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1. Illustration 257 ae Windshield Washer Washer fluid bottle 3 is on the left side of the machine ina compartment between battery box 1 and fuel tank 2 Open the access cover Remove the fluid bottle cap in order to fill the washer fluid bottle Window Wipers Inspect Replace If Equipped 1 Inspect front window wiper blade 1 the left window wiper blade 4 and right window wiper blade 5 HW ie J ae Illustration 258 2 Start rear wiper 2 and stop the wiper in the rightmost position 3 Inspect the rear window wiper blade or replace the wiper blade by using the appropriate three point contact only 175 Maintenance Section D6T LGP OEM Window Wipers Inspect Replace Reference See Mounting and Dismounting in this manual for additional information 3 Replace any wiper blades that are damaged or worn Replace any wiper blades that streak the window Windows Clean Use commercially available window cleaning solutions to clean the windows Illustration 259 Clean all the cab windows and the door windows Illustration 260 Clean the inside of the side windows with the window in the CLOSED position Cleaning From Ground Level Note Use the following method in order to clean
2. Table 11 Performance Screen 2 of 5 Description Value Status Units Regen mode Disabled Inactive Status control Manual mode Automatic Regen mode Active Active Status ARD status Machine XXXXXX X Hours hours Remaining XXX Fuel Level 1 Aftertreatment regeneration device system Table 12 Performance Screen 3 of 5 Description Units Engine Oil Pressure kPa or psi System Voltage V Engine Speed RPM Table 13 Performance Screen 4 of 5 Description Units Engine Coolant C or F Temperature Hydraulic Oil Temperature C or F TC Oil Temperature C or F Table 14 Performance Screen 5 of 5 Description Units Engine Load Factor Fuel Consumption L or Gal Air Filter Restriction kPa or IN H O 72 Operation Section D6T LGP OEM Machine Operation Illustration 92 Note The Main Menu can be displayed from any screen by pressing Main button 1 Press back button 2 the required number of times in order to return to the Performance screen Service Hour Meter This display indicates the total operating hours of the engine Use the display in order to determine the service hour maintenance intervals Engine Monitoring Mode The monitoring system display interfaces with the engine ECM Also this interaction displays the emissions data of the present engine operating state The inf
3. Illustration 57 Adjustable armrests Parking brake control Differential steering control Transmission direction selector Speed range selector Service brake Decelerator pedal Front work lights Rear work lights Gauges and indicators Mirror MVP switch Autoshift switch Auto kickdown switch Engine start switch Regeneration switch Engine fan reverse switch Throttle control switch Hydraulic lockout control Joystick control Horn ROO at an ana NINN TN Io Sj COON A OCOOONOOARWDY 0OY rrrrvrvrwvrw EE Se haa re ror SS SSS aS an an an an WEBM1000 Adjustable Armrests 1 Illustration 58 Use the following procedure in order to adjust the left armrest if necessary 1 Loosen the two bolts 2 2 Move armrest 1 to the desired height 3 Tighten the bolts 2 Parking Brake Control 2 NOTICE Do not engage the parking brake while the machine is moving unless an emergency exists The use of the parking brake as a service brake in regular operation causes severe damage to the parking brake system Illustration 59 51 Operation Section D6T LGP OEM Machine Operation Parking Brake 2 Use this switch to P engage the parking brake and lock the transmission in the NEUTRAL position When the parking brake switch is engaged the parking brake indicator on the dashboard will light and the machine should not move After the
4. Full marks 5 Warm oil 6 Cold oil 8 Maintain the oil level within the marks for the operating range on the dipstick If the engine is at idle and the oil is warm maintain the oil level within range 5 If the engine is stopped and the engine oil is cold maintain the oil level within range 6 9 Clean filler cap 3 and install the filler cap 10 Close the access cover not shown Transmission Oil Level Check Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Illustration 253 1 Open the access cover on the right side of the cab in front of the hydraulic tank 173 Maintenance Section D6T LGP OEM Transmission Oil Level Check f z x a a a a La D Illustration 254 2 Warm Oil 3 Cold Oil 2 Remove the transmission oil level gauge 1 Maintain the oil level within the marks for the operating range on the dipstick If the engine is at idle and the oil is warm maintain the oil level within range 2 If the engine is stopped and the engine oil is cold maintain the oil level within range 3 Note When you are operating the machine on severe slopes the quantity of oil in the transmission can be increased up to 10 percent When you are operating with the increased oil quantity prolonged operation in some machines can cause high tran
5. e Operation and Main Precleaner Clean enance Manual Engine Air e Operation and Main Level Check enance Manual Engine Oil e Operation and Maintenance Manual Fuel System Water Separator Drain e Operation and Maintenance Manual Hydraulic System Oil Level Check e Operation and Maintenance Manual Seat Belt Inspect 43 Operation Section D6T LGP OEM Before Operation e Operation and Maintenance Manual Transmission System Oil Level Check e Operation and Maintenance Manual Winch Oil Level Check Tool Storage Area Illustration 37 The tool storage area is located above the left fender The storage box is directly in front of the fuel tank filler cap 44 Operation Section D6T LGP OEM Machine Operation Machine Operation Seat Adjusting the Seat The operator s seat that is provided with this machine is in compliance with the appropriate class of ISO 7096 Note Adjust the seat for a new operator or at the beginning of each shift The operator should be seated against the seat backrest Adjust the seat so that the operator is allowed full travel of the pedals Adjusting the Fore and Aft Position of the Seat Illustration 38 Fore and Aft Adjustment 1 Pull up fore and aft lever 1 This will move the seat forward or this will move the seat back to the desired position Releas
6. e Frequent operation in ambient temperatures which are above 32 C 90 F e Frequent operation in ambient temperatures which are below 0 C 32 F Severe Operating Conditions Frequent operation with inlet air which has a corrosive content Operation with inlet air which has a combustible content Operation which is outside of the intended application Operation with a plugged fuel filter Extended operation at low idle more than 20 of hours Frequent cold starts at temperatures below 0 C 32 F Frequent dry starts starting after more than 72 hours of shutdown 122 Maintenance Section D6T LGP OEM Maintenance Support e Frequent hot shutdowns shutting down the engine without the minimum of 2 minutes to 5 minutes of cool down time e Operation above the engine rated speed e Operation below the peak torque speed e Operating with fuel which does not meet the standards for distillate diesel fuel as stated in Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Distillate Diesel Fuel e Operating with a blend of distillate fuel which contains more than 5 percent biodiesel Improper Maintenance Procedures Maintenance Procedures Which May Contribute to a Severe Service Application e Inadequate maintenance of fuel storage tanks from causes such as excessive water sediment and microorganism growth Extending maintenance intervals beyond th
7. LIVE end to lower Hook Block 12 Illustration 295 Installing hook load line A Wire rope from the winch 3 Install the hook load line from the winch drum onto the sheave blocks in the following manner e Install the cable for the hook winch from the winch drum to fairlead sheave 8 Note The cable for the hook winch should go over upper sheave 9 which is toward the front of the machine Anchor the cable for the hook winch toward the rear of the machine e Install the cable over upper sheave 9 Install the cable under lower sheave 10 Install the cable over upper sheave 11 Install the cable under lower sheave 12 Insert the cable into the pocket and around wedge 13 Allow an additional length of cable to form a tail end six inch minimum Use a mallet to tap the wedge and the wire rope into the pocket Insert the tail end of the wire rope through clamp 14 Add a short piece of wire rope through clamp 14 in order to secure the clamp as needed Tighten the nuts on the clamp Pull the cable until the line is tight in order to seat wedge 13 Lift the lower block above the ground Raise the boom Hydraulic System Oil Change Refer to the specific tractor Operation and Maintenance Manual Hydraulic System Oil Change for complete requirements and procedures 222 Maintenance and Lubrication Section Pipelayer Attachment Kit Hydraulic System Oil Change At oper
8. Illustration 114 Note Shutting down the machine safely is recommended 2 Snooze the display event screen Qe RN ee al ANU EN ea a Enter Limp Home YES Illustration 115 82 Operation Section D6T LGP OEM Machine Operation 3 Enter the screen for the limp home mode for steering Make the desired selection A gt RU A F l N fav a P oFFi Press Service Brake Pedal Illustration 116 First instruction 4 When the limp home mode is selected follow the instructions on the monitoring system display Then the operator may attempt to drive the machine Machine Status Primary Implet Machine Rear Implements Status Powertrain Illustration 117 The Machine Status menu option allows the operator or the technician to perform the real time monitoring of electrical components in the major systems of the machine From the Main Menu use the appropriate arrow button to highlight the Machine Status Then press the OK button in order to access the menu for Machine Status This menu organizes the systems into the following six categories e Engine e Primary Implements e Rear Implements WEBM1000 e Power Train e Steering e Brake Totals Display Menu The Totals menu option allows the operator or the serviceman to access lists of pertinent data about machine systems This data is useful in order to determine when service work needs to be
9. ee 124 Every 4500 Service Hours 124 Every 50 Service Hours or Weekly 00 123 Every 500 Service Hours cerc 123 Every 500 Service Hours or 3 Months 123 Every 5000 Service Hours s 124 Every 6000 Service Hours or 3 Years 124 Every Year de tines tetrreceda a a Sah danes 124 Exhaust ws TEE EE E E ieee 19 Exhaust Gas Recirculation Cooler a 20 Extended Life Coolant ELC Extender 131 Extension for the Back of the Seat 0 05 47 Extension of the Seat Belt 0 eee 49 F Fastening The Seat Belt eee 48 49 Final Drive Oil Change 0 00 0 ccceeeeeeeees 144 Final Drive Oil Level Check s a s 144 Final Drive Oil Sample Obtain c0 145 Fire Extinguisher ceceeceeeeeeeeeeteeee tenes 23 Fire Extinguisher Location 0 cece 24 Fire Prevention and Explosion Prevention 21 Fire Salet ecto deke a tts seeder aAA aS 24 Fluid Penetration o e 18 For ward aona wlan PAS Shei e 4 Free Fall Active Do Not Operate 000 00 184 Front Idler Position Check oo 145 Fuel Additives 2 2 2 2 cee ects cee tttttteeeeeees 119 Fuel Priming Pump Replace ce 147 Fuel System Prime ossai 147 Fuel System Primary Filter Water Separator DIEE U A E AAA EA E AA E 148 Fuel System Secondary Filters Replace 148 Fuel System Water Separator Element ReplaCe so
10. Harmonised Standards Taken Into Consideration EN 13309 EN 301 389 1 EN 301 489 02 EN 55022 EN 60950 1 EN 301 721 Done at Signature CATERPILLAR INC 100 N E Adams Street ML ith Bool hic AB 5410 yy Peoria IL 61629 U S A Date 2010 06 10 Name Position Michael R Verheyen Product Manager Illustration 124 90 Operation Section D6T LGP OEM WEBM1000 Machine Operation Pinte SA SWakrRNSRRSS CATS22_ D Part Name Pb Ho Cd Cr6 PBB PBDE maasia o ee e Internal Cables Pintea circu awemoy gt 2 o Oo oO o Printed Circuit Assembly leiden sss P oO 2 oO oO oO Metal Enclosure pt kalea phe peee Hardware SIM SIM Card SR MS Mik BA Rt Nuts bolts screws washers O MEAT AT Er I SE APPS I T 11363 2006 Pk EP IUE RK X eee Re A Oe MES I 7 11363 2006 HEF METI LUI SMEA ASHES Manufacturing Date Code Information Illustration 125 WEBM1000 Illustration 126 91 Operation Section D6T LGP OEM Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 Industry Canada Declaration of Conformity Trimble Navigation Limited declares under sole responsibility that the following products conform to Class B digital apparatus complies with Canadian ICES 003 Product Name Trimble MTS523 Caterpillar 523 Trimble MTS522 Caterpillar 522 Trimble MTS521 Product Description Telematics with M2M
11. Illustration 238 2 Add multipurpose grease MPGM through track adjustment valve 1 Add the MPGM until dimension A B is correct 3 Operate the machine back and forth in order to equalize the pressure Allow the machine to coast to a complete stop Do not use the brakes 4 Remeasure dimension C Reference See Operation and Maintenance Manual Front Idler Position Check for additional information on System One Undercarriage Tight Track Adjustment 1 Loosen relief valve 2 by one turn of 360 degrees Allow the grease to escape 2 Close the relief valve Tighten the valve to a torque of 834 7 N m 25 5 Ib ft 3 Add MPGM through track adjustment valve 1 Add grease until dimension A B C is correct 4 Install the access cover Bolt Torque for Track Shoes SystemOne Undercarriage The track shoe bolts are 22 0 mm 0 87 inch The torque requirement for track shoe bolts is 500 70 N m 370 50 Ib ft Tighten the bolts by an additional turn of 120 degrees If you are using bolts with a master link tighten the master bolts to a torque of 500 70 N m 370 50 Ib ft Then turn each bolt by an additional turn of 180 degrees WEBM1000 Track Pins Inspect Fingers can be burned from hot pins and bushings The pins and bushings in a dry joint can become very hot It is possible to burn the fingers if there is more than brief contact with these components Use the recommendations in
12. Manual A manual regeneration is initiated by pressing the force regeneration switch A manual regeneration is allowed when the soot level is equal to or greater than 15 The machine must be stationary the parking brake must be applied and the engine must be at low idle in order to perform a manual regeneration Disabled When the regeneration system is in disabled mode automatic regenerations will not be performed Regeneration System Warning Indicators rhe Illustration 83 Indicator will illuminate when DPF soot load is greater than 90 Regeneration should be performed as soon as possible Machine operation may not allow an automatic regeneration to take place A manual regeneration should be performed as soon as possible WEBM1000 Indicator will turn off once DPF regeneration has started Note In some situations the DPF indicator may stay illuminated when the soot load is below 90 The illuminated DPF indicator indicates that a complete regeneration has not been performed A complete regeneration is when the soot level is reduced to 0 If the DPF indicator stays illuminated perform a regeneration without interruption until the soot level is reduced to 0 A complete regeneration will reset the DPF indicator erro ae Illustration 84 If the amount of soot collected in the DPF has reached a level that a regeneration is required the DPF indicator and an action lamp will illuminate Stop the machi
13. for more information Duration Timer Lighting When Machine Setup of Monitoring System Display C is in use select Lighting Timer Duration Then select the amount of duration time for the lights in order to remain on Mirror 11 The operator will adjust the rear view mirror in order to get the best visibility Adjust the mirror before you operate the machine and after operators change 54 Operation Section D6T LGP OEM Machine Operation Speed Range Control MVP Switch 12 If Equipped Illustration 64 12 MVP switch 13 Bidirectional switch Autoshift 14 Auto kickdown switch 15 Engine start switch Multi Velocity Program If Equipped MVP 12 Your machine is equipped with one of two versions of speed ranges The first option is MVP that activates the configuration of five speed ranges Press the top part of the switch 12 in order to activate the five speed range The second option is MVP OFFand the three speed ranges Press the bottom part of the switch 12 in order to activate the three speed range The five speed ranges that are provided by MVP allow the operator to find the best match between the following items machine speed application ground conditions and skill of the operator The operation of the five speed range is indicated on the display with the following designations 1 5 2 0 2 5 3 0 and 3 5 The display also ind
14. Illustration 146 8 9 3 10 Brake control valve Brake valve ports Remove the seat and the floorplate from the operator s station Remove the pressure test fittings from the top of brake valve ports 9 Install one 123 0525 Adapter 7 into each of the brake valve ports Connect the FT1973 Adapter to the 123 0525 Adapters Route the pressure hose through the rear around the side and through the door of the cab Connect the pressure hose to the pump Install the pump temporarily on the platform Replace the floorplate and the seat Place the brake release pump in front of the operator Fasten the seat belt Continue to the next topic 110 Operation Section D6T LGP OEM Towing Information Brake Release Z e Illustration 147 5 Bypass valve 1 Turn bypass valve handle 5 to the closed position 2 Initially rapidly move the pump handle This will produce a large volume of oil flow 3 The brake piston seal must be fully seated The seating of the seal is evident by a sudden rise in the oil pressure When the seal is properly seated the pressure rises to the relief valve setting The setting is 3030 70 kPa 440 10 psi 4 Now the machine can be towed NOTICE Do not allow pressure to drop below 2756 kPa 400 psi while towing Partial brake engagement could occur
15. Inspect the hook assembly and the means for securing the hook assembly For additional information on the proper maintenance and on the proper inspection of hooks refer to American National Standard Institute ANSI ASME B30 14 Inspect Wire Cable Boom and Hook lines Make a visual inspection of all running cables that are in continuous use Make the inspection of the running cables on a daily basis before the machine is placed in operation Inspect all of the cables on a monthly basis All inspections shall be performed by a designated person Keep a dated report of the condition of the cable on file in a location that is available to designated personnel Perform a close inspection of the sections of the cable that are normally hidden during the visual inspection and the maintenance inspection This includes the sections of the cable that pass over the sheaves These points are the sections of the cable that are most likely to fail Note any deterioration that results in a notable loss of the original strength See the conditions that are described below Determine if further use of the cable will constitute a hazard Inspect the cable on a daily basis for the following conditions 220 Maintenance and Lubrication Section Pipelayer Attachment Kit Hook Load Line Install e Inspect the cable for a reduction in the diameter of the cable below the nominal diameter A loss of support in the cored wire of the cable
16. WEBM1000 Operation and Maintenance Manual 72H Pipelayer PLR1 Up Important Safety Information Most accidents that involve product operation maintenance and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential hazards This person should also have the necessary training skills and tools to perform these functions properly Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Safety precautions and warnings are provided in this manual and on the product If these hazard warnings are not heeded bodily injury or death could occur to you or to other persons The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER WARNING or CAUTION The Safety Alert WARNING label is shown below The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The message that appears under the warning explains the hazard and can be either written or pictorially presented A non exhaustive list of operations that ma
17. 115 WEBM1000 Maintenance Section D6T LGP OEM Lubricant Viscosities and Refill Capacities Table 18 Lubricant Viscosities for Ambient Temperatures C oF Oil Type and Performance wi tae Compartment or System Oil Viscosities Requirements Min Max Min Max Cat HYDO Advanced 10 Cat TDTO SAE 10W 20 40 4 104 Cat HYDO Advanced 30 Cat TDTO SAE 30 0 50 32 122 ISO 46 Multi Cat BIO HYDO Advanced Grade 30 45 22 113 Cat MTO Cat DEO ULS SAE10W 30 20 40 4 104 Hydraulic System Cat DEO Cat DEO ULS Cat DEO SAE15W 40 15 50 5 122 Cat TDTO TMS Multi Grade 15 50 5 122 Cat DEO ULS SYN Cat DEO SYN SAE 5W 40 25 40 13 104 Cat DEO ULS Cold Weather SAEOW 40 40 40 40 104 Cat TDTO Cold Weather SAE OW 20 40 40 40 104 Transmission and Axles Refer to the Lubricant Information section in the latest revision of the Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for detailed information This manual may be found on the Web at Safety Cat com 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 Cat dealer Table 19 Lubricant Viscosities for Ambient Temperatures Oil Type and C F ly ek na or Performance Oil Viscosities Requirements
18. 44 Adjusting the Bottom Seat Cushion 04 44 Adjusting the Fore and Aft Position of the Seat 44 Adjusting the Height of the Seat 0 0 08 45 Adjusting the Lumbar Support o 46 Adjusting the Seat 2 0 0 0 ccc eteeeeees 44 Adjustments ooo ccc cette a 100 ARD Spark Plug Replace cece 125 Asbestos Information 19 Auto Kickdown Mode s is 58 B Backup Alarm ainin an aa ia 94 Backup Alarm Test i a 125 Balenga erer iver re A aG 20 Battery Inspect eeeeeeeeeeeee eeren 126 Battery and Battery Cables cece 22 Battery Disconnect Switch ec 63 95 Before Operation ceeeee 25 42 187 197 Before Starting Engine ee 25 Belt Inspect Replace 1 1 126 Bidirectional Shift Mode ccceeeteeeeeeeeee 54 BIOGIOSED MEE E ESEE 119 Bolt Torque for Track Shoes a c 168 Boom Control accs aieniennsd r ea ie 202 Boom Stop Operation and Adjustment Do Not 81011 C EEE E E A 185 Boom Stop Valve n 202 Brake Engagement aiee 110 Brake Release 0 110 Brakes Indicators and Gauges Test 127 Braking System Test l a 127 Burn Prevention 0 cccceeececceeeeeeceeeteeteeeeeeeees 20 Cc Cab Filter Fresh Air Clean Inspect Replace If EQUIPPOC s ceiiticiacchachebeliton Uilenrteiaebstetavintees 128 Cab Filter Recirculation Clean Inspect Replace lf EqQuIPPEC uasa e a 129 California Proposition 65 Warning ss 5 Capacities Refill 0 0 0 0
19. A warning is given before this action occurs on the display with the machine lock icon and Security Pending When engine de rate has happened the machine display shows the machine lock icon and Security Enabled The operator should move the machine to a safe location apply the parking brake power the machine down notify the site supervisor and contact your local Caterpillar dealer Disable Some machines can be prevented from starting remotely by the owner of the machine When disabling has happened the machine display shows the machine lock icon and Security Enabled The operator should notify the site supervisor Tampering Tampering with the Product Link system to disable the Product Link can also result in engine de rating or disabling of the machine To avoid de rating or disabling prevent tampering with the Product Link If machine diagnostics occur due to Product Link notify your site supervisor immediately to prevent derating or disabling An example of this situation is an antenna becoming damaged Regulatory Compliance ORBCOMM TYPE APPROVAL 801QWI IC 4650A Q121415 CCO Illustration 123 WEBM1000 NOTICE Transmission of information using Product Link is subject to legal requirements that may vary from location to location including but not limited to radio frequency use authorization The use of Product Link must be limited to those locations where all legal requirements for
20. CA 94085 3642 CE Declaration of Conformity Trimble Navigation Limited declares under sole responsibility that the following product s Product Name Trimble MTS523 Trimble MTS522 Trimble MTS521 Caterpillar 523 Caterpillar 522 Product Description Telematics Complies with the essential requirements of the R amp TTE Directive 1999 5 EC as described in Article 10 using the following particular standards in full or in part Article 3 la EMC EN 55022 2006 A1 2007 Article 3 1b EMC EN 55024 1998 A1 2001 A2 2003 ISO 7637 2 2004 EN 301 489 1 v1 8 1 EN 301 489 3 v 1 4 1 EN 301 489 7 v1 3 1 T S 51 010 1 v8 3 0 3GPP EN 300 440 2 V1 2 1 GPS EN 301 511 V9 0 2 GSM GPRS Article 3 1a Safety EN 60950 1 2006 EN 62311 2008 Article 3 2 R amp TTE Mark First Applied 2009 This document is maintained under Trimble part number 78356 00 DC and the technical file is maintained under Trimble part number 78356 00 CE at Manufacturer Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 3642 USA Declaration Approved ra aay a the Signature f Date Name Chuck Maniscalco Title Director of Engineering Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 3642 USA Telephone 408 481 8000 MTSS500 series CE DoC Rev A Machine Operation 94 Operation Section D6T LGP OEM Machine Operation Bac
21. Check the machine when the engine is running and the charging system is in operation WEBM1000 Maintenance Section D6T LGP OEM Lubricant Viscosities and Refill Capacities Lubricant Viscosities Fluids Recommendations General Information for Lubricants When you are operating the machine in temperatures below 20 C 4 F refer to Special Publication SEBU5898 Cold Weather Recommendations for all Caterpillar Machines This publication is available from your Cat dealer For cold weather applications where transmission oil SAE OW 20 is recommended Cat Cold Weather TDTO is recommended Refer to the Lubricant Information section in the latest revision of the Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for a list of Cat engine oils and for detailed information This manual may be found on the Web at Safety Cat com The footnotes are a key part of the tables Read ALL footnotes that pertain to the machine compartment in question Selecting the Viscosity In order to select the proper oil for each machine compartment refer to the Lubricant Viscosity for Ambient Temperature table Use the oil type AND oil viscosity for the specific compartment at the proper ambient temperature The proper oil viscosity grade is determined by the minimum ambient temperature the air in the immediate vicinity of the machine Measure the temperature when the machine is started a
22. D6T LGP OEM Machine Operation up on height adjustment lever 4 and pull up on the seat in order to raise the height of the seat Pull up on height adjustment lever 4 and push down on the seat in order to lower the height of the seat Q Adjustment of the Seat Height 4 Pull Seats with Air Suspension and Toggle Switch Illustration 43 Adjustment of the Seat Height 5 a Remove the weight from the seat Hold toggle switch 5 upwardin order to raise the seat Hold toggle switch 5 downward in order to lower the seat Release the toggle switch at the preferred height 46 Operation Section D6T LGP OEM Machine Operation Seats with Air Suspension and Air Valve Knob Illustration 44 Adjustment of the Seat Height 6 Push in on the air valve knob 6 in order to raise the height of the seat Pull out on the air valve knob 6 in order to lower the height of the seat Weight Adjustment Seats with Mechanical Suspension Illustration 45 Weight Adjustment 7 Rotate knob 7 and observe gauge 8 in order to obtain the proper adjustment for the weight of the operator Seats With Air Suspension The weight adjustment is automatically controlled by adjusting the height of the seat Observe the gauge on the front of the seat suspension if equipped in order to obtain the prop
23. FLOAT position 62 Operation Section D6T LGP OEM Machine Operation Note Hydraulic lockout control 24 is designed to deactivate the control levers Disengage the locking tab on the switch to use the hydraulic lockout control Press the top switch 24 to the lock position in order to deactivate the control levers The action indicator for the attachment control will ensure that the control is locked Deactivate the control levers before you exit the seat or before you service the machine The control levers should always be deactivated when the machine is left unattended Reference You may lower the attachments after you stop the engine Refer to Operation and Maintenance Manual Equipment Lowering with Engine Stopped for more information Tilt Control Illustration 80 Hold 20A When you release the lever A the lever returns to the HOLD position The movement of the bulldozer blade stops in the TILT direction the left in order to lower the left side of the bulldozer blade Faster movement of the lever increases the moving speed of the blade Releasing the lever will return the lever to the HOLD position Tilt Right 20G Push the tilt lever toward the right in order to lower the right side of the bulldozer blade Faster movement of the lever increases the moving speed of the blade Releasing the lever will return the lever to the HOLD position tbs Tilt Left
24. Safety message 7 is located to the of the console on the upper winch guarding L A WARNING The machine may tip and personal injury may occur if the maximum load capacities are exceeded Load capacities assume that the machine is stationary on a level concrete surface with the counterweight extended Lift capacities will decrease on slopes or soft ground See Operation and Maintenance Manual Lifting Capacities 186 Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer Counterweight Crushing Hazard 8 Safety message 8 is located on the front and rear sides of the Counterweight arm A WARNING Crushing Hazard When the counterweight is in the fully extended position for servicing the machine secure the extended counterweight with the counterweight lock lever Use the counterweight lock lever to avoid possible personnel injury or death from crushing Use the lock to secure the counterweight when the machine is serviced Refer to Operation and Maintenance Manual Counterweight Lock Lever for details WEBM1000 Counterweight Crushing Hazard 9 Safety message 9 is located on the front and rear sides of the upper counterweight frame and on the front and rear counterweight swing links Crushing Hazard Be sure no one is under or near the counterweight before lowering the counterweight When the counterweight is in the fully extended position for servicing the machine secur
25. Unscrew and remove transmission breather 1 2 Install the new breather Illustration 244 3 Close the front access door on the right side of the cab 1 Open the front access door on the right side of the cab Transmission Magnetic Screen Clean When you change the transmission oil clean the magnet assembly and the screen Illustration 245 2 The transmission breather is located on the bulk head bracket Unscrew and remove the transmission breather 3 Clean the breather in clean nonflammable Illustration 247 solvent 1 Remove the bottom guard for access to the 4 Install the breather screen group 2 Remove the nuts which hold the cover to the 5 Close the front access door on the right side of housing the cab 3 Remove the screen and the magnet assembly from the housing WEBM1000 4 Wash the screen and the magnet assembly in a clean nonflammable solvent 5 Inspect the seal If the seal is damaged install a new seal 6 Install the screen and the magnet assembly 7 Install the cover on the screen housing 8 Install the bottom guard Transmission Oil Change Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suita
26. and mandates WEBM1000 Illustration 202 1 Cap 2 Housing for the filter element 3 Filter element 4 Cup Remove either the cap or the cup from the housing for the OCV filter Remove the OCV filter The filter may not be used again Dispose of the filter Place a new OCV filter inside the filter housing If the cap was removed replace the cap If the cup was removed replace the cup Tighten hand tight Note Caterpillar will not be held liable for an engine that does not comply with EPA emissions standards due to modification of the OCV filter or due to the use of a filter that is not approved by Caterpillar Fuses and Circuit Breakers Replace Reset Fuses Fuses protect the electrical system from damage that is caused by overloaded electrical circuits Replace a fuse if the element separates If the fuse of a particular electrical system requires frequent replacement check the electrical circuit Repair the electrical circuit if necessary NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result WEBM1000 NOTICE If it is necessary to replace fuses frequently an electrical problem may exist Contact your Cat dealer Illustration 203 On the left side of the machine open access door B to the circuit breakers and the fuses Fuses Illustration 204 Fuses are located behind the fuse block cover 153 Maint
27. debris for foreign material or for damage Clean filler cap 2 with a clean cloth Replace the radiator cap if the cap gasket is damaged 8 Install the filler cap 9 Close radiator access door 1 Cooling System Coolant Level Check At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury This machine radiator has a surge tank There is no top tank in this cooling system The surge tank has one sight glass Removing the filler cap is not necessary to check the coolant level The sight glass for checking the daily coolant level is inside the left engine compartment The filler cap is at the top of the coolant tank that is beneath the radiator access door on the top right side of the radiator guard WEBM1000 Illustration 163 Rear view 1 Observe the sight glass in order to verify the level of the coolant If the coolant completely covers the sight glass the coolant level is okay If the coolant level is visible in the sight glass the coolant is low Add coolant in order to fill the system Note The factory fill is Extended Life Coolant ELC Refe
