injury. If ﬂuid is injected

o your skin, you must get treatment immediately.

int 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.

•

uter coverings are chafed or cut.

•

Wires are exposed.

•

Outer coverings are swelling or ballooning.

•

g00687600

Do not sp 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 us

Do not store ether cylinders in living areas or in the opera ether cylinders in direct sunlight or in temperatures above 49° C (120.2° F). Keep ether cylinders away from

Dispose of used ether cylinders properly. Do not punc away from unauthorized personnel.

ray ether manually into an engine if the

inganetherspray.

tor compartment of a machine. Do not store

open ﬂames or sparks.

ture an ether cylinder. Keep ether cylinders

Fire Extinguisher

n additional safety measure, keep a ﬁre

As a extinguisher on the machine.

amiliar with the operation of the ﬁre extinguisher.

Be f Inspect the ﬁre extinguisher and service the ﬁre extinguisher regularly. Follow the recommendations

the instruction plate.

Consider installation of an aftermarket Fire

ppression System, if the application and working

Su conditions warrant the installation.

Page 23

SEBU8710 23

Safety Section

Fire Extinguisher Location

i03604131

Fire Extinguisher Location

SMCS Code: 7000

Make sure that

a ﬁre extinguisher is on the machine. Make sure that you are familiar with the operation of the ﬁre extinguisher. Inspect the ﬁre extinguishe

randservicetheﬁre extinguisher. Obey the recommendations on the instruction plate. Obey local regulations.

Illustration 30

g01929181

Mount the ﬁre extinguisher on the left side door. This is the recommended location.

Note: Do not weld on the ROPS in order to install the ﬁre extinguisher. Do not drill holes in the ROPS in order to mount the ﬁre extinguisher on the ROPS.

Illustration 31

(A) At leas t 15 m (50 ft) (B) At least 500 m (1500 ft)

g00337832

Do not approach a warm tire. Maintain a minimum distance, as shown. Stay outside the shaded area in Illustration 31.

Note: The tires may be ﬁlled with salt water in order to increase the weight of the machine.

If the combined weight of the machine, the towed attachment and the attachment cargo exceed the brake capacity available from both the machine and the towed attachment, a loss of control may occur. The operator must verify that the combined weight does not exceed the combined braking capacity. Loss of control could cause injury or death.

i01846194

Tire Information

SMCS

Explosions of air inﬂated tires have resulted from hea Explosions can be caused by heat that is generated by welding, by heating rim components, by external ﬁre

A tire explosion is much more violent than a bl components, and the axle components as far as 500 m (1500 ft) or more from the machine. Both the fo property damage, personal injury, or death.

Code: 7000

t-induced gas combustion inside the tires.

, or by excessive use of brakes.

owout. The explosion can propel the tire, the rim

rce of the explosion and the ﬂying debris can cause

aximum weight of the machine must not ex-

The m ceed the ROPS certiﬁcation weight. This weight is stamped on the ROPS plate. This plate is located

e cab exterior.

on th

To avoid overinﬂation, proper inﬂation equipment and

ining in the usage of the equipment are necessary.

tra 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

ocedures should perform this maintenance. If

pr correct procedures are not used for servicing tires and rims, the assemblies could burst with explosive

orce. This explosive force can cause serious

f personal injury or death. Carefully obey the speciﬁc instructions from your tire dealer.

Page 24

24 SEBU8710 Safety Section Electrical Storm Injury Prevention

i01122596

Electrical Storm Injur y Prevention

SMCS Code: 7000

When lightning is striking in the vicinity of the machine, the operator should never attempt the following p

Mount the machine.

•

Dismount the machine.

•

If you are i storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicini

rocedures:

n the operator's station during an electrical

ty of the machine.

i03626346

Before Starting Engine

SMCS Code: 1000; 7000

Thesteeringframelockmustbeintheunlocked position in order to steer the machine.

i01884100

Engine Starting

SMCS Code: 1000; 7000

Perform the da engine.

If a warning t the controls, do not start the engine. Also, do not move any controls.

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

Ensure that the cab door is shut. The machine cannot be driven with the cab door open.

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

Before O

ily inspection before starting the

ag is attached to the start switch or to

art the engine in a well ventilated area.

de.

i01963896

peration

The oscillation lock must be in the unlocked position.

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 parts that are worn or damaged. Regardless of the appearance, replace the seat belt after three years of use. Do not use a seat belt extension 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.

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

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

SMCS Code: 7000

Clear all personnel from the machine and from the area.

Remove all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc.

Be sure that all windows are clean. Secure the doors and the windows in either the open position or the

osition.

shut p

Adjust the rearview mirrors (if equipped) for best

on close to the machine. Make sure that the

visi machine horn, the backup alarm (if equipped) and all other warning devices are working properly.

Reference: Refer to Operation and Maintenance Manual, “Daily Inspection” in this manual.

Fasten the seat belt securely.

i03162317

Visibility Information

SMCS Code: 7000; 7615

Before you start the machine, perform a walk-around inspection in order to ensure that there are no hazards around the machine.

Page 25

SEBU8710 25

Safety Section

Operation

While the machi the area around the machine in order to identify potential hazards as hazards become visible around the machine.

Your machine may be equipped with visual aids. Some example Television (CCTV) and mirrors. Before operating the machine, ensure that the visual aids are in proper working con Adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual. If equipped adjusted according to Operation and Maintenance Manual, SEBU8157, “Work Area Vision System”.

It may not be possible to provide direct visibility on large machines to all areas around the machine. Appropria to minimize hazards that are caused by restricted visibility. Job site organization is a collection of rules and proce people that work together in the same area. Examples of job site organization include the following:

Safety instructions

•

Control

•

vehicle movement

Workers

•

ne is in operation, constantly survey

s of visual aids are Closed Circuit

dition and that the visual aids are clean.

, the Work Area Vision System shall be

tejobsiteorganizationisrequiredinorder

dures that coordinates machines and

led patterns of machine movement and

that direct trafﬁctomovewhenitissafe

Machine Operating Temperature Range

The standard machine conﬁguration is intended for use within an ambient temperature range of −40 °C (−40°F)to50°C(122°F).Special conﬁgurations for different ambient temperatures may be available. Consult your Caterpillar dealer for additional information on special conﬁgurations of your machine.

Operation

Only operate the machine while you are in a seat. Fasten the seat belt while you operate the machine. 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 go close to the edge of a cliff, an excavation, or an overhang.

Restricted areas

•

Operator training

•

ng symbols or warning signs on machines

Warni

•

or on vehicles

em of communication

A syst

•

Communication between workers and operators

•

r to approaching the machine

prio

Modiﬁcations of the machine conﬁguration by the

that result in a restriction of visibility shall be

user evaluated.

i03895256

Operation

S Code: 7000

SMC

Know the maximum dimensions of your machine.

Operate the machine up slopes and down slopes. Avoid operating the machine across the slope, when possible. If the machine begins to sideslip downward on a slope, immediately turn the machine down the hill.

Avoid any conditions that can lead to tipping the machine. The machine can tip when you work on hills, on banks and on slopes or when you cross ditches, ridges or other unexpected obstructions. The cab will also tip if the rear of the machine tips.

If the machine begins to tip, perform the following actions.

Pull in the extensions

•

Bend the second boom.

•

Slowly lower the load.

•

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

Lift the load into the air before the boom slews the load.

Never drive the cylinders to the outermost position at full speed.

Page 26

26 SEBU8710 Safety Section Work Tools

Ensure that the 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.

Before you maneuver the machine, make sure that no personnel are between the machine and the trailing eq equipment in order to align the hitch with the drawbar. Maneuver the machine. Connect the machine to the trailing eq

hitches and any towing devices

uipment. Block up the hitch of the trailing

uipment.

i03562303

Work Tools

SMCS Code: 6700

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

Work tools and work tool control systems, that are compatible with your Caterpillar 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 Caterpillar dealer.

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

Never use the wo

rk tool for a work platform.

i03933329

Lifting Objects

SMCS Code: 6513; 7000

There may be government regulations that govern the use of machines which lift heavy objects. Obey those regulatio

If this machine is used to lift objects within an area that i “2006/42/EC”, the machine must be equipped with a boom lowering control valve and an overload warning device.

Slope Op

SMCS Code: 7000; 7615

Machines that are operating safely in various applications depend on these criteria: the machine model, operating speed of the machine, conditions of the terrain, ﬂuid levels, and tire inﬂation pressures. The most im the operator.

conﬁguration, machine maintenance,

portant criteria are the skill and judgment of

some local regulations and/or

ns.

s controlled by the European Directive

i03745198

eration

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 ROPS certiﬁcation.

If your machine is equipped with an extendable stick, install the transport pin when you are using the following work tools: hydraulic hammers, augers, and compactors

Always wear protective glasses. Always wear the protective equipment that is recommended in the work tool's operation manual. 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.

trained operator that follows the instructions

Awell in the Operation and Maintenance Manual has the greatest impact on stability. Operator training

des a person with the following abilities:

provi observation of working and environmental conditions, feel for the machine, identiﬁcation of potential

rds, and operating the machine safely by making

haza appropriate decisions.

you work on side hills and when you work on

When slopes, consider the following important points:

ed of travel – At higher speeds, forces of inertia

Spe

tend to make the machine less stable.

ghness of terrain or surface – The machine

Rou

maybelessstablewithuneventerrain.

rection of travel – Avoid operating the machine

across the slope. When possible, operate the machine up the slopes and operate the machine

wn the slopes. Place the heaviest end of the

do machine uphill when you are working on an incline.

ounted equipment – Balance of the machine

may be impeded by the following components: equipment that is mounted on the machine, machine

onﬁguration, weights, and counterweights.

Page 27

SEBU8710 27

Safety Section

Equipment Lowering with Engine Stopped

Nature of surfa

ﬁlled with earth may collapse from the weight of the machine.

Surface material – Rocks and moisture of the surface material may drastically affect the machine's traction and promote side slipping of the machine.

Slippage du

downhill tracks or downhill tires to dig into the ground, which will increase the angle of the machine.

Width of tracks or tires – Narrower tracks or narrower tires further increase the digging into the ground whi

Implements attached to the drawbar – This may decrease t also decrease the weight on the uphill tires. The decreased weight will cause the machine to be less stable.

Height of the working load of the machine –

When the w stability of the machine is reduced.

ce – Ground that has been newly

machine's stability. Rocky surfaces may

e to excessive loads – This may cause

ch causes the machine to be less stable.

he weight on the uphill tracks. This may

orking loads are in higher positions, the

i01329161

Equipment Lowering with Engine Stoppe

SMCS Code: 7000

Before lowering any equipment with the engine stopped, clear the area around the equipment of all personn the type of equipment to be lowered. Keep in mind most systems use a high pressure ﬂuid or air to raise or low high pressure air, hydraulic, or some other media to be released in order to lower the equipment. Wear appro follow the established procedure in the Operation and Maintenance Manual, “Equipment Lowering with Engine Sto manual.

el. The procedure to use will vary with

er equipment. The procedure will cause

priate personal protective equipment and

pped” in the Operation Section of the

i03851551

Sound Information and Vibration Information

Operate

features of the equipment in operation and the effects on machine stability.

Operating techniques – Keep all attachments or pulled loads low to the ground for optimum stability.

Machine systems have limitations on slopes –

Slopes can affect the proper function and operation of the systems are needed for machine control.

Note:

special machine maintenance. Excellent skill of the operator and proper equipment for speciﬁc appl and Maintenance Manual sections for the proper ﬂuid level requirements and intended machine use.

d equipment – Be aware of performance

various machine systems. These machine

Safe operation on steep slopes may require

ications are also required. Consult the Operation

SMCS Code: 7000

Sound Level Information

g protection may be needed when the

Hearin machine is operated with an open operator station for extended periods or in a noisy environment. Hearing

tion may be needed when the machine is

protec operated with a cab that is not properly maintained.

atic exterior sound power level is 111 dB(A)

The st when the “ISO6393:2008” procedure is used to measure the value for the standard machine.

Sound Level Information for Machines in European Union Coun

tries and in Countries that

Adopt the “EU Directives”

The operator sound pressure level is 78 dB(A) when “ISO 5131:1996” is used to measure the value for

nclosed cab in high gear. The cab was properly

an e installed and maintained. The test was conducted with the cab doors and the cab windows closed.

The operator sound pressure level is 64 dB(A) when “ISO 5131:1996” is used to measure the value for

enclosed cab in low gear. The cab was properly

an installed and maintained. The test was conducted with the cab doors and the cab windows closed.

Page 28

28 SEBU8710 Safety Section Sound Information and Vibration Information

“The European Union Physical Agents (Vibra

tion) Directive

2002/44/EC”

Vibration Data for Wheel Loaders

Information Level

When the mac intended use, the hand/arm vibration of this machine is below 2.5 meter per second squared.

Information Concerning Whole Body Vibration Level

This section provides vibration data and a method for estimating the vibration level for wheel loaders.

Note: Vibration levels are inﬂuenced by many different parameters. Many items are listed below.

Operator training, behavior, mode, and stress

•

Job site

•

weather, and material

Machine

•

suspension system, attachments, and condition of the equipment

It is not possible to get precise vibration levels for this machine. The expected vibration levels can be estima to calculate the daily vibration exposure. A simple evaluation of the machine application can be used.

Concerning Hand/Arm Vibration

hine is operated according to the

organization, preparation, environment,

type, quality of the seat, quality of the

ted with the information in Table 1 in order

Estimate the vibration levels for the three vibration directions. For typical operating conditions, use the

ge vibration levels as the estimated level. With

avera an experienced operator and smooth terrain, subtract the Scenario Factors from the average vibration level

der to obtain the estimated vibration level. For

in or aggressive operations and severe terrain, add the Scenario Factors to the average vibration level in

r to obtain the estimated vibration level.

orde

Note: All vibration levels are in meter per second

ared.

squ

Page 29

SEBU8710 29

Safety Section

Sound Information and Vibration Information

Table 1

“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Machine

Type

Wheel

Loader

(1)

Loading at the face

(2)

Travel at high speed on the job site or on public roads

(3)

Loading a truck in short cycles

Typical Operating

Activity

load and carry motion 0,84 0,81 0,52 0,23 0,20 0,14

mining application

transfer

V-shape motion

(1)

(2)

(3)

X axis Y axis Z axis X axis Y axis Z axis

Vibration Levels Scenario Factors

1,27 0,97 0,81 0,47 0,31 0,47

0,76 0,91 0,49 0,33 0,35 0,17

0,99 0,84 0,54 0,29 0,32 0,14

Note: Refer to “ISO/TR 25398 Mechanical Vibration Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines” for more information about vibration. This publication uses data that is measured by international institutes, organizations and manufacturers. This document provides information about the whole body exposure of operators of earthmoving equipment. Refer to Operation and Maintenance Manual Supplement , SEBU8257 for more information about machine vibration levels.

The Caterpillar suspension seat meets the criteria of “ISO 7096”, if equipped. This represents vertical vibration level under severe operating conditions. This seat is tested with the input “spectral class EM3”. The seat has a transmissibility factor of “SEAT<1.0”.

The whole body vibration level of the machine varies. There is a range of values. The low value is 0.5 meter per second squared. The machine meets the short term level for the design of the seat in “ISO 7096”. The value is 1.13 meter per second squared for this machine.

Guidelines for Reducing Vibration Levels on Earthmoving Equipment

a. Remove any large rocks or obstacles.

b. Fill any ditches and holes.

c. Provide machines and schedule time in order

to maintain the conditions of the terrain.

4. Use a seat that meets “ISO 7096”. Keep the seat maintained and adjusted.

a. Adjust the seat and suspension for the weight

and the size of the operator.

b. Inspect and maintain the seat suspension and

adjustment mechanisms.

5. Perform the following operations smoothly.

a. Steer

b. Brake

c. Accelerate.

d. Shift the gears.

6. Move the attachments smoothly.

Properly adjust machines. Properly maintain machines. Operate machines smoothly. Maintain the conditions of the terrain. The following guidelines can help reduce the whole body vibration level:

1. Use the right type and size of machine, equipment, and attachments.

2. Maintain machines according to the manufacturer's recommendations.

a. Tire pressures

b. Brake and steering systems

c. Controls, hydraulic system and linkages

3. Keep the terrain in good condition.

7. Adjust the machine speed and the route in order

to minimize the vibration level.

a. Drive around obstacles and rough terrain.

b. Slow down when it is necessary to go over

rough terrain.