28. e Minimize repeated handling of loads and lifting of loads f Minimize any shocks and impacts during sports and leisure activities Sources The vibration information and calculation procedure is based on ISO TR 25398 Mechanical Vibration Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines Harmonized data is measured by international institutes organizations and manufacturers This literature provides information about assessing the whole body vibration exposure of operators of earthmoving equipment The method is based on 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 applicable law This document is not meant to substitute the original sources Other parts of these documents are based on information from the United Kingdom Health and Safety Executive WEBM1000 Refer to Operation and Maintenance Manual SEBU8257 The European Union Physical Agents Vibration Directive 2002 44 EC for more information about vibration Consult your local Caterpillar dealer for more information about machine features that minimize vibration levels Consult your local Caterpillar dealer about safe machine operation Use the following web site in order to find your local dealer Caterpillar Inc www cat com Operator Station Any modifications to
29. e Warning symbols or warning signs on machines or on vehicles e A system of communication e Communication between workers and operators prior to approaching the machine Modifications of the machine configuration by the user that result in a restriction of visibility shall be evaluated Restricted Visibility If Equipped The size and the configuration of this machine may result in areas that cannot be seen when the operator is seated Illustration 23 provides an approximate visual indication of areas of significant restricted visibility Illustration 23 indicates restricted visibility areas at ground level inside a radius of 12m 40 ft from the operator on a machine without the use of optional visual aids This illustration does not provide areas of restricted visibility for distances outside a radius of 12 m 40 ft This machine may be equipped with optional visual aids that may provide visibility to some areas with restricted visibility Refer to this Operation and Maintenance Manual Mirror for more information on additional visibility If your machine is equipped with cameras refer to this Operation and Maintenance Manual Camera for more information on additional visibility For areas that are not covered by the optional visual aids the job site organization must be utilized to minimize hazards of this restricted visibility See Operation and Maintenance Manual Visibility Information for more information
30. regarding job site organization WEBM1000 Illustration 23 Top view of the Track Type Tractor machine Note The shaded areas indicate the approximate location of areas with significant restricted visibility Operation Machine Operating Temperature Range The standard machine configuration is intended for use within an ambient temperature range of 40 C 40 F to 50 C 122 F Special configurations for different ambient temperatures may be available Consult your Caterpillar dealer for additional information on special configurations of your machine Machine Operation Only operate the machine while you are in a seat The seat belt must be fastened while you operate the machine Only operate the controls while the engine is running Before you move the machine make sure that no one will be endangered Check for proper operation of all controls and protective devices while you operate the machine slowly in an open area Do not allow riders on the machine unless the machine has the following equipment e additional seat WEBM1000 e additional seat belt e Roll over Protective Structure ROPS Never use the work tool as a work platform Report any needed repairs that were noted during operation Do not go close to the edge of a cliff an excavation or an overhang If the machine begins to sideslip perform the following procedure e Discard the load e Turn the machine downhill Be care
31. 20F Pull the tilt lever toward Horn 21 Horn Push the knob downward in 3 order to sound the horn Use the horn to alert the personnel Use the horn to signal the personnel WEBM1000 Additional Operator Controls Ground Level Service Center 23 22 26 24 25 ae Illustration 81 Secondary Engine Shutdown 22 Engine Stop Move the toggle switch to this position in order to stop the engine from ground level Engine Run With the toggle switch in this position the machine engine continues to operate Access Light 23 Platform Access Lighting Use this toggle switch to operate the access lighting when mounting the machine Note When the switch in the ground level service center is activated the lights remain on for 10 minutes The time limit of the lights is programmable Toggling the switch a second time will deactivate the lights The toggling of the switch will also turn off the lights if the lights were activated from the cab while exiting the machine Delayed Lighting Mode This function is enabled by leaving the lights in the ON position before turning the machine keyswitch to the OFF position The lights will stay on for a configured amount of time to light the machine for safe exit The default is 10 minutes The lights may be turned off using the ground level Access Lighting switch Jacket Water Heater 24 Engine Starting Aid Use this outlet to operate the
32. 29 Equipment Lowering with Engine Stopped 29 Sound Information and Vibration Information 29 Operator Statin ee T e 32 GUA AS melo coutaces comets deehautis att abeaere aeqetheosieebnaness 32 Product Information Section D6T LGP OEM General Information n 34 Identification INforMation eeceeeeeteeeteeeees 36 Operation Section D6T LGP OEM Before Operati irira eaves an ene diet 42 Machine Operation ccccccceccccssesteeeestseeeeeneeees 44 Engine Starting oo cceeceeseeeeeeeeeeetteeeeenees 97 AGJUSIMENTS hapa RES 100 3 Table of Contents Parkinge a a a Sie 101 Transportation INformation cccccccccceccceeeseeeees 104 Towing Information n 106 Engine Starting Alternate Methods 00 111 Maintenance Section D6T LGP OEM Lubricant Viscosities and Refill Capacities 113 Maintenance Support eee 121 Maintenance Interval Schedule ccc 123 Warranty Section D6T LGP OEM Warranty Information c cccccccccccccecececeeeseeeeeeenes 177 Reference Information Section D6T LGP OEM Reference Materials 178 Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer issen 180 Before Operation oo ccccesteeceesetseeeeensaees 187 Visibility INfOrmation n 187 DORON tastes cee teeter aa Ana E a ENEAN 189 Parkin enana e aden ere eddg eee 190 Slope Operation wwe waiters aes HA ee 190 Equipment Lowering with Engine Stopped 194 Sound Info
33. 30 minutes of operation Brakes Indicators and Gauges Test Inspect the dash panel for broken lenses indicator lights and switches Functional Test of the Monitoring System Display To ensure proper operation of Monitoring System Display 1 check the system on a daily basis Illustration 154 The battery disconnect switch must be ON in order to supply electrical power to the machine so that the electrical systems will function ON The engine start switch key 2 ap must be turned to the ON position This action will supply electrical power to the operator compartment so that the CMS will function 127 Maintenance Section D6T LGP OEM Brakes Indicators and Gauges Test Turn the engine start key to the ON position The system should act in the following manner e The indicator lights on the monitoring system display come on briefly e The action light comes on briefly e The action alarm sounds briefly e The pointers on the gauges point upward Then the pointers point to the left Then the pointers point to the right Then the pointers point to the final position If the system functions properly start the engine If any of the following events occur do not start the engine e The indicator lights on the monitoring system display do not come on e The action light does not come on e The action alarm does not sound Complete any necessary repairs before you start the engine Brak
34. 69 The European Union Physical Agents Vibration Directive 2002 44 EC ooo eee 30 192 Throttle Control Switch oo eects 60 Throttle control switch amp Operator Heater SWICI e o cece carted fair ang endive A S 203 THE COMPO aem n a O A 62 Tipover Hazard 00 0 cee eeeceeeeeeeeeeeeeeenees 185 Tool Storage Area eee 43 Torque Converter Scavenge Screen Clean 166 Totals Display Menu o an 82 Towing Information seeren 106 Towing the Machine eree 106 Track Check AdjUSt e 167 Track Information 0 0 0 0 eerren 24 Track Pins Inspect ieee 168 Track Roller Frame Guides Inspect 168 TACKS e hess er ve E cudetedieeiiouet an toni a wok 100 Tractor Operation 199 Transmission and Axles e 115 Transmission Breather Clean Replace 170 Transmission Control sesasi 52 Transmission Magnetic Screen Clean 170 Transmission Oil Change cn 171 Transmission Oil Filter Replace 08 172 Transmission Oil Level Check n 173 Transmission Scavenge Screen Clean 173 Transmission System Oil Sample Obtain 174 Transportation Information cccee 104 206 Trapped Pressure neee 18 U Use of Jump Start Cables 0 eee 114 Vv Vibration Data for Track Type Tractors 30 Visibility Information n 25 187 Ww Warning Categories 69 Warranty Information o 177 Warranty Section D
35. Cat DEO ULS and oils meeting Cat ECF 3 specification and the API Cu 4 and ACEA E9 oil categories have been developed with limited sulfated ash phosphorus and sulfur These chemical limits are designed to maintain the expected aftertreatment devices life performance and service interval If oils meeting the Cat ECF 3 specification and the API CJ 4 specifications are not available oils meeting ACEA E9 may be used ACEA E9 oils meet the chemical limits designed to maintain aftertreatment device life ACEA E9 oils are validated using some but not all ECF 3 and API CJ 4 standard engine performance tests Consult your oil supplier when considering use of an oil that is not Cat ECF 3 or API CJ 4 qualified Failure to meet the listed requirements will damage aftertreatment equipped engines and can negatively impact the performance of the aftertreatment devices The Diesel Particulate Filter DPF will plug sooner and require more frequent DPF ash service intervals Typical aftertreatment systems include the following e Diesel Particulate Filters DPF e Diesel Oxidation Catalysts DOC e Selective Catalytic Reduction SCR e Lean NOx Traps LNT Other systems may apply 114 Maintenance Section D6T LGP OEM WEBM1000 Lubricant Viscosities and Refill Capacities Table 17 Lubricant Viscosities for Ambient Temperatures C oF Oil Type and Performance avi s Compartment or System
36. Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Before you replace the secondary fuel filter elements replace the primary fuel filter element WEBM1000 Illustration 194 Rear view 1 Turn the handle of the fuel shutoff valve clockwise in order to shut off the fuel supply The fuel shutoff valve is located at the rear of the machine under the fuel tank 2 Open the engine access door on the left side of the machine The secondary fuel filters are mounted on the left side of the engine next to the primary fuel filter Illustration 195 Left view 3 Remove the secondary fuel filter Drain the fuel into a suitable container Note Discard any drained fluids according to local regulations Discard the fuel filter properly 4 Clean the filter base Make sure that all of the old seal is removed 5 Coat the seal of the new high efficiency fuel filters with clean diesel fuel 6 Install the new fuel filters by hand 149 Maintenance Section D6T LGP OEM Fuel System Water Separator Element Replace Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation in
37. Kit Certain conditions and precautions are peculiar to pipelaying operations The following represents the minimum considerations for safe operations Illustration 262 Safety Messages 72H Pipelayer WEBM1000 Safety Messages 72H Pipelayer NOTICE Other safety precautions related to the operation of the tractor also apply Refer to CATERPILLAR Tractor Operation and Maintenance manual Safety Section 181 Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer WEBM1000 Sep eS DN 3 Paes of Q SS a S Lr i ayy AA A Vt q hj e A A S la A TY D A 09 9 lr gt ALENA fie i ia E fl f ed ah So KD eons ARLS i S g Wr wy yA W e y Ry pP a Re X yi ANS 7 zr yr wr oe x RA fa 7 y 5 CAS 2 zA i VED J machine The exact location of the hazards and the There are several specific safety messages on this description of the hazards are reviewed in this section Please become familiarized with all safety Safety Messages 72H Pipelayer messages Illustration 263 182 Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer 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 visible When you cl
38. Ns DIRECT VISIBILITY EZZZZ2 INDIRECT VISIBILITY os NO VISIBILITY Illustration 264 Operator Field of View as per ISO 5006 2006 The operator is required to survey his her field of vision when operating the machine The operator shall take notice of the areas of no visibility located at the front and front left of the machine see figure Both the right hand overhead mirror and the right hand side view mirror shall be adjusted so that a person walking 1m to the right of the machine for the length L can be seen in a length of at least 200mm either directly or indirectly at every position see figure The left hand side view mirrors shall be adjusted so the operator is comfortable with his her vision to the rear of the machine Examples of job site organization include the following e Safety instructions e Controlled patterns of machine movement e Controlled patterns of vehicle movement e Restricted areas WEBM1000 e Operator training e Warning symbols or warning signs on machines or on vehicles e A system of communication e Communication between workers and operators prior to approaching the machine Operation Machine Operating Temperature Range The standard pipelayer component configuration is intended for use within an ambient temperature range of 40 C 40 F to 50 C 122 F Special configurations for different ambient temperatures may be available Consult your dealer for additional
39. OEM Machine Operation 4 Once the key off regeneration is complete the machine will initiate the delayed engine shutdown 5 The delayed engine shutdown will last for 5 minutes 6 After the delayed engine shutdown has been completed the engine will shut down Delayed Engine Shutdown The Delayed Engine Shutdown allows the engine to run for a time after the engine start switch is turned to the OFF position to cool the engine and the machine system components The engine start switch key may be removed Note There may be regulations that define the requirements for the operator and or support personnel to be present when the engine is running Leaving the machine unattended when the engine is running may result in personal injury or death Before leaving the machine operator station neutralize the transmission apply the parking brake lower work tools to the ground and deactivate all work tools Refer to Operation and Maintenance Manual Parking for more information Note Leaving the machine unattended when the engine is running may result in property damage in the event of a malfunction Turn the engine start switch to the OFF position Delayed Engine Shutdown The D delayed engine shutdown indicator will L illuminate or the following text will be displayed ENGINE COOLDOWN ACTIVE Delayed engine shutdown will run for a minimum of 30 seconds and will continue to run until the engine and machine sys
40. Oil Viscosities Requirements Min Max Min Max Cat DEO ULS Cold Weather SAE OW 40 40 40 40 104 Cat DEO ULS SYN SAE 5W 40 30 50 22 122 Engine Crankcase Cat DEO ULS SAE 10W 30 18 40 0 104 Cat DEO ULS SAE 15W 40 9 5 50 15 122 Hydraulic Systems e Cat DEO ULS Cold Weather Refer to the Lubricant Information section in the latest revision of the Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for detailed information This manual may be found on the Web at Safety Cat com The following are the preferred oils for use in most Cat machine hydraulic systems e Cat HYDO Advanced 10 SAE 10W e Cat HYDO Advanced 30 SAE 30W e Cat BIO HYDO Advanced Cat HYDO Advanced fluids have a 50 increase in the standard oil drain interval for machine hydraulic systems 3000 hours versus 2000 hours over second and third choice oils when you 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 for details When switching to Cat HYDO Advanced fluids cross contamination with the previous oil should be kept to less than 10 Second choice oils are listed below e Cat MTO e Cat DEO e Cat DEO ULS e Cat TDTO e Cat TDTO Cold Weather e Cat TDTO TMS e Cat DEO ULS SYN e Cat DEO SYN
41. Replace 158 Hydraulic System Oil Level Check 05 160 Hydraulic System Oil Sample Obtain 160 Hydraulic Systems i 114 Hydraulic Tank aerer 158 l Identification Information ie 36 IGAG nta he e A e a 98 Idling the Engine for Extended Periods 102 Implement Settings 0 0 0 0 cc ceceeee n 78 Improper Connections for Jump Start Cables 10 Improper Maintenance Procedures 005 122 Inhalation 20 ceesyecsbhecs eee eee es 19 Installing the Spark Plug n 125 Intended USE oo cceccccetteeeesetteeeeeeeennees 195 ISO SYMbOINS occ cece i E N A 38 J Joystick Control arare ent ccc cece AE TAN 61 K Key Off Regeneration o n 65 L Leaving the Machine e 102 Lengthening the Seat Belt 00 0 eee 48 Lift Conto f cist eicactcnette navahicweaace Mandhavamdeemaratnansenseys 61 Lift Cylinder Yoke Bearings Lubricate 161 Lifting and Tying Down the Machine 104 Lifting Capacities eee 27 189 195 Light Switches 00 ccc eee eteetteeeeeeteetnes 53 Limitations on Lifting Loads That Exceed the Working RANGE esse Meese gta tases Sau eee ee 27 189 Limp Home Mode Implement o n 81 Lines Tubes and HOSES o e 23 Listing of Abbreviations and Terms 00 83 Literature Information ereere 4 Loose Track Adjustment acc 167 Low Idling Speed ioeie 99 Lubricant Viscosities Fluids Recommendations
42. Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer Hydraulic Accumulator 3 Safety message 3 is attached to the hydraulic accumulator The hydraulic accumulator is located behind the access cover to the right side of the operator seat HIGH PRESSURE GAS HARGING MEDIUM A WARNING High Pressure Cylinder Rapid discharging from disconnecting or disassembly or failure to follow the instructions and warnings could cause an explosion resulting in possible injury or death Do not expose to fire Do not weld Do not drill Do not remove any hydraulic system lines taps or parts until pressure has been relieved Relieve pressure before discharging See Operation and Maintenance Manual Accumulator for charging and discharging See your Dealer for tools and detailed information Precharge only with dry nitrogen gas 184 Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer Hydraulic Accumulator 4 Safety message 4 is located on the lower right side of the console below the pipelayer controls a7 High Pressure Cylinder Rapid discharging from disconnecting or disassembly or failure to follow the instructions and warnings could cause an explosion resulting in possible injury or death Do not expose to fire Do not weld Do not drill Do not remove any hydraulic system lines taps or parts until pressure has been relieved Relieve pressure before discharging See Operation a
43. all the relevant provisions of hte following Directives Directives Notified Body Document No 2006 42 EC 2000 14 EC amended by 2005 88 EC Note 1 2004 108 EC Note 1 Annex Guaranteed Sound Power Level dB A Representative Equipment Type Sound Power Level dB A Engine Power per kW Rated engine speed rom Technical Documentation accessible through person listed above authorized to compile the Technical File Done at Signature Date Name Position Note The above information was correct as of August 2011 but may be subject to change please refer to the individual declaration of conformity issued with the machine for exact details WEBM1000 Emissions Certification Film Note This information is pertinent in the United States in Canada and in Europe Consult your Cat dealer for an Emission Control Warranty Statement This label is located on the engine 41 Product Information Section D6T LGP OEM Identification Information 42 Operation Section D6T LGP OEM Before Operation Operation Section D6T LGP OEM Before Operation Mounting and Dismounting Illustration 34 Typical example Mount the machine and dismount the machine only at locations that have steps and or handholds Before you mount the machine clean the steps and the handholds Inspect the steps and handholds Make all necessary repairs Face the machine wheneve
44. and maintenance manual for additional requirements and information Removal of the Boom 035 05 05 020B Illustration 278 Removal of the boom 1 Lower the boom enough to remove the load blocks and the sheave block WEBM1000 Illustration 279 Removal of boom steps 1 2 2 Remove cotter pin the retainer and pin 1 Lower the load block and the hook block to the ground The approximate weight of the load block is 88 kg 194 Ib The approximate weight of the hook block is 100 kg 220 Ib The combined weight of the load block and the hook block is approximately 188 kg 414 Ib 3 Replace the pin 1 in the boom Fasten the load block and the hook block to the machine for shipping as illustrated below Draw in the excess hook load line 207 Operation Section Pipelayer Attachment Kit Before Operation aA pra Da O35 20 S0 007 4 208 Operation Section Pipelayer Attachment Kit Before Operation 035 30 71 0044 Illustration 280 Fastening of Load Blocks for Transport 4 10 11 Remove pin 6 and insert stowing link 4 into bumper pocket 7 and reinstall pin 6 Place hook load line over guide 5 Slowly draw in the excess hook load line when the load block and hook block are suspended by the load line swing in the load block and hook block and lock into stowing link 4 and tighten up the load line being careful not to kink or damage load cable To remove load
45. capacity See Operation and Maintenance Manual Lifting Capacities for the load capacity of the boom 190 Safety Section Pipelayer Attachment Kit Parking When the load capacity is exceeded refer to American National Standards A N S I B3014 Also follow the procedures that are listed below e Inspect the wire cable for defects prior to the lift operation e Inspect the wire cable for defects after the lift operation e Do not exceed the load capacity of the boom e The load must be handled safely in order to minimize tipping effects e The lift operation and the inspections must be made under controlled conditions by an authorized person Electrical Power Lines Serious injury or death by electrocution can result if the machine or attachments are not kept the proper distance from electrical power lines Use the following charts in order to determine the safe distance from high voltage wires during these conditions e machine operation e machine transportation Table 28 When Operating Near High Voltage Power Lines Normal Voltage Phase to Phase Minimum Clearance Required 0 Volts to 50 kVolts 3 05 Meters 10 Feet Over 50 kVolts to 200 kVolts 4 60 Meters 15 Feet Over 200 kVolts to 350 kVolts 6 10 Meters 20 Feet Over 350 kVolts to 500 kVolts 7 62 Meters 25 Feet Over 500 kVolts to 750 kVolts 10 67 Meters 35 Feet Over 750 kVolts to 1000 kVolts 13 72 Meter
46. engine coolant heater if equipped WEBM1000 Battery Disconnect Switch 25 NOTICE Never move the battery disconnect switch to the OFF position while the engine is operating Serious damage to the electrical system could result On Insert the key and turn the key D clockwise in order to activate the electrical system The switch must be ON before you start the engine order to shut off the entire electrical O Off Turn the key counterclockwise in system See Battery Disconnect Switch in this manual for more information Service Hour Meter 26 Elapsed Operating Hours Use the service hour meter to determine the service hour maintenance intervals if equipped Diesel Particulate Filter Regeneration Regeneration Regeneration is the removal of soot from the Diesel Particulate Filter DPF The Caterpillar Regeneration System CRS is used to regenerate the DPF The DPF traps both soot and ash The ash is removed through a cleaning process Refer to Operation and Maintenance Manual Diesel Particulate Filter Clean for more information on the service of the DPF Regeneration Indicators Regeneration Active This indicator will illuminate in order to show that the CRS is active This indicator shows that elevated emission temperatures are possible This indicator will turn off when regeneration is complete DPF This indicator will illuminate in order to show that a regeneration
47. extended idling conditions to signal that a low speed regeneration is in progress A regeneration done in cold ambient extended idling conditions may activate below 30 soot level A regeneration done in cold ambient extended idling conditions will typically last for 5 10 minutes After the engine has been started allow the monitoring system to complete the self test 1 Allow a cold engine to warm up at LOW IDLE for at least 5 minutes To help the hydraulic components to warm up faster engage the attachment controls and disengage the attachment controls 2 You can begin to operate the machine with a reduced load 3 When the engine coolant temperature reaches the normal operating range and no faults are present you may operate the machine at full load 4 Look at the indicators and the gauges frequently during operation Refer to Operation and Maintenance Manual Monitoring System 5 Check oil levels in the power train the engine and the hydraulic systems when the oil is at operating temperature Maintain the oil levels to the FULL marks The hydraulic oil will warm up faster if the dozer blade control is held in the CLOSED position Hold the dozer in the CLOSED position for short periods of 10 seconds or less This action will allow the hydraulic oil to reach relief pressure which causes the hydraulic oil to warm up more rapidly Cycle all controls in order to allow warm hydraulic oil to circulate through all
48. for all maintenance procedures Maintenance Intervals Use the service hour meter to determine servicing intervals Calendar intervals shown daily weekly monthly etc can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading Recommended service should always be performed at the interval that occurs first Under extremely severe dusty or wet operating conditions more frequent lubrication than is specified in the maintenance intervals chart might be necessary Perform service on items at multiples of the original requirement For example at every 500 service hours or 3 months also service those items listed under every 250 service hours or monthly and every 10 service hours or daily California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling Certified Engine Maintenance Proper maintenance and repair is essential to keep the engine and machine systems operating correctly As the heavy duty off road diesel engine owner you are responsible for the performance of the required maintenance listed in the Owner Manual Operation and Maintenance Manual and Service Manual It is prohibited fo
49. if the machine does not have a diagnostic connector Reference Also refer to Systems Operation SENR2947 Starting and Charging Systems for Machines Equipped with Diagnostic Connector 2 Place the transmission control on the stalled machine in the NEUTRAL position Engage the parking brake switch Lower all attachments to the ground Move all controls to the HOLD position 3 Ona stalled machine turn the start switch key to the OFF position Turn off the accessories 4 Onastalled machine turn on the battery disconnect switch 5 Move the machines together in order for the cables to reach DO NOT ALLOW THE MACHINES TO CONTACT EACH OTHER 6 Stop the engine on the machine that is the electrical source When you use an auxiliary power source turn off the charging system 112 Operation Section D6T LGP OEM Engine Starting Alternate Methods 7 Check the battery caps for correct placement and for correct tightness Make these checks on both machines Make sure that the batteries in the stalled machine are not frozen Check the batteries for low electrolyte Tt eg ee eee t e n i Illustration 149 Top view 1 Negative cable terminal 2 Negative cable 3 Battery disconnect switch 4 Positive cable 5 Positive cable terminal NOTICE Do not allow positive cable clamps to contact any metal except for battery terminals Note Some positive cables and some covers for positive terminals a
50. in Seat Sensor oo ccc eens 68 Operator Preferences en 75 Operator Profile 74 Operator Seat ren 68 Operator Station eeeeeetteeeeteeeees 32 Other Guards ioeie inan teanta an Apai ENEA inie 33 P Parking enean a EE 28 101 190 Password Entry Screen ccce 77 Performance Screens 0 0 0 cece eeeeeetsteeeeeee 71 Pipelayer Operation ccccecccceeeeceeeeeeeee 200 Pivot Shaft Oil Level Check 0 0 0 0 162 Plate Locations and Film Locations 0 00 36 Power Train Settings cccceeceeeeeseeeeeee 77 Pressurized Air and Water 1 18 Primary Filter eee iisa E a E A 136 Procedure for Changing the Engine Oil and E ERA AEA TOA 140 Product Information Section D6T LGP OEM 34 Product Information Section Pipelayer Attachment ID Eann tat mate tts A cyanea 193 Product Link 0 00 ha O EE iU 14 86 R Radiator Core Clean 162 Radiator Pressure Cap Clean Replace 162 Recoil Spring Compartment Oil Level Check 163 Reference Information Section D6T LGP OEM aea e tes e a aa acute tee 178 Reference Materials 0 000 178 Refrigerant Dryer Replace ee 164 Regeneration ccceceecceceeeeeeeeeeeeeeneenaes 21 63 Regeneration Indicators 0ceeceeeeeeeees 59 63 Regeneration Switch 0 0 0 0 cccceeeeeeeetees 59 63 Regeneration System Warning Indicators 64 Regulatory Compliance 0 00 e 88 Releasing The Seat Be
51. information Refer to the specific tractor Operation and Maintenance manual for standard tractor capabilities Machine Operation Only operate the machine while you are in a seat The seat belt must be fastened while you operate the machine Only operate the controls while the engine is running Before you move the machine make sure that no one will be endangered Check for proper operation of all controls and protective devices while you operate the machine slowly in an open area Do not allow riders on the machine unless the machine has the following equipment e additional seat e additional seat belt Report any needed repairs that were noted during operation Do not go close to the edge of a cliff an excavation or an overhang If the machine begins to sideslip turn the machine downhill Be careful to avoid any condition which could cause the machine to tip The machine can tip when you work on hills banks and slopes Also the machine can tip when you cross ditches ridges or other obstacles 189 Safety Section Pipelayer Attachment Kit Operation Whenever possible operate the machine up the slopes and down the slopes Avoid operating the machine across the slope when possible Keep the machine under control Do not overload the machine beyond capacity Be sure that the towing eyes and towing devices are adequate Towing eyes and towing devices should only be used to recover the machine Connect
52. is needed This indicator will illuminate when the soot level reaches 90 Regeneration Disabled This indicator will illuminate in order to show that a regeneration has been disabled 63 Operation Section D6T LGP OEM Machine Operation Regeneration Switch Force Regeneration Press in the top of the switch for 2 seconds in order to begin regeneration Disable Regeneration Press in the bottom of the switch for 2 seconds in order to disable regeneration Note The MIDDLE position of the regeneration switch is the default position for automatic regeneration Note You may return to normal operation at any point during a regeneration Note To re enable automatic regeneration cycle the engine start switch key or press and hold down the force regeneration switch for 2 seconds If the soot level is above 15 regeneration will begin if the machine is at low idle and is parked Note If the engine start switch key is cycled while the regeneration system is disabled through the disable regeneration switch press and hold the disable regeneration switch for 2 seconds to reinitiate the disable regeneration Soot Level Monitoring Illustration 82 The soot level monitor indicates the level of soot that has accumulated within the DPF The five marks on the monitor represent a percentage of soot within the DPF The first mark indicates 0 soot level The second mark indicates 25 soot level The middle mark indic
53. is located at the rear of the machine under the fuel tank Turn the red handle of the fuel shutoff valve in order to shut off the fuel supply 2 Open the left engine access door Illustration 197 3 In order to drain primary filter 1 open drain valve 3 on water separator bowl 2 The water separator bowl is under primary filter 1 Catch the fuel in a suitable container Note Discard any drained fluids according to local regulations 4 Remove primary filter 1 and water separator bowl 2 5 Remove water separator bowl 2 from the primary filter element 1 6 Wash water separator bowl 2 in a clean nonflammable solvent Use pressure air to dry water separator bowl 2 7 Install the clean water separator bowl onto a new primary filter element WEBM1000 8 Wash the filter mounting base in clean nonflammable solvent Make sure that all of the old seal is removed 9 Coat the seal of the new filter element with clean diesel fuel 10 Install the new filter element by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 11 Open the fuel shutoff valve 12 Prime the fuel system if the machine is equipped with a priming pump Refer to the Operation and Maintenance Manual Fuel System Prime for the proper proce
54. is pushed away from HOLD the faster the hook will lower The closer the lever is toward HOLD the slower the hook will lower When the lever is released it will return to the HOLD position the winch brake will set and the hook will stop and remain at the position it is in Hook winch line speed varies with engine throttle setting Hook control is smoothest at engine speeds faster than idle by RAISE Move the lever to this position to raise the hook The further the lever is pulled away from HOLD the faster the hook will raise The closer the lever is toward HOLD the slower the hook will raise When the lever is released it will return to the HOLD position and the hook will stop and remain at the position it is in Hook winch line speed varies with engine throttle setting Hook control is smoothest at engine speeds faster than idle Note The hydraulic pilot system and some machine controls namely the hook quick drop are LIVE for as long as the accumulator holds a charge even if the engine is not running This pressure charge will take approximately four hours or more to bleed off Refer to the operation and maintenance manual Free Fall Active for dropping load hazard warning Refer to the operation and maintenance manual Accumulator Relieving Charge to bleed off the residual pressure if required and when safe to do so 202 Operation Section Pipelayer Attachment Kit Before Operation Accumulator Relievi
55. load and or under high temperature conditions sample all fluids at the 250 hour interval 1 Open the access cover on the right side of the cab that is in front of the hydraulic tank Illustration 220 The hydraulic oil sampling valve is shown 2 Remove the protective cap 3 Use 81 9190 Fluid Sampling Bottle 1 to obtain the sample 4 After you take a sample remove the cap with the probe from the bottle Discard the cap with the probe Install the sealing cap that is provided with 8T 9190 Fluid Sampling Bottle 1 5 Replace the protective cap 6 Close the access cover Reference Refer to Lubricant Viscosities in the Maintenance Section of this manual for the correct fluid for your machine 161 Maintenance Section D6T LGP OEM Lift Cylinder Yoke Bearings Lubricate Lift Cylinder Yoke Bearings Lubricate If Equipped Illustration 221 The grease fittings are on the left side of the radiator guard and on the right side of the radiator guard Lubricate the bearings by applying grease to the fittings Use MPGM grease Oil Filter Inspect Inspect a Used Filter for Debris Illustration 222 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indic
56. may be caused by internal corrosion external corrosion or wear of the outside wires Inspect the cable for broken outside wires Check for the degree of distribution of the broken outside wires Check for the concentration of outside broken wires Inspect the cable for worn outside wires Inspect the cable for corroded wires and for broken wires at the connection on the wire cable end Inspect the cable end for connections that are corroded cracked bent worn or improperly installed e Inspect the cable for sections that are crushed or kinked and for any loose wire strands Excessive wear or broken wires may occur in sections of the cable that are in contact with saddles equalizer sheaves or other sheaves Excessive wear or broken wires can also occur when cable travel is limited Take care to inspect the ropes at these locations When a machine is shutdown for a month or more inspect all of the cables thoroughly When a side boom machine has been in storage for a month or more inspect all of the cables thoroughly The inspection should be completed before the machine is returned to operation The inspection should be for all types of deterioration The inspection should be performed by a designated person or by an authorized person The authorized person s approval is required for further use of the cable A dated report on the condition of the cable should be kept on file Take care in the inspection of cable t
57. mode the hook and boom winch controls do not function Always place the speed lockout control lever in the LOCKED MODE and engage the speed lockout control lock whenever the machine is left unattended or when inadvertent control operation could result in a dangerous situation arising WEBM1000 2 LOW SPEED MODE WINCH CONTROLS UNLOCKED Pull the speed lockout control lever back for the hook winch low speed range maximum hook winch pull is available the boom winch speed unaffected Speed Lockout Control Lock 2 Use the speed lockout control lock lever 2 to lock the speed lockout control lever 1 in the LOCKED MODE position Move the boom control lever to HOLD position Move the hook control lever to HOLD position Move the speed lockout control lever to the centre position Flip the speed lockout control lever over the control lever in order to lock the lever in the LOCKED MODE position This locks the boom controls and the hook controls in HOLD in order to prevent accidental boom movement or hook movement Flip speed lockout control lock away from the speed lockout control lever in order to allow actuation of the speed lockout control lever Move the speed lockout control lever to the desired speed range in order to operate the winches Always move the speed lockout control lever to the LOCKED position before shutting off the engine or immediately after the engine quits running to prevent unintentional load relea
58. must be performed before removing a DPF that will be cleaned All three scenarios listed above require a reset of the ash monitoring system in the engine ECM Engine Air Filter Primary and or Secondary Element Clean Replace Primary Filter NOTICE Service the primary filter element only when the alert indicator for the intake air filter is flashing Do not open the filter compartment unless it is time for service Opening the filter compartment can cause dirt to get into the clean side of the filter housing NOTICE Extremely short air filter life can result if the precleaner system malfunctions If air filter life is drastically reduced from typical for the operating conditions consult your Caterpillar Dealer The exhaust system dust ejector for the strata tube precleaner must pull a minimum vacuum of 508 mm 20 inch of water NOTICE Service the engine air filters with the engine stopped Engine damage could result NOTICE Do not use the filter for longer than one year Illustration 168 WEBM1000 1 Open the engine access door on the left side of the machine Illustration 169 2 Remove air cleaner housing cover 1 Pull out in order to remove the element 3 Remove primary filter element 2 from air cleaner housing 4 4 Mark secondary filter element 3 in order to show that the primary filter element has been serviced The secondary filter element should be replaced when the pr
59. of Automotive Engineers SAE Specifications can be found in your SAE handbook This publication can also be obtained from the following locations local technological society local library and local college If necessary consult SAE at the following address SAE International 400 Commonwealth Drive Warrendale PA USA 15096 0001 Telephone 724 776 4841 The International Organization for Standardization ISO offers information and customer service regarding international standards and standardizing activities ISO can also supply information on the following subjects that are not controlled by ISO national standards regional standards regulations certification and related activities Consult the member of ISO in your country International Organization for Standardization ISO 1 rue de Varemb Case postale 56 CH 1211 Gen ve 20 Switzerland Telephone 41 22 749 01 11 Facsimile 41 22 733 34 30 E mail central iso ch web site http www iso ch 179 Reference Information Section D6T LGP OEM Reference Materials Decommissioning and Disposal When the product is removed from service local regulations for the product decommissioning will vary Disposal of the product will vary with local regulations Consult the nearest Cat dealer for additional information 180 Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer Safety Section Pipelayer Attachment
60. on the monitoring system display again This interval is dependent upon the severity of the warning level Consult the appropriate warning category for the proper instruction After all screens with warning messages are acknowledged the first performance monitor screen will appear This screen is the default screen Machine Start up Upon starting the machine key ON the Monitoring System will perform a self test The first preliminary screen asks the operator to select a name from the saved profiles Press the OK button in a timely manner in order to use the active set of customer preferences If no setting is accepted as OK or if Default is selected then the ECM default settings will remain Main Menu As many as five items are available for setup WEBM1000 MAIN MENU SELECTION Bi dir Auto Shift Power Train Implement Engine Display Machine Diagnostics Ee mmp mp service Jmm Eem Summary Impl Limp Home Engine Primary Imple Machine Status ments Rear Imple Machine status ments Power Train Steering Brake Select Operator mmp Edit reate Delete Illustration 98 Menu for the Operator Profile Access the Operator Profile menu by pressing the button for the operator menu Also you may navigate to the Operator Profile menu by pressing the following buttons Menu button Operator Operator Profile 25 balm n Ga 2F Operator lt a Service man Machine Status
61. order to extend the life of the undercarriage Use the recommendations in order to avoid excessive downtime 1 During the machine operation listen for unusual squeaking and for unusual squealing This noise can indicate a dry joint 2 Check the machine for dry joints weekly Check for dry joints immediately after machine operation After machine operation lightly touch the end of each track pin or bushing Touch the track pin or the track bushing with the back of your hand Make a mark on any dry track pin joint that is hot to the touch Consult the Custom Track Service expert at any Cat dealer if you detect dry joints or leaks The Custom Track Service expert at the Cat dealer can perform track inspection Track Roller Frame Guides Inspect Measure the rotational movement of the front roller frame relative to the rear roller frame Illustration 239 Some components are removed for clarity WEBM1000 1 Raise the front of the machine with the hydraulics of the dozer Place a 100 mm 4 inch block under the outside edge of a track grouser Place the block near the track idler Lower the machine onto the block a tek ee gt Illustration 240 2 Use a grease pencil to make a mark on the tubular section of the front roller frame Make a mark on the rear of the roller frame This mark should correspond with the mark that is on the tubular
62. password any leading zero s can be ignored For example if the password is 123 then the password would be entered into the 5 digit entry screen as 1 2 3 with the remaining 2 right most spaces left blank Pressing the OK key submits the entered password Contact your Cat dealer if you do not know what the password is for your machine or you would like the password changed Power Train Settings Auto Kickdown If a significant increase in machine load is detected this function automatically downshifts the transmission This function works in forward and reverse gears Maximum Forward Gear This selection sets the maximum gear that the machine travels in the forward direction Maximum Reverse Gear This selection sets the maximum gear that the machine travels in the reverse direction Eco Reverse Mode Select this mode in order to activate the Eco Reverse mode during reverse travel in third gear 78 Operation Section D6T LGP OEM Machine Operation Note Bidirectional shift can be used to shift to Eco Reverse 3rd reverse automatically Implement Settings All the parameters in this category relate to the operator preferences for the work tool operational modes The following parameters may be adjusted Blade Float Enabled disabled Blade Installation Status Not installed Single tilt Power Angle Tilt Blade Rear Attachment Installation Status if equipped Not installed Single ax
63. pedal changes according to the setting of the throttle switch At partial throttle settings the modulation of the pedal is increased This increase in modulation allows more precise control of the engine speed Light Switches 8 9 Front Work Lights 8 This switch is a three position switch The positions are OFF front work lights and the front work lights with ROPS lights Rear Work Lights 9 Move the switch to this position in order to turn on the rear work lights 53 Operation Section D6T LGP OEM Machine Operation Gauges and Indicators 10 Monitoring System Display D A E sw p ae F B a G Cc H J Illustration 63 Main menu display Speed and direction Main menu Display menu Left Up and Right Down button OK button Back to the previous screen Return to operator menu Return to main menu Backlight adjustment TODMOOODS SLLLN jc The monitoring system display is located in gauge and instrument module 11 of the front console The monitoring system display communicates with the machine electronic control modules sensors and the instrument module The monitoring system display provides various machine information to the operator and the service technician Items A B and C on the screen display system data at all times Some functions of the monitoring system display are password protected Refer to Operation and Maintenance Manual Monitoring System
64. performed e Total Fuel Used e Total Idle Fuel e Total Engine Hours e Total Distance e Total Forward distance e Total Reverse distance e Total Idle Hours e Total Time in Neutral e Power Train Oil Bypass The Cat ET service tool may be used to access the data 2F Operator a Service Main Machine Status Menu otals a Illustration 118 Use the appropriate arrow button and highlight the Totals display menu from the Main Menu Then press the OK button WEBM1000 Illustration 119 O 2F Totals Tot Fuel Used 636870907 L f p Tot idie Fuel 536870907 L Tot Eng Hrs yoo x Hr Illustration 120 Electrical Connector Location Illustration 121 Location of electrical connectors for the D6T Track Type Tractor tier iv equipped with a cab A Two connectors are 12 V power outlets These power outlets are located behind the operator seat on the right side of the compartment 83 Operation Section D6T LGP OEM Machine Operation Data link connector B is located near the power outlets as shown This data link connector is for use with the Caterpillar Electronic Technician ET Also this connector is used for the flash programming of software Illustration 122 Location of data link on OROPS machine if equipped Refer to Service Manual SENR8367 Electrical Component And Connector Locations for addition
65. person with the following abilities observation of working and environmental conditions feel for the machine identification of potential hazards and operating the machine safely by making appropriate decisions When you work on side hills and when you work on slopes consider the following important points WEBM1000 Speed of travel At higher speeds forces of inertia tend to make the machine less stable Roughness of terrain or surface The machine may be less stable with uneven terrain Direction of travel Avoid operating the machine across the slope When possible operate the machine up the slopes and operate the machine down the slopes Place the heaviest end of the machine uphill when you are working on an incline Mounted equipment Balance of the machine may be impeded by the following components equipment that is mounted on the machine machine configuration weights and counterweights Nature of surface Ground that has been newly 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 machine s stability Rocky surfaces may promote side slipping of the machine Slippage due to excessive loads This may cause 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 tire
66. recommendations Diesel Fuel Requirements 6 One of the following messages is located next to the fuel filler cap ULTRA LOW SULFUR FUEL ONLY oo S lt 15 mg kg Illustration 10 Illustration 11 Use only Ultralow Sulfur Diesel ULSD fuel Note In Europe diesel fuels that are identified as meeting European Standard EN590 2004 requirements for lt 10 ppm sulfur fuel typically referred to as sulfur free generally meet Cat requirements for ULSD fuel Refer to Operation and Maintenance Manual Lubricant Viscosities for more information FCC Compliance 7 This message is located on the product link module on the back right ROPS of the cab WEBM1000 Orbcomm Type Approval 146KME CAT C 08880 e IC 216701105A R AYAA0011 J98 0601 0 Illustration 12 Consult your Cat dealer with any questions that concern the operation of the Product Link in a specific country No Weld No Drill 8 This message is located on the left hand ROPS post Illustration 13 General Hazard Information Illustration 14 17 Safety Section D6T LGP OEM General Hazard Information Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls Attach the warning tag before you service the equipment or before you repair the equipment These warning tags Special Instruction SEHS7332 are available from your Cat dealer a Operati
67. secures the message Loose adhesive will allow the message to fall Replace any message that is damaged or missing If amessage is attached to a part that is replaced install a message on the replacement part Any Cat dealer can provide new messages WEBM1000 Illustration 4 Steering Control 1 This message is located on the left side console outward from the differential steering control O LL Illustration 5 NOTICE When the steering lever is moved with the transmission in NEUTRAL or in gear and the engine is running the machine will turn Engage the steering control lock by engaging the parking brake in order to prevent machine movement Air Conditioner 2 This message is located in the cab on the left side of the instrument panel if equipped 15 Safety Section D6T LGP OEM Additional Messages R134a L_ Ikg PAG 4C 2959 Illustration 6 This message for the air conditioner has the appropriate information for the following services the air conditioner lubricant the refrigerant charge and the refrigerant capacity Also this safety message instructs the usage of the proper safety information Follow instruction in order to avoid engine damage Air Cleaner 3 This message is located on the cover of the air cleaner 307 6202 Illustration 7 To avoid engine damage use only Caterpillar radial seal air filters as replacement filters Refer to the following to
68. structure This will void the certification Consult your Cat dealer to determine this structure s limitations without voiding its certification The protective structure certification is located on the outside of the left post 38 Product Information Section D6T LGP OEM Identification Information Illustration 32 A Film on ROPS support assembly ROPS SAEJ1040 MAY94 IS03471 2008 DST D6T XL kg LB DET XW D amp T LGP 27735 61 145 CATERPILLAR INC PEORIA ILLINGIS USA 299 8067 1 N Illustration 33 Structural damage an overturn modification alteration or improper repair can impair this structure s protective capability thereby voiding this certification Do not weld on or drill holes in the structure Consult a Caterpillar dealer to determine this structure s limitations without voiding its certification This machine has been certified to the standards that are listed on the certification plate The maximum mass of the machine which includes the operator and the attachments without payload should not exceed the mass on the certification plate Refer to Operation and Maintenance Manual Guards Operator Protection for more information WEBM1000 ISO Symbols Model Usage The following list contains all of the ISO Symbols that appear in this publication On or Start Off or Stop Electrical Disconnect Switch Engine On Engine Start Ether Starting Aid
69. sure that all clamps guards and heat shields are installed correctly During machine operation this action will help to prevent vibration rubbing against other parts excessive heat and failure of lines tubes and hoses Do not operate a machine when a fire hazard exists Repair any lines that are corroded loose or damaged Leaks may provide fuel for fires Consult your Cat dealer for repair or for replacement parts Use genuine Cat parts or the equivalent for capabilities of both the pressure limit and temperature limit Ether Ether if equipped is commonly used in cold weather applications Ether is flammable and poisonous Follow the correct cold engine starting procedures Refer to the section in the Operation and Maintenance Manual with the label Engine Starting Do not spray ether manually into an engine if the machine is equipped with a thermal starting aid for cold weather starting Use ether in ventilated areas Do not smoke while you are replacing an ether cylinder or while you are using an ether spray Do not store ether cylinders in living areas or in the operator compartment of a machine Do not store ether cylinders in direct sunlight or in temperatures above 49 C 120 2 F Keep ether cylinders away from open flames or sparks Dispose of used ether cylinders properly Do not puncture an ether cylinder Keep ether cylinders away from unauthorized personnel Fire Extinguisher As an ad
70. the machine is moving forward pull the steering control backward for a right turn When you move the steering control farther in either direction the machine will turn faster When the machine is moving backward push the steering control forward for a right turn When the machine is moving backward pull the steering control backward for a left turn When you move the steering control farther in either direction the machine will turn faster To pivot the machine in the clockwise direction place the power train in NEUTRAL and pull the steering control backward toward the operator In order to pivot the machine in the counterclockwise direction place the power train in NEUTRAL and push the steering control forward Table 6 Machine travel Movement of Machine steering control direction turn FORWARD PUSH LEFT FORWARD PULL RIGHT REVERSE PULL LEFT REVERSE PUSH RIGHT NEUTRAL PUSH LEFT NEUTRAL PULL RIGHT WEBM1000 Transmission Control 4 Illustration 62 Direction Control Switch 4 Use direction control switch 4 in order to change the direction of the machine Forward Push direction control switch 4 in order to change the direction of the machine to FORWARD Neutral Move direction control switch 4 to the center position in order to move the machine into NEUTRAL Reverse Push direction control switch 4 in order to change the direction of the mach
71. the autoshift function are listed sequentially in the next topic Seiting the Bidirectional Autoshift with Monitor ing System Display Use the Message Display on the instrument module in order to set the configurable setting and the installation status Table 8 MVP Active Setting MVP Inactive Setting 1 5F 3 0R 1F 3 0R 1F 3R 1F 3R 1 Configurable setting when the Eco Reverse Mode is ON 2 Setting when the Eco Reverse Mode is OFF D l 2 5R 1 5F 203 2 5R ey Engine Oil Pressure 10 PSI E System Voltage 32y l Engine RPM 120 3 a amp wa SENA T Illustration 65 The configurable setting for the autoshift function will be adjusted through the Settings menu in the Message Display The diagram below shows the location of Bidirectional settings for Autoshift mode in the Message Display 55 Operation Section D6T LGP OEM Machine Operation Onboard Display MAIN MENU SELECTION Bi dir Auto Shift Power Train Implement Engine ones Machine Diagnostics ECM Summary Impl Limp Home Select Edit Dormer ume ES Delete Illustration 66 56 Operation Section D6T LGP OEM WEBM1000 Machine Operation 1N 1 5F 1 5R x160034 4 Hydraulic Oil Temp 100 C 30 100 C Fuel Level Engine Coolant Temp Menu Button Main Miena Operator hd Service ORK Button OR Butona AN 1
72. the corrosion e Increase the deposits WEBM1000 e Lower fuel economy e Shorten the time period between oil drain intervals more frequent oil drain intervals e Increase overall operating costs Failures that result from the use of improper fuels are not Cat factory defects Therefore the cost of repairs would not be covered by a Cat warranty Caterpillar does not require the use of ULSD in off road and machine applications that are not Tier 4 Stage IIIB certified engines ULSD is not required in engines that are not equipped with after treatment devices For Tier 4 Stage IIIB Stage IV certified engines always follow operating instructions Fuel tank inlet labels are installed in order to ensure that the correct fuels are used Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more details about fuels lubricants and Tier 4 requirements This manual may be found on the Web at Safety Cat com Fuel Additives Cat Diesel Fuel Conditioner and Cat Fuel System Cleaner are available for use when needed These products are applicable to diesel and biodiesel fuels Consult your Cat dealer for availability Biodiesel Biodiesel is a fuel that can be made from various renewable resources that include vegetable oils animal fat and waste cooking oil Soybean oil and rapeseed oil are the primary vegetable oil sources In order to use any of these oils or fats as fuel the oils or f
73. the distance that is involved Do not use a chain for pulling a disabled machine A chain link can break This may cause possible personal injury Use a wire cable with ends that have loops or rings Put an observer in a safe position in order to watch the pulling procedure A safe position would be at a distance away from either machine that is greater than two times the length of the towing cable The observer can stop the procedure if necessary The procedure should be stopped if the cable starts to break Also stop the procedure if the cable starts to unravel Stop pulling whenever the towing machine moves without moving the towed machine Shields must be provided on both machines This will protect the operator if either the tow line or the bar breaks Before towing make sure that the tow line or the bar is in good condition Make sure that the tow line or the bar has enough strength for the towing procedure that is involved The strength of the towing line or of the bar should be at least 150 percent of the gross weight of the towing machine This is true for a disabled machine that is stuck in the mud and for towing on a grade For towing only attach the tow line to the tow eyes on the frame if equipped Keep the tow line angle to a minimum Do not exceed a 30 degree angle from the straight ahead position Quick machine movement could overload the tow line or the bar This could cause the tow line or the bar to break G
74. the inside of the operator station should not project into the operator space or into the space for the companion seat if equipped The addition of a radio fire extinguisher and other equipment must be installed so that the defined operator space and the space for the companion seat if equipped is maintained Any item that is brought into the cab should not project into the defined operator space or the space for the companion seat if equipped A lunch box or other loose items must be secured Objects must not pose an impact hazard in rough terrain or in the event of a rollover Guards Operator Protection 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 WEBM1000 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 sp
75. to reduce the engine speed to low idle Engage the parking brake 3 Lower all implements to the ground 4 Stop the engine by turning the engine start switch key to the OFF position Remove the key 5 Turn the key for the battery disconnect switch to the OFF position Remove the key when you exit the machine for an extended period 6 When you dismount use the steps and the handholds Use both hands and face the machine WEBM1000 7 Inspect the engine compartment for debris Clean out any debris and paper in order to avoid a fire Install all the vandalism protection covers and install the locks where equipped Padlocks are factory installed for the following areas e Master Switch Locking Cover e Fuel Drain Lock the cab doors and the windows if equipped 103 Operation Section D6T LGP OEM Parking 104 Operation Section D6T LGP OEM Transportation Information Transportation Information Shipping the Machine Investigate the travel route for overpass clearances Make sure that there is adequate clearance for the machine that is being transported This proceeding is especially true for machines that are equipped with a ROPS FOPS structure a cab or a canopy Remove ice snow or other slippery material from the loading dock and from the truck bed before loading Removing ice snow or other slippery material will prevent the machine from slipping as you load the machine Removing ice snow or
76. to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Illustration 185 1 Position one final drive so that oil level mark 1 is horizontal The drain plug 3 will point downward 2 Remove oil filler plug 2 3 Remove drain plug 3 Allow the oil to drain into a suitable container 4 Inspect the drain plug seal Replace the drain plug seal if the drain plug seal is damaged WEBM1000 5 Clean the drain plug and install the drain plug 6 Fill the final drive with oil to the bottom of the filler plug opening See Operation and Maintenance Manual Capacities Refill 7 Inspect the condition of the seal of the filler plug Replace the plug seal if the plug seal is damaged Wipe the magnet in order to clean the plug Install the plug 8 Repeat Step 185 to Step 7 in order to change the oil in the other final drive For additional information about final drive oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Final Drive Oil Level Check Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Illustration 186 1 Position one final drive so that oil level mark 1 is horizontal and drain plug 3 is at the bottom 2
77. top bolts 1 to a torque of 800 100 N m 590 74 Ib ft Tighten the four bottom bolts 2 to a torque of 460 60 N m 340 45 Ib ft Note Apply oil to all bolt threads for the ROPS before you install the bolts Improper bolt torque can result if you do not apply oil to the threads Do not weld reinforcement plates to the ROPS in order to straighten the ROPS Do not weld reinforcement plates to the ROPS in order to repair the ROPS If the ROPS has any cracks in the welds in the castings or in any metal section consult your Cat dealer for repairs Seat Belt Inspect Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine 165 Maintenance Section D6T LGP OEM Rollover Protective Structure ROPS Inspect Illustration 231 Typical example Inspect buckle 1 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect seat belt 2 for webbing that is worn or frayed Replace the seat belt if the webbing is worn or frayed Inspect all seat belt mounting hardware for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Contact your Cat deale
78. trailing equipment to a drawbar or to a hitch only When you maneuver the machine to connect equipment be sure that there are no personnel between the machine and trailing equipment Block the hitch of the trailing equipment in order to align the equipment with the drawbar Never straddle a wire cable or allow other personnel to straddle a wire cable Know the maximum dimensions of your machine Lifting Capacities Maintain control of the machine Do not overload the machine beyond the machine capacity Ensure that the correct load chart is referenced Loads must be within the capabilities of the machine Lifting capacity decreases as the load is moved further from the machine Use lifting slings that are approved and use lifting slings that are load tested Also all wire ropes or chains must be properly maintained The wire ropes and chains must meet local regulations You must know the load carrying capacity of these devices and you must know the correct use of these devices Wire rope limitations soil conditions and slope of terrain reduce actual capacity All lifts must be made with the load line vertical and the boom centerline directed toward the load To prevent cable from slipping off the drum a minimum of five full wraps of cable must remain on the winch drum at maximum working extension of the hook or boom Limitations on Lifting Loads That Exceed the Working Range Do not load the boom beyond the maximum load
79. while the engine is operating Serious damage to the electrical system could result 96 Operation Section D6T LGP OEM Machine Operation Checking the Battery Disconnect System NOTICE To ensure no damage to the engine occurs verify that the the engi operatio Perform engine is fully operational before cranking ne Do not crank an engine that is not fully nal the following procedure in order to check the battery disconnect system 1 With posi oper the battery disconnect switch in the ON ion verify that electrical components in the ator compartment are functioning Verify that the hour meter is displaying information Verify that the engine will crank 2 Turn posi the battery disconnect switch to the OFF ion 3 Verify that the following items are not functioning elec rical components in the operator compartment hour meter and engine cranking If any of the items continue to function with the battery disconnect switch in the OFF position contact your Caterpillar dealer WEBM1000 97 WEBM1000 Operation Section D6T LGP OEM Engine Starting Engine Starting 4 Turn key start switch 3 to the ON position The monitoring system performs an automatic self test The action alarm sounds and all of the Engine Starting indicator lights come on briefly The indicator light for the parking brake will stay on until the parking brake is released If the attachment