8. Minimize vibrations for a long work cycle or a long travel distance.

a. Use machines that are equipped with

suspension systems.

b. Use the ride control system on wheel loaders.

c. If no ride control system is available, reduce

speed in order to prevent bounce.

Page 30

30 SEBU8710 Safety Section Operator Station

d. Haul the machin

9. Less operator comfort may be caused by other risk

factors. The f in order to provide better operator comfort:

a. Adjust the se

to achieve good posture.

b. Adjust the m

posture.

c. Provide bre

of sitting.

d. Avoid jump

e. Minimize repeated handling of loads and lifting

of loads.

f. Minimize any shocks and impacts during sports

and leisu

re activities.

es between workplaces.

ollowing guidelines can be effective

at and adjust the controls in order

irrors in order to minimize twisted

aks in order to reduce long periods

ing from the cab.

Sources

The vibration information and calculation procedure is based

- Guideline for the assessment of exposure towholebodyvibrationofrideonoperated earthmo measured by international institutes, organizations and manufacturers.

This literature provides information about assessing the whole body vibration exposure of operators of earth measured vibration emission under real working conditions for all machines.

You should check the original directive. This document summarizes part of the content of the appl substitute the original sources. Other parts of these documents are based on information from the United King

on “ISO/TR 25398 Mechanical Vibration

ving machines”. Harmonized data is

moving equipment. The method is based on

icable law. This document is not meant to

dom Health and Safety Executive.

i03634321

Operator Station

SMCS Code: 7000

Any modiﬁcati should not project into the operator space or into the space for the companion seat (if equipped). The addition equipment must be installed so that the deﬁned operator space and the space for the companion seat (if equippe into the cab should not project into the deﬁned operator space or the space for the companion seat (if equipp be secured. Objects must not pose an impact hazard in rough terrain or in the event of a rollover.

ons to the inside of the operator station

of a radio, ﬁre extinguisher, and other

d) is maintained. Any item that is brought

ed). A lunch box or other loose items must

i03656846

Guards (Operator Protection)

SMCS Code: 7000

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.

Refer to Operation and Maintenance Manual

plement , SEBU8257 for more information about

Sup vibration.

sult your local Caterpillar dealer for more

Con information about machine features that minimize vibration levels. Consult your local Caterpillar dealer

out safe machine operation.

Use the following web site in order to ﬁnd your local

aler:

Caterpillar, Inc.

w.cat.com

Page 31

SEBU8710 31

Safety Section

Engine Electronics

Rollover Protective Structure (ROPS), Falling Object Protective Structure (FOPS) or Tip Over Protection Structure (TOPS)

The ROPS/FOPS Structure (if equipped) on your machine is speciﬁcally designed, tested and certiﬁed for that machine. Any alteration or any modiﬁcation to the ROPS/FOPS Structure could weaken the structure. This places the operator into an unprotected environment. Modiﬁcations or attachments that cause the machine to exceed the weight that is stamped on the certiﬁcation plate also place the operator into an unprotected environment. Excessive weight may inhibit the brake performance, the steering performance and the ROPS. The protection that is offered by the ROPS/FOPS StructurewillbeimpairediftheROPS/FOPS Structure has structural damage. Damage to the structure can be caused by an overturn, a falling object, a collision, etc.

Do not mount items (ﬁre extinguishers, ﬁrst aid kits, work lights, etc) by welding brackets to the ROPS/FOPS Structure or by drilling holes in the ROPS/FOPS Structure. Welding brackets or drilling holes in the ROPS/FOPS Structures can weaken the structures. Consult your Caterpillar dealer for mounting guidelines.

The Tip Over Protection Structure (TOPS) is another type of guard that is used on mini hydraulic excavators. This structure protects the operator in the event of a tipover. The same guidelines for the inspection, the maintenance and the modiﬁcation of the ROPS/FOPS Structure are required for the Tip Over Protection Structure.

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 needs to be installed when a work tool that creates ﬂying objects is used. Mesh front guards that are approved by Caterpillar or polycarbonate front guards that are approved by Caterpillar are available for machines with a cab or an open canopy. On machines that are equipped with cabs, the windows 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:

Rock quarries

•

Forestry products

•

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

Engine Elec

SMCS Code: 1000; 1400; 1900

Electrical Shock Hazard. The unit injector system uses 90 - 120 volts. The ECM sends this signal to the unit injectors. Do not come in contact with the unit injector harness connector while the engine is operating. Failure to follow this instruction could resulting in personal injury or death.

This engine has a comprehensive, programmable Engine Monitoring System. The Engine Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will initiate an immediate action.

The following actions are available for engine monitoring control: WARNING, DERATE, and SHUTDOWN. These engine monitoring modes have the ability to limit engine speed and/or the engine power.

Many of the parameters that are monitored by the ECM can be programmed for the engine monitoring functions. The following parameters can be monitored as a part of the Engine Monitoring System:

Operating Altitude

•

Engine Coolant Level

•

Engine Coolant Temperature

•

Engine Oil Pressure

•

Engine Speed

•

Intake Manifold Air Temperature

•

System Voltage

•

Manual for your machine or your

i03539803

tronics

Demolition applications

•

Page 32

32 SEBU8710 Safety Section Engine Electronics

The Engine Moni engine models and different engine applications. However, the monitoring system and the engine monitoring co

Note: Many of the engine control systems and display modules that work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring Refer to the Electronic Troubleshooting Manual for more information on the Engine Monitoring System.

toring package can vary for different

ntrol will be similar for all engines.

are available for Caterpillar Engines will

function for the speciﬁc engine application.

Page 33

SEBU8710 33

Product Information Section

General Information

Product Information Section

General Information

i03933271

Speciﬁcations

SMCS Code: 1000; 4480; 6319; 6320; 6461; 6700;

6700-KH; 7000; 7426; 7451; 7490; 7615

Illustration 32

g01919475

Page 34

34 SEBU8710 Product Information Section General Information

Table 2

Speciﬁcations

Model

2748 Forwarder Standard-

Rear

Frame

2748 Forwarder

Long-

Rear

Frame

Height of Log Loader

(A)

Storage

Position

4140.20 mm

(163.0

inch)

4140.20 mm

(163.0

inch)

Height of Cab

(B)

3667.50 mm

(144.4

inch)

3667.50 mm

(144.4

inch)

Length

Between

Bogie

Centers

(C)

6512.6

mm (256.4

inch)

5728 mm

(18.8 ft)

Length

Between

Centers of

the Tires

(D)

1664.71 mm

(65.5 inch)

1664.71 mm

(65.5 inch)

Overall Length

(E)

11084.3 mm

(436.4

inch)

Bunk

Arrangement

(F)

2768.6 mm (109 inch)

3263.9 mm

(128.5 inch)

2768.6 mm (109 inch)

3263.9 mm

(128.5 inch)

Width

Over Tires

(G)

3269

(128.7

inch)

3269

(128.7

inch)

Operating

Weight

44600 kg

(98326 lb)

49600 kg

(109350 lb)

Max

Payload

18000 kg

(39683

lb)

18000 kg

(39683

lb)

Dimension H is 655.32 mm (25.8 inch).

Note: A Forwarder with the Standard-Rear Frame is equipped with a Fixed Loader.

Note: A Forwarder with the Long Rear-Frame is available as a Fixed Loader only.

Reach of the Boom

Table 3

Reach of Boom

Model

F111 F78

F111 F85

Extendable

Reach

1350 mm (4.42 ft)

(A)

1850 mm (6.06 ft)

(C)

Maximum

7830 mm

(25.7 ft)

8500 mm

(27.88 ft)

Lifting Capacity of the Boom

F111 F78 S wing Boom

107 kN (24055 lb)

F111 F85 S wing Boom

106 kN (23830 lb)

Reach

(B)

(D)

Illustration 33

(1) Model F111 F78 (2) Model F111 F85

g01929296

Page 35

SEBU8710 35

Product Information Section

General Information

Additional Information for Swing Boom

Table 4

Technical Information

Model

F111 F78

F111 F85

(1)

Bottom to upper joint

(2)

Weight without oil, grapple, and outriggers

Boom Slewing

(Torque)

41 kN

(9217 lb)

41 kN

(9217 lb)

Boom

Swing Angle

(Degrees)

380

Loader

(Height)

1955 mm

(6.4 ft)

1955 mm

(6.4 ft)

(1)

Road

(Width)

1740 mm

(5.7 ft)

1790 mm

(5.9 ft)

Empty

Weight

1960 kg

(4321 lb)

2010 kg

(4431 lb)

(2)

Pump

(Working

Pressure)

21.5 MPa (3100 psi)

Oil Flow

(Displacement)

80 L/min (21 US gpm) to 100 L/min

(26.4 US gpm)

80 L/min (21 US gpm) to 100 L/min

(26.4 US gpm)

Speciﬁcations of the Grapple

Table 5

Speciﬁcations SG360S SGII420S

Weight

Maximum Load

Maximum Opening (A)

Minimum Opening (B)

160 kg

(353 lb)

4000 kg

(8818 lb)

1490 mm

(58.6 inch)

90 mm

(3.5 inch)

170 kg

(375 lb)

4000 kg

(8818 lb)

1575 mm

(62.0 inch)

108 mm

(4.3 inch)

Intended Use

The 2748 Forwarder and the 2948 Forwarder are self-propelled forest machines with articulated steering. In forestry applications, the Forwarder is designed to pick up trees. The Forwarder loads the trees or parts of trees. The Forwarder transports these trees, or parts of trees to a different location (usually off road). Then, the machine can discharge the trees or parts of trees for piling, stacking, or loading. If the Forwarder is used for other applications, equip the machine properly and operate the machine per the instructions in the OMM.

Illustration 34

g00514024

Page 36

36 SEBU8710 Product Information Section Identiﬁcation Information

Identiﬁcation Information

i03933331

Plate Locations and Film Locations

SMCS Code: 1000; 7000

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

Machine Product Identiﬁcation Number (PIN)

Transmission Serial Number

ion 37

Illustrat

The transmission serial number is located on the transmis

Transmission Serial Number

sion gearbox.

_____________________________

g00989089

Certiﬁcation Plate

Note: This plate is on machines that are used in the

European Union.

tration 35

Illus

The plate for the machine product identiﬁcation numbe the left side of the machine.

Mach

Seri

r (PIN) is located near the articulation hitch on

ine PIN

_________________________________________________

al Number Plate

g01140726

The certiﬁcation plate is used to verify the product conformance to all of the requirements that were

ished by a country or group of countries. The

establ product is tested by a testing group in order to verify conformance.

Illustration 38

This plate is located near the center hitch on the left side of the machine.

Power (kW)

__________________________________________________

g00939718

Illustration 36

The Serial Number Plate is located on the left side of the cylinder block near the rear of the engine.

Engine Serial Number

_____________________________________

g00123229

Weight (kg)________________________________________________ ___

Page 37

SEBU8710 37

Product Information Section

Identiﬁcation Information

i03638040

Emissions Certiﬁcation Film

SMCS Code: 1000; 7000; 7405

Note: This inf

States, in Canada and in Europe.

Consult your Control Warranty Statement.

This label i

ormation is pertinent in the United

Caterpillar dealer for an Emission

s located on the engine.

Page 38

38 SEBU8710 Product Information Section Identiﬁcation Information

i03933369

Declaration of Conform ity

SMCS Code: 1000; 7000

S/N: PCL1-Up

Table 6

An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with speciﬁc requirements for the European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with the machine. The extract shown below from an EC Declaration of Conformity for machines that are declared compliant to “2006/42/EC” applies only to those machines originally “CE” marked by the manufacturer listed and which have not since been modiﬁed.

EC DECLARATION OF CONFORMITY OF MACHINERY

Manufacturer: Caterpillar Inc., 100 N.E. Adams Street, Peoria, IL 61629 USA

Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of European Union Member States on request:

Standards & Regulations Manager,Caterpillar France S.A.S 40, Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France

I, the undersigned, _________, hereby certify that the construction equipment speciﬁed hereunder

Description:

Generic Denomination:

Forestry equipment

on:

Functi

Model/Type: 2748 & 2948

Serial Number:

Commercial Name: Caterpillar

Fulﬁlls all the relevant provisions of the following Directives

Directives

2006/42/EC

2000/14/EC amended by 2005/88/EC, Note (1)

04/108/EC

Note (1) Annex -- ___ Guaranteed Sound Power Level - ____ dB (A)

Done at:

Date:

Representative Equipment Type Sound Power Level - ____ dB (A) Engine Power per _____ kW Rated engine speed - _____ rpm Technical Documentation accessible through person listed above authorized to compile the Technical File

Forwar

der

Notiﬁed Body

Document No.

Signature

Name/Position

Note: The above information was correct as of May 2010, but may be subject to change, please refer to the individual

declaration of conformity issued with the machine for exact details.

Page 39

SEBU8710 39

Operation Section

Before Operation

Operation Section

Before Operation

i03642886

Mounting and Dismounting

SMCS Code: 7000

ration 39

Illust

Typical example

Mount the machine and dismount the machine only at locations that have steps and/or handholds. Before you mo 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.

unt the machine, clean the steps and the

g00037860

Operator Access Ladder

Illustration 40

The machine uses an access ladder as the primary access system. The ladder opens to the down position when the following conditions are met.

The parking brake is engaged.

•

The cab door is opened.

•

The machine shutdown control is activated.

•

A hand hold next to the left engine hood will provide a three-point contact when you use the access platform.

g01954857

i01899563

Daily Inspection

SMCS Code: 1000; 7000

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

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

hands.

two

Do not mount a moving machine. Do not dismount a

ving machine. Never jump off the machine. Do

mo not carry tools or supplies when you try to mount the machine or when you try to dismount the machine.

e a hand line to pull equipment onto the platform.

Us Do not use any controls as handholds when you enter the operator compartment or when you exit the

perator compartment.

lternate Exit

Machines that are equipped with cabs have alternate

xits. For additional information, see Operation and

e Maintenance Manual, “Alternate Exit”.

a sta ble work platform placed in a secure lo-

Use cation w hen lubricating the pillar, working on the fuel tank, or working on the hydraulic tank. If a se-

e location is not availa ble, use the appropriate

cur safety equipment to prevent falling off of the m achine. Failure to work from a secure location may

sult in injury or death from a sli p or a fall.

Note: An inspection of the machine should be

ompleted at the beginning of each shift.

Inspect the engine compartment. Remove any

•

ebris buildup from the engine compartment.

Inspect the engine for any obvious component

•

amage. If any belts are worn, cracked or frayed,

d replace the damaged belts.

Page 40

40 SEBU8710 Operation Section Before Operation

Inspect the coo

•

hoses. If leaks are observed, ﬁnd the source of the leak and correct the leak. If leaks are suspected, ch than the recommended intervals. Replace hoses, as needed. Remove any debris buildup from the radiator. Re Manual, “Radiator Core - Clean”.

Inspect the

•

hydraulic tank, all hoses and all tubes. Also, check all plugs, all seals, all couplings and all ﬁ ttings. If leaks are ob correct the leak. If leaks are suspected, check the ﬂuid levels more frequently than the recommended intervals

Inspect the engine air ﬁlter service indicator. Refer

•

to Operati Filter Service Indicator - Inspect/Replace”.

Inspect t

•

inlet screen. Inspect the precleaner tube openings. Refer to Operation and Maintenance Manual, “Engine A

Inspect the working lights and all exterior lights for

•

broken b bulbs or the lenses, as needed.

Inspect

•

Make sure that the guide path for the gate is free from obstructions. Any debris in the guide path may pre Any debris in the guide path may prevent the gate from moving up and down. Inspect the gate for any damag

Inspect the following items for wear and for

•

damag and grapple. Tighten any loose bolts.

Insp

•

sure that the bunks are mounted properly to the machine. Ensure that the brackets are properly secu

. Replace hoses, as needed.

he engine air precleaner. Inspect the air

the condition and mounting of the gate.

vent the gate from moving back and forth.

e and repair the gate, if necessary.

e: boom, stick, extension, damper, rotator,

ect the bunks and stakes for damage. Make

red into the bunk arrangement.

ling system for leaks and for faulty

eck the ﬂuid levels more frequently

fer to Operation and Maintenance

hydraulic system for leaks. Check the

served, ﬁnd the source of the leak and

on and Maintenance Manual, “Engine Air

ir Precleaner - Clean”.

ulbs and for broken lenses. Replace the

Inspect the ste

•

Remove any debris. Repair any damage or replace any damaged parts.