80. with MVP inactive status Auto Kickdown Mode 14 Auto Kickdown This feature provides tof the operator with an auto kickdown mode of operation Once the feature has been activated by the operator the transmission will automatically downshift to a lower speed range when a significant load increase is detected Once the load on the machine has been reduced the operator can return to the desired speed range by manually upshifting The auto kickdown will only downshift the transmission The feature will not automatically upshift the transmission The auto kickdown functions in FORWARD and REVERSE speed range WEBM1000 To activate the auto kickdown mode of operation push switch 14 that is located on the right side of the dashboard An indicator light on the upper display module will illuminate when the auto kickdown is active When the machine is started the transmission is in the previously selected mode If you start up the machine and the auto kickdown is not selected push switch 17 If the auto kickdown is active the light is illuminated In order to achieve the best results select the auto kickdown with the transmission in NEUTRAL If the autoshift function is not desired the machine can be operated in the manual mode Autokickdown mode selection is done using the setting screen in the monitoring system display message module The auto kickdown can be used in the following modes Manual shift in Auto Kickd
81. 000 Reference See Operation and Maintenance Manual Lubricant Viscosities in this manual for the correct viscosity grade 3 Install the oil plugs 4 Repeat Steps 1 through 3 on the other side of the machine Radiator Core Clean Illustration 224 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core and the aftercooler core However the use of compressed air is preferred See Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core Radiator Pressure Cap Clean Replace At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury WEBM1000 163 Maintenance Section D6T LGP OEM Recoil Spring Compartment O
82. 05 0024 035 05 05 0214 Illustration 266 Standard shipping specifications height and width WEBM1000 Table 29 72H Pipelayer Approximate operating weight of the standard machine 29 207 kg 64 390 Ib Approximate shipping weight of the standard machine 28 780 kg 63 450 Ib Weight of the 20 ft boom the boom sheave blocks and the load blocks 936 kg 2064 Ib 24 ft boom add 286 kg 630 Ib Height of the machine without the boom A 3219 mm 10 feet 6 3 4 inch Length of the machine B 4498 mm 14 feet 9 inches Width of the machine without the boom C 3725 mm 12 feet 2 11 16 inch Height of the machine with the 20 ft boom 6884 mm 22 feet 7 inch 24 ft boom add 1223 mm 48 1 8 inch Ground clearance of the machine 434 mm 1 foot 5 inch 1 Operating weight Includes lubricants coolant 100 fuel hydraulic controls and fluids backup alarm seat belt 660 mm 26 in single grouser shoes drawbar counterweight boom and pulley blocks and cable and operator 2 Shipping weight Includes lubricants coolant 10 fuel hydraulic controls and fluids backup alarm seat belt 660 mm 26 in single grouser shoes drawbar counterweight and pulley blocks and cable Intended Use This machine is a Pipelayer that is described in ISO 6165 2001 The machine is intended to perform the following functions lift handle and lay dow
83. 113 Lubricant Viscosities and Refill Capacities 113 LUD FIGAINES ioeie eE r th adenine coeds sadea tests 155 M Machine Capacity er 5 Machine Description i 4 Machine Operating Temperature Range 26 189 Machine Operation s n 26 44 189 Machine Security ee 87 Machine Settings eree 78 Machine Start up eerie rrirerrirernee 74 Machine Status re 82 Main Menu ccc cececceceeeceeeeeeceectnceeeeeeeeeeeees 74 Maintenance anini aaa a i aea 4 Maintenance Interval Schedule 008 123 Maintenance Intervals n 5 Maintenance Section D6T LGP OEM 113 Maintenance Support ceecee 121 Menu for the Operator Profile 74 Mirota rises e erna ee Gaus AALS 53 Modes of Regeneration 64 229 Index Section Monitoring System o ee cceeeetteeeeteeeeeeeeenaees 66 Monitoring System Display cee 53 70 Mounting and Dismounting 0 42 197 MVP SWICK ia aeaa E aAA E 54 0 Oil Filter Inspect occ cc ccceeeeeeeees 161 OIG foe E DEE heal a etter AE 20 Onboard Display 0 0 ccccceeeeteeceteeetteeees 55 Operating The Machine 0 cece 94 OPEMALION rekaida aa tiee 4 26 189 Operation in a Blast Site cece 87 Operation Information n 94 Operation Section D6T LGP OEM 42 Operation Section Pipelayer Attachment Kit 197 Operator Controls 2 0 00 cece eeeteeeeeeeeteeeees 50 Operator
84. 14 Oil Drain Coupling and attach a 1 inch hose Make sure that enough of the swivel hose bypasses the track assembly and fills into a suitable container 4 Remove oil drain plug 3 which is located under the right fender of the machine 5 Install the swivel hose into the drain plug opening 6 Rotate the swivel hose clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 7 Remove the swivel hose The internal drain valve for the hydraulic tank will close 8 Clean the drain plug and install the drain plug Tighten the drain plug to a torque of 68 7 Nm 50 5 Ib ft 9 Change the hydraulic system filter Reference See Operation and Maintenance Manual Hydraulic System Oil Filter Replace 10 Install the filler strainer 11 Fill the hydraulic oil tank Reference See Operation and Maintenance Manual Lubricant Viscosities and Capacities Refill for additional information 12 Inspect the filler cap gasket Replace the gasket if damage or wear is evident WEBM1000 13 Install the filler cap 14 Start the engine Operate the engine for a few minutes Illustration 207 15 Maintain the oil level to the FULL mark in sight gauge 2 Add oil if necessary 16 Stop the engine Hydraulic System Oil Filter Pilot Replace At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause pe
85. 158 Recoil Spring Compartment Oil Level Check 163 Window Wipers Inspect Replace s is 175 Every 1000 Service Hours or 6 Months Battery INSP Ct oer eeeeeeeeeeeteees 126 Rollover Protective Structure ROPS Inspect 165 Torque Converter Scavenge Screen Clean 166 Transmission Breather Clean Replace 170 Transmission Magnetic Screen Clean 6 170 Transmission Oil Change sssr 171 Transmission Oil Filter Replace 172 Transmission Scavenge Screen Clean 4 173 124 Maintenance Section D6T LGP OEM Maintenance Interval Schedule Every 2000 Service Hours Fumes Disposal Filter Element Replace 152 Every 2000 Service Hours or 1 Year Cooling System Coolant Sample Level 2 Obtain etait Sw alah te oS aah atte tect ecto Acie Anyi sd A ET 134 Final Drive Oil Change cccccccceceeesteeeeeneeees 144 Hydraulic System Oil Change s 155 Hydraulic System Oil Filter Pilot Replace 157 Track Roller Frame Guides Inspect 168 Every 2000 Service Hours or 2 Years Cooling System Water Temperature Regulator Re DIAC E raecdlt rad cater EEA bara 135 Every 2500 Service Hours Engine Valve Lash Check Adjust 0 0 00 142 Every Year Refrigerant Dryer Replace 164 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace oo ceeeeteeeeeetteeeeerenes 165 Every 4500 Service Hours ARD Spark
86. 5F 4 5R Auto shif Press OK To Set Illustration 67 Typical information panels of the Message Display SETTINGS MENU Auto Shift Set se Bi Directional Auto Shift E Auto Shift Set Reverse Range Illustration 68 For the complete list of options in the Settings Menu see Monitoring System in this manual WEBM1000 Selecting the bidirectional Autoshift function will take the user directly to the interface for the bidirectional Autoshift modes The interface will have up arrows and down arrows in the lower right section of the LCD screen The up arrow will represent the forward gear and the down arrow will represent the reverse gear The following text is displayed on the LCD screen and Press OK to Set The LCD will display the following information from left to right and gear and lever positioncurrent Bidirectional Autoshift settings and Autoshift text A screen that is an example of the interface for the Bidirectional Autoshift is shown in illustration 68 Pgh Ly N d Q X 100 1N 1 5F 1 5R Auto Shift Press OK To Set Illustration 69 Illustration 70 First speed forward to third reverse directional shift mode Configurable setting A Push button 13 once for the autoshift function A directional shift to the FORWARD position will always shift to the first physical gear or operator configured gear A directional shift to
87. 6 1 m 20 ft 19 05 mm 50 3 m 165 ft 0 75 inch 7 3 m 24 ft 19 05 mm 57 3 m 188 ft 0 75 inch 1 Lower the boom to the horizontal position N Remove the anchor for the wire rope from the drum for the hook Remove the old wire rope 3 Unroll the new wire rope from the spool Note Weld the cable ends in order to prevent fraying NOTICE Unroll all of the cable from the spool Lay the wire rope on a flat surface Never lift the wire rope off the spool in coils WEBM1000 Kit Illustration 294 Installing hook load line cable anchor assembly 1 Install the cable 1 into the small slot and through the larger slot in the drum for the hook load line e Make sure that 2 to 4 threads of capscrew 2 are engaged into the cable anchor assembly 4 Start with the capscrew and insert the cable anchor assembly into the longer slot as far as allowed Make sure that the lip of retainer 3 faces the top edge 5 of the small slot in order to hold the retainer in place Make a loop with the cable end and insert the cable end into the slot past the cable anchor assembly Pull the cable until the cable and anchor assembly are securely seated inside the slot Tighten the capscrew to a torque 6 of 44 3 Nm 32 2 lb ft 2 Wind one half of the cable evenly across the load drum 7 221 Maintenance and Lubrication Section Pipelayer Attachment secure
88. 6T LGP OEM 177 Weight Adjustment 0 0 0 0 e 46 Welding on Machines and Engines with Electronic CONINOIS aria T AE Hae awit deveads 121 When Required cccccceeceeeesseteeeeeeeeeeeeees 123 Whole Body Vibration Level 0 ccs 30 231 Index Section Window Washer Reservoir Fill l a 174 Window Wipers Inspect Replace s 175 Windows Clean wo ccccsesesesenereaeeeas 175 WVIPIIVG 4c te ste eedstts Sats Sots eRe eM tectonic cis Ute aS 22 2012 Pipeline Machinery International All Rights Reserved Printed in USA
89. ATION OF GEAR OIL AND MPGM IS NOT HARMFUL TO THE MACHINE When you operate the machine in arctic conditions lubricate the equalizer bar with EMGARD EP 75W90 gear lubricant EMGARD EP 75W90 gear lubricant is a synthetic lubricant This lubricant is available from Hudson Corporation Ether Starting Aid Cylinder Replace Illustration 184 1 Open the left engine access door 1 The ether cylinder is mounted on the bracket assembly which is seated toward the front of the cab Loosen the retaining clamp Remove the old ether cylinder by turning the cylinder counterclockwise 2 Install the new ether cylinder Turn the cylinder clockwise Hand tighten the ether cylinder in order to seal the gasket to the cylinder Tighten the clamp around the cylinder 144 Maintenance Section D6T LGP OEM Final Drive Oil Change Note The ether starting aid cylinder must be installed with the appropriate gasket The gasket must be clean in order to make a proper seal 3 Close the left engine access door Final Drive Oil Change Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer
90. Amp Engine ECM 28 15 Amp Spare F29 15 Amp Spare F30 10 Amp Spare F31 10 Amp Standard 12 V Converter F33 15 Amp Spare F34 15 Amp Caterpillar Regeneration System CRS Heater nozzle F35 20 Amp Condenser F36 15 Amp Condenser F37 15 Amp Spare F38 15 Amp Circuit Breakers Circuit Breaker Reset Push in the Ea button in order to reset the circuit breaker If the electrical system is working properly the button will remain depressed Note If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary Blower fan motor CB1 15 Amp Spare CB3 15 Amp Fuel priming CB4 15 Amp Spare CB5 15 Amp 155 Maintenance Section D6T LGP OEM Hydraulic System Oil Change Hydraulic System Oil Change Note The normal hydraulic oil change interval is at every 2000 Service Hours or 1 Year By performing S O S oil analysis the hydraulic oil change interval may be extended to 6000 Service Hours or 1 Year S O S oil analysis must be performed at every 500 Service Hours or 3 Months in order to extend the hydraulic oil change interval The results from the S O S oil analysis will determine if the hydraulic oil change interval may be extended If S O S oil analysis is not available the hydraulic oil change interval must remain at every 2000 Service Hours or 1 Year Refer to the Operation an
91. Check _ 160 Seat Belt INSPECT s e 165 Transmission Oil Level Check ccnn 173 123 Maintenance Section D6T LGP OEM Maintenance Interval Schedule Every 50 Service Hours or Weekly Cab Filter Recirculation Clean Inspect Replace AEL E dea tetecaa ssl hentt 5c eat EET 129 Equalizer Bar Center Pin Lubricate 142 Lift Cylinder Yoke Bearings Lubricate 161 PACKPINS INSPSCt ra R NR 168 Every 250 Service Hours or Monthly Belt Inspect Replace sce 126 Engine Oil Sample Obtain eee 139 Equalizer Bar End Pins Oil Level Check 143 Final Drive Oil Level Check cccceeeeeeeeeees 144 Fuel Tank Water and Sediment Drain 151 Track Check AdjuSt oo eecceeeeeeeeeereneees 167 Every 250 Service Hours or 3 Months Pivot Shaft Oil Level Check s e 162 Every 500 Service Hours Final Drive Oil Sample Obtain ee 145 Hydraulic System Oil Sample Obtain 160 Transmission System Oil Sample Obtain 174 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 Obtain pibbihed acess thai ar e a ascent waaladidini es iba 133 Engine Oil and Filter Change s 139 Fuel System Secondary Filters Replace 148 Fuel System Water Separator Element Replace 149 Fuel Tank Cap Filter and Strainer Replace Clean Aa EEE AE E ed A ena Se A a 150 Hydraulic System Oil Filters Replace
92. EBM1000 Delayed Lighting Mode Enable this function by leaving the Forward ROPS lights in the ON position before turning the machine keyswitch to the OFF position The lights will remain ON for a configured amount of time 10 minute default Use the access lighting switch to turn OFF the lights if necessary Daily Inspection For maximum service life of the machine perform a thorough walk around inspection before you mount the machine and before you start the engine Inspect the area around the machine and under the machine Look for loose bolts trash buildup oil leaks coolant leaks broken parts or worn parts Inspect the tracks track roller frames idlers and rollers for oil leaks and excessive wear Do not operate the machine until all necessary repairs have been made Note Watch closely for leaks If you observe a leak find the source of the leak and correct the leak If you suspect a leak or if you observe a leak check the fluid levels more frequently Inspect the condition of the work tool and of the hydraulic components Sound the horn Check all oil levels coolant levels and fuel levels Daily perform all of the procedures that are applicable to your machine e Operation and Maint Alarm Test enance Manual Backup ion and Maintenance Manual Brakes ors and Gauges Test e Opera Indicat e Operation and Maintenance Manual Cooling System Coolant Level Check
93. EQUIPPED View Version Hardware amp Software Display Illustration 105 Access the Service Menu al Dx sse 2F Cn P Limp Home ECM Summary Service 2F Settings N Operator Main 2a Menu Machine Status Illustration 107 The Service Menu contains the following three Illustration 106 categories The following screen will now be displayed e Diagnostics e ECM Summary e Limp Home Mode Implement Codes and events that are contained in the Diagnostics option may be viewed at any time But logged codes cannot be cleared until the Service Mode is enabled 80 Operation Section D6T LGP OEM Machine Operation From the Service menu use the appropriate arrow button to highlight the desired menu option Then press the OK button in order to display that screen Diagnostic and Event Codes Illustration 108 The Diagnostics menu option will show a complete list of all active events and logged event codes Also the list of active diagnostics and logged diagnostics is shown Aftrtrtmnt Fuel Pres 1 High 2 System Engine eC ee Illustration 109 Diagnostic display Illustration 110 Diagnostic message screen WEBM1000 Each line that is listed contains the following information about that event or that code Fault Code 1 Component Identifier or Failure Mode Identifier CID EID Occ 2 Number of occurrences First 3
94. Engine Starting Aid Battery Charging Condition Fuel Level Indicator Parking Brake Implement Control Shutoff Engine Failure Malfunction Transmission Failure Malfunction Braking System Failure Malfunction Engine Filter Element Indicator POBOBOOOSE OOO Transmission Filter Indicator I I L Engine Oil Pressure Engine Oil Temperature Engine Coolant Temperature Torque Converter Oil Temperature Hydraulic Oil Temperature Engine Service Engine RPM SOOHOOO 3 WEBM1000 POOMOD D QO SSOOSVM OMLL Ripper Rear Work Light Panel Lights Switch Flood Lights Front Work Light Horn Backup Alarm Seat Back Angle Adjustment Seat Adjustment Fore and Aft Seat Adjustment Height Lumbar Support Adjustment Transmission Forward Transmission Reverse Transmission Neutral Ripper Hold Winch Spool In Winch Brake Neutral Winch Brake Off Winch Free Spool Winch Spool Out Fuses Alternator Power Train ECM 39 Product Information Section D6T LGP OEM OSG OE PBOOC Identification Information Engine ECM Blower Motor Panel Test Switch Window Washer Regeneration Active indicator Regeneration Disabled indica
95. GP OEM Machine Operation Joystick Control 20 Lift Control Illustration 79 HOLD 20A The lever will return to the HOLD position when you release the lever from the RAISE position or from the LOWER position Also the movement of the bulldozer blade stops in the up and down direction al RAISE 22B Pull back on the lever in order to raise the blade Faster movement of the lever increases the moving speed of the blade Releasing the lever will return the lever to the HOLD position G LOWER 22C Push the lever forward in order to lower the blade Faster movement of the lever increases the moving speed of the blade Releasing the lever will return the lever to the HOLD position QUICK DROP 22D Push the lever beyond the Lower position to activate the blade quick drop function The blade will be allowed to drop to the ground Releasing the lever returns the lever to the HOLD position FLOAT 22E Push the lever forward past the detent in order to activate the blade FLOAT function The float function is not deactivated when the lever is released into the NEUTRAL position When in float the blade moves up and down with the ground contour Float will be deactivated if the lever is moved through the NEUTRAL position to the RAISE position or the LOWER position Note The control moves through the quick drop range as you go from the LOWER position to the
96. INE ARRANGEMENT NUMBER SEQUENCE NUMBER ARRANGEMENT NUMBER SERIAL ISMISSION ARRANGEMENT NUMBER CATERPILLAR II PEORIA IL Illustration 26 MADE IN UNITED STATES ICA INC PARTS ORDER WEBM1000 The Service Information Number Plate is located inside the cab on the left side of the dash Illustration 27 Transmission Serial Nu mber SERIAL NUMBER ARRANGE MENT ENGINE MODEL NUMBER MADE IN U S A ALWAYS GIVE ALL NUMBERS Illustration 28 The Serial Number Plate is located on the left side of the cylinder block near the rear of the engine The following information is stamped on the Serial Number Plate engine serial number model and arrangement number Engine Serial Number WEBM1000 AT oN SER N ENGINE MODEL MAX ALT FULL LOAD RPM ROTATION FUEL PUMP GOV AR NO INJECTOR BARE ENG HI IDLE RPM TURBO POWER kW Illustration 29 The Information Plate is on the engine valve cover The following information is stamped on the Information Plate engine maximum altitude horsepower high idle full load rom fuel settings and other information The serial number plate for the dozer blade is attached to the back side of the dozer if equipped Certification CE Mark This plate is positioned on the PIN plate on the left side of the fron
97. Install Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual Failure to follow the instructions or heed the warnings could result in injury or death Contact your dealer or Vanguard Equipment or visit our website at vanguardequip com for replacement manuals Proper care is your responsibility Personal injury or death can result from worn wire rope cable Worn or frayed cable could break causing injury Check the wire rope cable If cable is worn or is frayed install new cable Wear gloves when handling the wire rope cable Proper care is your responsibility WEBM1000 Kit NOTICE Make sure that the construction of the wire rope is 6x25 IWRC XIPS Independent Wire Rope Core eXtra Improved Plow Steel USA MADE Also the established grade of the wire rope is the improved plow bolt steel 26670 kg 58 800 Ib minimum breaking strength Table 34 SPECIFICATIONS WIRE ROPE Boom Line Cable Boom Length Diameter of Length of Cable Cable 6 1 m 20 ft 19 05 mm 40 2m 0 75 inch 132 ft 7 3 m 24 ft 19 05 mm 45 7m 0 75 inch 150 ft Table 7 Boom line wire rope specifications 1 Lower the boom to the ground and support the boom Note The loaded force in the winch drum must be neutralized before removing the wire rope from a loaded drum 2 Remove the anchor for the wire rope from the drum for
98. Install the wire rope over sheave 8 from the front of the machine toward the rear of the machine 7 Install the wire rope under sheave 9 in the lower sheave block 8 Install the wire rope over sheave 10 in the upper sheave block WEBM1000 Kit SS gt See Illustration 287 Inserting wire rope into cable anchor 9 Insert the wire rope into the pocket and around the wedge 11 Allow an additional length of cable to form a tail end six inch minimum Use a mallet to tap the wedge and the wire rope into the pocket 10 Insert the tail end of the wire rope through clamp 12 Add a short piece of wire rope through clamp 12 in order to secure the clamp as needed Tighten the nuts on the clamp Note Do not clamp the loaded end of the wire rope and the tail end of the wire rope together 11 Apply the first load in order to seat wedge 11 Boom Pivot Pins Lubricate The grease fittings for lubricating the boom pivot pins are located on the left side of the machine There is one grease fitting for each pin The grease fittings are located on the end of the pin on the outside face of the boom 217 Maintenance and Lubrication Section Pipelayer Attachment BA Rnd i 035 05 30 015 Figure 1 Boom pivot pins grease fittings Illustration 288 Boom pivot pins grease fittings Lubricate the boom pivot pins through the two fittings 218 Maintenance and Lubrication Section Pip
99. It is possible to burn the fingers if there is more than brief contact with these components Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine the operator should never attempt the following procedures e Mount the machine e Dismount the machine If you are in the operator s station during an electrical storm stay in the operator s station If you are on the ground during an electrical storm stay away from the vicinity of the machine Before Starting Engine Start the engine only from the operator s compartment Do not short across the battery terminals and do not short across the batteries Bypassing the engine neutral start system can damage the electrical system Inspect the condition of the seat belt and mounting hardware Replace any damaged parts or worn parts Regardless of appearance replace the seat belt after three years of use Do not use an extension for a seat belt on a retractable seat belt Adjust the seat so that full pedal travel can be achieved Make sure that the operator s back is against the back of the seat 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 working on the machine working underneath the machine or working close to the machine Make sure that the area is fr
100. Maintain the grouser height rise to the following dimensions 146 Maintenance Section D6T LGP OEM Front Idler Position Check a A Front Idlers Minimum 0 mm 0 inch Maximum 20 mm 0 8 inch b B Rear Idlers Minimum 10 mm 0 4 inch Maximum 40 mm 1 6 inch 4 Repeat Steps 1 through 3 in order to determine the proper height dimension under each idler Illustration 189 Adjustment shim center tread idler 5 For machines with the SystemOne Undercarriage remove one shim under each track idler block when the wear on the link and roller system is at 50 Consult your Caterpillar dealer for detailed information about adjustments to the center tread idler See Operation and Maintenance Manual Track Check Adjust for information on needed track adjustments Reference See Operation and Maintenance Manual Reference Material for publications and Special Instructions on removal and installation of SystemOne Track as needed WEBM1000 Conventional Design Illustration 190 A Adjusting shims B Dimension between the height of the front idler tread and the height of the roller tread The following check is for undercarriage systems that have the conventional idler The height of the front idler tread should always be higher than the height of the roller tread The dimension B is set approximately to 9 0 mm 35 inch at the factory Dimension B
101. Mens Totals Illustration 99 The Operator Profile menu option is entered by selecting Operator from the Main menu Press the up arrow button or the down arrow button until Operator is highlighted Then press the OK button Note The Main Menu can be displayed from any screen by pressing the Main Menu button The following explains the usage of each menu option WEBM1000 Select Profile This option allows the selection of a saved profile and the associated settings The operator is given this option in order to edit the settings See Illustration 100 Edit Profile This option allows the operator to edit the settings of the active operator profile Press the OK button in order to edit the settings for the currently selected profile When all settings have been modified select the EXIT button and press the OK button in order to save the settings Create Profile This option defines a profile name When this step is completed the Settings screen for the operator profile is displayed Now the operator can edit the settings When the new profile is exited the settings are saved to the Profile As many as 20 operator profiles may be entered Delete Profile The operator can delete an existing profile Highlight the profile that will be deleted Then press the OK button in order to delete that profile Note The selected p
102. Min Max Min Max Cat TDTO Cold Weather SAE OW 20 40 10 40 50 SAE 10W 20 10 4 50 Power Shift Transmission Cat TDTO SAE 30 0 35 32 95 SAE 50 10 50 50 122 Cat TDTO TMS Multi Grade 20 43 4 110 116 Maintenance Section D6T LGP OEM WEBM1000 Lubricant Viscosities and Refill Capacities Where recommended for use Cat FDAO SYN Cat FDAO or commercial oil that meets Cat FD 1 are the preferred oil types to maximize gear and bearing life Do not use Cat FDAO Cat FDAO SYN or Cat FD 1 in compartments containing clutches and or brakes Cat TDTO Cat TDTO TMS or commercial oil that meets Cat TO 4 oil types must be used in any compartment containing friction material unless specified otherwise by Caterpillar For the Final Drives in severe usage or in continuous operations WARM UP is required Exercise the final drives for several minutes with the engine at a partial throttle in order to warm up the oil prior to production operation Table 20 Lubricant Viscosities for Ambient Temperatures Compartment or PEN Oil Type and Wi mp C F Syston Application lagehication Oil Viscosities TT eS ET Cat FDAO SAE 60 7 50 19 122 commercial FD 1 Moderate Usage or Cat TDTO COLD SAE 50 15 32 5 90 Intermittent WEATHER Operation Cat TDTO SAE 30 25 15 13 59 Cat TDTO TMS commercial TO 4 Cat TDTO TMS 35 15 31 59 Final Drive Cat FDAO SAE 60 25 50 13 122 Severe Usageor at TDTO COLD SAE 50 33 14 27 58 Conti
103. OVE FRONT RIGHT PANEL TO CHARGE REMOVE RIGHT HAND PANEL TO REPLACE CHARGE VALVE 046 40 71 3004 Illustration 283 Accumulator located behind access panels to right of operator seat 046 60 71 3064 214 Maintenance and Lubrication Section Pipelayer Attachment Kit Boom Stop Valve Operation and Adjustment Table 33 Ambient air temperature Accumulator precharge PGF pressure kPa psi 70 kPa 10 psi 7C 20 F 3100 kPa 450 psi 1 C 30 F 3170 kPa 460 psi 4 C 40 F 3240 kPa 470 psi 10 C 50 F 3310 kPa 480 psi 16 C 60 F 3375 kPa 490 psi 21 C 70 F 3445 kPa 500 psi 27 C 80 F 3515 kPa 510 psi 32 C 90 F 3580 kPa 520 psi 38 C 100 F 3650 kPa 530 psi 43 C 110 3720 kPa 540 psi 49 C 120 F 3790 kPa 550 psi Boom Stop Valve Operation and Adjustment The Boom Stop system stops the boom winch from hauling in when the boom is vertical preventing overloading of key machine components Incorrectly adjusting or defeating the boom stop valve could result in serious equipment damage personal injury or even death Its operation must be check and verified daily KICK OUT Illustration 284 Boom stop valve located behind access cover in Left Hand tower e To check the operation boom in slowly taking care not to over tension the boom lines when the boom goes vertical When the boom is vertical the
104. Plug Replace nn 125 Every 5000 Service Hours Diesel Particulate Filter Clean Replace 136 Fuel Priming Pump Replace cece 147 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 131 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 129 WEBM1000 WEBM1000 ARD Spark Plug Replace Removing the Spark Plug Personal injury can result from air pressure Personal injury can result without following proper procedure When using pressure air wear a protective face shield and protective clothing The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded NOTICE If the engine is running or the key is in the ON position the ARD plug will continue to fire Turn the key to the OFF position before servicing the ARD plug 1 Open the right engine access door Illustration 152 1 Wiring harness 2 ARD spark plug aftertreatment regeneration device 2 Remove wire harness 1 from spark plug 2 3 Debris may have collected in the spark plug well Thoroughly remove any debris Use compressed air The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi Ensure that the area around the spark plug is clean and free of dirt and debris 125 Maintenance Section D6T LGP OEM ARD Spark Plug Replace 4 Use a deep well sock
105. RNING Shock Electrocution Hazard 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 WEBM1000 Rotating Shaft 6 This safety message 6 is located on top of the guard which is covering the drive shaft for the PTO pump The film is visible by removing the floorplate of the cab Rotatins shaft pinch hazard The shaft under this cover is rotating anytime the engine is running Contact with a rotating shaft could cause injury or death Keep hands away 11 Safety Section D6T LGP OEM Safety Messages Do Not Weld on the FOPS 7 Safety message 7 is positioned on the right side of the cab roof FOPS SAEJAS03449 APR96 LEVEL II 1803449 1992 LEVEL II Structural damage an overturn modification alteration or improper repair can impair this structure s protection capability thereby voiding this certification Do not weld on or drill holes in the structure This will void the certification Consult your Cat dealer to determine this structure s limitations without voiding its certification This machine has been certified to the standards that are listed on the certification 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 A typical example of t
106. Remove oil filler plug 2 3 The oil level should be at the bottom of the filler plug opening Add oil if necessary See the Table in the article Lubricant Viscosities for the type of oil 4 Install oil filler plug 2 5 Repeat Step 186 to Step 4 in order to check the oil level in the other final drive WEBM1000 Final Drive Oil Sample Obtain Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Obtain the sample of the differential and final drive oil as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of S O S oil analysis establish a consistent trend of data Illustration 187 1 Position one final drive so that oil level mark 1 is horizontal Drain plug 3 should face downward 2 Remove oil filler plug 2 and obtain the oil sample w
107. SAE OW 20 40 0 40 32 SAE OW 30 40 10 40 50 Track Roll SAE 5W 20 35 0 31 32 rack Roller Frame Gi me SAE 10W 30 0 22 32 Recoil Spring Normal Cat Arctic TDTO Pivot Shaft eaba T04 SAE 30 20 25 4 77 Bearings commercia SAE 40 10 40 14 104 SAE 50 0 50 32 122 Cat TDTO TMS 25 25 13 77 Cat DEO SAE 30 20 25 4 77 Cat DEO SYN Ta e og Normal Cat ECF 1 SAE 40 10 40 14 104 API CG 4 API CF SAE 5W 40 35 40 31 104 Special Lubricants Each pin joint should be flushed with the new grease Ensure that all old grease is removed Failure to meet this requirement may lead to failure of Grease a pin joint In order to use a non Cat grease the supplier must certify that the lubricant is compatible with Cat grease 118 Maintenance Section D6T LGP OEM WEBM1000 Lubricant Viscosities and Refill Capacities Table 22 Recommended Grease C oF Compartment or System GreaseType NLGI Grade Min Max Min Max Cat Advanced 3Moly NLGI Grade 2 20 40 4 104 NLGI Grade 2 30 50 22 122 Cat Ultra 5Moly NLGI Grade 1 35 40 31 104 External Lubrication Points NLGI Grade 0 40 35 40 95 Cat Arctic Platinum NLGI Grade 0 50 20 58 68 Cat Desert Gold NLGI Grade 2 20 60 4 140 Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for additional information about grease This manual may be found on the Web at Safety Cat com Dies
108. Service hour of the first occurrence Last 4 Service hour of the last occurrence Act 5 X means that the event or the code is currently active Logged codes and logged events are cleared with password protection only Active Faults A second popup screen appears when active faults or events are reported to the Monitoring System Display by any ECM Warning information appears on the screen and the operator must acknowledge the warning message by pressing the OK button Monitoring System Display will scroll through all the warning messages that are generated by active faults or events The warning messages are not cleared from system memory by pressing the OK button The message may reoccur after a time according to the severity of the warning information ECM Summary A 10 Wl K e N 4A B L 25 Oure x al 2F Mach Cntri Mod ECM Implement Sd Monitoring Illustration 111 The ECM Summary menu option allows the user to display a list of each ECM with the associated part numbers on the machine WEBM1000 Limp Home Mode Implement w al 2F Imp Limp Home lt ad it OK Select Blade Pitch bis Ripper Raise Illustration 112 The Implement Limp Home menu option allows slow incremental movement of the following functions e Blade raise e Blade tilt e Blade angle if equipped e Ripper raise if equipped This movement is done without using the implement control l
109. The recommended sampling interval is every 250 service hours In order to receive the full effect of S O S oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Open the engine access door on the right side of the machine Illustration 174 2 Remove the protective cap 3 Use 169 8373 Fluid Sampling Bottle in order to obtain a sample of the engine oil 139 Maintenance Section D6T LGP OEM Engine Oil Sample Obtain 4 Replace the protective cap 5 Close the engine access door Refer to Operation and Maintenance Manual Lubricant Viscosities for the correct fluid for your machine Engine Oil and Filter Change Selection of the Oil Change Interval NOTICE A 500 hour engine oil change interval is available provided that the operating conditions and recommended multigrade oil types are met When these requirements are not met shorten the oil change interval to 250 hours or use an S O S Services oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine Cat oil filters are recommended Refer to this Operation and Maintenance Manual Lubricant Viscosities for further information about oils that may be used in Cat engines Refer to this Operation and Maintenan
110. a solid rear window 176 Maintenance Section D6T LGP OEM Windows Clean Clean the outside of the rear window from the ground or with the use of a man lift unless appropriate handholds are available Illustration 261 WEBM1000 WEBM1000 Warranty Section D6T LGP OEM Warranty Information Emissions Warranty Information Caterpillar Inc Caterpillar warrants to the ultimate purchaser and each subsequent purchaser that 1 Newnon road diesel engines and stationary diesel engines less than 10 liters per cylinder operated and serviced in the United States and Canada including all parts of their emission control systems emission related components are a Designed built and equipped so as to conform at the time of sale with applicable emission standards prescribed by the United States Environmental Protection Agency EPA by way of regulation b Free from defects in materials and workmanship in emission related components that can cause the engine to fail to conform to applicable emission standards for the warranty period 2 New non road diesel engines operated and serviced in the state of California including all parts of their emission control systems emission related components are a Designed built and equipped so as to conform at the time of sale to all applicable regulations adopted by the California Air Resources Board ARB b Free from defects in materials an
111. ace toward the rear of the machine Illustration 291 Counterweight hinge pins located right side of machine Lubricate the two lower pins through the grease fittings Note If the counterweight is fully extended install the counterweight lock lever in order to lubricate the counterweight hinge pins Refer to Operation and Maintenance Manual Counterweight Lock Lever for more details WEBM1000 Kit 035 05 05 01 96 Illustration 292 Counterweight hinge pins lubrication points Fairlead Sheave Lubricate 035 05 05 004 Illustration 293 Fairlead sheave lubrication points Lubricate one fitting in the lower sheave and lubricate one fitting in the upper pin 219 Maintenance and Lubrication Section Pipelayer Attachment Hook and Wire Cable Inspect Inspect the Hook Inspect the hook frequently The inspections should include observation of the hook during operation of the hook A designated person determines if the conditions that are found during the inspections constitute a hazard The designated person will determine if a more detailed inspection is required e Inspect the hook for any distortion such as bends in the hook or twists in the hook Inspect the hook for any wear Inspect the hook for cracks nicks or gouges If alatch is provided inspect the latch Make sure that the latch engages properly Inspect the latch for any damage Make sure that the latch is not malfunctioning
112. achine that is being transported Remove ice snow or other slippery material from the loading dock and from the truck bed before loading Removing ice snow or other slippery material will prevent slippage while you load the machine Removing ice snow or other slippery material will prevent the machine form slipping in transit NOTICE Obey all state and local laws governing the weight width and length of a load Observe all regulations governing wide loads Illustration 277 1 Place blocks under the trailer wheels or under the rail car wheels before loading as shown 2 Move the transmission control lever to the NEUTRAL position 3 Engage the parking brake switch 4 Stop the engine 5 Turn the start switch key to the OFF position Remove the key and lock the parking brake switch 6 Turn the battery disconnect switch to the OFF position Remove the key 7 Attach any vandalism protection and lock the access covers WEBM1000 8 Install the tie downs at several locations and chock the tracks in the front and in the rear 9 Cover the opening for the engine exhaust in order to prevent rotation of the turbocharger that is caused by the force of the wind NOTICE Rotation of the turbocharger without engine operation can result in damage to the turbocharger Cover the exhaust opening or secure the rain cap in order to prevent the turbocharger from wind milling in transit Refer to the tractor operation
113. ain fluids Do not pour waste onto the ground down a drain or into any source of water Crushing Prevention and Cutting Prevention Support the equipment properly before you perform any work or maintenance beneath that equipment Do not depend on the hydraulic cylinders to hold up the equipment Equipment can fall if a control is moved or if a hydraulic line breaks Do not work beneath the cab of the machine unless the cab is properly supported Unless you are instructed otherwise never attempt adjustments while the machine is moving or while the engine is running 20 Safety Section D6T LGP OEM Burn Prevention Never jump across the starter solenoid terminals in order to start the engine Unexpected machine movement could result Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement Stay clear of all rotating and moving parts If it is necessary to remove guards in order to perform maintenance always install the guards after the maintenance is performed Keep objects away from moving fan blades The fan blade will throw objects or cut objects Do not use a kinked wire cable or a frayed wire cable Wear gloves when you handle wire cable When you strike a retainer pin with force the retainer pin can fly out The loos
114. ain fluids on Cat products Dispose of all fluids according to local regulations and mandates WEBM1000 Obtain the sample of the transmission oil as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of S O S oil analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced If the machine is operated under high load and or under high temperature conditions sample all fluids at the 250 hour interval Illustration 256 The oil sampling valve for the power train is shown 1 Open the access cover on the right side of the cab in front of the hydraulic tank 2 Remove the protective cap 3 Use 8T 9190 Fluid Sampling Bottle 1 to obtain a sample 4 After you take a sample remove the cap with the probe from the bottle Discard the cap with the probe Install the sealing cap that is provided with 8T 9190 Fluid Sampling Bottle 1 5 Replace the protective cap 6 Install the access cover Reference Refer to Lubricant Viscosities in the Maintenance Section of this manual for the correct fluid for your machine Window Washer Reservoir Fill NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent WEBM1000
115. ainers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates WEBM1000 If the transmission oil filter indicator in the monitoring panel comes on before 1000 hours the filter should be changed The transmission oil filter is located behind the front access cover on the right side of the cab Illustration 251 1 Remove transmission oil filter housing 1 from the transmission oil filter base 2 2 Remove the transmission oil filter element and properly dispose of the filter element 3 Clean the transmission oil filter housing with a clean cloth 4 Inspect the seal If the seal is damaged replace the seal 5 Install the new filter element into the oil filter housing Then install transmission oil filter housing 1 into base 2 Note Lubricate the threads of the transmission oil filter housing 6 Remove cap 3 from transmission oil filler tube 4 7 Fill the transmission system with oil Reference See Operation and Maintenance Manual Lubricant Viscosities in this manual for the correct viscosity grade of oil WEBM1000 sie none ar Le a a a D j f z x y ma e 9 rae Las D Illustration 252
116. al information about these service tools Note The engine start switch must be in the ON position in order for the electrical connectors to be activated Reporting a Problem Report all of the information about problems to your Caterpillar dealer Report all of the service code information and indicate if the codes are active or logged Report an action indicator that lights but does not create a service code Report if an action lamp is flashing or the action alarm is sounding Your Caterpillar dealer can remove the service codes Consult your Caterpillar dealer for more information Refer to Special Instruction REHSO126 Caterpillar Electronic Controls Listing of Abbreviations and Terms The Monitoring System Display uses abbreviations when the display area shows the information inputs The following tables describe the abbreviation with the full term 84 Operation Section D6T LGP OEM Machine Operation WEBM1000 Abbreviation and Term For Monitoring System Display Abbreviation Term kpig kilometers Imperial gallon kpl kilometers liter L Liter L Hr Liters Hour It left m Meter max maximum Mi Miles min minimum mm millimeter mm s millimeters second mpg m
117. al Instruction SEHS7633 Battery Test Procedure e Special Instruction SEHS7768 6V 2150 Starting Charging Analyzer Group e Tool Operating Manual NEHS0973 271 8590 Analyzer Group 24 V e Special Instruction REHSO0354 Charging System Troubleshooting e System Operation Troubleshooting Testing and Adjusting RENR8148 Product Link PL522 523 e Special Instruction REHS2368 An Installation Guide for the Product Link PL522 523 Cellular e Special Instruction REHS1642 Operation of the Product Link System e Special Publication NENG2500 Cat Dealer Service Tool Catalog e Special Instruction SEHS9031 Storage Procedure for Caterpillar Products WEBM1000 e Special Instruction REHS1110 Installation and Removal of SystemOne Track e Special Instruction REHS2403 Installation and Removal of SystemOne Track with the Multi Pitch SystemOne Track Press Tool e Special Instruction REHS2350 SystemOne Undercarriage Overview e Specifications SENR3130 Torque Specifications e Special Publication SEBU5898 Cold Weather Recommendations for all Caterpillar Equipment e Special Publication SEBD0640 Oil and Your Engine e Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations e Special Publication SEBU6981 Emissions Control Warranty Information e Service Manual SENR5664 Air Conditioning and Heat
118. allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure The hydraulic tank is on the right rear corner of the machine Illustration 301 Hydraulic Tank 1 The counterweight should be fully retracted when you check the oil level 2 Maintain the oil level to the FULL mark in sight gauge 1 225 Maintenance and Lubrication Section Pipelayer Attachment 3 Ifthe hydraulic system requires additional hydraulic oil remove filler cap 2 and add oil Clean filler cap 2 and install filler cap 2 Hydraulic System Oil Sampling Refer to the tractor s operation and maintenance manual for the specific procedures regarding Hydraulic System Sampling Oil Filter Inspection Illustration 302 Oil filter Use a Filter Cutter CAT 4C 5084 or similar to cut the filter element open Spread apart the pleats and inspect the element for metal and other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals would indicate wear on steel parts and on cast iron parts Non ferrous metals would indicate wear of the brass or aluminum part of the hydraulics such as main bearings pu
119. and can result in brake damage Brakes must be fully released when towed machine is moving WEBM1000 Brake Engagement Illustration 148 5 Bypass valve Open bypass valve 5 in order to apply the brakes This will completely dump the oil The brake system can only be applied by turning the bypass valve The service brake pedal and the steering levers do not function After towing remove the brake release pump Repair the machine Install the floorplate and the seat WEBM1000 Engine Starting Alternate Methods Engine Starting with Jump Start Cables Batteries give off flammable fumes which can explode To avoid injury or death do not strike a match cause a spark or smoke in the vicinity of a battery Failure to properly service the batteries may cause peronal injury Prevent sparks near the batteries They could cause vapors to explode Do not allow the jump start cable ends to contact each other or the machine Do not smoke when checking battery electrolyte levels Electrolyte is an acid and can cause personal injury if it contacts skin or eyes Always wear eye protection when starting a machine with jump start cables Improper jump start procedures can cause an explosion resulting in personal injury Always connect the battery positive to battery positive and the battery negati
120. ank will close 7 Clean drain plug 2 and install drain plug 2 Tighten drain plug 2 to a torque of 68 7 Nm 50 5 Ib ft 8 See the Operation and Maintenance Manual Maintenance and Lubrication section Hydraulic System Oil Filter Replace Change the hydraulic system filter 4 9 See the Operation and Maintenance Manual Maintenance and Lubrication section Hydraulic System Case Drain Filter Replace Change the hydraulic system case drain filter 5 10 Install the filler strainer 5 BEHIND GUARD 046 6465 3004 Illustration 297 Winch Drains and Case Drain Filter 11 Drain the oil from both of the winches 6 amp 7 into a suitable container WEBM1000 Kit 12 See the Operation and Maintenance Manual Capacities Refill in order to determine the amount of hydraulic oil that is needed to fill the hydraulic oil tank Fill the hydraulic oil tank 13 Inspect the filler cap gasket Install a new gasket if damage or wear is evident Install the filler cap 14 Start the engine Run the engine for a few minutes Check for leaks 15 Maintain the oil level to the FULL mark in sight gauge 3 Add oil if necessary Stop the engine Hydraulic System Oil Filter Replace At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Remove the filler cap only whe
121. ar dealer Caterpillar S O S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system S O S Coolant Analysis is a program that is based on periodic samples See Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluid Recommendations S O S Coolant Analysis for more information Perform a Coolant Analysis Level 2 at initial 500 hours for systems that contain extended life coolant ELC Perform the analysis yearly after the initial 500 hours Illustration 166 Location of coolant sampling port 1 Park the machine on a hard level surface Set the engine at low idle speed 2 Open the left side engine compartment Remove the protective cap from the sampling valve 3 Obtain a sample For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 4 Replace the protective cap Close the left side engine compartment Submit the sample for Level 2 analysis 135 Maintenance Section D6T LGP OEM Cooling System Water Temperature Regulator Replace Cooling System Water Temperature Regulator Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening a
122. at fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Table 26 Cat ELC Extender and the Cooling System Capacity Recommended Cooling System Capacity D6T Track Type Tractor a ace ELC 64 4 L 17 0 US gal 1 2 L 41 02 64 4 L 14 2 Imp gal 1 2 L 41 02 When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity 131 Maintenance Section D6T LGP OEM Cooling System Coolant Extender ELC Add For additional information about adding an extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Extended Life Coolant ELC Extender Use a 81 5296 Coolant Conditioner Test Kit to check the concentration of the coolant Personal injury can result from hot coolant steam and alkali At
123. ate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts 162 Maintenance Section D6T LGP OEM Pivot Shaft Oil Level Check Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage Pivot Shaft Oil Level Check Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Illustration 223 The oil plugs are located on both sides of the machine on top of the track roller frame 1 Remove the oil plugs on one side of the machine Check the oil level The oil level should be at the bottom of the threaded hole 2 If necessary add oil in order to bring the oil level up to the bottom of the threaded hole WEBM1
124. ates 50 soot level The fourth mark indicates 75 soot level The last mark indicates 100 soot level The soot level monitor can be used to optimize DPF regenerations based upon the work cycle of your machine If machine conditions do not allow for an automatic regeneration a manual regeneration should be performed before the soot level gauge indicates 100 64 Operation Section D6T LGP OEM Machine Operation Modes of Regeneration Automatic The engine ECM uses multiple inputs from the engine and the machine to determine the best time to perform an automatic regeneration Automatic regenerations can take place throughout the operating cycle of the engine The regeneration active indicator will be illuminated when a regeneration is being performed Interruptions of the regeneration are acceptable If a regeneration is in progress and needs to be stopped for any reason it is permissible to press the disable regeneration switch or turn off the engine Note Automatic adjustments of engine speed may be noticed during automatic regenerations If a regeneration is taking place and the engine is taken to low idle the engine speed may remain elevated in order to maintain the regeneration Note If an automatic regeneration is started while the engine is at low idle and the machine is taken back to work this may stop the regeneration The engine ECM will continue to monitor inputs to determine the best time to restart the regeneration
125. ating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling and component containing fluids Dispose of all fluids according to local regulations and mandates Operate the machine in order to warm the oil Park the machine on level ground Engage the parking brake and stop the engine Illustration 296 Hydraulic tank filler cap Remove the hydraulic tank filler cap 1 slowly in order to relieve any pressure 1 Wash the filler strainer and the filler cap in a clean nonflammable solvent 2 Remove oil drain plug 2 3 Attach a hose to a 1 inch NPT pipe nipple This 1 inch NPT pipe nipple should have a length of 100 mm 4 inch WEBM1000 4 Install the pipe nipple into the drain plug opening 5 Rotate the pipe nipple clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 6 Remove the pipe nipple The valve for the hydraulic t
126. ats are chemically processed esterified The water and contaminants are removed U S distillate diesel fuel specification ASTM D975 09a includes up to B5 5 percent biodiesel Currently any diesel fuel in the U S may contain up to B5 biodiesel fuel European distillate diesel fuel specification EN 590 includes up to B5 5 percent and in some regions up to B7 7 percent biodiesel Any diesel fuel in Europe may contain up to B5 or in some regions up to B7 biodiesel fuel Note The diesel portion used in the biodiesel blend must be Ultra Low Sulfur Diesel 15 ppm sulfur or less per ASTM D975 In Europe the diesel fuel portion used in the biodiesel blend must be sulfur free diesel 10 ppm sulfur or less per EN 590 The final blend must have 15 ppm sulfur or less 119 Maintenance Section D6T LGP OEM Lubricant Viscosities and Refill Capacities Note Up to B20 biodiesel blend level is acceptable for use in the engine When biodiesel fuel is used certain guidelines must be followed Biodiesel fuel can influence the engine oil aftertreatment devices non metallic fuel system components and others Biodiesel fuel has limited storage life and has limited oxidation stability Follow the guidelines and requirements for engines that are seasonally operated and for standby power generation engines In order to reduce the risks associated with the use of biodiesel the final biodiesel blend and the bio
127. bags e Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location 134 Maintenance Section D6T LGP OEM Cooling System Coolant Sample Level 2 Obtain e Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the shipping sleeve immediately after obtaining the sample in order to avoid contamination e Never collect samples from expansion bottles e Never collect samples from the drain for a system Illustration 165 Location of coolant sampling port 1 Park the machine on a hard level surface Set the engine at low idle speed 2 Open the left engine compartment Remove the protective cap from the sampling valve 3 Obtain a sample For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 4 Replace the protective cap Close the left side engine compartment Submit the sample for Level 1 analysis Note Level 1 results may indicate a need for Level 2 Analysis Level 2 is a comprehensive analysis which should be performed annually See Operation and Maintenance Manual Cooling System Coolant Sample Level 2 Obtain for more information WEBM1000 Cooling System Coolant Sample Level 2 Obtain Level 2 Analysis Personal injury can result from hot
128. bands lining material clutch plates and some gaskets The asbestos that is used in these components is bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present there are several guidelines that should be followed e Never use compressed air for cleaning e Avoid brushing materials that contain asbestos e Avoid grinding materials that contain asbestos e Use a wet method in order to clean up asbestos materials e A vacuum cleaner that is equipped with a high efficiency particulate air filter HEPA can also be used 19 Safety Section D6T LGP OEM Crushing Prevention and Cutting Prevention e Use exhaust ventilation on permanent machining jobs e Wear an approved respirator if there is no other way to control the dust e Comply with applicable rules and regulations for the work place In the United States use Occupational Safety and Health Administration OSHA requirements These OSHA requirements can be found in 29 CFR 1910 1001 e Obey environmental regulations for the disposal of asbestos e Stay away from areas that might have asbestos particles in the air Dispose of Waste Properly Illustration 18 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 dr
129. be installed with new mounting hardware Date of installation labels should be marked and affixed to the seat belt retractor and buckle Note Date of installation labels should be permanently marked by punch retractable belt or stamp non retractable belt If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension Torque Converter Scavenge Screen Clean When you change the transmission oil clean the torque converter scavenge screen 1 Remove the bottom guard in order to gain access to the torque converter Note Drain all fluids into a suitable container WEBM1000 Illustration 233 Rear view 2 Disconnect hose 1 from torque converter housing 2 om E Illustration 234 3 Remove the torque converter scavenge screen from the torque converter housing 4 Wash the screen in a clean nonflammable solvent 5 Install the screen in the torque converter housing 6 Connect hose 1 to torque converter housing 2 7 Install the bottom guard WEBM1000 Track Check Adjust Illustration 235 Check the track adjustment Check the track for wear and for excessive dirt buildup Personal injury or death can result from grease under pressure Grease coming out of the relief valve under pressure can penetrate the body causing injury or death Do not
130. ble containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Drain The Oil Operate the machine in order to warm the power train oil The machine must be level Lower the attachments with slight down pressure See the Topic Transmission Oil Filter Replace in this manual for the procedure to change the filters Use a 126 7538 Nozzle if the machine is equipped with the high speed oil change arrangement The high speed oil change arrangement removes oil from the sump in the bevel gear case The high speed oil change arrangement does not remove oil from the torque converter or from the transmission case 171 Maintenance Section D6T LGP OEM Transmission Oil Change Illustration 248 1 Remove the plug from the drain in the bevel gear case Install a 4C 8563 Swivel into the valve Clamp a hose to the swivel A 25 4 mm 1 inch pipe and hose can be used Use a 25 4 mm 1 inch pipe with 1 11 1 2 NPTF threads Do not tighten the pipe Turn the swivel or pipe clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container Change the filter element See the Topic Transmission System O
131. block and hook block from stowing link reverse the above steps and ensure the stowing link is placed firmly back into the slot in bumper Lower the boom to the horizontal position onto wood blocks that are sufficient to support the boom Remove the cotter pin the retainer and pin 2 The approximate weight of the luff block is 76 kg 168 Ib Replace the pin and the retainer 2 in the boom Move the luff block clear of the boom and area it will be secured after the boom has been removed WEBM1000 A 035 30 71 01 2h Illustration 281 Location of pins for removal of boom 12 Fasten an appropriate lifting device to the boom The approximate weight of the boom is 936 kg 2064 Ib 13 Remove the cotter pins the retainers and the pins 8 from both sides of the support 14 Remove the boom from the machine Replace the pins in the support 209 WEBM1000 Operation Section Pipelayer Attachment Kit Before Operation 035 05 30 0194 Illustration 282 Location of Luff Block stowing point and stowing pin 9 15 Draw in the line for the boom and fasten the luff block to the machine at the luff block stowing point on the track frame for shipping using stowing pin 9 16 Draw in the excess line for the boom ensuring not to over tighten the cables to avoid causing kinks 210 Maintenance and Lubrication Section Pipelayer Attachment Kit Lubricant Viscosities Maintenance and Lubrication Secti
132. boom winch should stop No increase in tension should occur once the boom comes into contact with the left hand tower If the boom winch does not stop and continues to increase the cable tension STOP the operation at once and lower the boom to release the tension Adjust the boom stop valve as set out below WEBM1000 e Raise the boom vertical so that it is JUST in contact with the tower the boom kick out rod is fully retracted into the tower Do not over tighten the lines to the point that the boom or structures are overly stressed Remove the boom stop valve access panel from the tower Loosen the boom stop valve nuts Move the valve so that it just contacts the boom kick out rod Move the valve an additional 10 mm 3 8 in towards the boom so that the valve s piston is fully depressed Tighten the valve in position with the valve nuts Test the boom stop valve to see that it works properly Lower the boom until the boom stop valve piston is free from the kick out rod Replace the boom stop valve access panel from the tower Boom in slowly taking care not to over tension the boom lines when the boom goes vertical When the boom is vertical the kick out rod will move the boom stop valve piston in 9 5 mm 3 8 in and the boom winch should stop with the boom vertical No increase in tension should occur once the boom comes into contact with the left hand tower readjust the boom stop valve as required Boom Line
133. capability of 29484 kg 65000 Ib when the slope is less than 45 degrees WEBM1000 To obtain the proper lubrication a maximum slope should not exceed a grade of 100 percent or 45 degrees Reference See Slope Operation in this manual for more information Do not use the machine in explosive environments Special attachments and operating instructions are required for waste handling applications forestry applications and other custom configurations 35 Product Information Section D6T LGP OEM General Information 36 Product Information Section D6T LGP OEM Identification Information Identification Information Plate Locations and Film Locations The Product Identification Number PIN will be used to identify a powered machine that is designed for an operator to ride Caterpillar products such as engines transmissions and major attachments that are not designed for an operator to ride are identified by Serial Numbers For quick reference record the identification numbers in the spaces that are provided below the illustration Sar Cera E NUMBER CAT CATERPILLAR O r CATERPILLAR INC PEORIA IL 61629 USA PARTS MADEIN ORDER ba J 239 6006 1 Illustration 25 The PIN plate is attached to the ROPS mounting pad on the transmission Machine PIN Year of Manufacture MODEL NUMBER SERVICE INFORMATION MACH
134. ccc e 120 Caterpillar Product Identification Number 5 CE MNK aeaiee E I EA R 37 Certification cece n a 37 Certified Engine Maintenance 0eeeeee 5 Change the Hydraulic Oil 0 cee 156 Changing Direction and Speed l a 95 Checking the Battery Disconnect System 96 227 Index Section Circuit Breakers a e 155 Commercial Oils 155 Componer midis etchant ee 193 Compressed Recoil Spring oee 14 Connection for the PUMP s 109 Connection of Brake Release Pump 107 Containing Fluid Spillage 0 00ceee 18 E atol FE TAN AEE fate can wieemee EE 20 Coolant Information s 119 Cooling System Coolant ELC Change 129 Cooling System Coolant Extender ELC Add 131 Cooling System Coolant Level Check 132 Cooling System Coolant Sample Level 1 ASOT urdea E ia ery te tiles tat 133 Cooling System Coolant Sample Level 2 Otai s Sie ashok sts e Mie shades asia he las baka 134 Cooling System Water Temperature Regulator Replace sr E O a amauta 135 Counterweight Control a 202 Counterweight Control Lockout Lever 202 Counterweight Crushing Hazard 0 06 186 Counterweight Lock Lever ee 203 Counterweight Lock Lever Thrown or Flying Objects Full Body Exposure s 187 Crushing Prevention and Cutting Prevention 19 D Daily CHECKS l enn 198 Daily INSPECTION ereere 43 Data Broadcasts ecne oaa 87 D
135. ce Manual Severe Service Application to determine if oil change interval should be reduced from the normal change interval If operating in any of the conditions or environments outlined in the Severe Service Application use S O S Services oil analysis to determine the best oil change interval If S O S Services oil analysis S is not being used oil change interval should be reduced to 250 hrs 140 Maintenance Section D6T LGP OEM Engine Oil and Filter Change Table 27 WEBM1000 Oil Change Interval Multigrade Oil Type Operating Conditions ACEA C9 E6 Specification TBN below 10 4 Normal Severe Service Application Cat DEO ULS 500 hr 250 hr Oil meeting the requirements of the Cat 500 hr 250 hr ECF 3 Specification or the API CJ 4 classification 8 minimum TBN Preferred Oil meeting the requirements of the 500 hr 250 hr 1 The standard oil change interval in this engine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met If the type of oil the quality of the oil and the operating conditions fail to meet certain standards the oil change intervals must be decreased to 250 hours Refer to Special Publication PEHJ0192 Optimizing Oil Change Intervals in order to determine whether the oil change interval should be reduced to 250 hours Procedure for Changing the Engine Oil and Filter Hot oil and components can cause personal
136. cell and GPS Receiver Antenna used in MTS500 family of telematics has overall antenna gain which complies with limits per Cinterion requirements for GSM antennas in Canada S 850 150 10 0 56667 mW em R 20cm P 1771 mW Maximum Gain 2 06 dBi Laird antenna TRP GSM strongest measurements Frequency 848 8 Mhz Antenna Port Power 33 dBm Maximum Gain 0 255211 dBi Maximum Power Peak EIRP 33 2552 dBm Mobile Mark Antenna CVS 900 1900 uses CVS RG 174 cable Antenna transmission gains up to 2 5dB based on data based on Azimuth plot However cable loss of 0 34dB ft and data sheet specify 8 foot cable resulting in 2 5 8 0 34 0 22 db maximum gain Both product antennas comply with FCC requirements This Class B digital apparatus complies with Canadian ICES 003 Cet appareil num rique de la classe B est conforme la norme NMB 003 du Canada This document is maintained under Trimble part number 78356 00 DC and the technical file is maintained under Trimble part number 78356 00 CE at Manufacturer Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 3642 USA Declaration Approved Sign ture Name Chuck Maniscalco Title Director of Engineering Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 3642 USA Telephone 408 481 8000 FCC DoC Rev A Machine Operation 92 Operation Section D6T LGP OEM Machine Operation Ill