Inspect the operator compartment. Remove any

•

trash buildup. Keep the operator compartment clean.

Inspect the dash panel for broken gauges and for

•

broken indi

Inspect the seat belt, the buckle, and the mounting

•

hardware. R or damaged. Consult your Caterpillar dealer for repairs.

Adjust the mirrors for best visibility.

•

Inspect th

•

vision is not impaired by dust, by mud, or by other foreign materials. Clean the windows, if necessary. Refer to O “Windows - Clean”.

Visually

•

Tighten any loose bolts.

ps, the walkways and the handholds.

cator lights. Replace any broken parts.

eplace any components that are worn

e windows. Make sure that the operator's

peration and Maintenance Manual,

inspect the machine for any loose bolts.

i03474285

Steering Frame Lock

SMCS Code: 7506

No clearance for person in this area when machine turns. Severe injury or death from crushing could occur.

The steering frame lock link prevents the machine from articulating.

Inspect the tires for damage. Replace any missing

•

ve caps.

val

Inspect the axles, the bogies, the rims, the

•

ferentials and the power train for leaks. Fix any

dif leaks.

ke sure that all access doors, all access covers

•

and all guards are secured. Inspect the access doors, the access covers and the guards for

mage.

llustration 41

Stored position

g01814555

Page 41

SEBU8710 41

Operation Section

Before Operation

Locked Position

Illustration 42

Locked position of the 584 Forwarder

1. Before you perform any of the following operations, insert steering frame lock link (1) into the LOCKED position:

Lift the machine.

•

Transport the machine.

•

Perform any work near the center of the

•

machine.

2. Install pins (2).

g01869057

Unlocked Position

1. Remove the steering frame lock link before the

machine is operated.

2. SecurethesteeringframelocklinkintheSTORED position with locking pins (2). See Illustration 41.

Page 42

42 SEBU8710 Operation Section Machine Operation

Machine Operation

i03488020

Alternate Exit

SMCS Code: 7310

ration 43

Illust

Alternate exit

g01002993

Therightsidewindowcanbeusedasanalternate exit. The window can be opened from the inside of the cab

and from the outside of the cab. Make sure that the alternate exit is unlocked during machine operation.

lustration 44

Outside Handle

g01869093

Illustration 45

Inside handle

g01016339

Push the handle in a downward motion in order to open the door.

i03489242

Seat

SMCS Code: 7312

Note: The operator's seat that is provided with this

machine is in compliance with the appropriate class of ISO 7096.

Note: Seats may vary. Basic seat operation will be similar.

Always use the seat belt when you operate the machine.

Note: Machines may have a slide assembly or an adjuster that allows the seat to be offset in any of the following directions: forward, backward, and opposite.

Seat Adjustment

At the beginning of each work period, the seat must be adjusted. Whenever operators are changed, the seat must be adjusted.

The seat must be adjusted so all of the controls are easily reached. The seat must be adjusted so that the service brake can be fully depressed.

Adjust the seat in order to allow full travel of the pedals. Make the seat adjustments when the operator is sitting against the back of the seat.

Page 43

SEBU8710 43

Operation Section

Machine Operation

i03415082

Seat Belt

SMCS Code: 7327

Note: This mac

when the machine was shipped from Caterpillar. At the time of installation, the seat belt and the instruction the SAE J386 and ISO 6683 standards. See your Caterpillar dealer for all replacement parts.

Always check the condition of the seat belt and the condition of the mounting hardware before you operate th

Seat Belt A Non-Retractable Seat Belts

Adjust both ends of the seat belt. The seat belt should be snug but comfortable.

Lengthening the Seat Belt

hine was equipped with a seat belt

s for installation of the seat belt meet

e machine.

djustment for

2. To r e m o ve t h e sl

ack in outer loop (1), rotate buckle (2). This will free the lock bar. This permits the seat belt to move through the buckle.

3. Remove the slack from the outer belt loop by pulling on the buckle.

4. Loosen the other half of the seat belt in the same manner. If the seat belt does not ﬁt snugly with the buckleinth

e center, readjust the seat belt.

Shortening the Seat Belt

Illustration 46

1. Unfa

sten the seat belt.

g00100709

Illustration 48

g001007

1. Fasten the seat belt. Pull out on the outer belt loop in order to tighten the seat belt.

2. Adjust the other half of the seat belt in the same manner.

3. If the seat belt does not ﬁt snugly with the buckle in the center, readjust the seat belt.

Fastening The Seat Belt

Illustration 47

g00932817

Illustration 49

asten the seat belt catch (3) into the buckle (2).

g00932818

Make sure that the seat belt is placed low across the lap of the operator.

Page 44

44 SEBU8710 Operation Section Machine Operation

Releasing The S

ion 50

Illustrat

Pull up on the release lever. This will release the seat belt.

Seat Bel

tAdjustmentfor

eat Belt

g00100717

Retractable Seat Belts

Fastening The Seat Belt

Releasing The S

ion 52

Illustrat

Push the release button on the buckle in order to release t retract into the retractor.

he seat belt. The seat belt will automatically

eat Belt

g00039113

Extension of the Seat Belt

Illustration 51

l seat belt (4) out of the retractor in a continuous

Pul motion.

ten seat belt catch (3) into buckle (2). Make sure

Fas that the seat belt is placed low across the lap of the operator.

The retractor will adjust the belt length and the retractor will lock in place. The comfort ride sleeve

ll allow the operator to have limited movement.

g00867598

When usi belt extensions, or personal injury or death can result.

The retractor system may or may not lock up depending on the length of the extension and the size of up, the seat belt will not retain the person.

Longe the non-retractable seat belts are available.

Cate be used with a seat belt extension.

Cons and for information on extending the seat belts.

ng retractable seat belts, do not use seat

the person. If the retractor does not lock

r, non-retractable seat belts and extensions for

rpillar requires only non-retractable seat belts to

ult your Caterpillar dealer for longer seat belts

i03933394

Operator Controls

SMCS Code: 7300; 7301; 7451

Note: Your machine may not be equipped with all of

the controls that are described in this topic.

Page 45

SEBU8710 45

Operation Section

Machine Operation

Front Console

Illustration 53

(1) Left joystick and console (2) Front storage c ompa rtment (3) Service brakes

(4) Travel pedal (5) Right joystick and console (6) Alternate exit

Left joystick and Console (1)

This joystick controls the log loader boom, the boom extension, and the boom swing of the log loader.

Illustration 54

Left joystick and console

g01912593

g01912504

(7) Right armrest (8) Seat

Forward (A) – Press the switch in order to drive the machine forward from the operator seat.

Reverse (B) – Press the switch in order to drive the machine rearward from the operator seat.

Differential Lock Switch (C) (Front) –

Press switch (C) in order to lock the front differential from the operator seat.

Differential lock switch (D) (Rear) –

Press switch (D) in order to lock the rear differential from the operator seat.

Page 46

46 SEBU8710 Operation Section Machine Operation

High gear (E) – Press gear speed selector “H” once in order to upshift by one gear speed.

Low gear (F) – Press gear speed selector “L” once in order to downshift by one gear speed.

Blade Float (I) – Activate the blade ﬂoat with this switch. (Press the blade control switch ﬁrst

SteeringSwitch(G)

Press the s left.

Pull the sw the machine to the right.

Blade (H)

Press the front of the switch in order to LOWER the blade.

Press the rear of the switch forward in order to RAISE the blad

Left Joystick Control (J)

Refer to Operation and Maintenance Manual, “Monitoring System” for the “Joystick Functions” of the mac

witchinordertosteerthemachinetothe

itch toward the operator in order to steer

hine control patterns.

Front Storage compartment (2)

Keep the front glove box securely closed during operation of the machine.

Service Brakes (3)

ervice brake (3) in order to slow or stop the

Use s machine.

el Pedal (4)

Trav

Illustration 55

Right joystick and console

Wiper control (A) – Activation of the wiper control is set by the seat direction. Press

theswitchinordertoactivateonesweepof the wiper on the visible window that faces the seated position.

Enable Crane Boom (B) – Press the

switch in order to enable the crane

boom. Press the switch again in order to disable the crane boom. The crane boom turns off automatically whenever the seat is swiveled.

Swivel Seat (C) – Press the switch in order

to release the seat. Then, swivel the seat

to the opposite direction.

Up Gate (D) – Press the switch and hold

the switch in order to raise the gate so that

the pile of logs is not higher than the top of the gate.

Note: If the gate up/down stalls, hold the grapple closed in order to increase the pressure to the gate up/down.

Down Gate (E) – Press the switch in

order to lower the gate. The gate should

beloweredasmuchaspossibleinorderto provide better visibility for the operator.

g01912594

Travel pedal (4) controls the machine speed of the

warder.

For

Right Joystick and Console (5)

This joystick controls the boom, the rotator, and the operation of the grapple.

Lights (G) – Press the switch once in order

to turn on all the work lights. Pressing the

switchagainwillturnoffthesidelights. Pressingtheswitch(thirdtime)againwillturnoffthe rear lights. A fourth press of the switch turns off all the lights.

Horn (H) – Press the switch in order

to sound the horn. This horn alerts the

personnel and equipment in the area.

Page 47

SEBU8710 47

Operation Section

Machine Operation

Steering Switc

Press the switch in order to steer the machine to the right. Pull th

Note: Steering switch (F) has a default setting to the inactive sta left steering switch loses the steering inputs. Steering control by the left steering inputs or right steering inputs may b

Right Joystick Control (I)

Refer to Operation and Maintenance Manual, “Monitoring System” for the “Joystick Functions” of the machin

h(F)

e switch in order to steer to the left.

te. The switch becomes active when the

e set by the IQAN MDL.

e control patterns.

Alternate Exit (6)

Use the alternate exit on the right side of the cab, as needed.

Right Armrest (7)

The righ

t armrest is adjustable.

Seat (8)

Adjust the seat of the Forwarder for operator comfort. Always use the seat belt when the machine is

ing in work mode.

operat

Page 48

48 SEBU8710 Operation Section Machine Operation

Rear Console

Illustration 56

(9) IQAN MDL module (10) Radio

(11) Service brake (12) Travel p edal

IQAN MDL Module (9)

IQAN MDL consists of a display screen, 11 keys, and a rotary knob.

The two main screens of the IQAN are the operation state and the function state. When the engine start key is turned to the ON position, the IQAN is in the operation mode.

Refer to the Operation and Maintenance Manual, “Monitoring System” for more information.

Radio (10)

The radio is located underneath the IQAN module on the rear console. Satellite radio with the compact disc (CD) is also an attachment ready option.

g01912535

(13) Left armrest

Service Brake (11)

Use service brake (11) in order to slow or stop the machine.

Travel Pedal (12)

Travel pedal (12) controls the machine speed of the Forwarder.

Left Armrest (13)

The left armrest is adjustable.

Page 49

SEBU8710 49

Operation Section

Machine Operation

Right Console

Illustration 57

(14) Engine start switch key (15) Machine shutdown switch (16) J1939 CAN module (17) 12 V power receptacle (18) Lumbar support knob (19) A/C and heating controls

g01912554

Note: If the eng

ine fails to start, return the engine start switch to the OFF position. Wait for 30 seconds before you start the engine. This action will allow the starter to coo

l down.

Machine Shutdown Switch (15)

If the machine must be shut down, press the emergency stop button. The engine, the power train and all of th

e implements will stop. The electrical system will be turned off, and the parking brake will engage.

Note: Do not use this switch in order to shut down the machine under normal conditions.

J1939 CAN Module (16)

Engine Start Switch Key (14)

When you turn the key to the ON position, electrical power is supplied to the systems.

Off – When you insert the key and when you remove the key, the engine start switch

must be in the OFF position. A running engine will stop running when the key is returned to the OFF position. Also, turn the engine start switch to the OFF position in order to disconnect the power to the IQAN control system in the cab.

Note: The preheat system will not be turned off when theenginestartswitchisturnedoff.

On – To activate the electrical system

and the IQAN control system, turn the

engine start switch key clockwise to the ON position.

Start – To start the machine engine, turn

the key clockwise to the START position.

After the engine starts, release the key. The key will return to the ON position.

Note: The IQAN system must perform a self test before you start the engine.

Illustration 58

Activation switches

* Optional features (if equipped)

(A) – Hydraulic pressure (pilot)

(B) – Hazard lights

)–Front washer ﬂuid

g01912578

Page 50

50 SEBU8710 Operation Section Machine Operation

(E) – Side washer ﬂuid

(F) – Rear washer ﬂuid

Parking brake (G) – Press the switch in

order to engage the parking brake.

(H) – Lights (Interior)

(I) – Left turn

(J) – Front wiper

(K) – Side wiper

The a/c and heat

ing control is located on the right

cab console below the J1939 CAN module.

Consult with y

our authorized dealer for periodic maintenance of the heating and air conditioning system.

“C°/ F°” – Press this key in order to change from degree celsius to degree fahrenheit in the display.

ON – Press the ON key in order to turn on the a/c and heating controls.

OFF – Press the OFF key in order to turn off the a/c and heating controls.

AUTO – The a/c and heating control will run on automatic control.

ECON – The air temperature in the cab is regulated in the economy mode.

Fan S pee d – Blower fan motor for the heating and air conditioning system

Temperature Status – The grade of temperature is displayed here.

(L) – Rear wiper

12 V Power Receptacle (17)

Use the 12 vdc power supply for accessory items.

Lumbar Support Knob (18)

Adjust the seat in order to provide lumbar support.

A/C and Heating Controls (19)

Increase – Press the proper UP key for

more air ﬂow or a higher temperature.

Decrease – Press the proper DOWN key for less air ﬂow or a cooler temperature.

Preheat System (20)

Illustration 60

g01913596

Illustration 59

g01912574

Page 51

SEBU8710 51

Operation Section

Machine Operation

Your ma chin e ma

y be equipped with a preheat system (20). This system will warm the engine by heating the coolant to the engine before engine start-up. War

mingacoldenginebeforestart-up

extends the service life of the engine.

Note:Iftheb

attery disconnect switch is turned

off, the preheat system remains operational.

Operating t

he Preheat System

The control panel for the preheat system is located in the headl

iner on the right side of the cab. Use the

control panel to program the preheat system.

Reference

: See “Engine Preheat System” in this

manual for more information.

i03850774

Battery Disconnect Switch

SMCS Code

Never move the battery disconnect switch to the OFF position while the engine is operating. Serious damagetoth

: 1411

NOTICE

e electrical system could result.

OFF – Turn the battery disconnect switch counterclockwise to position (A) in order to deactivate th

e entire electrical system. This

includes the preheat system.

The battery disconnect switch and the engine start switch

perform different functions. The entire electrical system is disabled when you turn off the battery disconnect switch. The battery remains connected t

o the electrical system when you turn off

the engine start switch.

Turn the bat

tery disconnect switch to the OFF position and remove the key when you service the electrical system or any other machine components.

Note: Turning off the battery disconnect switch with the secondary switch in the ON position does not erase the s

ettings in the preheat system.

NOTICE To ensure no damage to the engine occurs, verify that the engi

ne is fully operational before cranking the engine. Do not crank an engine that is not fully operational.

m the following procedure in order to check the

Perfor battery disconnect switch for proper operation:

ustration 61

Ill

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

g00406959

Note: There are two disconnect switches on this machine: a battery disconnect switch and a

condary disconnect switch. The battery disconnect

se switch is the bottom switch.

– Turn the battery disconnect swit ch

clockwise to position (B) in order to activate theelectricalsystem.Theswitchmustbein

his position before you start the engine.

1. With th

e battery disconnect switch in the ON position, verify that electrical components in the operator compartment are functioning. Verify that

ur meter is displaying information. Verify

the ho that the engine will crank.

2. Turn t

he battery disconnect switch to the OFF

position.

fy that the following items are not

3. Veri functioning: electrical components in the operator compartment, hour meter, and engine cranking.

y of the items continue to function with the

If an battery disconnect switch in the OFF position, consult your Caterpillar dealer.

Page 52

52 SEBU8710 Operation Section Machine Operation

Secondary Disconnect Switch

Illustration 62

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

Note: If

the machine has a preheat system, there are

g0184131

two disconnect switches: A battery disconnect switch and a secondary disconnect switch. The secondary disconn

ect switch is the switch above the battery

disconnect switch.