137. ch Recoil Spring Housing 25 6 6 5 5 Pivot Shaft per Side 5 1 3 1 1 Note When you are operating on severe slopes the quantity of oil in the power train can be increased up to 10 percent When you are operating with the increased oil quantity prolonged operation in some machines can cause high power train oil temperatures After the work on the severe slopes has been completed drain the excessive oil quantity from the bevel gear case Ecology Drains Table 24 Ecology Drain Components Drain Location Component Needed 12 7 mm 0 5 inch pipe with 1 2 14 NPTH thread Transmission 12 7 mm 0 5 inch pipe with 1 2 14 NPTH thread Torque Converter 19 mm 0 75 inch pipe Engine Oil with 3 4 14 NPTH thread 126 7914 Oil Drain Coupling Hydraulic Tank or 25 4 mm 1 inch pipe with 1 11 1 2 NPTH thread 33 mm 1 31 inch pipe with 1 5 16 12 NPTH thread Bevel Gear Case WEBM1000 S 0 S Information S 0 S Services is a highly recommended process for Cat 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 Re
138. chine Connect a machine on each end of towed machine Be sure all necessary repairs and adjustments have been made before a machine that has been towed to a service area is put back into operation Note Consult your Caterpillar dealer for towing a disabled machine This machine is equipped with spring applied brakes These brakes are also oil pressure released brakes If the power train oil system for pressure oil is inoperable the brakes are applied and the machine cannot be moved Do not allow an operator to be on the machine that is being towed unless the operator can control the steering and or the braking Do not attempt to tow a machine without reading and understanding the following procedures WEBM1000 These towing instructions are for moving a disabled machine for a short distance at low speed Move the machine at a speed of 2 km h 1 2 mph or less to a convenient location for repair These instructions are only for emergencies Always haul the machine if long distance moving is required When any towed machine is loaded the machine must be equipped with a brake system that is operable from the operator s compartment Normally the towing machine should be as large as the disabled machine or larger than the disabled machine Make sure that the towing machine has enough brake capacity enough weight and enough power The towing machine must be able to control both machines for the grade that is involved and for
139. cked third gear Auto kickdown 7 This indicator is illuminated when the auto kickdown mode is active Parking Brake 8 This status indicator P indicates that the parking brake is engaged If this indicator is illuminated disengage the parking brake before attempting to move the machine Fuel Level 9 This status indicator is illuminated when the fuel level is low DPF Filter 10 This indicator illuminates when the amount of soot that is collected in the DPF is above 90 High Temperature Indicator Lamp 11 An illuminated HEST lamp shows that the aftertreatment regeneration device ARD is active D OS Battery Charging 12 This indicator is illuminated when the charging system is not OK SE EE KEL WEBM1000 Implement Lockout 13 This indicator is illuminated when the implement lockout switch is activated indicates that the freespool mechanism is latched and active Winch Freespool 14 This indicator Float 15 This status indicator is illuminated when the float mode is active Operator Seat 16 The Operator is Not in Seat 16 This status indicator is illuminated when the engine is running and the operator leaves the seat unoccupied e Operator in Seat Sensor The sensor unit that is mounted under the operator seat prevents movement of the machine or implements if the operator is out of t
140. commendations 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 Consult your Cat dealer for complete information and assistance in establishing an S O S program for your equipment WEBM1000 Maintenance Support Welding on Machines and Engines with Electronic Controls Do not weld on any protective structure If it is necessary to repair a protective structure contact your Caterpillar dealer Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings When possible remove the component that must be welded from the machine or the engine and then weld the component If you must weld near an electronic control on the machine or the engine temporarily remove the electronic control in order to prevent heat related damage The following steps should be followed in order to weld on a machine or an engine with electronic controls 1 Turn off the engine Place the engine start switch in the OFF position 2 If equipped turn the battery disconnect switch to the OFF position If there is no battery disconnect switch remove the negative battery cable at the battery NOTICE Do NOT use electrical components ECM or sensors or electronic component grounding points for grounding the welder 3 Clamp the ground cable fr
141. conditions e machine operation e machine transportation 28 Safety Section D6T LGP OEM Parking Table 1 When Operating Near High Voltage Power Lines Normal Voltage Phase to Phase Minimum Clearance Required 0 Volts to 50 kVolts 3 05 Meters 10 Feet Over 50 kVolts to 200 kVolts 4 60 Meters 15 Feet Over 200 kVolts to 350 kVolts 6 10 Meters 20 Feet Over 350 kVolts to 500 kVolts 7 62 Meters 25 Feet Over 500 kVolts to 750 kVolts 10 67 Meters 35 Feet Over 750 kVolts to 1000 kVolts 13 72 Meters 45 Feet While In Transit Near High Voltage Power Lines Normal Voltage Phase to Phase Minimum Clearance Required 0 Volts to 75 kVolts 1 22 Meters 4 Feet Over 75 kVolts to 50 kVolts 1 83 Meters 6 Feet Over 50 kVolts to 345 kVolts 3 05 Meters 10 Feet Over 345 kVolts to 750 kVolts 6 10 Meters 20 Feet Over 750 kVolts to 1000 kVolts 7 62 Meters 25 Feet Parking Park on a level surface If you must park on a grade use blocks to prevent the machine from rolling Apply the service brake in order to stop the machine Move the transmission control lever to NEUTRAL position and move the engine speed switch to the LOW IDLE position Engage the parking brake Lower the boom to the ground and fully retract the counterweight Turn the engine start switch key to OFF position and remove the key Turn the key for the battery disconnect swi
142. controls are locked out the indicator light for the hydraulic lockout control will stay on until the controls are unlocked The indicator light for the auto kickdown will stay on until the function is unselected If the system detects a fault check the electrical system Make all of the necessary repairs before you start the engine 5 Before you start the engine check for the presence of bystanders or maintenance personnel Ensure that all personnel are clear of the machine Briefly sound the forward horn before you start the engine 6 Turn start switch key 3 to the START position Crank the engine Release the key when the engine starts Illustration 133 Location of battery disconnect switch A _ NOTICE Do not crank the engine for more than 30 seconds Allow the starter to cool for two minutes before cranking again Turbocharger damage can result if the engine rpm is not kept low until the oil gauge display verifies that the oil pressure is sufficient 1 Turn the battery disconnect switch to the ON position The battery disconnect switch is inside of the access door in front of the battery compartment on the left side of the machine Ether Starting Aid If Equipped Ether Starting Aid The machine may be equipped with an ether starting aid The ether starting aid is continuously available to the engine for cold weather starting The engine ECM will determine automatically when the premeasured amount of ethe
143. coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates WEBM1000 Testing the coolant can be done at your Caterpill
144. cs ee Eco Enter Enable BladeFloat mmm 52h Not Installed Implement ET Installatio Enter Single Tilt ma ap Password em Pwr Ang Tilt Bld Not Installed Rear Attachment retalation Satu MD Enter gt Single Axis Ripper retallation Satu Statug Password Mechanical Winch 3 Function Hydrualic Fan Fan purge ise Cycle ET Install maa Parameters m 5 60 seconds 5 60 seconds Fan oe Cycle if ET Install Engine Setul Engine Fan Enable Engine Idle Enter Enable eae pee mm Password gt Disable ne ine Idle Enter ae m Password gt Adjust Set Desired Measurement Displayed Backlight Day gt Backlight Night gt l ra co Machine Lighting Timer oe Satie me os gt q Password Enabled Display Setup Illustration 101 The Settings menu allows the user to adjust e Monitoring System Display parameters for the following categories e Machine operation Bidirectional shift Operating conditions preferences of the operator e Power train operation and requirements for efficient operation inform the operator that adjustments to the parameters are e Implement operation needed The setup of the machine determines the display of variable parameters e Engine operation WEBM1000 The Settings menu option is entered by selecting Settings from the main menu Press the UP arrow button or the DOWN arrow button until Settings is highlighted in order to sele
145. cs rubbers fabrics and resins in fiberglass panels are also flammable Fire Extinguisher Location Make sure that a fire extinguisher is available Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher Obey the recommendations on the instruction plate Mount the fire extinguisher in the accepted location per local regulations If your machine is equipped with a ROPS structure strap the mounting plate to the ROPS in order to mount the fire extinguisher If the weight of the fire extinguisher exceeds 4 5 kg 10 Ib mount the fire extinguisher near the bottom of the ROPS Do not mount the fire extinguisher at the upper one third area of the ROPS Do not weld the ROPS structure in order to install the fire extinguisher Also do not drill holes in the ROPS structure in order to mount the fire extinguisher on the ROPS Consult your Cat dealer for the proper procedure for mounting the fire extinguisher Track Information Track adjusting systems use either grease or oil under high pressure to keep the track under tension WEBM1000 Grease or oil under high pressure coming out of the relief valve can penetrate the body causing injury or death Do not watch the relief valve to see if grease or oil is escaping Watch the track or track adjustment cylinder to see if the track is being loosened The pins and bushings in a dry track pin joint can become very hot
146. ct the Settings menu Then press the OK button Refer to Illustration 103 Note Press the main menu button in order to display the Main Menu 1s A PEE TES se gt K l ly D O 25 Ora E l 2F Operator Main Service Cs d Memu Machine Status Illustration 102 The following screen will now be displayed Setting Menu Engine Illustration 103 The Settings menu has six categories with adjustable parameters that are listed above The six categories are Bidirectional Shift Power Train Implement Engine Display Setup and Machine Setup To adjust to the associated parameters press the UP arrow button or the DOWN arrow button until the desired category is highlighted Then press the OK button in order to access the parameters in that category From this point follow the screen prompts in order to adjust to the available parameters 77 Operation Section D6T LGP OEM Machine Operation Password Entry Screen Some of the Settings are password protected The display will bring up the password screen automatically when a password is needed Once a password has been entered the display will remember this password and not ask for one again until the next key cycle lt gt to enter amp to cancel Illustration 104 Passwerd entry screen The password length can be from 1 to 5 numbers When entering the
147. d if necessary repair the service brake before returning the machine to operation WEBM1000 Cab Filter Fresh Air Clean Inspect Replace If Equipped aw by A A Illustration 156 Top view 1 4 Remove filter cover 1 and filter element 2 The filter cover is in front of the front window of the cab The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side Look through the filter toward a bright light Inspect the element for damage Inspect the gaskets for damage Replace damaged filters Install the filter element Note Clean the filters more often in dusty conditions WEBM1000 Cab Filter Recirculation Clean Inspect Replace If Equipped Illustration 157 1 Remove the filter element that is positioned in the operator s compartment below the left side of the dash 2 The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side 3 Look through the filter toward a bright light Inspect the element for damage Inspect the gaskets for damage Replace damaged filters 4 Install the filter element Note Clean the filters more often in dusty conditions 129 Maintenance Section D6T LGP OEM Cab Filter Recirculation Clean Inspect Replace Cooling Sys
148. d workmanship which cause the failure of an emission related component to be identical in all material respects to the component as described in the Caterpillar application for certification for the warranty period A detailed explanation of the Emission Control Warranty that is applicable to new non road and stationary diesel engines including the components covered and the warranty period is found in supplement Special Publication SELF9001 Federal Emission Control Warranty and Emission Control Warranty for California Consult your authorized Cat dealer to determine if your engine is subject to an Emission Control Warranty 177 Warranty Section D6T LGP OEM Warranty Information 178 Reference Information Section D6T LGP OEM Reference Materials Reference Information Section D6T LGP OEM Reference Materials Reference Material The following literature can be obtained from any Cat dealer e Special Publication SEBD0518 Know Your Cooling System e Special Publication SEBDO970 Coolant and Your Engine e Special Publication SEBD0717 Diesel Fuels and Your Engine e Service Magazine SEBD1587 28October 1985 e What ROPS FOPS Certification Means e Special Instruction SEHS6929 Inspection Maintenance and Repair of Rollover Protective Structures ROPS and Attachment Installation Guidelines e Special Instruction SEHS7392 Storage of Diesel Engines e Speci
149. d Maintenance Manual Hydraulic System Oil Sample Obtain Machines that are used in severe conditions are not included in the 6000 hour maintenance interval Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule Lubricants Approved hydraulic oil must be used to obtain the 4000 hour hydraulic oil change Refer to the list that follows for approved oils Caterpillar Hydraulic Oils e Cat HYDO Advanced e Cat TDTO e Cat TDTO TMS e Cat DEO e Cat BIO HYDO Advanced HEES e Cat MTO Commercial Oils If Caterpillar oils cannot be used oils that meet the following oil specifications can be used in most Caterpillar hydraulic systems and in most Caterpillar hydrostatic transmission systems Engine oils that meet the performance requirements of one of the following oil specifications Cat ECF 1 a Cat ECF 2 and Cat ECF 3 The oils must have a minimum level of zinc additive of 0 09 percent 900 ppm Biodegradable oils that meet the performance requirements of Cat BF 2 oil specification 156 Maintenance Section D6T LGP OEM Hydraulic System Oil Change e Oils that meet the Cat TO 4 performance requirements that have a minimum zinc additive level of 0 09 percent 900 ppm Note Industrial hydraulic oils are not recommended for the hydraulic systems of Caterpillar machines Industrial hydraulic oils are more likely to allow corrosion and industrial hydraulic o
150. d nuts Tighten nuts 1 to 370 50 N m 273 37 lb ft 13 Add the coolant solution See the following topic in this publication e Capacities Refill Note Caterpillar antifreeze contains additive If you are using Caterpillar antifreeze do not add the supplemental coolant additive at this time Also do not change the supplemental coolant additive element at this time 14 Start the engine Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes 332 6001 Illustration 160 15 Open the left engine access door Check the coolant level Make necessary adjustments to the coolant level Fill the coolant level to the top of the sight glass as shown 16 If the gasket is damaged replace the filler cap Install the filler cap WEBM1000 17 Stop the engine Illustration 161 18 Clean the radiator cores with compressed air You may need to use water in order to remove debris 19 Close the left engine access door Cooling System Coolant Extender ELC Add NOTICE Care must be taken to ensure th
151. decreases as the undercarriage wears If a rebuilt idler or a new idler is installed with track rollers that are worn dimension B decreases Adjustment of the front idler to the correct height can improve the ride of the tractor and the performance of the dozer Use the following procedures to determine the best operating position If the machine is operated on FIRM UNDERFOOT conditions and excess vibration occurs shims can be removed in order to raise the front idler If the machine is operated on SOFT UNDERFOOT conditions and dozing performance is poor shims can be installed in order to lower the front idler Lowering the front idler can improve dozing performance If ground rippling by the dozer or excess vibration occur in soft material shims can be removed in order to raise the front idler Consult your Caterpillar dealer for detailed information about checking the idler and about adjustments to the idler WEBM1000 Fuel Priming Pump Replace Illustration 191 A replacement kit is available for the electronic fuel priming pump Contact your Cat dealer for the correct part number and details for your application Fuel System Prime Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery whe
152. diesel fuel used must meet specific blending requirements All the guidelines and requirements are provided in the latest revision of Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations This manual may be found on the Web at Safety Cat com Coolant Information The information provided in this Coolant Recommendation section should be used with the Lubricants Information provided in the latest revision of Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations This manual may be found on the Web at Safety Cat com The following two types of coolants may be used in Cat diesel engines Preferred Cat ELC Extended Life Coolant Acceptable Cat DEAC Diesel Engine Antifreeze Coolant NOTICE Never use water alone without Supplemental Coolant Additives SCA or without inhibited coolant Water alone is corrosive at engine operating temperatures In addition water alone does not provide adequate protection against boiling or freezing 120 Maintenance Section D6T LGP OEM Lubricant Viscosities and Refill Capacities Capacities Refill Table 23 APPROXIMATE REFILL CAPACITIES Compartment or Imperial System Liters USgal gallon Cooling System 51 13 5 11 2 Fuel Tank 425 112 3 93 5 Engine Crankcase and Filter 24 5 6 5 5 4 Power Train Oil System 148 39 1 32 6 Hydraulic Tank Oil 96 25 4 21 1 Each Final Drive 13 5 3 6 3 Ea
153. ditional safety measure keep a fire extinguisher on the machine 24 Safety Section D6T LGP OEM Fire Safety Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Follow the recommendations on the instruction plate Consider installation of an aftermarket Fire Suppression System if the application and working conditions warrant the installation Fire Safety Note Locate secondary exits and how to use the secondary exits before you operate the machine Note Locate fire extinguishers and how to use a fire extinguisher before you operate the machine If you find that you are involved in a machine fire your safety and that of others on site is the top priority The following actions should only be performed if the actions do not present a danger or risk to you and any nearby people At all times you should assess the risk of personal injury and move away to a safe distance as soon as you feel unsafe Move the machine away from nearby combustible material such as fuel oil stations structures trash mulch and timber Lower any implements and turn off the engine as soon as possible If you leave the engine running the engine will continue to feed a fire The fire will be fed from any damaged hoses that are attached to the engine or pumps If possible turn the battery disconnect switch to the OFF position Disconnecting the battery will remove
154. ditioning lights and others that are powered by the main power relay This function can be enabled or disabled by using the onboard display Note Engine Idle Shutdown may be required for local regulations The Engine Idle Shutdown EIS shuts down the engine if the following conditions are met e The parking brake is applied or the transmission is in neutral e The service brake is released e The throttle pedal is released e The implement controls are not active At 20 seconds before the engine shuts down the control limits engine speed to 1000 rom and turns on the action lamp and action alarm An operator can move one of the controls in order to cancel a shutdown Using the service brake pedal to cancel a shutdown is the recommended option for the operator 73 Operation Section D6T LGP OEM Machine Operation Display Module aw A i pA B E F Senco G Machine Status H J Illustration 97 A Gear and Direction B Menu option Display menu Four way button OK button Back to previous screen Operator menu Return to main menu J Backlight adjustment Requested gear A This display area shows the requested gear and the current direction of the machine Menu Option B This display area shows the selected menu Display Menu C This display area shows the numerous menus and submenus in order to navigate from one screen to another screen Also this display area depends
155. dure 13 Close the left engine access door Fuel Tank Cap Filter and Strainer Replace Clean Illustration 198 The fuel tank is located on the rear of the machine The filler cap is on the left side of the machine next to the ROPS WEBM1000 Illustration 199 1 Lift lever 3 in order to remove the fuel tank filler cap Turn the lever counterclockwise until the lever stops Lift the cap straight up in order to remove the cap 2 Remove the fuel strainer from the filler neck 3 In order to replace the filter assembly remove two screws that secure filter assembly 2 to the fuel cap Remove filter assembly 2 valve 1 and the gaskets 4 Wash the cap and the strainer in a clean nonflammable solvent 5 Inspect the tank cap seal If the seal is damaged replace the seal 6 Replace the filter assembly the valve the gaskets and the screws Use a 9X 2205 Cap Filter Kit 7 Install the strainer 8 Install the fuel cap Rotate the fuel cap clockwise until three tabs 5 drop into the slots in the adapter Rotate lever 3 clockwise until the lever stops Lower lever 3 over locking tab 4 151 Maintenance Section D6T LGP OEM Fuel Tank Water and Sediment Drain Fuel Tank Water and Sediment Drain NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with
156. e lever 1 in order to lock the seat in place WEBM1000 Adjusting the Angle of the Back of the Seat Illustration 39 Back Angle Adjustment 2 Lift lever 2 and allow the seat back to tilt forward Push the front of the backrest in order to tilt the seat backward Release lever 2 at the desired position Adjusting the Bottom Seat Cushion The bottom seat cushion has two positions Illustration 40 The bottom seat cushion is shown in the lower or the flattest posi tion WEBM1000 The bottom seat cushion is in the lower or the flattest position when the end of the rod is in the bottom of the groove in bracket 3 Pull forward and pull upward on the bottom seat cushion in order to change the position of the bottom seat cushion back to the upper position Illustration 41 The bottom seat cushion is shown in the upper position or the angled position The bottom seat cushion is in the upper position or the angled position when the end of the rod is in the top of the groove in bracket 3 Pull forward and push down on the bottom seat cushion in order to change the position of the bottom seat cushion back to the lower position Adjusting the Height of the Seat Seats with Mechanical Suspension Illustration 42 45 Operation Section
157. e crankcase close shutoff valve 2 Remove the hose Install the crankcase drain access cover in the crankcase guard Illustration 178 5 Open the engine access door on the right side of the machine 6 Clean the area around engine oil filter 2 before you remove the engine oil filter Remove the engine oil filter with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 141 Maintenance Section D6T LGP OEM Engine Oil and Filter Change 7 Clean the base of the engine oil filter housing Make sure that all of the old filter gasket is removed 8 Apply a thin coat of oil to the seal on the new filter 9 Install the new engine oil filter by hand until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 10 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Cat filters use the instructions that are provided with the filter Note You may need to use a Cat strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the ins
158. e of injury Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for the following items e Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids e Tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids WEBM1000 Inhalation Illustration 17 Exhaust Use caution Exhaust fumes can be hazardous to your health If you operate the machine in an enclosed area adequate ventilation is necessary Asbestos Information Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free Caterpillar recommends the use of only genuine Cat replacement parts Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris Use caution Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers Inhaling this dust can be hazardous to your health The components that may contain asbestos fibers are brake pads brake
159. e recommended intervals Using fluids which are not recommended in Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Extending maintenance intervals for changing the engine oil and engine coolant without S O S validation Extending maintenance intervals for changing air filters oil filters and fuel filters Failure to use a water separator Using filters which are not recommended by Special Publication PEWJ0074 2008 Cat Filter and Fluid Application Guide Storing the engine for more than 3 months but less than 1 yr For information about engine storage refer to Special Publication SEHS9031 Storage Procedure for Caterpillar Products WEBM1000 WEBM1000 Maintenance Interval Schedule Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may requi
160. e Inspect the winch final drive for leaks Repair any final drive leaks e Inspect covers and the guards for damage for loose bolts and for missing bolts e Inspect the condition of the steps and of the handholds Inspect the steps and the handholds for cleanliness If necessary repair the steps or clean the steps e Inspect the operator compartment for cleanliness Remove any trash buildup and any dirt buildup e Inspect mirrors and make sure they are in good condition and replace if broken WEBM1000 035 05 05 019B Note Refer to the tractor operation manual for detailed information on the specific daily inspection of the tractor unit NOTICE Accumulated grease and oil on a machine is a fire hazard Remove debris with steam cleaning or high pressure water at the specified interval in the Maintenance Interval Schedule or each time any significant quantity of oil is spilled on the machine Daily Checks After you inspect the machine perform the daily maintenance that is listed in the maintenance interval schedule Perform the daily maintenance before you mount the machine in order to operate the machine Refer to Operation and Maintenance Manual Maintenance Interval Schedule for the correct procedures for the following checks e Boom Pivot Pins Lubricate e Cooling System Coolant Level Check e Counterweight Cylinder Bearings Lubricate WEBM1000 Counterweight Hinge Pins Lubricate Fair
161. e Machine for the proper technique for securing the machine Refer to Operation and Maintenance Manual Specifications for specific weight information g Ww Illustration 141 An image of a Track Type Tractor with an attached ripper is shown for example only NOTICE Improper lifting or tiedowns can allow load to shift and can cause injury and damage WEBM1000 Note Do not use handles or steps in order to lift or tie down the machine 1 The approximate machine shipping weights are found in the Operation and Maintenance Manual Specifications The instructions that are listed below describe the units that are manufactured by Caterpillar Inc Note Significant deviations can affect shipping the machine or significant deviations can affect lifting the machine Some examples of these deviations are listed below e Different implements e Additional fuel e Wider track shoes e Tracks with accumulated mud The parking brake must be engaged before you sling the machine Engage the parking brake before you secure the machine with tie downs Use properly rated cables and use properly rated slings for lifting For a machine without a ripper position the slings beneath the front of the track and beneath the rear of the track Fora machine with a ripper position the slings beneath the front of the track and under the ripper at the rear of the machine On sharp corners use corner protectors The crane
162. e The operating frequency range for the Product Link 121SR system is 148 to 150 MHz e The transmit power rating for the Product Link 522 523 transmitter is approximately 1 W e The operating frequency range for the Product Link 522 523 system is 824 to 849 MHz 880 to 915 MHz 1710 to 1785 MHz and 1850 to 1910 MHz Consult your Cat dealer if there are any questions Information for the initial installation of the Product Link 121SR system is available in Special Instruction REHS2365 An Installation Guide for the Product Link PL121SR and for the PL300 Information for the initial installation of the Product Link 522 523 system is available in Special Instruction REHS2368 Installation Procedure For Product Link PL522 523 Cellular Operation configuration and troubleshooting information for the Product Link 121SR system can be found in the Systems Operation Troubleshooting Testing and Adjusting RENR7911 Product Link 121 821 Operation configuration and troubleshooting information for the Product Link 522 523 system can be found in the Systems Operation Troubleshooting Testing and Adjusting RENR8143 Product Link PL522 523 Machine Security Machine Lock Icon wo 88 Operation Section D6T LGP OEM Machine Operation De rate Some machines can have the machine engine de rated remotely by the owner of the machine The action causes the machine to operate much slower than normal
163. e brake pedal 3 in order to stop the machine 2 Move transmission control 2 to NEUTRAL 3 Engage parking brake 1 4 Lower the bulldozer blade and lower all of the attachments to the ground Apply slight downward pressure Stopping the Engine NOTICE Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of engine components Refer to the following procedure to allow the engine to cool and to prevent excessive temperatures in the turbocharger housing which could cause oil coking problems 101 Operation Section D6T LGP OEM Parking 1 While the machine is stopped run the engine for 5 minutes at low idle Illustration 136 2 Turn the start switch key to the OFF position Remove the start switch key Delayed Engine Shut Down N Y iy OFF Dl Engine Cooldown 0 ACTIVE AUT Illustration 137 This message display alerts the operator that an engine cooldown is active The engine key start switch is in the OFF position After the delayed engine shutdown has been completed the engine will shut down See Diesel Particulate Filter Regeneration in this manual for additional information on delayed engine shutdown 102 Operation Section D6T LGP OEM Parking Idling the Engine for Extended Periods If the machine is parked and left running for extended periods set the engine speed at a slightly higher RPM than l
164. e engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check the coolant level only after the engine has been stopped Ensure that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure Cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Oils Hot oil and hot components can cause personal 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 enough to touch with a bare hand Follow the standard procedure in this manual in order to remove the hydraulic tank filler cap Batteries Electrolyte is an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended WEBM1000 Fire Prevention and Explosion Prevention I Illustration 19 Regeneration The exhaust gas temperatures during regeneration will be elevated Follow proper fire prevention instr
165. e retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pin Chips or other debris can fly off an object when you strike the object Make sure that no one can be injured by flying debris before striking any object Burn Prevention Do not touch any part of an operating engine Allow machine systems to cool before any maintenance is performed 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 Exhaust Gas Recirculation Cooler The exhaust gas recirculation EGR cooler may contain a small amount of sulfuric acid The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid that is formed The sulfuric acid may spill from the EGR cooler during service of the engine The sulfuric acid will burn the eyes skin and clothing on contact Always wear eye shields rubber gloves and protective clothing when you may come in contact with fluids that may spill from the EGR cooler If fluid contacts the eyes immediately flush with water and seek medical help WEBM1000 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 th
166. e the counterweight control 5 to the HOLD position Flip the counterweight control lockout lever 6 forward in order to lock the counterweight control 5 in the HOLD position Flip the lock lever 6 to the rear position in order to allow actuation of the counterweight control 203 WEBM1000 Operation Section Pipelayer Attachment Kit Before Operation Throttle control switch amp Operator Heater switch 7 B Removed replaced with C 046 05 63 30G4 Illustration 272 Control Switches Throttle Control Switch Refer to tractor s operation and maintenance manual for correct operation Hydraulic lockout switch Removed use Speed d gt Lockout Control Lock 2 and Counterweight p Control Lockout Lever 6 j gt s Operator Heater switch if equipped Use the switch to vary the flow of heated air to the operator station High flow Low flow or Off in the middle position P a Horn location moved 8 NOTE New location of this tractor s control refer to the tractors operation and maintenance manual for correct operation Illustration 273 Counterweight Lock Lever 1 locked in the extended position front view 1 Counterweight Lock Lever Crushing Hazard When the counterweight is in the fully extended position for servicing the machine secure the extended counterweight with the counterweight lock lever Use the counterweight lock lever to avoid possible personnel injury or death from crush
167. e the extended counterweight with the counterweight lock lever Use the counterweight lock lever to avoid possible personnel injury or death from crushing Keep all personnel away from the counterweight when lowering the counterweight to avoid possible personnel injury or death WEBM1000 Counterweight Lock Lever Thrown or Flying Objects Full Body Exposure 10 Safety message 10 located on the right side near the counterweight control Thrown or flying objects full body exposure Do not operate counterweight while the counterweight lock lever is engaged Retracting the counterweight while the lock lever is engaged could cause serious equipment damage personnel injury or even death Ensure the counterweight lock lever is fully disengaged before retracting the counterweight Before Operation 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 Make sure that the 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 and in the Tractor s manual Fasten the seat belt securely 187 Safety Section Pipelayer Attachment Kit Before Operation Visibility Information Before starting the machine the operator shall perform a walk around inspection in order to ensure that there are no
168. e the following CAT0O789BG 6 8L12345 Doo o Illustration 1 Where 1 Caterpillar s World Manufacturing Code characters 1 3 2 Machine Descriptor characters 4 8 3 Check Character character 9 4 Machine Indicator Section MIS or Product Sequence Number characters 10 17 These were previously referred to as the Serial Number Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format Components such as engines transmissions axles etc and work tools will continue to use an 8 character Serial Number S N 6 Safety Section D6T LGP OEM WEBM1000 Safety Messages Safety Section D6T LGP OEM Safety Messages Illustration 2 WEBM1000 7 Safety Section D6T LGP OEM Safety Messages z SAEWASO3449 APR96 LEVEL Il 1803449 1992 LEVEL II Illustration 3 There are several specific safety messages on this machine The exact location of the hazards and the description of the hazards are reviewed in this section Become familiarized with all safety messages Make sure that all 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 visible When you clean the safety messages use a cloth water and soap Do not use solven
169. ean 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 messages Loose adhesive will allow the safety message to fall Do not use pressure washers to clean the warning signs Replace any safety message that is damaged or missing If a safety message is attached to a part of the machine that is replaced install a safety message on the replacement part WEBM1000 Do Not Operate 1 Safety message 1 is located outside of the left hand operator console arm rest Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in injury or death Contact your dealer for replacement manuals Proper care is your responsibility WEBM1000 Electrical Power Lines 2 Safety message 2 is located on the right side of the console on the guarding to the front of the pipelayer controls Electrocution Hazard Keep the machine and attachments a safe distance from electrical power Stay clear 3 M 10 ft plus twice the line insulator length Read and understand the instructions and warnings in the Operation and Maintenance Manual Failure to follow the instructions and warnings will cause serious injury or death 183
170. ecelerator Pedal c ccccccsssccesssssseeeeestseseeeenes 53 Declaration of Conformity 0 00 eee 40 Decommissioning and Disposal 066 179 Delayed Engine Shut Down ssanie 72 101 Delayed Engine Shutdown i 65 Diagnostic and Event Codes c cece 80 Diesel Fuel Recommendations 0cee 118 Diesel Particulate Filter Clean Replace 136 Diesel Particulate Filter Regeneration 0 63 Differential Steering Control 0 0 00 cece 51 Digital Display Window n 69 Display Module ou eee a a a 73 Display Readout sortiren enii 70 Display Settings ccc ccc eeeeeeeteeeeeeneeees 78 Dispose of Waste Properly cece 19 Do Not Operate 0 0 0 ccccccceeeeteteeeeneeeees 8 182 Do Not Weld on the FOPS niii 11 Do Not Weld on the ROPS o 9 Duration Timer eisie e a 53 E ECM Summary re 80 Ecology Drains ai eei sert iiie aiee a 120 Electrical Connector Location 0 c eee 83 Electrical Power Lines 27 183 190 Electrical Shock Hazard 0 ccceeceeetteeeee 10 Electrical Storm Injury Prevention 0 065 25 Emergency Shutdown Override 0 eee 73 228 Index Section Emissions Certification Film 0 0 00 41 Emissions Warranty Information 06 177 Engine Air Filter Primary and or Secondary Element Clean Replace 136 Engine Air Precleaner Clean 138 Engine and Machine Warm Up saec 98 Eng
171. ecifically 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 Structure will be impaired if the ROPS 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 Loggin
172. ect load chart is referenced Loads must be within the capabilities of the machine Lifting capacity decreases as the load is moved further from the machine Use lifting slings that are approved and use lifting slings that are load tested Also all wire ropes or chains must be properly maintained The wire ropes and chains must meet local regulations You must know the load carrying capacity of these devices and you must know the correct use of these devices Limitations on Lifting Loads That Exceed the Working Range Do not load the boom beyond the maximum load capacity See Operation and Maintenance Manual Lifting Capacities for the load capacity of the boom When the load capacity is exceeded refer to American National Standards A N S I B3014 Also follow the procedures that are listed below Inspect the wire cable for defects prior to the lift operation Inspect the wire cable for defects after the lift operation Do not exceed the load capacity of the boom e The load must be handled safely in order to minimize tipping effects The lift operation and the inspections must be made under controlled conditions by an authorized person Electrical Power Lines Serious injury or death by electrocution can result if the machine or attachments are not kept the proper distance from electrical power lines Use the following charts in order to determine the safe distance from high voltage wires during these
173. ections before operating or performing lubrication maintenance and repair on this machine Operation The section entitled Pipelayer Attachment Kit of this manual contains an operation section and the section entitled D6T LGP OEM contains an operation section The operation sections are references for the new operator and a refresher for the experienced operator These sections include a discussion of gauges switches machine controls attachment controls transportation and towing information Photographs and illustrations guide the operator through correct procedures of checking starting operating and stopping the machine Operating techniques outlined in this publication are basic Skill and techniques develop as the operator gains knowledge of the machine and its capabilities Maintenance The section entitled Pipelayer Attachment Kit of this manual contains a maintenance section and the section entitled D6T LGP OEM contains a maintenance section The maintenance sections are guides to equipment care The Maintenance Interval Schedules MIS list the items to be maintained at a specific service interval Items without specific intervals are listed under the When Required service interval The Maintenance Interval Schedules liststhe page number for the step by step instructions required to accomplish the scheduled maintenance Use the Maintenance Interval Schedules as an index or one safe source
174. ective equipment and follow the established procedure in the Operation and Maintenance Manual Equipment Lowering with Engine Stopped in the Operation Section of the manual Sound Information and Vibration Information Sound Level Information The operator Equivalent Sound Pressure Level Leq is 81 dB A when ANSI SAE J1166 OCT 98 is used to measure the value for an enclosed cab This proceeding is a work cycle sound exposure level The cab was properly installed and maintained The test was conducted with the cab doors and the cab windows closed Hearing protection may be needed when the machine is operated with an open operator station for extended periods or in a noisy environment Hearing protection may be needed when the machine is operated with a cab that is not properly maintained or when the doors and windows are open for extended periods or in a noisy environment The average exterior sound pressure level is 86 dB A when the SAE J88Apr95 Constant Speed Moving Test procedure is used to measure the value for the standard machine The measurement was conducted under the following conditions distance of 15 m 49 2 ft and the machine moving forward in an intermediate gear ratio Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives The dynamic operator sound pressure level is 79 dB A when ISO 6396 1992 is used to measure the va
175. ee of personnel Engine Starting If a warning tag is attached to the start switch or attached to the controls do not start the engine Also do not move any controls 25 Safety Section D6T LGP OEM Electrical Storm Injury Prevention Move all hydraulic controls to the HOLD position before starting the engine Move the direction control switch to NEUTRAL Engage the parking brake switch Diesel engine exhaust contains products of combustion These products can be harmful to your health Always start the engine and always operate the engine in a ventilated area If you are in an enclosed area vent the exhaust to the outside Check for the presence of bystanders or maintenance personnel Ensure that all personnel are clear of the machine Briefly sound the horn before you start the engine Before Operation 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 shut position Adjust the rearview mirrors if equipped for best vision close to the machine Make sure that the 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 Visibility Informa
176. el Fuel Recommendations ULTRA LOW SULFUR FUEL ONLY oO S lt 15 mg kg Illustration 150 Illustration 151 Diesel fuel must meet Cat Specification for Distillate Fuel and the latest versions of ASTM D975 or EN 590 in order to ensure optimum engine performance Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for the latest fuel information and for Cat fuel specification This manual may be found on the Web at Safety Cat com NOTICE Ultra Low Sulfur Diesel ULSD fuel 0 0015 percent lt 15 ppm mg kg sulfur is required by regulation for use in engines certified to nonroad Tier 4 standards U S EPA Tier 4 certified and that are equipped with exhaust aftertreatment systems European ULSD 0 0010 percent lt 10ppm mg kg sulfur fuel is required by regulation for use in engines certified to European nonroad Stage IIIB and newer standards and are equipped with exhaust aftertreatment systems Misfueling with fuels of higher sulfur level will invalidate the warranty and have the following negative effects e Shorten the time interval between aftertreatment device service intervals cause the need for more frequent service intervals e Adversely impact the performance and life of aftertreatment devices cause loss of performance e Reduce regeneration intervals of aftertreatment devices e Reduce engine efficiency and durability e Increase the wear e Increase
177. elayer Attachment Kit Counterweight Cylinder Bearings Lubricate Counterweight Cylinder Bearings Lubricate 035 05 05 019B Illustration 289 Counterweight cylinder bearings fittings location 035 60 68 002 035 60 68 001 Illustration 290 Counterweight cylinder bearings location 1 Extend the counterweight and lock the counterweight into position Refer to the Operation and Maintenance Manual Counterweight Lock Lever for the proper procedure to lock the counterweight into position 2 Lubricate the upper grease fitting that is located in the head end of the cylinder 3 Lubricate the grease fitting that is located in the rod end of the cylinder 4 Follow the procedure to unlock the counterweight and retract the counterweight 5 Follow the procedure to unlock the counterweight and retract the counterweight There are two grease fittings for the counterweight cylinder WEBM1000 Counterweight Hinge Pins Lubricate Use a stable work platform placed in a secure location when lubricating the counterweight hinge pins If a secure location is not available use the appropriate safety equipment to prevent falling off of the machine Failure to work from a secure location may result in injury or death from a slip or a fall Lubricate the six pins through the grease fittings There are three grease fittings that face toward the front of the machine and there are three grease fittings that f
178. elease pump that is being used Note The axles must not be removed when you use a brake release pump Connection of Brake Release Pump Note This machine is free to move This machine is free to roll away This machine has no braking ability with the parking brake or with the service brake when both brakes have been released The pressure hoses from the pump connect to the brake valve The pump takes oil from the sump of the brake release pump Then the pump pressurizes the brake piston cavity in order to release the brake 108 Operation Section D6T LGP OEM Towing Information 1 bo Illustration 142 1 FT1973 Adapter Gp 8T 0855 Pressure Gauge 81 0477 Relief Valve Handle 6V 5016 Ball Valve FT1845 Brake Release Pump 123 0525 Brake Release Adapter Not shown 5P 2909 Plug Rat Rae ere 2 3 4 5 6 7 The machine brakes can be released for towing Use FT1973 Adapter Gp 1 two 123 0525 Adapters 7 and FT1845 Brake Release Pump 6 Relief Valve Setting NOTICE Possible brake piston seal damage could result without checking relief valve Opening pressure must be checked and adjusted before connection is made WEBM1000 Illustration 143 1 The main pressure hose connects to 9J 6190 Adapter Unio
179. eling Fill the fuel tank outdoors Properly clean areas of spillage Never store flammable fluids in the operator compartment of the machine Battery and Battery Cables Illustration 21 The following actions are recommended 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 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 action 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 WEBM1000 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 e Fraying e Abrasion e Cracking e Discoloration e Cuts on the insulation of the cable e Fouling e Corroded terminals damaged term
180. elt Seat Belt Adjustment for Retractable Seat Belts Fastening The Seat Belt Illustration 55 Pull seat belt 4 out of the retractor in a continuous motion Fasten seat belt catch 3 into buckle 2 Make sure 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 will allow the operator to have limited movement Illustration 56 Push the release button on the buckle in order to release the seat belt The seat belt will automatically retract into the retractor Extension of the Seat Belt When using retractable seat belts do not use seat 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 the person If the retractor does not lock up the seat belt will not retain the person Longer non retractable seat belts and extensions for the non retractable seat belts are available Caterpillar requires only non retractable seat belts to be used with a seat belt extension Consult your Cat dealer for longer seat belts and for information on extending the seat belts 50 Operation Section D6T LGP OEM WEBM1000 Machine Operation Operator Controls
181. em is still under pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system Note The refrigerant dryer contains the orifice tube and the desiccant that dries the liquid refrigerant WEBM1000 Illustration 228 Location of the refrigerant dryer is behind the lower access door on the left side of the machine Illustration 229 This refrigerant dryer does not have quick couplers Reference For the correct replacement procedure refer to Service Manual SENR5664 Air Conditioning and Heating R 134a All Caterpillar Machines In Line Refrigerant Dryer Remove and Install or the Disassembly and Assembly Manual for your machine WEBM1000 Rollover Protective Structure ROPS Inspect Illustration 230 A Front view B Side view Inspect the Rollover Protective Structure ROPS for bolts that are loose or damaged Replace any damaged bolts and any missing bolts with original replacement parts only Tighten the 12
182. emove the element 6 Install anew secondary filter element Push the element firmly in order to properly seat the element Write the date on the element if the element is replaced 7 Install primary filter element 2 and air cleaner housing cover 1 8 Close the engine access door 138 Maintenance Section D6T LGP OEM Engine Air Precleaner Clean Engine Air Precleaner Clean Illustration 171 1 Inspect the air inlet screen for dirt and for trash 2 Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner tubes for dirt and for dust 4 Use pressure air to clean the tubes Put the tubes on a flat surface Direct the pressurized air into the tubes from the top This proceeding loosens up the dirt Install the screens NOTICE Service the air cleaner only with the engine stopped Engine damage could result Engine Oil Level Check Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage 1 The engine oil level gauge relies on gravity The machine must be on a level surface for an accurate check WEBM1000 2 Open the engine access cover that is on the left side of the machine Illustration 172 3 Check the engine oil level gauge while the engine is stopped and the oil is at cold The engine oil level may a
183. enance Section D6T LGP OEM Fuses and Circuit Breakers Replace Reset 154 Maintenance Section D6T LGP OEM Fuses and Circuit Breakers Replace Reset O 3 DA F31 CB3 10A 15A Illustration 205 Relays R2 Front flood lights Cab pressurizer Forward Flood lights Access Egress Light Fuel priming relay Spare Spare 1 Spare Implement lever F1 15 Amp Implement control ECM F2 15 Amp Power train control ECM F3 15 Amp Unswitched auxiliary Service connector power F4 15 Amp Wipers F5 15 Amp Product link F6 10 Amp Engine control ECM F7 15 Amp Soot sensor F8 15 Amp Service brake F9 10 Amp High low voltage F10 10 Amp 12 V Converter F11 20 Amp WEBM1000 Rv R5 Rv R4 DIR F16 F19 15A 15A CAES Navigator F12 10 Amp Rear ROPS floodlights F13 15 Amp Auxiliary Converter switched power F14 15 Amp Horns F15 15 Amp Front floodlights F16 15 Amp Ignition key F17 10 Amp AccuGrade F18 15 Amp Forward floodlights cab post F19 15 Amp Parking brake solenoid F20 15 Amp Monitoring system display F21 15 Amp Accugrade electric mast F22 15 Amp WEBM1000 Spare F23 15 Amp Spare F24 15 Amp Cab pressurizer F25 10 Amp Seat F27 15
184. ent setting 13 Use the differential steering control in order to turn the machine 14 Drive the machine forward for best visibility and for control Changing Direction and Speed NOTICE For operator comfort and maximum service life of power train components deceleration and or braking is recommended before any directional shifts are made Speed changes and directional changes at full engine speed are possible 1 In order to decrease engine speed push down on the decelerator pedal 2 2 When the machine slows shift the transmission to the desired direction with direction selector 4 3 Increase the engine speed by releasing the decelerator pedal 2 4 Select the desired speed with speed range selector 5 95 Operation Section D6T LGP OEM Machine Operation Battery Disconnect Switch Illustration 132 The battery disconnect switch is on the left side of the machine behind the access door in front of the battery box On Insert the key and turn the key ay clockwise in order to activate the electrical system The switch must be ON before you start the engine Off Turn the key counterclockwise in OQ order to shut off the entire electrical system Remove the key when you exit the machine overnight or when you exit the machine for an extended period Also remove the key when you service the electrical system NOTICE Never move the battery disconnect switch to the OFF position
185. er adjustment for the weight of the operator WEBM1000 Adjusting the Lumbar Support Illustration 46 Adjustment for the Lumbar Support 9 a Rotate the knob 9 clockwise in order to increase support for the lower back Rotate the knob 9 counterclockwise in order to decrease support for the lower back WEBM1000 Extension for the Back of the Seat if equipped jar E H D gt P Illustration 47 Extension for the Back of the Seat 10 Lift up on extension 10 in order to remove the extension When you install extension 10 push the extension all the way downward The extension should touch the top of the seat 47 Operation Section D6T LGP OEM Machine Operation Seat Belt Illustration 48 Retractable Seat Belt 11 When the seat has been adjusted to fit the operator secure retractable seat belt 11 Storage for the Operation and Maintenance Manual Illustration 49 The Operation and Maintenance Manual should be stored and secured in the seat storage area 12 48 Operation Section D6T LGP OEM Machine Operation Seat Belt Note This machine was equipped with a seat belt when the machine was shipped from Caterpillar At the time of installation the seat belt and the instructions for installation of the seat belt meet the SAE J386 and ISO 6683 standards Consult your Cat dealer
186. erienced operator and smooth terrain subtract the Scenario Factors from the average vibration level in order to obtain the estimated vibration level For aggressive operations and severe terrain add the Scenario Factors to the average vibration level in order to obtain the estimated vibration level Note All vibration levels are in meter per second squared WEBM1000 WEBM1000 Table 2 31 Safety Section D6T LGP OEM Sound Information and Vibration Information ISO Reference Table A Equivalent vibration levels of whole body vibration emission for earthmoving equipment Machine Typical Operating Vibration Levels Scenario Factors Type Activity X axis Y axis Z axis X axis Y axis Z axis dozing 0 74 0 58 0 70 0 31 0 25 0 31 Track Type Tractors ripping 1 25 1 19 1 02 0 40 0 41 0 28 transfer 0 87 0 80 0 97 0 43 0 40 0 34 Table 3 ISO Reference Table A Equivalent vibration levels of whole body vibration emission for earthmoving equipment Machine Typical Operating Vibration Levels Scenario Factors Type Activity X axis Y axis Z axis X axis Y axis Z axis Pipelayers work cycle 0 21 0 23 0 24 0 09 0 11 0 14 1 If equipped Note Refer to ISO TR 25398 Mechanical Vibration a Tire pressures Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving b Brake and steering systems machines fo
187. erify that the oil level is below the FULL mark before you remove the filler cap WEBM1000 Illustration 219 Right side of cab 2 If the hydraulic system requires additional hydraulic oil remove the filler cap slowly in order to relieve any pressure Add oil through the filler tube 3 Clean the filler cap and install the filler cap Hydraulic System Oil Sample Obtain Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Obtain the hydraulic oil sample as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of S O S oil analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced WEBM1000 If the machine is operated under a high
188. ersonal protective equipment The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Trapped Pressure Pressure can be trapped in a hydraulic system Releasing trapped pressure can cause sudden machine movement or attachment movement Use caution if you disconnect hydraulic lines or fittings High pressure oil that is released can cause a hose to whip High pressure oil that is released can cause oil to spray Fluid penetration can cause serious injury and possible death WEBM1000 Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure Illustration 16 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 typ
189. ervice Application 121 Shipping the Machine 104 206 Shortening the Seat Belt 00 eee 48 Slope Operation eerren 28 190 Soot Level Monitoring seeen 63 Sound Information and Vibration Information ENA O KATETE stan tie See eae ates gee ass 29 191 Sound Level Information 00 00c ee 29 191 Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives wcnein Arie ini ananed aul an 29 Sound Performance for Machines that are Offered in European Union Countries and in Countries that Adopt the EU Directives 0 0 0 0 eee 191 SOUICOS Aa ata e nie a ta RS 32 Special Applications 2 00 0 eee eeeeteees 116 Special Lubricants escenes ais 117 Specifications 0 ccc eneeier rererere 34 194 Speed Range Control 00 0 cceccceeeeeeeteeeeerenes 54 Speed Lockout Control Lever isie 200 Speed Lockout Control Lock s 201 Status INdiCAtOrS oo cece a 68 Steering Charge Filter 0 0 0 0 cece 159 Steering Limp Home Mode cccecceeeeees 81 Stopped Engine or Drive Line Defect 107 Stopping the Engine cc ceceeseeeeenteee 101 Stopping the Engine if an Electrical Malfunction OGCUIS TRA R AN 102 Stopping the Machine a 101 Storage for the Operation and Maintenance Manual e Aeae A E E A AE 47 Structure certification ROPS n 37 Subsequent Engine Starting Procedures 98 T TFachometen wise paii aaa eid
190. et and a breaker bar to loosen the spark plug If necessary see your Caterpillar dealer for the part number of the socket After the spark plug has been loosened use the socket to remove the spark plug by hand in order to detect problems with the threads After the spark plug has been removed inspect the used spark plug and the gasket If the spark plug could not be removed by hand clean the threads with a 305 2389 Brush This tool scrapes debris from the seat and from the threads NOTICE Do not use a thread tap A thread tap will remove metal unnecessarily The threads could be stripped and the combustion group could be damaged Installing the Spark Plug Note Do not use anti seize compound on the spark plug Most of the heat is transferred through the threads and the seat area of the spark plug Contact of the metal surfaces must be maintained in order to provide the heat transfer that is required 1 Ensure that the spark plug is clean and free of dirt and oil NOTICE Do not overtighten the spark plug The shell can be cracked and the gasket can be deformed The metal can deform and the gasket can be damaged The shell can be stretched This will loosen the seal that is between the shell and the insulator allowing combustion pressure to blow past the seal Serious damage to the engine can occur Use the proper torque 2 Install the spark plug by hand until the spark plug contacts the ARD Torque the spark plug to the
191. evers Implement Limp Home mode may be selected by the operator or the technician in order to move the implements to a safe position This exercise may be needed in order to move the machine in the event of a major failure in one of the machine systems An example is a failure such as the bulldozer control lever From the Service menu use the appropriate arrow button to highlight the Implement Limp Home option Then press the OK button in order to access the Implement Limp Home menu This menu will display a list of implements that may be slowly moved by using the keys on the Monitoring System Display To move an implement in this fashion use the appropriate arrow button to highlight the desired implement function from the menu Then press the OK button in order to access that function This action will result in a screen that will display instructions for moving the implement Follow the prompts on the screen and the directions in order to move the implement Reference See Service Manual KENR5160 Features for more information on the Limp Home Mode 81 Operation Section D6T LGP OEM Machine Operation Steering Limp Home Mode Steering Enter Limp Home gt Limp Home Yes No Illustration 113 Menu display If a failure occurs in the machine steering system a level II event will be activated and the brakes applied 1 Stop the machine and engage the parking brake
192. excessive heat during machine operation Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should be avoided Consult your Cat dealer for repair or for replacement parts Keep wiring and electrical connections free of debris Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Use the appropriate backup wrenches in order to tighten all connections to the recommended torque Illustration 22 Check lines tubes and hoses carefully Wear Personal Protection Equipment PPE in order to check for leaks Always use a board or cardboard when you check for a leak Leaking fluid that is under pressure can penetrate body tissue Fluid penetration can cause serious injury and possible death A pin hole leak can cause severe injury If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Replace the affected parts if any of the following conditions are present 23 Safety Section D6T LGP OEM Fire Prevention and Explosion Prevention e End fittings are damaged or leaking e Outer coverings are chafed or cut e Wires are exposed e Outer coverings are swelling or ballooning e Flexible parts of the hoses are kinked e Outer covers have exposed embedded armoring e End fittings are displaced Make
193. ey to this position This position overrides the delayed engine shutdown or the key off regeneration in an emergency The engine shuts down without delay START 3 Turn the start switch key i s 25 Operator Override 1 Hot Shutdown Illustration 75 Warning category 2s displays for 15 seconds after the engine shutdown occurred The action lamp flashes Note The engine can be restarted at the discretion of the operator for the allowance of system cooling 59 Operation Section D6T LGP OEM Machine Operation Regeneration Switch 16 16A 16B Illustration 76 ARD disable switch The MIDDLE position of the regeneration switch is the default position for automatic regeneration 16A Enable the aftertreatment regeneration device system Press top of the switch and hold for 2 seconds 16B Disable the aftertreatment regeneration device system Press the bottom of the switch and hold for 2 seconds Illustration 77 Soot level indicator The soot level threshold to enable a manual regeneration is 15 Push the top of regeneration switch 16 for a manual regeneration Then the high exhaust system temperature indicator HEST lamp illuminates during the regeneration cycle The high exhaust system temperature indicator HEST lamp will deactivate when the regeneration cycle is completed Regeneration Indicators DPF DPF lamp indicates when a regeneration cycle is needed This indicato
194. f fuel 3 If the water separator is not full of fuel turn the engine start switch OFF and then turn the engine start switch ON This operation will cycle the fuel priming pump again 4 When the water separator is full of fuel attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate at low idle until the engine is running smoothly If the engine cannot be started or if the engine continues to misfire or smoke repeat Step 1 148 Maintenance Section D6T LGP OEM Fuel System Primary Filter Water Separator Drain Fuel System Primary Filter Water Separator Drain Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire To help prevent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not allow dirt to enter the fuel system Th
195. for all replacement parts Always check the condition of the seat belt and the condition of the mounting hardware before you operate the machine Seat Belt Adjustment for Non Retractable Seat Belts Adjust both ends of the seat belt The seat belt should be snug but comfortable Lengthening the Seat Belt Illustration 50 1 Unfasten the seat belt Illustration 51 2 To remove the slack in outer loop 1 rotate buckle 2 This will free the lock bar This permits the seat belt to move through the buckle WEBM1000 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 buckle in the center readjust the seat belt Shortening the Seat Belt Illustration 52 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 53 Fasten the seat belt catch 3 into the buckle 2 Make sure that the seat belt is placed low across the lap of the operator WEBM1000 Releasing The Seat Belt 49 Operation Section D6T LGP OEM Machine Operation Releasing The Seat Belt Illustration 54 Pull up on the release lever This will release the seat b
196. ft side of the machine that is forward of the fuel tank Illustration 217 Steering charge filter 2 Remove the filter element that is next to the window washer reservoir with a strap type wrench 3 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 4 Install the new steering charge filter element by hand 160 Maintenance Section D6T LGP OEM Hydraulic System Oil Level Check Note Instructions for the installation of the filter are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 5 Close the access door Hydraulic System Oil Level Check At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure Lower the bulldozer and the ripper to the ground Place the ripper shanks in the vertical position The hydraulic tank is on the right fender of the machine Illustration 218 1 Maintain the oil level to the FULL mark in the sight gauge Check the oil level when the oil is cold V