ON – Tur

n the secondary disconnect switch clockwise to position (B) in order to activate the preheat system.

OFF – Tu

rn the secondary disconnect switch counterclockwise to position (A) in order to disable the preheat system.

The preheat system will not be disabled when

Note:

the battery disconnect switch is in the OFF position.

the secondary disconnect switch to the OFF

Turn position when you are leaving the machine for the day.

i03933429

Monitoring System

SMCS Code: 5258; 7490

The IQAN computer monitors the machine systems. The IQAN computer controls the travel system and the implement functions of the machine. IQAN receives electrical signals from the sensors, the switches, the potentiometers, the travel pedals, the joysticks, and the engine control (ADEM). IQAN processes the electrical input signals. IQAN then outputs the signals to the solenoids, the engine control (ADEM), the warning system, and the monitoring system.

Illustration 63

IQAN-MDL (Front Side)

g0 1 91117 5

Themaindisplaymodule(IQAN-MDL)isthemain unit of the control system. The IQAN-MDL contains the system application software. The CAN bus is also initiated from the IQAN-MDL.

The front of the IQAN-MDL consists of a control panel with a display, 11 keys, and one dial.

There are ﬁve function keys: “F1”, “F2”, “F3”,

•

“F4”, and “F5”. The functions for these keys are conﬁgured for items that appear on the screen.

There are four function keys: “A”, “B”, “C”, and “D”.

•

The functions for these keys are conﬁgured for instructions on the screen.

(1) menu key is used in order to display the main

•

screen (page).

(2) encoder is a rotary knob with a push button.

•

Use the knob for adjusting values, selecting values, and changing screens.

(3) left arrow key (“ESC” or back key) is used in

•

ordertoreturntoapreviousscreen.

Note: IQAN MDL uses two screens in order to test the production diagnostics, if necessary. These screens can be useful for obtaining system diagnostic information. To view these screens, press “MENU” key (1). Then, press “F1” key or the appropriate F key in order to view the desired screen. Press the menu key again in order to exit.

Page 53

SEBU8710 53

Operation Section

Machine Operation

Display Module

Illustration 64

IQAN-MDL

g01908496

There are two types of screens on the IQAN-MDL:

a black screen

•

a white screen

•

The black screens are custom programmed screens for a speciﬁc machine application. The black screens display information about the operation of the machine and information about the machine systems. The white screens describe internal system parameters. The white screens are used to make adjustments to system parameters. Also, the white screens can check the status of the working components.

Operation State

Illustration 66

(1) Home screen (2) Engine (3) Hydraulics (4) Joystick (5) Operator preference

g01911098

There are several screens that can be displayed in this state. The operational state will remain active unless an alarm is detected or the respective F key is pressed.

Information Display

The following items are a description of the machine icons that are displayed on the bottom row of the main screen.

Home screen (1) – Whentheiconforthe home screen is displayed, press the F1 key in order to return to the main screen.

Engine Information (2) – Press the F2 key in order to display engine information.

Hydraulic Infor m ation (3) – Press the F3 key in order to display information about the

ulic system.

hydra

Illustration 65

g01944333

This screen is the ﬁrst screen that is displayed whenyouturnonthesystem.Thescreendisplays information such as the engine speed, coolant temperature, oil temperature, oil pressure, and fuel level.

Joystick Functions (4) – Press the F4 key in order to display the joystick functions.

creen displays the “SAE” control or

This s the “Forest” control mode with the functions that can be performed. These functions include the available

ple operations.

grap

Operator Preference (5) – Press the F5

key in order to select user preferences and

e changes to machine conﬁgurations.

mak

Note: The encoder (knob) will allow the user to scroll through all the screens in either direction.

Page 54

54 SEBU8710 Operation Section Machine Operation

Engine Informa

ion 67

Illustrat

The following engine information is displayed.

Engine hours

•

Coolant

•

Engine oil pressure

•

Battery voltage

•

Engine

•

Press the “F1” or the “ARROW” key in order to return to the m

Note: This display may be shown in metric units or in Engli the units. Use the encoder in order to scroll to the desired units. This will display the desired units on all sc

temperature

speed (rpm)

ain screen.

sh units. Press the “F5” key in order to change

reens.

tion

g01909114

Hydraulic System

Propel (forwar

•

Propel (reverse pressure)

•

Main hydraulic pump pressure

•

Cooling fan s

•

Propel (motor speed in rpm)

•

Press the “F1” key or the “ARROW” key in order to return to the main screen.

Note: This display may be shown in metric units or in English units. Press the “F5” key in order to change the units. desired units. Press the knob in order to accept the units.

d pressure)

peed (rpm)

Use the encoder in order to scroll to the

Setting Operator P references

Press the preferences. Use the encoder in order to scroll to the desired “operator mode”. Press the knob in order to accep order to reset the selection. Then, press the F2 key in order to continue or press the F3 key in order to exit the “Preferences” and return to the “Preferences” list selection mode. The new “operator mode” will be displa

See “Preferences” in this story for more information on sett

Joyst

Do not extend the cylinders to the fullest extent at full spee ward end of the cylinder with less impact to prevent cylinder damage.

“F5” key in order to access the operator

t the operator mode or press the F3 key in

setting. Press the knob in order to select

yed on the “Preferences” screen.

ing operator preferences.

ick Functions

NOTICE

d. Make sure that the rod pistons contact the for-

Illustration 68

The following hydraulic system information is displayed.

Hydraulic oil temperature

•

01909175

The joystick function is controlled by the software that is installed in the IQAN monitoring system. Two

ﬁgurations are available for the joystick functions.

con

The operator may select SAE or Forest Control.

ch conﬁguration is represented in the following

Ea illustrations.

e functions of the grapple and the boom extension

Th are reversible.

Page 55

SEBU8710 55

Operation Section

Machine Operation

SAE and Forest C

ontrol

Illustration 69

Joystick Co ntr ol

(A) SAE control (B) Forest control

The “F4” key displays the screen for the joystick controls.

Control Lever Direction – Move the joystick control in the proper direction in order to regulate one of the multiple

function operations.

g01927570

The machine control pattern is initially set at the factory to the SAE pattern, as shown. The pattern for the “Forest” control differs from the SAE control at the multi-functional levers, as shown. The pattern on the left pertains to the left joystick and the pattern on the right pertains to the right joystick. Refer to the pictograph symbol for an explanation of the function of each joystick control.

Page 56

56 SEBU8710 Operation Section Machine Operation

Note: The joyst dealer.

Indicator Fun

(1) – Retract the boom.

(2) – Extend the boom.

(3) – Rotate the pillar counterclockwise.

(4a)(9b) – Lower the extension.

(5a)(8b) – Raise the extension.

ick control must be changed by your

ctions (Joystick)

(6) – Rotate the pillar clockwise.

(7) – Rotate the grapple counterclockwise.

(8a)(5b) – Lower the boom.

(9a)(4b) – Raise the boom.

(10) – Rotate the grapple clockwise.

(11) – Open the grapple.

(12) – Close the grapple.

Page 57

SEBU8710 57

Operation Section

Machine Operation

Status Indicat

ors

Illustration 70

Top r o w (IQ A N MDL )

Electrical system (13) – This indicator indicates a malfunction in the electrical

system. If this alert indicator lights, the system voltage is too high or too low for machine operation.

Hydraulic oil level (14) – This indicator

lights when the hydraulic oil level is too low.

Hydraulic ﬁlter restriction (15) – This

indicator illuminates when the hydraulic

ﬁlter is bypassed.

Engine oil (16) – This indicator lights when

the engine is low on oil. Check the engine

oil level.

Disconnected axle (17) – This indicator

lights when the axles are disconnected.

king brake (18) – This “W” lights when

Wor

the working brakes are in the work mode.

g01945240

Differential lock (19) – This indicator lights with a green color when either of the differentials are active. Also, the indicator

lights when both differentials are active.

Enable crane (20) – This indicator lights when the crane boom is enabled to work.

Frame lock (21) – This indicator with arrows lights when the hydraulic system

locks the front and rear machine frames together. This adds ballast to the machine that assists the operation of the crane boom. The machine must be stationary in order to turn on the hydraulic lock.

High gear (22) – This indicator lights when

thetransmissionissetinthehighspeed

mode.

Low gear (22) – This indicator lights when

the transmission is set in the low speed

mode.

Neutral (23) – This indicator lights when

thetransmissionisinNEUTRAL.

Page 58

58 SEBU8710 Operation Section Machine Operation

Forward (23) – This indicator lights when thetransmissionisinFORWARD.

Reverse (23) – This indicator lights when thetransmissionisinREVERSE.

Turn signals (24) – The turn signals illuminate upon usage.

Transmission oil pressure (25) – This indicator l pressure is too low.

Brake malfunction (26) – This indicator lights whe failure mode.

Note: The indicator for the brake malfunction may light whe

brake.

ntheladderisraisedincoldweather.

Parking Brake (27) – This indicator indicat If this indicator lights, disengage the parking

ights when the transmission oil

n the machine brakes are in a

es that the parking brake is engaged.

This is the ﬁrst the menu button is pressed. The screen displays selections for the following topics: Adjustment, Measure, Pref

“Adjustments

When the F1 key is pressed, the “Adjust” screen is displayed.

Illustration 72

IQAN MDL uses conﬁgurable parameters screens in order to make valve adjustments and machine adjustments.

Before making adjustments, ensure that the correct operator has been chosen from the “OPERATOR ” preference menu of the IQAN.

screen that is displayed when

erences, and Information.

”

g01944108

Main Screen

The m ai machine.

Illustration 71

n screen displays basic information for the

Menu button – Press the menu button above the encoder in order to display the main screen.

g01908635

The following values can be adjusted.

“Preferences”

•

“Valves”

•

“Hydrostat”

•

“Fine c ontrol Adjust”

•

Factory Settings

•

Scroll to the desired adjustment with the encoder. Then,presstheknobinordertoselectthetopic.

Use the following screens to make the necessary adjustments.

Note: A padlock next to the topic indicates that the user may not change these values. Values in these topics are only accessible by your dealer.

Page 59

SEBU8710 59

Operation Section

Machine Operation

Preference Men

ion 73

Illustrat

g01944121

Operator Setti

Illustration 75

Thefollowingvaluescanbeveriﬁed and selected.

Factory default

•

Operator 1

•

Operator 2

•

Operator 3

•

g01910144

Illustration 74

e encoder in order to scroll to the appropriate

Use th topic. Press the knob in order to select the highlighted topic.

Operator

•

control

Boom

•

Rotator (direction)

•

Boom (direction)

•

er (delay)

Wip

•

Oil heater circuit

•

Working brake (mode)

•

its

•

Steering control

•

Rear axle

•

QAN MDL uses conﬁgurable parameters screens

I in order to set operator preferences. The following items are available user preferences.

g01910074

The operator setting saves the following functions: valve speeds (crane) and steering functions. The other functions are not saved.

Note: The setting for the factory default cannot be changed.

Working Brake (Mode)

Illustration 76

efollowingvaluescanbeveriﬁed and selected.

Working brake OFF

•

Working brake ON

•

hen the machine is not moving and the working

W brake mode is active, the service brake will be applied by pressing the accelerator pedal.

g01910145

Page 60

60 SEBU8710 Operation Section Machine Operation

Hydrostatic Fu

Illustration 77

nction

g01910253

The following values can be veriﬁed and selected.

Normal

•

Limp home mode

•

Thelimphomemodeallowsthemachinetobe propelled in the case of an electrical failure. The motor will not be allowed to shift so the speed is reduced.

Rotator (Direc

Illustration 79

tion)

g01910256

Thefollowingvaluescanbeveriﬁed and selected.

Normal

•

Opposite

•

The rotator (direction) allows the operator to reverse the direction of control. In the normal mode, a movement of the joystick in the right, outward direction causes clockwise rotation of the grapple.

Boom Control

ustration 78

Ill

g01910254

The following values can be veriﬁed and selected.

SAE control

•

orestry” control

“F

•

The boom control allows the selection between

e SAE joystick control pattern and the “Forestry”

th joystick control patterns.

In the opposite mode, a movement of the joystick in the right directions causes a counterclockwise rotation of the grapple.

Extendable Boom (Direction)

1910257

Illustration 80

Thefollowingvaluescanbeveriﬁed and selected.

rmal

•

Opposite

•

The extendable boom (direction) allows the operator to reverse the direction of the extendable boom. In

he normal mode, pressing the top of the rocker

t switch extends the extendable boom. Pressing the bottom of the rocker switch retracts the boom.

Page 61

SEBU8710 61

Operation Section

Machine Operation

In the opposite

mode,pressingthetopoftherocker switch will retract the boom and pressing the bottom of the rocker switch will extend the boom.

Rear Axle

Illustration 81

g01910258

The following values can be veriﬁed and selected.

Disconnection (high gear)

•

Connection (high gear)

•

Wiper (Delay)

Illustration 83

g01910260

A setting between two values can be selected.

1000 ms

•

10000 ms

•

Press the “A” key in order to select the minimum number. Use the encoder to adjust the number. Press the knob when the number is correct.

To increase power train wear life, the rear axle should be disconnected in high gear unless ground conditions require high gear.

To reduce wear of the differential lock, the rear axle should be disconnected in high gear unless ground conditions require high gear.

Differential Lock (High Gear)

Illustration 82

e following values can be veriﬁed and selected.

Disabled

•

Enabled

•

g01910259

Press the “F3” key in order to reset the value to the highlighted number.

Units

944133

Illustration 84

Unit selection mode

ess the knob in order to select the unit selection

g01

mode. Use the encoder to select English units or Metric units. Press the knob in order to select the

its or press “F3” key in order to reset the selection.

un Then, press the “F2” key in order to continue or press the “F3” key in order to exit the setting. Press the

nob in order to select “Preferences” and return to

k the “Preferences” list selection mode.

Page 62

62 SEBU8710 Operation Section Machine Operation

Oil Heater Circ

uit

NOTICE Do not operate the engine under a load in the cold mode. While in the cold mode, the low idle will be reducedtoth

e customer programmed low idle and the

power will be reduced.

Illustration 85

Hydraulic heater ON

•

g01944134

Illustration 87

The hydraulic heater is ON.

g01944465

Keep the engine at idle and do not operate the machine. Warmthehydraulicoiltoaworking

temperature.

Press the F4 key in order to turn off the hydraulic heater.

Steering Control

Hydraulic heater OFF

•

ustration 86

Ill

The hydraulic heater is ENABLED.

g01944464

When the hydraulic oil is cold, press the F2 key in order to start the hydraulic heater.

Note: The machine will start when the hydraulic heater is ON, but the machine will not operate.

stration 88

Illu

Right hand

•

Left hand

•

h steering controls are active.

Bot

•

g01954194

Steering control allows a choice among the following

pes: left steering, right steering, and both types.

Page 63

SEBU8710 63

Operation Section

Machine Operation

Valves

ion 89

Illustrat

Valve adjustment

Select the proper “VALVE” in order to select the function for adjustment.

Press “SELECT (+)” or “SELECT (-)” in order to adjust the appropriate direction.

The following values can be adjusted:

Steerin

•

g01911213

The following v

Hydrostatic motor (shift point)

•

alue can be adjusted:

The hydrostatic motor (shift point) can be adjusted in order to improve performance. In hilly conditions, the shift pressu

re can be lowered in order to reduce the engine lugging. In ﬂat conditions, the shift pressure canberaisedinordertoincreasespeed.

High Gear (Shift Point)

Illustration 91

High gear (shift point)

g01911216

Slew

•

Stick

•

ope

Te l e s c

•

Rotator

•

Main

•

le open and grapple close

Grapp

•

“Hydrostatic System”

Hydrostatic Motor (Shift Point)

The following value can be adjusted:

Hydrostatic motor in high gear (shift point)

•

Press the “A” key in order to select the minimum number. Use the encoder to adjust the number. Press the knob when the number is correct. The word “Min” will appear in the center.

Press the “F3” key in order to reset the value to the highlighted number.

Fine Control (Adjustment)

Illustration 90

Hydrostatic motor (shift point)

g01911215

Illustration 92

Adjustment of ﬁne control valves

The following values can be adjusted:

g01911214

Page 64

64 SEBU8710 Operation Section Machine Operation

Steering ﬁne co

•

Slew (ﬁne control)

•

Stick (ﬁne control)

•

Te l e s c op e ( ﬁ

•

Rotator (ﬁne control)

•

Main boom (ﬁne control)

•

Grapple ope

•

ntrol

ne control)

n and grapple close (ﬁne control)

Steering Fine Control

Stop (D) – The ti

me in milliseconds for the output to

go from maximum to minimum

The + symbol (p

lus sign) sets values (A, B, C, D) for the work port at the A valve. The (minus sign) sets values(A,B,C,D)fortheworkportattheBvalve. The function

of the changes to the A and B valve ports will depend on the boom control (mode) that is active.

Illustration 93

Illustration 94

Current and slope times

IQAN MDL gr aph

(A) Minimum current (B) Maximum current (C) Start (slope) (D) Stop (slope)

g01911213

g01954195

Min (A) – The minimum current that is required for the solenoid to shift the spool

Max (B) – The current to the solenoid at the extreme position of the joystick

Start (C) – Thetimeinmillisecondsfortheoutputto go from minimum to maximum

Page 65

SEBU8710 65

Operation Section

Machine Operation

Fine Adjustmen

t (Graph)

Illustration 95

Curve that is affected by ﬁne control

The ﬁne adjustment responds in a stepping action that is based on thejoystick position. With 0%, the function response is directly proportional to the joystick position. As you increase the percentage of ﬁne control, the function is reduced at any given joystick p osition until you reach 100% joystick displacement.

Factory Settings

Only the factory or the Dealer technician can change the factory setpoints.

g01954196

“MEASURE” MENU

910862

Illustration 96

IQAN MDL provides predeﬁned screens that display measurement data about the system in order to aid

roubleshooting. Use the encoder in order to scroll

in t to the desired measurement. Press the knob when the selection is correct.

g01

Use the encoder in order to scroll to the desired measurement. Press the knob when the selection is

rrect. Connect a computer with IQAN software to

co the monitor for a graph of the values.

Page 66

66 SEBU8710 Operation Section Machine Operation

The values on th IQAN system. Press the “A” key in order to view the raw voltage in the IQAN system.

The following measurement data is available on these screens.

Brakes

•

Crane (inpu

•

Crane (outputs)

•

Engine

•

Factory ( s

•

Hydrostatic

•

Hydraulic inputs

•

Lights an

•

Steering and Blade

•

e monitor are the full scale in the

ts)

tart-up)

d wipers

Screens with Measured Values

Right joystick

•

Right joystick Y-axis-1

•

Right joystick Y-axis-2

•

Illustration 98

Continued crane (inputs)

Right joystick Z-axis

•

Door switch

•

X-axis-2

g01954267

Crane (I

Illustration 97

The following values can be checked and veriﬁed. Turn the encoder in order to scroll down the list and up the list.

•

nputs)

g01910883

Left joystick X-axis-1

Left joystick X-axis-2

Left joystick Y-axis-1

Crane “enable”

•

Arming

•

“Seat Prox” (Front)

•

“Seat Prox” (Rear)

•

Main Pump Pressure

•

Crane (Outputs)

Illustration 99

g01910887

Left joystick Y-axis-2

•

Left joystick Z-axis

•

Right joystick X-axis-1

•

he following values can be checked and veriﬁed.

T Turn the encoder in order to scroll down the list and up the list.

Slew

•

Page 67

SEBU8710 67

Operation Section

Machine Operation

Stick

•

Te l e s c op e

•

Rotator

•

Main

•

Grapple open or grapple close

•

Front differential lock

•

Rear differ

•

ential lock

Left steering

•

Right steering

•

Steering COUT

•

Steering sen

•

Blade control

•

Blade COUT

•

Blade FLOAT

•

“Seat prox” (front)

•

“Seat prox” (rear)

•

Hydrostat

ic System

sor

Illustration 100

Continued crane (outputs)

Frame lock

•

Vacuum pump control

•

Up gate

•

Down gate

•

Load dump (sense)

•

Steering and Blade

g01954274

Illustration 102

The following values can be checked and veriﬁed. Turn the encoder in order to scroll down the list and up the list.

“Speed pedal” (rear)

•

“Speed pedal” (front)

•

Desired engine speed

•

Actual engine speed

•

“Hydro pump” COUT

•

“Hydro motor” COUT

•

“Hydro pressure” Rev (B)

•

g01954321

Illustration 101

he following values can be checked and veriﬁed.

T Turn the encoder in order to scroll down the list and up the list.

g01910888

“Hydro pressure” Fwd (A)

•

“Hydro m otor” speed

•

Page 68

68 SEBU8710 Operation Section Machine Operation

Engine

Illustration 103

Continued hydrostatic system

Speed control “pot”

•

Door switch

•

Forward IDC

•

Reverse IDC

•

Arming IDC

•

Engine overspeed (hyd pump)

•

“Hydro HP control” ILC

•

“Rear speed pedal” LS

•

“Front speed pedal” LS

•

g01910889

Illustration 105

The following values can be checked and veriﬁed. Turn the encoder in order to scroll down the list and up the list.

Engine pressure

•

Battery voltage

•

Boost pressure

•

Desired engine speed

•

Actual engine speed

•

Engine temperature

•

Air inlet temperature

•

Hydraulic temperature

•

Fanpump(displacement)

•

g01910891

Illustration 104

Continued hydrostatic system

“Low gear prox”

•

“High gear prox”

•

“Charge pressure low”

•

“Rear axle disconnect”

•

g01954290

Illustration 106

ontinued engine data

“Cooling fans speed”

•

Fuel level (front)

•

g01954356

Page 69

SEBU8710 69

Operation Section

Machine Operation

Fuel level (rea

•

Air ﬁlter restriction

•

Thermal bypass

•

Cooling ﬂow

•

Brakes

Illustration 107

The following values can be checked and veriﬁed. Turn the encoder in order to scroll down the list and up the list.

g01910892

Illustration 108

Continued brake inputs

“Service Brake Signal to Front TOC2”

•

Hydraulic Inputs

g01954373

Front A service brake

•

Front B service brake

•

Rear A service brake

•

Rear B service brake

•

Parking brake

•

Front accumulator (low pressure)

•

Front brake (low pressure)

•

Rear accumulator (low pressure)

•

Rear brake (low pressure)

•

Illustration 109

ollowing values can be checked and veriﬁed.

The f Turn the encoder in order to scroll down the list and up the list.

Return ﬁlter restriction

•

ot ﬁlter restriction

Pil

•

Charge ﬁlter (restriction)

•

“Charge pressure low”

•

ydraulic oil level low”

“H

•

g01910893

Page 70

70 SEBU8710 Operation Section Machine Operation

Lights and Wipe

Illustration 110

The following values can be checked and veriﬁed. Turn the encoder in order to scroll down the list and up the list.

Left cab lights

•

Right cab lights

•

Front cab lights

•

Rear cab lights

•

g01910894

“Washer bottle

•

“Washer bottle side”

•

“Washer bottle rear”

•

Horn

•

Factory (Start-up)

Illustration 112

The following values of the factory (start-up) can be checked and veriﬁed. Turn the encoder in order to scroll down the list and up the list.

front”

g01910895

Boom lights (crane)

•

Rear lights

•

Left turn

•

Right turn

•

Front wiper

•

Illustration 111

Continued lights and wipers (data)

g01954413

Rotator

•

Stick

•

Tel es c op e

•

Main

•

Slew

•

Grapple open and grapple close

•

Steering

•

Blade

•

Propel (direction)

•

Side wiper

•

Rear wiper

•

Page 71

SEBU8710 71

Operation Section

Machine Operation

Date and Time

Illustration 113

Factory settings (additional data)

Propel motor

•

Down gate

•

Up gate

•

Frame lock

•

Differential lock (rear)

•

Differential lock (front)

•

g01954433

Preference Menus

“Date, Time, Display and Language” Menu

Illustration 115

“Date/time”

g01945547

Use this screen to change the date and time in the IQAN monitor. Press the A function key in order to highlight the date. Turn the “encoder” clockwise in order to increase the values. Turn the “encoder” counterclockwise in order to decrease the values. Press the knob in order to accept the value. Press the “encoder” in order to scroll to the day and month. Press the B function key in order to highlight the time. Turn the “encoder” clockwise in order to increase the values. Turn the “encoder” counterclockwise in order to decrease the values. Press the knob in order to accept the value. Press the “encoder” in order to scroll through the hours and scroll through the minutes.

Display

Illustration 114

g01911218

The following values can be veriﬁed and selected.

Date or time

•

Display

•

Language

•

lustration 116

“Display”

g01945546

Highlight “Display” in order to change parameters for the display screen.

Page 72

72 SEBU8710 Operation Section Machine Operation

Press the A func the backlight. The backlight is the brightness of the screen. Turn the “encoder” clockwise in order to incre counterclockwise in order to decrease the values. 100 is full brightness.

Press the B function key in order to change the screen saver. The screen saver is displayed after the “Timeout” s

“OFF”

•

“DIMMED”

•

“BLACK”

•

The screen saver will activate after the number of minutes in setting is chosen, the screen fades to the “Backlight” setting. The screen saver will deactivate when any keyispre

Press the C function key in order to change the “timeout order to increase the number of minutes. Turn the “encoder” counterclockwise in order to decrease the number o

ssed.

” time. Turn the “encoder” clockwise in

f minutes.

tion key in order to change

ase the values. Turn the “encoder”

etting. The screen saver has three values:

the “Timeout” setting. If the “DIMMED”

Operator Preferences

Using the Menus

Press the operator preference F5 key in order to access the “information” menus.

Operator Preference (F5) – Press the button for operator preferences in order to access the preferred screen for the inputs,

as needed. Then, selections can be made.

Main menu button or “ARROW” key –

The following screens are available to scroll: adjustment, measure, preference,

and main menu (information).

Four “INFORMATION” screens are provided:

“Machine ID”

•

“Module information”

•

“Log ﬁle directory”

•

Access the “INFORMATION” screens b y pressing the F4 key from “Adjustment” screen.

Press the D function key in order to change the dimmed l brightness of the dimmed screen saver. Turn the “encoder” clockwise in order to increase the number. Turn th decrease the number.

Press direction of scrolling. “Standard” will scroll clockwise. “Goofy” will scroll counterclockwise.

Language

Illustration 117

“Language”

ight function. “Dimmed Light” is the

e “encoder” counterclockwise in order to

the “Encoder” key (F5) in order to change the

g01945544

Machine ID

Illustration 118

Machine ID

This screen displays basic information about the IQAN monitor. Press the A function key in order to display the modules. Press the B function key in order to display “modem” information. Press the C function key in order to view the logs.

Machine ID

•

g01909273

Change the language of the display.

Page 73

SEBU8710 73

Operation Section

Machine Operation

“Module” Infor

ion 119

Illustrat

Module information

This screen displays the status of each of the IQAN modules on the machine.

Modules – Use the encoder to scroll to the selected module. Press the knob in order to select the

hted module (A). Press “F1” key in order to

highlig cancel your selection and return to the main screen.

The “MOD information.

ULES” screen contains the following

mation

g01909276

“Logs” Informa

ion 120

Illustrat

Log ﬁle directory

This screen allows access to several “system logs”. The logs record events and times of signiﬁcant machine e

“Logs” – Use the encoder to scroll to the selected topic (C highlighted topic. Press “F1” key in order to return the main screen and cancel the selection .

System log

•

vents:

). Press the knob in order to select the

tion

g01909277

MDL

•

XA2 Cab (Right)

•

XA2-2 Cab (Left)

•

XA2 Re

•

12 Pos Switch

•

Right Pod Switches

•

Left

•

I-Select Module

•

CAT Engine

•

ar Right

Pod Switches

Engine

•

Warning incidents

•

designations (stops)

i03638511

Camera (If Equipped)

SMCS Code: 7347; 7348

TheWorkAreaVisionSystem(WAVS)isa closed circuit television system that is designed to supplement the view for the operator during machine operation. The system may include one, two, or three cameras, depending on the type of machine and the application.

Page 74

74 SEBU8710 Operation Section Machine Operation

Illustration 121

Display for WAVS

g01223034

Obstruct the vi

•

Obstruct the view of any indicators, gauges, or

•

monitoring sy

Impair access to any operator controls or impair

•

movement of a

sibility of the operator.

stem.

ny operator controls.

Prior to operating the machine, ensure that the camera lens

and the display are clean.

Refer to Operation and Maintenance Manual, SEBU8157, “

Work Area Vision System” for additional information about WAVS.

i03895257

Operation Information

SMCS Code:

Adjusta jury. Use caution when adjusting the adjustable bunks. Do not adjust the bunks beyond the farthest po

7000

ble bunks may fall causing personal in-

sition.

Illustration 122

Camera for WAVS

g01223051

Prior to operating the machine, ensure proper orientation of images by the camera(s). The camera(s) has been set up by t he factory or by a Caterpillar dealer in order to provide views which comply with the guidelines that have been documented. Consult your Caterpillar dealer before any adjustments are made to the camera(s).

Prior to operating the machine, ensure that the features of the display are properly adjusted. Ensure that the brightness and the contrast are adjusted prior to operating the machine. Ensure that the brightness and the contrast are adjusted after changes in the conditions for ambient light.

Prior to operating the machine, ensure that the display is positioned in order to provide clear visibility of the display from the operator seat. Do not position the display in a way that will cause the following conditions:

Cover any safety messages or other important

•

information.

NOTICE Do not operate any hydraulic controls if the engine speed is less than 1200 RPM. The hydraulic system will stall the engine and damage to the engine may result.

Note: To prevent injury, make sure that no one is working on the machine or near the machine. Always maintain control of the machine.

Reduce the machine speed when you maneuver in tight quarters or when you are going over a hill. For operator comfort, deceleration is recommended before any directional shifts are made.

Do not allow the machine to overspeed when you travel downhill. Release the accelerator pedal in order to reduce the machine speed. You may also use the service brake pedal in order to slow the machine. The parking brake comes on when the machine is not moving and the working brake (mode) is active.

NOTICE The machine is equipped with a shutdown switch. Do not use the shutdown switch duringnormal operation. Using the shutdown switch will result in full braking power and the machine will stop suddenly. This may cause additional wear on machine components.

Impede the entry to the cab or impede the exit

•

from the cab.

Page 75

SEBU8710 75

Operation Section

Machine Operation

Watch the warni are operating the machine. If an alarm is triggered, stop the machine immediately and determine the cause of the pr

Watch for overhead obstructions and power lines. While you are low as possible. Logs should not be stacked higher than the top of the gate.

ng lights and the indicators while you

oblem.

driving the machine, keep the boom as

Operating the Machine

1. Close the cab door.

2. Adjust the o

the seat belt.

3. Start the m

perator seat and armrests. Fasten

achine.

Note: The ladde is released. The ladder will lower when the parking brake is engaged or when the pilot hydraulics are turned off.

9. Gently press the accelerator pedal. The

brakes and th automatically.

Reference:

or roading, refer to Operation and Maintenance Manual, “Transportation Information”.

10. Press the accelerator further. The machine will

now travel.

11. Steer the machine.

12. In order to

accelerator.

Note: Whe working brake mode, releasing the accelerator pedal automatically applies the brakes and the oscillation lock. The pedal in order to release the brakes.

r will raise when the parking brake

eoscillationlockwillbereleased

For information regarding transporting

stop the machine, release the

n the machine stops with an active

operator must press on the accelerator

Illustration 123

(1) Emergency shutdown switch (2) Pilot hydraulics (switch) (3) Parking brake switch

NOTICE

t attempt to move the machine until the ladder

Do no is in the full raised position. Moving the machine prior to raising the ladder could result in machine damage.

4. Press switch (2) for pilot hydraulics in order to operate the machine. This switch is located on the

ht hand console.

rig

5. Release the brake.

6. Use the steering activation switch in order to

activate the steering system. Press the terrain

eering switch in order to steer the machine. Set

st up left or right steering, as needed.

otate the seat and select the transmission

7.R

direction switch for travel direction. The machine defaults to the low gear speed.

8. Release the parking brake by pressing parking brake switch (3).

g01930914

Crane Bo

when the seat is facing the back of the cab. The idle speed defaults to 1500 rpm when

the cran

Note: When the crane boom is not active, the engine is at 1000 rpm (low idle) until the accelerator pedal is pushed

Do not extend the cylinders to the fullest extent at full speed. Make sure that the rod pistons contact the forward end of the cylinder with less impact to prevent cylinder damage.

Reference: For more information on the above topics, refer to Operation and Maintenance Manual, “Operator Controls”.

e boom (function) is active.

om – This function is active only

NOTICE

Lifting

Lifting should be done in the following order:

Lift the load upward.

•

Move the load closer to the loader.

•

Slew the load.

•

Lower the load.

•

Page 76

76 SEBU8710 Operation Section Machine Operation

When the liftin in order to move away, the lifting capacity may be exceeded and the booms will lose height. If this happens, brin following actions:

Bend the boom

•

Pull in the extension so that the cylinder pressure

•

correspond

g of a load begins closer to the loader

g the load closer to the loader by the

s to the pressure setting.

Finished Loading

Perform the following procedures when the forwarder has ﬁnished loading.

Repeat the last loader motions without a load in

•

order to properly lubricate the joints.

Put the boom assembly as far down as possible

•

on the load. Keep the center of gravity as low as possible

Close the jaws of the grapple on the load so that

•

the load

When you move the forwarder, make sure that the

•

loader c

Never leave the booms only supported by the

•

hydrau

Changi

er cannot swing to the side.

annot move freely.

lic system.

ng Direction and Speed

i03541667

Machine Shutdown Control

SMCS Code: 7300

Illustration 124

Machine shutdown switch (emergency stop)

If the machine must be shut down immediately because of a hazardous operating condition, press the machine shutdown switch that is located to the right side of the seat.

The machine and the engine will stop immediately. You should be prepared for a sudden stop.

g01869813

i03867472

Secondary Disconnect Switch

NOTICE

For operator comfort and maximum service life of pow-

in components, deceleration and/or braking is

er tra recommended before any directional shifts are made.

ust decelerate the machine in order to change

You m direction. The hydrostatic braking slows down the machine.

Gear changes at full engine speed are not possible. The machine must be stopped in order to change

nsmission gear speeds.

tra

Reference: For more information, refer to Operation

d Maintenance Manual, “Operator Controls”.

SMCS Code: 1411-SE

Illustration 125

econdary disconnect switch

The secondary disconnect switch is located on the

eftsideofthemachine.

g01869858

Page 77

SEBU8710 77

Operation Section

Machine Operation

Illustration 126

g00998693

Note: There are two disconnect switches on this machine: a battery disconnect switch and a secondary disconnect switch. The secondary disconnect switch is the switch above the battery disconnect switch.

ON – Turn the secondary disconnect switch clockwise to position (B) in order to activate the preheater system.

The operator pr

esets the time for the activation of the preheat system. The system will operate automatically at the selected start time until the start time is change

d by the operator.

The default operating duration is set at 30 minutes. The operatin

g duration can be regulated by the operator. Due to drainage of the battery, the maximum operating duration is between 1 hour and 1 1/2 hours.

The control panel for the preheat system is located in the headliner on the right side of the cab. Use the control pan

el to program the preheat system.

OFF – Turn the secondary disconnect switch counterclockwise to position (A) in order to disable the preheater system.

Turn the secondary disconnect switch to the OFF position when you are leaving the machine and the preheater system will not be used.

If the machine will not be used for an extended period of time, turn the battery disconnect switch to the OFF position.

Note: The preheat system and the ﬁre suppression system (if equipped) will not be disabled if only the battery disconnect switch is turned to the OFF position.

Reference: For more information, refer to Operation and Maintenance Manual, “Battery Disconnect Switch”.

i03541800

Engine Preheat System

SMCS Code: 1383

Your machine may be equipped with a preheat system. This system will warm the engine by heating the coolant to the engine before engine start-up. Warming a cold engine before start-up extends the service life of the engine.

Illustration 127

Webasto timer

Illustration 128

(1) Display (2) Days (3 memory inputs) (3) Day of the Week (4) Time (5) Heater ON Indicator (6) Select Key (Time and Day) (7) Select Key (System Settings) (8) On/Off Key (9) Arrow Key (Decrease) (10) Arrow Key (Increase)

g01869895

g00887861

Operating the Preheat System

Note: Before you activate the system, turn the

temperature variable control to MAXIMUM and turn the fan control to LOW.

Page 78

78 SEBU8710 Operation Section Machine Operation

Setting the Tim

e of Day and the Day of

the Week

The time of day continuously when the engine start switch is in the ON position. Press select key (6) in order to display thetimeofda OFF position. The values will be displayed for ten seconds.

To set the time of day, hold down select key (6). Then, press arrow keys (9) and (10) until the correct time of day i

To set the day of the week, hold down select key (6). Then, pres day of the week is shown at the top of display (1).

Manually S

and the day of the week are displayed

y when the engine start switch is in the

s shown on display (1).

s select key (9) and (10) until the correct

tarting the Preheat System with the Engine Start Switch in the OFF Position

Press on/off key (8) in order to start the preheat system at any time. The remaining preheat time and the symb timecanbechangedbypressingarrowkeys(9)or (10).

Press on/off key (8) again in order to shut off the preheat system. The preheat system will cool down automa off.

Manual

ol are shown on display (1). The preheat

tically for ﬁve minutes after the system is shut

ly Starting the Preheat System with the Engine Start Switch in the ON Position

Press on/off key (8) in order to start the preheat system. The preheat system will remain on until the

e start switch is turned to the OFF position.

engin

After the engine start switch is turned to the OFF

tion, the preheat system will remain active for

posi ﬁve minutes. This time period can be increased by pressing arrow key (10). The maximum time period is

hours.

four

Programming th

e Preselected Start

Times and Days

Three differe can be programmed into the preheat system. The preheat system can also be programmed to start once in seven setting for the desired start time in order to change the start time. Press select key (7) until the desired setting is d

To include the day of the week in the selection, select the desired Press arrow key (9) or (10)until the desired day of the week is selected. Then, proceed with the selection of the start t

The default for the ﬁrst setting in the memory is

•

“1:11”.

The default for the second setting in the memory

•

is “2:22”

The default for the third setting in the memory is

•

“3:33”.

When the select key(7) is pushed for the fourth

•

time, th point. The display will go out in ten seconds.

To prog key (7) until the desired setting is selected. Within ten seconds, begin setting the desired start time by

ng keys (9) and (10). When the correct start

pressi time is shown, do not press any keys on the display. The display will turn off in ten seconds and the

ted start time will be automatically entered.

selec

If the desired start time has been previously

ammed into the system, press select key (7)

progr until the desired setting is displayed. Release all of the keys. The display will turn off in ten seconds and

tart time will be automatically entered.

the s

Note: If the display is at the original starting point,

ext start time that is stored in the memory is

the n automatically selected.

nt start times within a 24 hour period

days. The operator must select the

isplayed.

setting and hold down select key (7).

ime.

e display returns to the original starting

ram a preselected start time, press select

Press on/off key (8) again in order to shut off the

heat system. The preheat system will cool down

pre automatically for ﬁve minutes after the system is shut off.

Page 79

SEBU8710 79

Operation Section

Engine Starting

i03509044

Engine Starting

SMCS Code: 1000; 7000

Illustration 129

g018922

1. Move battery disconnect switch (1) and the

secondary disconnect switch (2) to the ON

on. Both switches are located on the left side

positi of the machine.

Illustration 130

Right side console

g01892293

2. Machine shutdown switch (3) must be in the raised

position in order to start the engine.

Illustration 131

Vacuum pump control for the 584 Forwarder

g01892456

3. Check that switch (5) for the vacuum pump is in the OFF position. The switch for the vacuum pump is located on left side of the machine.

Note: Starting the machine will deactivate the vacuum pump. The vacuum pump will not run when the machine is off.

4. Turn engine start switch (4) to the ON position. This will activate the IQAN monitoring system.

5. After the system check is performed, turn engine start switch (4) to the START position. Release the key as soon as the engine starts. Do not allow the engine to run faster than 1100 rpm for the ﬁrst twenty seconds.

6. If the engine does not start, repeat step 4. Wait for twenty seconds and then repeat step 5. Do not attempt to start the engine if the motor starter is still turning.

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

Turbocharger and/or engine damage can occur if the engine speed is not kept low until the oil light/gauge veriﬁes the oil pressure is sufﬁcient.

Page 80

80 SEBU8710 Operation Section Engine Starting

i03627116

Engine and Machine Warm-Up

SMCS Code: 1000; 7000

NOTICE Keep engine speed low until the engine oil pressure alert indicator goes out. If the alert indicator does not go out within ten seconds, stop the engine and investigate the cause before starting again. Failure to do so can cause engine damage.

NOTICE

DO NOT OPERATE ANY HYDRAULIC SYSTEM WHEN THE ENGINE IS RUNNING AT THE LOW IDLE SPEED

stall the engine and may damage the engine. Wait until the engine speed is greater than 1200 RPM to operate t

1. Allow a cold engine to warm up at low idle (less

than 110

2. After ﬁve minutes, increase the engine speed

above 1

3. A selection for a hydraulic warm-up is available

when th necessary.

. Operating the hydraulic systems will

he hydraulic systems.

0 rpm) for at least ﬁve minutes.

200 rpm.

e ambient temperatures are cold, if

Illustration 133

b. Enable the warm up function. When the

hydraulic oil heater is enabled, the hydraulic system warm-up comes on at temperatures below 15.5° C (60° F). Then, the hydraulic oil heater shuts off when hydraulic oil temperature reaches 18.3° C (65° F).

c. No machine function is possible when the

warm up circuit is enabled.

Reference: See “Monitoring System” in this

manual for more information.

Note: The hydraulic warm up function can be cancelled at any time by pressing the F4 key.

4. Cycle all hydraulic controls in order to allow warm hydraulic oil to circulate through all hydraulic cylinders and through all hydraulic lines.

After the engine has started and the engine is idling, observe the following recommendations:

Allow the engine to warm up for 10 minutes

•

when the ambient temperature is higher than 0°C (+32°F).

g01944464

Illustration 132

a. The operator may make a selection in order to

turn on the hydraulic heater automatically.

g01944134

Allow the engine to warm up for 15 minutes when

•

the ambient temperature is below 0°C (+32°F).

More time may be required if the ambient

•

temperature is less than −18°C (0°F) or if the hydraulic functions are sluggish.

Preheat System (If Equipped)

Note: The warm-up times may be greatly reduced

when the preheat system is activated, if equipped.

Make sure that the secondary disconnect switch is ON.

Reference: See “Engine Preheat System” for more information.

Page 81

SEBU8710 81

Operation Section

Parking

i03955893

Stopping the Machine

SMCS Code: 7000

1. Release the accelerator pedal in order to stop the

machine. When the working brake mode is active, the service brake comes on after the machine comestoastop.

Illustration 134

Right console

2. Press switch (1) for pilot hydraulics.

g01946153

Illustration 136

g01892713

4. Press parking brake switch (3) in order to engage the parking brake. This action will also lower the ladder.

Illustration 137

d position without a load

Store

g01892734

Illustration 135

Left joystick

ve the transmission direction control (2) to the

3. Mo NEUTRAL position.

1892674

Illustration 138

Stored position with a partial load

g02146174

Page 82

82 SEBU8710 Operation Section Parking

Note: Opening t and turns off the pilot function. The door must remain closed in order to store the boom.

5. Place the boom into the stored position.

When the m ach be lowered on top of the logs and resting on the top of the logs, as shown.

When the machine is not loaded, the grapple must be resting on the bed of the rear frame.

Reference: Refer to Operation and Maintenance Manual, “Operator Controls” for more information.

he door engages the parking brake

ine is partly loaded, the boom must

i00982184

Stopping the Engine

SMCS Code

Stopping the engine immediately after it has been working under load, can result in overheating and accelerated wear of the engine components.

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

: 1000; 7000

NOTICE

i03568953

Stopping the Engine if an Electrical Ma

SMCS Code: 1000; 7000

tion 139

Illustra

Right console

Turn engine start switch (2) to the OFF position.

If the en switch (1).

Do not o malfunction has been corrected.

gine does not stop, press machine shutdown

perate the machine again until the

lfunction Occurs

g01892833

1. While the machine is stopped, run the engine for ﬁve minutes at low idle. This allows hot areas of the engine to cool gradually.

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

i03607245

Leaving the Machine

SMCS C

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

2. Insp

3. Turn the secondary disconnect switch

Note: The preheat system remains enabled if the

secondary disconnect switch is ON.

4. Install all covers and all vandalism protection

ode: 7000

the ma debris before you dismount.

guard for debris. Clean out any debris in order to avoid a ﬁre hazard. Dispose of th e debris properly.

counterclockwise to the OFF position in order to dis

If the machine will not be operated for an extended per counterclockwise to the OFF position and remove the key. This will disable the electrical system.

locks.

chine. Make sure that the steps are clear of

ect the engine compartment and the bottom

able the preheat system. Remove the key.

iod of time, turn the battery disconnect switch

Page 83

SEBU8710 83

Operation Section

Transportation Information

i03509328

Shipping the Machine

SMCS Code: 7000; 7500

Loading the Machine

1. Investigate the travel route for overpass

clearances. Make sure that there will be adequate clearance if the machine that is transported has a ROPS, a cab, or a canopy.

Illustration 141

g01892873

2. Remove ice, snow, or other slippery material from the loading dock and from the transport machine before you load the machine. This will help to prevent slippage of the machine. This will also help to prevent a shift while the machine is moving in transit.

3. Obey the appropriate laws that govern the parameters of the load (weight, width, and length).

Illustration 140

4. Cho

ck the trailer wheels or the rail car wheels

g00872270

before you load the machine.

6. Place the grapple on the rear frame and rest the boom in the brace at the rear of the machine. This is the STORED position.

Illustration 142

Location of pump handle

g01954055

er the machine is positioned, connect the

5. Aft steering frame lock.

ference: For more information, refer to

Operation and Maintenance Manual, “Steering Frame Lock”.

Illustration 143

Pump handle as lock ba r

g01954036

7. If the ladder is too wide for the loading space, use the pump handle to hold the ladder in the full upright position.

8. Turn the engine start switch to the OFF position. Ensure that the engine has stopped.

Page 84

84 SEBU8710 Operation Section Transportation Information

9. Turn the second OFF position. This disables the preheat system. Remove the key from the secondary disconnect switch if the m extended period of time.

10. Turn the batt position. Remove the key from the battery disconnect switch if the machine will not be operated fo

11. Lock the door and the access covers and attach any vandali

12. Secure the machine, any equipment and any tools with movement during shipping.

Reference

Operation and Maintenance Manual, “Lifting and TyingDowntheMachine”.

13. Cover the exhaust opening. The turbocharger should not rotate when the engine is not operating. Damage to

Oscilla

tion Lock (Manual

ary disconnect switch to the

achine will not be operated for an

ery disconnect switch to the OFF

r an extended period of time.

sm protection.

adequate tie-downs in order to prevent

: For more information, refer to

the turbocharger can result.

Procedure)

The oscillation lock cylinder must be locked before shipping a machine.

i03904070

Roading the Machine

SMCS Code: 7000

Adjustable bunks may fall causing personal injury. Use caution when adjusting the adjustable bunks. Do no thest position.

Check with required licenses and other similar items.

Before you for recommended tire pressures and for speed limitations of the tires that are being used. Limitations for TON-k must be obeyed.

Inﬂate t

Perform a daily inspection and measure the ﬂuid levels i

Travel at a moderate speed. Observe all speed limits when yo

When you travel for long distances, schedule stops in order t Stop for 30 minutes after every 40 km (25 miles) or after every hour.

he tires to the correct air pressure.

n the various compartments.

o allow the tires and the components to cool.

t adjust the bunks beyond the far-

the proper ofﬁcials in order to obtain any

road a machine, consult your tire dealer

ilometers per hour (TON-miles per hour)

u road the machine.

Illustration 144

1. In order to manually lock the oscillation lock cylinder, install the lock collar.

2. In order to unlock the oscillation lock cylinder after shipping, remove the lock collar.

g01892914

Note: Travel without a load over long distances.

Illustration 145

Stored Position Without a Load

Place the boom in the stored position when you are roading the machine without a load.

g01892873

Page 85

SEBU8710 85

Operation Section

Transportation Information

i03569270

Roading Lights

SMCS Code: 1429

Illustration 146

g01893616

Note: Proper storing of the grapple is necessary in order to prevent the damper from binding against the loader in the stored position.

The damper must not rest against the stop when the grapple is stored. Leave a gap between damper (1) and stop (2). The gap is shown in Illustration 147.

If the grapple is not properly stored during movement of the machine, damage may occur to the linkage and bushings.

The roading li

ghts must be used whenever the

machine is operated on the road.

Illustration 148

g018936

The rear lights are installed on the back of the rear frame of the machine.

Illustration 147

Stored Position With a Load

g02146174

Place the grapple on top of the logs when you are roadingthemachinewithaload.Theproperstorage position is shown in Illustration 147.

Illustration 149

g01893680

Roading lights are located on the sides and front of the cab.

Page 86

86 SEBU8710 Operation Section Transportation Information

Illustration 150

Right joystick control

The roading lights are operated by the light switch inside the cab.

g01893775

i03510580

Lifting and Tying Down the Machine

The spreader ba preventing contact with the machine.

Install tie-d front of the wheels and behind the wheels.

Note: Machin attachments.

Improper lifting or tie-downs can allow the load to shift and cause in lock link before lifting.

Separate t is operated.

Referenc

refer to Operation and Maintenance Manual, “Steering Frame Lock”.

Reference: For information on shipping your machine, refer to Operation and Maintenance Manual,

e: For information on the steering frame,

“Shipping the Machine”.

r widths should be sufﬁcient for

owns at several locations. Place blocks in

e weights may vary with different

NOTICE

jury or damage. Install the steering frame

he steering frame lock before the machine

SMCS Code: 7000; 7500

Improper lifting and improper tie-downs can allow the loa Use only properly rated cables and slings with lift and tie down points provided.

Follow the instructions in Operation and M aintenance Manual, “Lifting and Tying Down the Machi the machine. Refer to Operation and Maintenance Manual, “Speciﬁcations” for speciﬁc weight inform

Obey the appropriate laws that govern the dimensions of th

Reference: Refer to Operation and Maintenance Man machine.

Eac

d to shift or fail and cause injury or damage.

ne” f or the proper technique for securing

ation.

e load (weight, width and length).

ual, “Speciﬁcations” for the dimensions of the

h machine has points for tying down.

Proper tie-down points are marked on

e machine by this decal.

Use proper rated cables and proper rated slings for lifting the machine, as needed.

Page 87

SEBU8710 87

Operation Section

Towing Information

i03627529

Towing the Machine

SMCS Code: 7000

Personal injury or death could result when towing a disabled machine incorrectly.

Block the machine to prevent movement before releasing the brakes. The machine can roll free if it is not b

Follow the recommendations below, to properly perform t

These towing instructions are for moving a disabled machine distance should not exceed 10 km (6.2 miles). The towing speed should not exceed 10 km/h (6.2 mph). Haul th

Before you tow the machine, make sure that the tow line or that the tow line or the tow bar has enough strength for the conditions that are involved. The strength of the to percent of the gross weight of the towing machine. This pertains to a disabled machine that is stuck in the mu

Do not use a chain for pulling a disabled machine. Acha injury. Use a wire cable with ends that have loops or rings. Place an observer in a safe position in order to watc the procedure, if necessary. The procedure should be stopped if the cable starts to break or the cable

rts to unravel. Stop pulling whenever the towing

sta machine moves without moving the towed machine.

Not

ofﬁcials about the allowed towing devices.

ep the tow line angle to a minimum. Do not exceed

Ke a 30 degree angle from the straight ahead position.

ick machine movement could overload the tow

Qu line or the tow bar. This could cause the tow line or the tow bar to break. Gradual, steady machine

ovement will be more effective.

locked.

he towing procedure.

for a short distance at low speed. The towing

e machine if long distance moving is required.

the tow bar is in good condition. Make sure

w line or the tow bar should be at least 150

d or on a grade.

in link can break. This may cause personal

h the pulling procedure. The observer can stop

e: Before you tow the machine, check with local

Normally, the t as the disabled machine. Make sure that the towing machine has enough brake capacity, enough weight, and enough pow able to control both machines for the grade that is involved and for the distance that is involved.

You must provide sufﬁcient control and sufﬁcient braking when you are moving a disabled machine downhill. T additional machines that are connected to the rear of the disabled machine. This will prevent the machine from rollin

All situation requirements cannot be listed. Minimal towing mac level surfaces. Maximum towing machine capacity is required on inclines or on surfaces that are in poor condition

Shields must be provided on both machines. This will prot tow bar breaks.

ect the operator if the tow line breaks or the

owing machine should be as large

er. The towing machine must be

his may require a larger towing machine or

g away out of control.

hine capacity is required on smooth,

Towing with a Running Engine

Do not al is being towed unless the operator can control the steering and/or the brakes.

The engine must be running and the hydraulic system must be intact for the steering to work and for the brake r

Turn off the working brake in the IQAN-MDL module. See “M

The drive shafts must be disconnected and the conne disconnected. The operator must depress the accelerator pedal in order to release the brakes. The oper

Towi

If the engine is dead or there is no operator to control amac frame lock in the locked position and release the brakes manually. Disconnect the drive shafts.

Reference: For information about releasing the parking brake manually, refer to Operation and Mai Release”.

No downhill, the towing connection must be r igid.

lowanoperatortobeonthemachinethat

elease to work.

onitoring System” for more information.

ctors at the power train pump must be

ator can now control the machine.

ng with a Stopped Engine

hine with a running engine, secure the steering

ntenance Manual, “Parking Brake Manual

te: In order to move a disabled machine

nsult your Caterpillar dealer for the equipment that

Co is necessary for towing a disabled machine.

Page 88

88 SEBU8710 Operation Section Towing Information

i03569430

Parking Brake Manual Release

SMCS Code: 4267; 7000

Personal injury or death can result from a brake malfunction. Do not operate the machine if the brake was applied due to a malfunction of the brake system.

Correct any problem before attempting to operate the machine.

The parking brakes in the axles are applied with spring pressure. Also, the parking brakes are oil pressure released. If the engine fails or a problem with the hydraulics exists, the brakes will not release. The brakes must be released manually. Use the following procedure in order to manually release the brakes.

Note: Brakes (1

)arelocatedoneachsideof differential (2). The front axle and the rear axle have brakes that need to be released.

2. Remove cover (3) on the brakes. Use the supplied

M12 x 25 bolt for releasing the brakes.

3. Thread this bolt into the tapped hole of the brakes.

Turn the bolt until the bolt cannot be turned. This releases th

e pressure on the brake pack by fully

compressing the spring.

4. Perform thi

s procedure for the other three brakes

on the machine.

Illustration 151

1. Plac

e wheel chocks under the tires in order to

g01893953

prevent the machine from moving when the brakes are released.

Illustration 152

g01894137

Page 89

SEBU8710 89

Operation Section

Engine Starting (Alternate Methods)

i03636778

Engine Star Start Receptacle

SMCS Code: 1

There are two cable assemblies that can be used to jump the st jump started from another machine that is equipped with an auxiliary start receptacle or a stalled machine can be jump Your Caterpillar dealer can provide the correct cable lengths for your application.

Auxiliary Start Receptacle

alled machine. A stalled machine can be

startedfromanauxiliarypowerpack.

ting with Auxiliary

463

Jump Starting P

1. Determinethefailureofthemachinetostart.Refer

to Special Ins System Troubleshooting”.

2. Place the tra

lever in the NEUTRAL position on the stalled machine. Engage the parking brake. Move all controls to

3. On the stalle d machine, turn the start switch key

to the OFF po

4. Turn on the battery disconnect switch.

5. Move the machine that is used for the electrical

source close to the stalled machine. The cables must reach

TO CONTACT EACH OTHER.

6. Stop the e

theelectricalsource.Whenyouuseanauxiliary power source, turn the charging system to the OFF posit

ngine on the machine that is used for

ion.

rocedure

tructions, REHS0354, “Charging

nsmission direction and speed control

the HOLD position.

sition. Turn off all of the accessories.

. DO NOT ALLOW THE MACHINES

Illustration 153

An auxiliary start receptacle provides a dedicated connection that is available for jump starting.

g01175768

Arrangement 1

Note: When an electrical power source is connected

to the auxiliary start receptacle, the battery disconnect switch is bypassed and the electrical system will energize when the battery disconnect switch is in the OFF (disabled) position. This allows jump starting capabilities regardless of the position of the battery disconnect switch.

Arrangement 2

Note: When an electrical power source is connected

to the au xili ary start receptacle and the battery disconnect switch is in the OFF (disabled) position, the electrical system will remain de-energized. This prevents jump starting capabilities when the battery disconnect switch is in the OFF position.

Illustration 154

liary start receptacle

Auxi

7. On the stalled machine, connect the appropriate

le to the auxiliary start receptacle.

cab

8. Connect the other end of this cable to the

ctrical source. You must connect the cable to

ele the auxiliary start receptacle.

art the engine on the machine that is used

9. St

for the electrical source. Energize the charging system if an auxiliary power source is used.

10. Allow the electrical source to charge the batteries

for two minutes.

11. Attempt to start the stalled engine. Refer to

Operation and Maintenance Manual, “Engine

tarting”. See the beginning of this topic.

g01951713

Page 90

90 SEBU8710 Operation Section Engine Starting (Alternate Methods)

12. Immediately af disconnect the cable from the electrical source.

13. Disconnect th stalled machine.

14. Conclude wit charging system. Check the stalled machine, as required. Check the machine when the engine is running and

Note: Refer to Special Instruction, SEHS7633, “Battery Te about testing and about charging. This document is available from your Caterpillar dealer.

st Procedure” for complete information

ter the stalled engine starts,

e other end of this cable from the

h a failure analysis on the starting

the charging system is in operation.

Page 91

SEBU8710 91

Maintenance Section

Tire Inﬂation Information

Maintenance Section

Tire Inﬂation Information

i03766713

Tire Inﬂation Pressure

SMCS Code: 4203; 7500

The tire inﬂation pressures in the following tables are cold inﬂation pressures.

Table 7

584 Forwarder

Tire Size

650/

65-

26.5

750/

55-

26.5

700/

70-

(1)

Ply rating

(2)

Load capacity (kg) at speed

(3)

Tire inﬂation pressure with tracks

(4)

Standard tire inﬂation pressure without tracks

(5)

DW20A

(1)

Rim

20 20 7170 8250

20 24 7810 9000

16 20

km/h

(5)

5990 6900

(2)

km/h

(2)

PSI

550 kPa

(80

psi)

550 kPa

(80

psi)

240 kPa

(35

psi)

(3)

PSI

500 kPa

(72.5

psi)

500 kPa

(72.5

psi)

240 kPa

(35

psi)

(4)

i02610518

Tire Inﬂation Pressure Adjustment

SMCS Code: 4203

Always obtain the proper tire inﬂation pressures and maintenance recommendations for the tires on your machine fro in a warm shop area 18° to 21°C (65° to 70°F) will signiﬁcantly change when you move the machine into freezi the correct pressure in a warm shop, the tire will be underinﬂated in freezing temperatures. Low pressure shortens t

Reference: When you operate the machine in freezing t SEBU5898, “Cold Weather Recommendations for All Caterpillar Machines” in order to adjust tire inﬂation pressure

m your tire supplier. The tire pressure

ng temperatures. If you inﬂate the tire to

he life of a tire.

emperatures, refer to Special Publication,

Note: Operating the machine with an underinﬂated tire can lead to immediate tire failure or damage to the sidewall of the tire. Tire slippage on the rim may also result from an underinﬂated tire.

The tire inﬂation pressure is based on the weight of a ready-to-work machine without attachments, at rated payload, and in average operating conditions. Pressures for each application may vary. Always obtain the proper pressures from your tire supplier.

Page 92

92 SEBU8710 Maintenance Section Cooling System Speciﬁcations

Cooling System Speciﬁcations

i03867512

Extended Life Coolant (ELC)

SMCS Code: 1350; 1352; 1395

Caterpillar provides Extended Life Coolant (ELC) for use in the following application:

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

The anti-corrosion package for ELC is different from the anti-corrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Caterpillar ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems.

ELC extends the service life of the coolant to 12000 service hours or six years. ELC does not require a frequent addition of a Supplemental Coolant Additive (SCA). An Extender is the only additional maintenance that is needed at 6000 service hours or one half of the ELC service life.

i03867549

Extended Life Coolant (ELC) Cooling Syste

SMCS Code: 1350; 1352; 1395

Proper additions to the Extended Life Coolant

Use only Caterpillar products or commercial products that have passed Caterpillar's EC-1 speciﬁcation for pre-mixed

Use only Caterpillar Extender with Extended Life Coolant.

Mixing Extended Life Coolant with other products reduces the follow the recommendations can reduce cooling system components life unless appropriate corrective action is pe

In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of Extended Life Coolant (ELC). Lowering the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits.

or concentrated coolants.

Extended Life Coolant service life. Failure to

rformed.

m Maintenance

NOTICE

ELC is available in a 1:1 premixed cooling solution with distilled water. The Premixed ELC provides freeze protection to −36 °C (−33 °F). The Premixed ELC is recommended for the initial ﬁll of the cooling system. The Premixed ELC is also recommended for topping off the cooling system.

Cat ELC Concentrate is also available. Cat ELC Concentrate can be used to lower the freezing point to −51 °C (−60 °F) for arctic conditions.

Containers of several sizes are available. Consult your Caterpillar dealer for the part numbers.

Note: Caterpillar developed the EC-1 speciﬁcation. TheEC-1speciﬁcation is an industry standard. The EC-1 speciﬁcation deﬁnes all of the performance requirements that are needed for an engine coolant to be sold as an extended life coolant for Caterpillar engines. Cat ELC can be used in most OEM engines of the following types: diesel and gasoline. ELC meets the performance requirements of “ASTM D4985” and “ASTM D6210” for heavy-duty low silicate antifreeze/coolants. Cat ELC does not require treatment with a conventional SCA.

NOTICE Do not system that is ﬁlled with Extended Life Coolant (ELC).

Do no (SCA). Only use ELC Extender in cooling systems that are ﬁlled with ELC.

use a conventional coolant to top-off a cooling

t use standard supplemental coolant additive

Caterpillar ELC Extender

erpillar ELC Extender is added to the cooling

Cat system halfway through the ELC service life. Treat the cooling system with ELC Extender at 6000 hours

one half of the coolant service life. Use Table 8

or in order to determine the proper amount of ELC Extender that is required.

Containers of several sizes are available. Consult your Caterpillar dealer for the part numbers.

Use the formula in Table 8 to determine the proper amount of ELC Extender for your cooling system.

efer to Operation and Maintenance Manual,

R “Capacities (Reﬁll)” in order to determine the capacity of the cooling system.

Page 93

SEBU8710 93

Maintenance Section

Cooling System Speciﬁcations

Table 8

Formula For Adding ELC Extender To ELC

V×0.02=X

V is the total capacity of the cooling system.

X is the amount of ELC Extender that is required.

Care m ust be ta during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂu

id with suitable containers before open-

ing any compartment or disassembling any compo-

NOTICE

kentoensurethatﬂuids are contained

nent containing ﬂuids.

Table9isanexampleforusingtheformulathatis in Table 8.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies

Table 9

Example Of The Equation For Adding ELC

Total Vol u

of the Cooling

System (V)

Extender To ELC

Multiplic

ation

Factor

Amount of ELC

Extender that is

Required (X)

suitable to products.

Dispose of a mandates.

collect and contain ﬂuids on Caterpillar

ll ﬂuids according to local regulations and

1. Drain the coolant into a suitable container.

9L(2.4USgal)

× 0.02 0.18 L

(0.05 US gal)

or (6 ﬂ oz)

2. Dispose of the coolant according to local

regulations.

NOTICE When using Cat ELC, do not use standard SCA's or SCA ﬁlters. To avoid SCA contamination of an ELC system, remove the SCA ﬁlter base and plug off or by-pass the coolant lines.

ELC Cooling System Cleaning

Note: If the cooling system is already using ELC,

cleaning agents are not required to be used at the speciﬁed coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage.

Clean water is the only cleaning agent that is required when ELC is drained from the cooling system.

After the cooling system is drained and after the cooling system is reﬁlled, operate the engine while the cooling system ﬁller cap is removed. Operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes. As needed, add the coolant mixture in order to ﬁll the system to the speciﬁed level.

3. Flush the system with clean water in order to remove any debris.

4. Use Caterpillar cleaner to clean the system. Follow the instruction on the label.

5. Drain the cleaner into a suitable container. Flush the cooling system with clean water.

6. Fill the cooling system with clean water and operate the engine until the engine is warmed to 49° to 6

6°C (120° to 150°F).

NOTICE

Improper or incomplete ﬂushing of the cooling system

esult in damage to copper and other metal com-

can r ponents.

oiddamagetothecoolingsystem,makesureto

To a v completely ﬂush the cooling system with clear water. Continue to ﬂush the system until all the signs of the

ning agent are gone.

clea

7. Drain the cooling system into a suitable container

ﬂushthecoolingsystemwithcleanwater.

and

Changing to Caterpillar ELC

To change from the heavy-duty coolant/antifreeze to the Caterpillar ELC, perform the following steps:

Note: The cooling system cleaner must be thoroughly

shed from the cooling system. Cooling system

ﬂu cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling

stem.

8. Repeat Step 6 and Step 7 until the system is

ompletely clean.

9. FillthecoolingsystemwiththeCaterpillar

remixed ELC.

Page 94

94 SEBU8710 Maintenance Section Cooling System Speciﬁcations

ELC Cooling System Contamination

NOTICE Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only Perkins Products for premixed or concentrate coolants. Use only Perkins ELC extender with Perkins ELC. Failure to follow these recommendations can result in shortened cooling system component life.

ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy-duty coolant/antifreeze or SCA. If the contamination exceeds ten percent of the total system capacity, perform ONE of the following procedures:

Drain the cooling system into a suitable container.

•

Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Caterpillar ELC.

Drain a portion of the cooling system into a suitable

•

container according to local regulations. Then, ﬁll the cooling system with premixed ELC. This should lower the contamination to less than 10 percent.

Maintain the system as a conventional Diesel

•

Engine Antifreeze/Coolant (DEAC). Treat the system with an SCA. Change the coolant at the interval that is recommended for the conventional Diesel Engine Antifreeze/Coolant (DEAC).

Commercial ELC

If Caterpillar ELC is not used, then select a commercial ELC that meets the Caterpillar speciﬁcation of EC-1 and either the “ASTM D5345” speciﬁcation or the “ASTM D4985” speciﬁcation. Do not use an extended life coolant that does not meet theEC-1speciﬁcation. Follow the maintenance guide for the coolant from the supplier of the commercial ELC. Follow the Caterpillar guidelines for the quality of water and the speciﬁed coolant change interval.

Reference: See Special Publication, SEBU6250, “Caterpillar Machine Fluid Recommendations”, “Extended Life Coolant Cooling System Maintenance” for additional information.

i01908729

Diesel Engine Antifreeze/ Coolant (DEAC

SMCS Code: 1350; 1352; 1395

Caterpillar recommends using Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) for cooling systems tha Caterpillar DEAC is an alkaline single-phase ethylene glycol type antifreeze that contains corrosion inhibitors

Caterpillar DEAC is formulated with th e correct amount of C (SCA). Do not use SCA at the initial ﬁll when DEAC is used.

Containers of several sizes are available. Consult your Caterpillar dealer for the part numbers.

If concentrated DEAC is used, Caterpillar recommends mixing the concentrate with distilled water or deionized water is not available, use water which has the required properties. For the water properties, see this pub (Maintenance Section).

t require a heavy-duty coolant/antifreeze.

and antifoam agents.

aterpillar Supplemental Coolant Additive

with deionized water. If distilled water or

lication, “General Coolant Information” topic

)

i03628996

Supplemental Coolant Additive (SCA)

SMCS Code: 1350; 1352; 1395

Caterpillar SCA has the following beneﬁts:

prevention of corrosion to metals

•

prevention of deposit formations of minerals

•

prevention of cavitation of the cylinder liners

•

elimination of foaming of the coolant

•

Test the SCA concentration or submit a coolant sample to your Caterpillar dealer at every oil change. After every 250 service hours, liquid SCA or a SCA maintenance element may be needed. SCA additions are based on the results of coolant analysis. Your Caterpillar dealer has test kits that will evaluate the concentration of additives in Caterpillar DEAC.

The following table indicates the amount of Caterpillar SCA that is needed at the initial ﬁll to treat commercial heavy-duty coolant/antifreezes. The table also shows the addition of an SCA for either liquid SCA or for the maintenance elements of a SCA.

Page 95

SEBU8710 95

Maintenance Section

Cooling System Speciﬁcations

These addition

s are for commercial heavy-duty

coolant/antifreezes and for Caterpillar DEAC.

Table 10

Caterpillar SCA Requirements for Heavy-Duty Coolant/Antifreezes

Cooling System Capacity

inL(USgal)

22 to 30 (6 to 8) 0.95 L (32 oz) 0.24 L (8 oz)

31 to 38 (8 to 10) 1.19 L (40 oz) 0.36 L (12 oz)

39 to 49 (10 to 13) 1.42 L (48 oz) 0.36 L (12 oz)

50 to 64 (13 to 17) 1.90 L (64 oz) 0.47 L (16 oz)

65 to 83 (17 to 22) 2.37 L (80 oz) 0.60 L (20 oz)

84 to 114 (22 to 30) 3.32 L (112 oz) 0.95 L (32 oz)

115 to 163 (30 to 43) 4.75 L (160 oz) 1.18 L (40 oz)

164 to 242 (43 to 64) 7.60 L (256 oz) 1.90 L (64 oz)

(1)

Use a Caterpillar SCA when you do not use a Ca terpillar A ntifreeze.

(2)

Do not exceed the 6 percent maximum concentration. Check with the supplemental coolant additive test kit.

Initial Fill

Caterpillar Liquid SCA

(1)

250 Service Hour Maintenance

Note: Due to the individual engine applications,

the maintenance practices need to be periodically reviewed in order to maintain the cooling system.

(2)

Cleaning the Heavy-Duty Cooling System

Caterpillar Cooling System Cleaners are designed to clean the system of harmful scale and of corrosion. Caterpillar Cleaners dissolve mineral scale, corrosion products, light oil contamination, and sludge. For the recommended service interval, refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for your machine.

Page 96

96 SEBU8710 Maintenance Section Lubricant Viscosities and Reﬁll Capacities

Lubricant Viscosities and Reﬁll Capacities

i03913458

Lubricant V

iscosities

SMCS Code: 7581

NOTICE Caterpill

ar does not warrant the quality or perfor-

mance of non-Caterpillar ﬂuids.

The proper oil viscosity grade is determined by the minimum outside temperature when the machine is started. The proper oil viscosity grade is also determined by the maximum outside temperature while the machine is operated. Use the column that has the title of “Min” on the table to determine the oil viscosity grade that is required for starting a cold machine. Use the column that has the title of “Max” on the table to determine the oil viscosity grade for operating the machine at the highest temperature that is anticipated. Use the oil with the highest viscosity that is allowed for the ambient temperature when you start the machine.

Machines that are continuously operated should use oils that have a higher viscosity in the ﬁnal drives and differentials in order to maintain the highest possible oil ﬁlm thickness. Consult your dealer if additional information is needed.

The oil viscosity grade is speciﬁctothemachine compartment. Some machine models and/or machine compartments do not allow the use of all available viscosity grades. For guidance on selecting the oil viscosity, refer to the “Lubricant Viscosities for Ambient Temperatures” table and the associated footnotes in the table. Refer to Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” for detailed information.

Table 11

Lubricant Viscosities for Ambient Temperatures

mpartment or System

Engine Crankcase

(2)(3)

l Type and Classiﬁcation

Caterpillar Multigrade DEO

Cat DEO SYN

Cat Arctic DEO SYN

Cat ECF-2

Cat ECF-1-a

(1)

l Viscosities

SAE 0W30

SAE 0W40

(4)

(5)

SAE 5W30

SAE 5W40 −30 +50 −22 +122

SAE 10W30

SAE 15W40

(6)

(7)

°C °F

Min Max Min Max

−40 +30 −40 +86

−40 +40 −40 +104

−30 +30 −22 +86

−18 +40 0 +104

−9.5 +50 +15 +122

(continued)

Page 97

SEBU8710 97

Maintenance Section

Lubricant Viscosities and Reﬁll Capacities

(Table 11, contd)

Lubricant Viscosities for Ambient Temperatures

Compartment or System Oil Type and Classiﬁcation Oil Viscosities

SAE 80W90 +10 +50 +50 +122

SAE 0W30

SAE 5W30

Two-Speed Transmission

Caterpillar TDTO

Caterpillar TDTO-TMS

Caterpillar TO-4

(8)

SAE 10W

SAE 30

Caterpillar TO-4M

SAE 50

Multi-Season Transmission Oil

(8)

(TMS)

SAE 0W20

SAE 0W30

SAE 5W30

SAE 5W40 −30 +40 −22 +104

SAE 10W −20 +40 −4+104

SAE 30 +10 +50 +50 +122

SAE 10W30 −20 +40 −4+104

SAE 15W40 −15 +50 +5 +122

Caterpillar MTO (Multipurpose Tractor

Hydraulic Systems

Caterpillar HYDO Advanced

(9)(1 0)

Cat HYDO

Cat MTO Cat DEO

Cat DEO ULS

Cat TDTO

Cat TDTO-TMS

Cat DEO SYN

(9)(1 0)

(9) (1 0)

(9)(1 0)

(9) (1 0)

Cat Cold Weather DEO SYN

Cat ECF-1-a, Cat ECF-2, Cat

ECF-3, Cat TO-4, Cat TO-4M,

Cat BF-1

(9) (1 0)

(9)(1 0)

Oil)

Cat TDTO-TMS

Final Drives

Differentials

Bogies

Cat GO (Gear Oil)

commercial API GL-5 gear oil

(11)

SAE 80W90 -20 +40 -4 +104

(1 2)

(1)

°C °F

Min Max Min Max

(6)

−40 +20 −40 +68

−30 +20 −22 +68

−20 +10 −4+50

0 +35 +32 +95

+10 +50 +50 +122

−10 +35 +14 +95

(6)

−40 +40 −40 +104

−30 +40 −22 +104

−25 +40 −13 +104

(8)

−15 +50

(continued)

+122

Page 98

98 SEBU8710 Maintenance Section Lubricant Viscosities and Reﬁll Capacities

(Table 11, contd)

Lubricant Viscosities for Ambient Temperatures

Compartment or System Oil Type and Classiﬁcation Oil Viscosities

Grease Points

(1)

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

Recommendations for all Caterpillar Machines”. This publication is available from your Caterpillar dealer.

(2)

Supplemental heat is recommended for cold-soaked starts below the minimum ambient temperature. Supplemental heat may be required for cold-soaked starts that are above the m inimum temperature that is stated, depending on the parasitic load and other factors. Cold-soaked starts occur when the engine has not been operated for a period of time, allowing the oil to become more viscous due to cooler ambient temperatures.

(3)

API CF oils are not recommended for Caterpillar 3500 Series and smaller D irect Injection (DI) diesel engines. API CF-4 oils are not recommended for Caterpillar machine diesel engines.

(4)

Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil.

(5)

API CI-4, API CI-4 PLUS, and API CH-4 oils are acceptable if the req uirements of Caterpillar's E CF -1-a (Engine Crankcase Fluid speciﬁcation - 1 -a) are met. API CI-4, API CI-4 PLUS, and API CH-4 oils that have not met the requirements of C aterpillar's ECF-1-a or ECF-2speciﬁcation may cause reduc ed engine life.

(6)

These special oils that have synthetic base stocks do not contain polymer viscosity index improvers. The high viscosity index of the “synthetic” oils provides natural multiviscosity properties.

(7)

SAE 10W-30 is the preferred viscosity grade for the 3116, 3126, C7, C-9 and the C 9 diesel engines when the ambient temperature is between -18° C (0° F) and 40° C (104° F).

(8)

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

(9)

Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydro static transmission sy st ems when ambient temperature is between −20 °C (−4 °F) and 40 °C (104 °F). C at HYDO A dvanced 10 has an SAE viscosity grade of 10W. Cat HYDO Advanced 10 has a 50% increase in the standard oil drain interval (up to 3000 hours) for machine hydraulic systems over second and third choice oils when y ou follow the maintenance interval schedule for oil ﬁlter changes and for oil sampling that is stated in the Operation and Maintenance Manual for your particular machine. 6000 hour oil drain intervals are possible when using S·O·S Services oil analysis. Consult your Cat dealer fo r details. In order to gain the most beneﬁt from the improved performance designed into Cat HYDO Advanced 10, when switching to Cat HYDO Advanced 10, cross contamination with the previous oil should be kept to less than 10%.

(10)

Second choice oils are Cat HYDO, Cat MTO, Cat DEO, Cat DE O-ULS, Cat TDTO, Cat Arctic TDTO, Cat TDTO-TMS, Cat DEO SYN, Cat Arctic DEO SYN. Third choice oils are commercial oils that meet Cat ECF-1-a, Cat ECF-2, C at ECF-3, Cat TO-4, or the Cat TO-4M speciﬁcations, and that have a minimum zinc additive level of 0.09 percent (900 ppm). Commercial biodegradable hy draulic oil must meet the Cat BF-1 speciﬁcation. Refer to the machine Operation and Maintenance Manual and/or contact your local Caterpillar dealer before using commercial oils that meet Cat BF-1 in C at Hydraulic Excavators. The minimum viscosity for commercial alternative oils used in most Cat machine hydraulic and hyd rostatic transmission systems is 6.6 cSt at 100 °C (212 °F) (“ASTM D445”).

(11)

When the use of gear oil is speciﬁed, use Cat GO or Cat S ynthetic GO in order to maximize the component life.

(12)

Gear lubricants are classiﬁed by the API service c ategory and by the SAE viscosity grade that is deﬁned in “SAE J306”. Non - Caterpillar commercial API GL-5 gear oils are second choice oils.

(13)

If MPGM is not available, us e multipurpose type grease which contains 3 to 5 percent molybdenum.

(13)

Caterpillar MPGM 3% Moly -20 40 -4 104

(1)

°C °F

Min Max Min Max

Page 99

SEBU8710 99

Maintenance Section

Lubricant Viscosities and Reﬁll Capacities

i03933590

Capacities (Reﬁll)

SMCS Code: 7560

Table 12

Approximate Reﬁll Capacities

2748 & 2948 Forwarder

Compartment or System

Fuel Tank 255 67.3

Cooling System

Boom Base 15.0 3.96

Transmission Gearbox (Drop Box)

Hydraulic System 248 65.5

Engine Oil

Front Axle

Rear Axle

(1)

This amount includes changing the oil ﬁlter.

(1)

Differential 16.0 4.23

2X) 32 8.45

Bogie (

Planetary (Final Drive) (4X)

Differential

Bogie (2X)

Planetary (Final Drive) (4X)

Liters

35.7 9.4

5.5

31.0 8.2

5.0 1.32

14.0 3.70

32 8.45

5.0 1.32

Gallons

1.45

Consult your Ca

terpillar dealer for complete information and assistance in establishing an S·O·S program for your equipment.

i01822901

S·O·S Information

SMCS Code: 1348; 1395; 3080; 4070; 5050; 7542

S·O·S Services is a highly recommended process for Caterpillar 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 Services can help determine the cause of an existing 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.

Page 100

100 SEBU8710 Maintenance Section Maintenance Access

Maintenance Access

i03933609

Hood Tilting

SMCS Code : 72

Illustration 155

1. Unfasten the guide lines on both front sides of the hood.

51-084

g02154685

3. Standonthepla

Illustration 158

tform when you raise the hood.

g02154688

4. Use the grab handle to open the engine hood. The engine hood tilts forward.

5. Reversesteps1through4inordertoclosethe tilted hood.

i03569712

Cab Tilting

Illustration 156

2. Low

er the front guard on the machine, if equipped.

g02154679

SMCS Code: 7301-084; 7301-506; 7301-509

If the cab tilt cylinder is connected and a crane is used to tilt the cab instead of the cab tilt cylinder,

us damage to the machine and/or serious in-

serio jury or death may occur. Ensure that the cab tilt cylinder is disconnected from the cab when using

ne as the li fting device to tilt the c ab.

acra

lustration 159

Electric controls (1) an d manual control (2) for the cab tilt pump are located on the left side of the machine.

g01894675

Illustration 157

g02154686