197. ful to avoid any condition which could cause the machine to tip The machine can tip when you work on hills banks and slopes Also the machine can tip when you cross ditches ridges or other obstacles Whenever possible operate the machine up the slopes and down the slopes Avoid operating the machine across the slope when possible Keep the machine under control Do not overload the machine beyond capacity Be sure that the towing eyes and towing devices are adequate Towing eyes and towing devices should only be used to recover the machine Connect trailing equipment to a drawbar or to a hitch only When you maneuver the machine to connect equipment be sure that there are no personnel between the machine and trailing equipment Block the hitch of the trailing equipment in order to align the equipment with the drawbar Never straddle a wire cable or allow other personnel to straddle a wire cable When you maneuver to connect the equipment make sure that no personnel are between the machine and trailing equipment Block the hitch of the trailing equipment in order to align the equipment with the drawbar Know the maximum dimensions of your machine Always keep the Rollover Protective Structure ROPS installed during machine operation 27 Safety Section D6T LGP OEM Operation Lifting Capacities Maintain control of the machine Do not overload the machine beyond the machine capacity Ensure that the corr
198. g Tmp Temperature Trb Turbocharger Trn Transmission Thmb Thumb Trig Trigger Torq Conv Torque converter Viv Valve VPAT Variable position angle tilt WOFuelinj Without fuel injection Product Link Display Additional Term Abbreviation Term Inhbt Inhibit Inj Injector Intk Intake Lf Left Lvl Level Lwr Lower Mn Main Man Manifold Mhifld Manifold Mod Module Mod Modulation Mtr Motor Mtrng Metering MVP Multi Velocity Program Offst Offset Oper Operator Out Outlet Out Output Param Parameter Pdl Pedal Perm Permanent Pmp Pump Prm Primary Prog Program PT Power train Recirc Recirculation Regen Regeneration Rip Ripper Note Your machine may be equipped with the Product Link system The Product Link 121SR system utilizes satellite technology to communicate machine information The Product Link 522 523 is a cellular based communication device that transmits machine information This information is communicated to Caterpillar Cat dealers and Caterpillar customers Both Product Link systems contain Global Positioning System GPS satellite receivers The capability of two way communication between the machine and a remote user is available with the Product Link 121SR and 522 523 system The remote user can be a dealer or a customer At any time a user can request updated information from a machine such as hours of use or the location of the machine Also the system parameters for Product L
199. g 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 33 Safety Section D6T LGP OEM Guards e Demolition applications e Rock quarries e Forestry products Additional guards may be required for specific applications or work tools The Operation and Maintenance Manual for your machine or your work tool will provide specific requirements for the guards Consult your Caterpillar dealer for additional information 34 Product Information Section D6T LGP OEM General Information Product Information Section D6T LGP OEM General Information Specifications A ot A l gj li j i C cin Se ja B Illustration 24 The basic machine specifications are listed below WEBM1000 Table 4 D6T Track Type Tractor LGP Engine Power 200
200. hat 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 When you perform maintenance above ground level use appropriate devices such as ladders or man lift machines If equipped use the machine anchorage points and use approved fall arrest harnesses and lanyards Pressurized Air and Water Pressurized air and or water can cause debris and or hot water to be blown out The debris and or hot water could result in personal injury When pressurized air and or pressurized water is used for cleaning wear protective clothing protective shoes and eye protection Eye protection includes goggles or a protective face shield The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the nozzle is deadheaded and the nozzle is used with an effective chip deflector and p
201. hat define the requirements for the operator and or support personnel to be present when the engine is running Leaving the machine unattended when the engine is running may result in personal injury or death Before leaving the machine operator station neutralize the transmission apply the parking brake lower work tools to the ground and deactivate all work tools Refer to Operation and Maintenance Manual Parking for more information Note Leaving the machine unattended when the engine is running may also result in property damage in the event of a malfunction Key off regeneration allows for regeneration when the engine start switch key has been removed To begin a key off regeneration the soot level must be between 15 and 100 on the soot level monitor and or a regeneration is in progress The following steps outline the procedure of a key off regeneration 1 Turn the engine start switch to the OFF position 2 The engine will continue to run for 15 seconds During this 15 second interval if a regeneration is desired press and hold the force regeneration switch for 2 seconds Note If a regeneration is not desired the machine will initiate the delayed engine shutdown 3 The key off regeneration will activate and the key off regeneration will last for up to 15 minutes Note If at anytime the regeneration needs to be stopped press and hold the disable regeneration switch 65 Operation Section D6T LGP
202. hat is resistant to rotation Any new poured socket or swaged socket assembly that is used as a standing cable guy shall be proof tested Test the cable to the lift capacity of the side boom machine or to the manufacturer s recommendation Never give the cable a rating that is greater than 50 percent of the wire rope s nominal strength or of the structural strand s nominal strength WEBM1000 Note For additional information on the proper maintenance and on inspection of the cable refer to American National Standards Institute ANSI ASME B30 14 Hook Load Line Install Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and maintenance Manual Failure to follow the instructions or heed the warnings could result in injury or death Proper care is your responsibility Personal injury or death can result from worn wire rope cable Worn or frayed cable could break causing injury Check the wire rope cable If cable is worn or is frayed install new cable Wear gloves when handling the wire rope cable NOTICE Make sure that the construction of the wire rope is 6x25 IWRC XIPS Independent Wire Rope Core eXtra Improved Plow Steel USA MADE Also the established grade of the wire rope is the improved plow bolt steel 26670 kg 58 800 Ib minimum breaking strength Table 35 SPECIFICATIONS WIRE ROPE Hook Load Line Cable Boom Length Diameter Length
203. hazards around the machine While the machine is in operation the operator should constantly survey the area around the machine The operator needs to identify potential hazards as a hazard becomes visible around the machine Your machine may be equipped with mirrors or other visual aids An example of a visual aid is Closed Circuit Television CCTV The operator should ensure that the visual aids are in proper working condition and that the visual aids are clean Adjust the visual aids for the best visibility of all areas around the machine It may not be possible to provide direct visibility on large machines to all areas around the machine Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area 188 Safety Section Pipelayer Attachment Kit Visibility Information WEBM1000 2 13 50 ke 0 34m J Hy J GO L RROR a LEFT HAND SIDE VIEW aaa of CLEAR DIRECT gE VISIBILITY lt 25 AVAILABLE AT DO N 130 34 IN 3 31m x AHEAD LE 1 MIRROR RIGHT HAND OVERHEAD 2 L IRROR RIGHT HAND SIDE VIEW IMENSIONS IN NCHES AND METERS VIZ LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL LLL KA 39 37 1m TYPICAL ALL THE WAY AROUND 170 23 4 32m e r L
204. he engine 2 Open the right engine access door WEBM1000 AN Laa oro K We 7 SS oa Pi iv E Illustration 153 3 Inspect the condition of serpentine belt 1 visually Note This machine is equipped with one belt tensioner 2 The belt tensioner automatically adjusts the belt to the correct position 4 Close the right engine access door Replace the Belt Note Replace a belt that is in poor condition when a new belt is required Replace the belt if any of the following conditions exist e excessive cracking e excessive wear e excessive damage 1 Park the machine on level ground Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 2 Open the right engine access door 3 Turn the battery disconnect switch to the OFF position 4 Release the tension on serpentine belt 1 Insert a 12 7 mm 0 50 inch ratchet into the square hole in the belt tightener 2 and pry the belt tightener in a clockwise direction 5 Remove the belt from the pulleys WEBM1000 6 Install the new belt around the pulleys 7 When you release the tension off the belt tensioner the belt tensioner will automatically adjust the belt to the correct position Recheck the belt tension 8 Turn the battery disconnect switch to the ON position 9 Close the right engine access door Note If a new belt is installed recheck the belt adjustment after
205. he certification plate is shown above Refer to Operation and Maintenance Manual Guards Operator Protection for more information 12 Safety Section D6T LGP OEM Safety Messages Hot Fluid Under Pressure 8 Safety message 8 is located on the bottom side of the radiator access cover A WARNING 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 WEBM1000 Hydraulic System Accumulator 9 Safety message 9 is located inside the enclosure on the right hand platform z Hydraulic accumulator contains 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 WEBM1000 High Pressure Recoil Spring 10 Safety message 9 is located inside the cover for the twister resister on both track roller frames Recoil spring force if not relieved can result in personal injury or death Relieve spring force before removing the threaded retainer performing repairs on the recoil spring housing or removing the recoil spring Consu
206. he lift capacities are based on a stationary machine with the following specifications Table 30 72H Pipelayer 19 05 mm 0 75 inch 261 56 kN 58 800 Ib Wire rope diameter Minimum breaking strength of the wire rope 4 part load line 4 part boom line Mass of the extended counterweight 5822 kg 12 835 Ib Standard boom length 6 1 m 20 ft Total operating weight of 29 127 kg 64 215 Ib the machine 24 ft boom add 286 kg 630 Ib 1 Operating weight Includes lubricants coolant 100 fuel hydraulic controls and fluids backup alarm seat belt 660 mm 26 in single grouser shoes drawbar counterweight boom and pulley blocks and cable and operator If the lift capacity chart indicates that the lift operation is within the capability of the machine attempt to perform the operation but proceed with care Remember that the load may weigh more than the estimate for the load The lift capacity chart is for estimating the lift operation only WEBM1000 The following are as per ANSIASME B30 14 ISO 3813 1992 A Load capacity CO W12 Load overhang C Rated tipping load lift capacity D Working range WEBM1000 Operation Section Pipelayer Attachment Kit Before Operation Mounting and Dismounting Illustration 269 Mounting and dismounting machine Use steps and handholds whenever you mount the machine Use steps and handholds whenever you dismo
207. he seat When the sensor unit indicates that an operator is present in the seat the Machine ECM will enable specific system operation The operation of the travel system of the machine and the implement control system is now active WEBM1000 Note When the machine is moving and the operator raises from the seat the electric power train systems and the implement operation will not shut down until the machine is stopped After the machine is stopped the Machine ECM will again require the sensor unit to indicate that an operator is in the seat This seating of the operator must occur before the travel and implement systems will be enabled Note The parking brake will not disengage and the implements will not respond unless the operator is seated Digital Display Window 17 See Monitoring System Display in this section for more information on the digital display window Tachometer 18 The following range marks for engine speed are displayed on the tachometer 18 White zone Yellow zone and Red zone Engine Speed White zone 0 2300 me Engine Overspeed Yellow zone 2300 RPM 2600 RPM is a visual warning This zone indicates that the machine is approaching the maximum recommended speed The monitoring system display will display a level ii warning above 2600 RPM Engine Overspeed Red zone 2600 RPM is a visual warning that the engine is overspeeding Both the alert indicator a
208. hen the recoil spring is still held in compression Refer to Special Instruction SMHS8273 which contains the disassembly procedure that must be used to decrease the possibility of injury while performing service on the track roller frame WEBM1000 Product Link 13 Safety message 13 is located on the console to the right of the operator seat Refer to Operation and Maintenance Manual SEBU7351 Product Link for information about this service tool This machine is equipped with a Caterpillar Product Link communication device When electric electronic detonators are used this communication device should be deactivated within 12 m 40 ft of a blast site or within the distance mandated under applicable legal requirements Failure to do so could cause interference with blasting operations and result in serious injury or death Additional Messages There are several specific messages on this machine The exact location of the hazards and the description of the hazards are reviewed in this section Become familiarized with all messages Make sure that all of the messages are legible Clean the messages or replace the messages if you cannot read the words Replace the illustrations if the illustrations are not legible When you clean the messages use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the messages Solvents gasoline or harsh chemicals could loosen the adhesive that
209. his will make the machine brakes inoperable and the machine can move freely The towed machine will be totally dependent on the towing machine for control and for braking If you are towing a machine without axle shafts you may not be able to use the implements to stop the machine The implement hydraulic system is pilot controlled With an inoperable engine or an inoperable hydraulic pump the accumulator pressure will bleed off rapidly The implement controls will not operate when there is no pressure in the accumulator The implements can not be lowered with the implement control lever in order to stop a towed machine when there is no pressure in the accumulator 107 Operation Section D6T LGP OEM Towing Information One or more towing machines must provide sufficient control and sufficient braking when you are moving a disabled machine downhill This may require a larger towing machine and additional machines that are connected to the rear This will prevent the machine from rolling away out of control Consult your Caterpillar dealer or refer to the machine s Service Manual for axle shaft removal and installation procedures For the second method use a brake release pump If a brake release pump is used to tow the machine the brakes can not be applied with the service brake pedal or with the parking brake control If the brake release pump is used and you need to apply the brakes the brakes must be applied with the brake r
210. hp std Engine Make and Model Caterpillar C9 3 Engine Displacement 9 3 L 567 in Engine Rated Speed 2010 RPM Engine No of Cylinders 6 Height Top of ROPS A 3233 ro Length of the Machine 4089 mm 161 0 B inch Height to Top of Exhaust 3193 mm 125 7 Stack C inch Ground Clearance D 396 mm 15 6 inch Track Gauge E 2286 mm 90 0 inch Width Over Trunnions F 3479 mm 137 0 inch Height of the Drawbar 511 mm 20 1 inch Width of Track Shoe 660 mm 26 inch Length of Track on Ground 3243 mm 127 7 inch Shipping Weight 19527 kg 43050 Ib Drawbar Length 165 mm 6 5 inch 1 NACD Engine Rated Speed North America 2 Non NACD Engine Rated Speed is 1920 RPM 3 The length of the machine is measured from the front of the machine to the end of the drawbar Add 145 mm 5 7 inch for long drawbar assembly 4 VPAT trunnions are attached at the case and frame 5 The weight includes the machine and the following items 10 tank of fuel all lubricants coolant hydraulic controls the rops fops structure and and the standard track Restrictions to Application and Configuration Maximum approved operating weight is 29484 kg 65000 Ib Maximum towing force of a drawbar is 320 kN 71940 Ib Maximum vertical load for a drawbar is 137 kN 30800 Ib The capability of the brake is equal to the ROPS
211. hydraulic cylinders and hrough all hydraulic lines Idling When you idle the engine in order to warm up the engine observe the following recommendations WEBM1000 e Allow the engine to warm up for approximately 15 minutes when the temperature is higher than 0 C 32 F e Allow the engine to warm up for approximately 30 minutes or more when the temperature is below 0 C 32 F e More time may be required if the temperature is less than 18 C 0 F More time may also be required if the hydraulic functions are sluggish Additional Low Idling Speed Note If the engine is running at low idle with the parking brake ON and the engine coolant temperature below 70 C 158 0 F for 10 minutes the engine speed will automatically increase to 1000 RPM This action increases the coolant temperature faster 99 Operation Section D6T LGP OEM Engine Starting 100 Operation Section D6T LGP OEM Adjustments Adjustments Tracks NOTICE If tracks are too tight or loose wear of components is accelerated If they appear too tight or too loose adjust the track Follow the procedures in the Maintenance Section for adjustment WEBM1000 WEBM1000 Parking Stopping the Machine NOTICE Park on a level surface If it is necessary to park ona grade block the tracks securely Do not engage the parking brake while the machine is moving unless an emergency exists Illustration 135 1 Apply servic
212. icates F for FORWARD N for NEUTRAL and R for REVERSE The 2 0 speed range is a limited version ground speed of the 2 5 speed range For 2 0 the engine speed is reduced below high idle in order to limit ground speed There is no loss of power operating in the 2 0 range when power is compared to the 2 5 range The same condition is true for the 3 0 speed range and the 3 5 speed range The operation of the three speed range is indicated on the display with the following designations 1 2 and 3 The display also indicates F for FORWARD N for NEUTRAL and R for REVERSE WEBM1000 Bidirectional Shift Mode 13 Autoshift Mode The bidirectional shift function allows the operator to preset the FORWARD and the REVERSE gear for directional changes and shifts out of NEUTRAL Bidirectional shifting can be selected with switch 13 The selected mode is shown on the digital display window Three different modes can be selected by the operator by toggling this switch Note When the bidirectional shift mode is activated and the transmission direction selector is in the NEUTRAL position the digital display window shows N only Whenever a directional shift or shifting from neutral occurs the transmission shifts to the selected gear for that direction by the active mode If the machine is operating in the third gear forward with the autoshif
213. il Filter Replace in this manual Remove the swivel or remove the pipe from the drain in the bevel gear case The drain valve will close Clean the oil drain plug and install the oil drain plug Fill with Oil 1 Open the access cover on the right side of the cab in front of the hydraulic tank Illustration 249 2 Remove cap 1 from the transmission oil filler tube 172 Maintenance Section D6T LGP OEM Transmission Oil Filter Replace 3 Fill the bevel gear case with oil See Topic Refill Capacities in this manual Hg DEE NA T Lo CLE wa wa D D 2 F z x a ae a a La D Illustration 250 2 Warm oil 3 Cold oil 4 Maintain the oil level within the marks for the operating range on the dipstick If the engine is at idle and the oil is warm maintain the oil level within range 2 If the engine is stopped and the engine oil is cold maintain the oil level within range 8 5 Clean the oil filler cap Install the oil filler cap 6 Close the access door Transmission Oil Filter Replace Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable cont
214. il Level Check Illustration 225 1 Open the radiator cap access cover Slowly remove the radiator cap in order to relieve system pressure 2 Inspect the radiator cap for damage for deposits or for foreign material Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 3 Install the radiator cap Recoil Spring Compartment Oil Level Check Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Illustration 226 1 Remove all of the debris around the cover plate on the top of the track roller frame 2 Remove the cover plate for the oil filler Observe the level of the oil Illustration 227 3 Maintain the oil level above the top of the track adjusting cylinder 1 Do not fill the oil above the track adjustment valve 2 4 Install the cover plate 5 Repeat the procedure for the other recoil spring housing 164 Maintenance Section D6T LGP OEM Refrigerant Dryer Replace Refrigerant Dryer Replace If Equipped Personal injury can result from contact with refrigerant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when refrigerant lines are opened even if the gauges indicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the syst
215. iles US gallon MPH MILES HOUR mpig miles Imperial gallon n neutral Nm Newton meter occ occurrence p n part number pos position prs pressure press pressure PSI Pounds per square inch ptrain power train pwr power r reverse rel release ren renewal req required ret return rev reverse rpm revolutions per minute rt right scrn screen Table 15 Abbreviation and Term For Monitoring System Display Abbreviation Term act active autocal automatic calibration aux auxiliary bi dir bidirectional bld blade cal calibration ctrl control cur current cyl cylinder DC direct current degrs degrees dist distance ecm electronic control module eng engine exten extension f forward fil filter filt filter forwrd forward freq frequency ft feet ftlb foot pound Gal US Gallon Gal Hr US Gallons Hour hi high hrs hours hyd hydraulic IGal Imperial Gallon IGal Hr Imperial Gallons Hour impl implement in inch in sec inches second init initialization km kilometer kPa kilopascal KPH Kilometers Hour WEBM1000 Abbreviation and Term For Monitoring System 85 Operation Section D6T LGP OEM Machine Operation Display Abbreviation Term sec Second secs seconds seg segment set setting shkin shank in shkout shank out snr sensor sns
216. ils are more likely to allow excessive wear Change the Hydraulic Oil At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Operate the machine in order to warm the oil Park the machine on level ground Lower the bulldozer blade to the ground and apply slight downward pressure If equipped lower the ripper to the ground Engage the parking brake and stop the engine WEBM1000 Illustration 206 Right side of cab 1 Remove hydraulic tank filler cap 1 slowly in order to relieve any pressure 2 Wash the filler strainer and the filler cap ina clean nonflammable solvent 3 Use a 126 79
217. imary filter element is serviced for the third time Refer to the section Secondary Filter 5 Clean the inside of air cleaner housing 4 Keep the secondary filter element in place while you clean the housing 6 Install a new primary air filter NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Do not wash the filter elements 7 Push the filter element firmly in order to properly seat the element Write the date on the element if the primary element is replaced 8 Install air cleaner housing cover 1 9 Close the engine access door 137 Maintenance Section D6T LGP OEM Engine Air Filter Primary and or Secondary Element Clean Secondary Filter NOTICE Always replace the secondary filter element Never attempt to reuse the filter by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time NOTICE The filter should be kept in service for no longer than 1 year NOTICE Always leave the secondary filter element in place while you clean the air cleaner housing 1 Open the left engine access door Illustration 170 2 Remove air cleaner housing cover 1 3 Remove primary filter element 2 Refer to the section Primary Filter 4 Clean the inside of air cleaner housing 4 5 Remove secondary filter element 3 Pull out in order to r
218. inals and loose terminals Replace damaged battery cable s and replace any related parts Eliminate any fouling which may have caused insulation failure or related component damage or wear Ensure that all components are reinstalled correctly An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface A battery cable short produces heat from the battery current which may be a fire hazard An exposed wire on the ground cable between the battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes into contact with a grounded surface This action may result in an unsafe condition for servicing the machine Repair components or replace components before servicing the machine Fire on a machine can result in personal injury or death Exposed battery cables that come into contact with a grounded connection can result in fires Replace cables and related parts that show signs of wear or damage Contact your Cat dealer Wiring Check electrical wires daily If any of the following conditions exist replace parts before you operate the machine e Fraying e Signs of abrasion or wear WEBM1000 e Cracking e Discoloration e Cuts on insulation e Other damage Make sure that all clamps guards clips and straps are reinstalled correctly This actioin will help to prevent vibration rubbing against other parts and
219. increase machine efficiency Monitor alert indicator The monitoring system display indicates a detected fault by the monitoring system If a fault indication occurs the message will override any screen that was displayed on the monitoring system display Note You may snooze the fault display from the screen by pushing the OK button Display Readout The digital display window provides readouts for the Monitoring System Display WEBM1000 Performance Screens PERFORMANCE MENU SELECTION Performance Performance Performance 1of5 2of5 3 of 5 Screen Screen Screen Performance Performance 5 of 5 4 of 5 Screen Screen Illustration 90 The Performance screens allow the operator or the technician to view five pages of information These pages of information monitor critical data from the machine systems during machine operation This information can only be viewed The Performance menu uses five screens for the real time monitoring of the following information Illustration 91 The up down arrow buttons switch the page from one screen to another screen The page that displays Performance 1 of 5 screen is the default setting after the operator preference is completed Key ON Table 10 71 Operation Section D6T LGP OEM Machine Operation Performance Screen 1 of 5 Description Units DPF Soot level 25 50 75 100 1 Bar scale
220. ine Fan Reverse Switch siec 60 Engine Idle Shutdown n 73 Engine Monitoring Mode aan 72 Engine Ol reia atar te aces ARR Aes 113 Engine Oil and Filter Change na se 139 Engine Oil Level Check isiin 138 Engine Oil Sample Obtain 0 ee 139 Engine Start Switch eeen 58 Engine Starting 00cc cc iis eiia 25 97 Engine Starting Alternate Methods 114 Engine Starting with Jump Start Cables 111 Engine Stopping ccceccccceceeteeeeeeeeeeeeeeneees 29 Engine Valve Lash Check Adjust 142 Equalizer Bar Center Pin Lubricate 142 Equalizer Bar End Pins Oil Level Check 143 Equipment Lowering with Engine Stopped ee eee eee rer ee 29 191 205 UMD tes csdeest EEE E tad te ttiinn ied cavetlapeieens 23 Ether Starting Aid ssaa 97 Ether Starting Aid Cylinder Replace 143 Every 10 Service Hours or Daily 08 123 Every 1000 Service Hours or 6 Months 123 Every 12 000 Service Hours or 6 Years 124 Every 2000 Service Hours 124 Every 2000 Service Hours or 1 Year 124 Every 2000 Service Hours or 2 Years 124 Every 250 Service Hours or 3 Months 123 Every 250 Service Hours or Monthly 123 Every 2500 Service Hours 124 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
221. ine to REVERSE OFORO Speed Control 5 LOW Roll thumb wheel 5 to the left when a lower gear is desired GD Note Thumb wheel 5 allows gear changes via the incremental rotation of the wheel HIGH Roll thumb wheel 5 to the right when a higher gear is desired eD The changes in gear selection will show in the monitoring system display when this information is requested When MVP is ON the following five gears are available in each direction WEBM1000 35 If MVP is OFF then the following three speeds are available in each direction Service Brake Control 6 Push down on the brake pedal in order to apply the service brakes Use pedal 6 for slowing the machine and for stopping the machine Use the service brakes on a downgrade in order to prevent overspeed The service brakes are especially needed when you change directions on a steep slope Release pedal 6 in order to allow the machine to move Release pedal 6 in order to increase the ground speed Decelerator Pedal 7 Engine speed may also be reduced below the maximum operating speed by pushing down on the decelerator pedal Push down on pedal 7 in order to override the throttle control This action will reduce the engine speed Use pedal 7 in order to reduce engine speed for directional shifts Also use pedal 7 in order to reduce engine speed when you maneuver in tight locations Note The sensitivity of the decelerator
222. ing 204 Operation Section Pipelayer Attachment Kit Before Operation 035 05 62 031 Illustration 274 Counterweight Lock Lever 1 locked in the extended position side view 1 046 05 63 300B Illustration 275 Counterweight control lockout 2 open position NOTICE When you engage the locking device for the counterweight or when you disengage the locking device for the counterweight use the Counterweight Control Lockout lever for the counterweight controls Lock the counterweight controls in HOLD in order to avoid the inadvertent movement of the counterweight Refer to the topic Counterweight Control Lockout Lever in the Operation and Maintenance Manual Operator Controls Lock the counterweight control lockout 2 in the operator station when you service the machine Lock the counterweight when you service the machine WEBM1000 Locked Extend counterweight cylinders to maximum length Engage the lock lever 1 Slowly retract the counterweight slightly until there is pressure on the lock lever 1 Do not continue to retract the counterweight against the lock lever once the lock lever is engaged Refer to Operation and Maintenance manual Safety Section Counterweight Lock Lever Thrown or Flying Objects Full Body Exposure Unlocked Unlock the counterweight control lockout 2 in the operator station Extend counterweight cylinders to maximum length Disengage the lock lever 1 Retract
223. ing R 134a All Caterpillar Machines e Service Manual RENR2014 Caterpillar Monitoring System e Operation and Maintenance Manual SEBU8257 The European Union Physical Agents Vibration Directive 2002 44 EC e Safety Manual SEBU5311 Crawler Tractor Loader Safety Manual AEM Form CLT80 1 e Service Manual UENR2067 D6T O E M Track Type Tractor e Parts Manual SEBP5819 PLR1 Up Operation and Maintenance Manuals are available in other languages Consult your Cat dealer for information about obtaining these Operation and Maintenance Manuals Additional Reference Material ASTM D2896 TBN Measurements This reference can normally be obtained from your local technological society from your local library or from your local college SAE J313 Diesel Fuels This reference can be found in the SAE handbook Also this publication can be obtained from your local technological society from your local library or from your local college WEBM1000 SAE J754 Nomenclature This reference can normally be found in the SAE handbook SAE J183 Classification This reference can normally be found in the SAE handbook Engine Manufacturers Association Engine Fluids Data Book Engine Manufacturers Association Two North LaSalle Street Suite 2200 Chicago Illinois USA 60602 E mail ema enginemanufacturers org 312 644 6610 Facsimile 312 827 8737 The Society
224. ing System Test If the machine moves during the test reduce the engine speed immediately and engage the parking brake If the machine moved while testing the brakes consult your Caterpillar dealer for brake inspection and repair Damaged brakes must be repaired before returning the machine to Operation Note Driving through the brakes in the first speed range is possible for this machine Make sure that the area around the machine is clear of personnel and clear of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes 128 Maintenance Section D6T LGP OEM Cab Filter Fresh Air Clean Inspect Replace Illustration 155 1 Start the engine 2 Raise all attachments 3 Depress the service brake pedal 4 Release the parking brake 5 While the brake pedal is depressed move the directional control to the SECOND SPEED FORWARD position 6 Gradually increase the engine speed to full load speed The machine should not move 7 Move the directional control to the NEUTRAL position 8 Reduce the engine speed to LOW IDLE Engage the parking brake Lower all attachments to the ground Apply a slight down pressure Stop the engine 9 Make any necessary repairs before you operate the machine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect an
225. injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage yeti i ig ij 4 ee i ee Illustration 175 Left view If the machine is equipped with a high speed oil change use a 126 7539 Nozzle Illustration 176 Top view WEBM1000 1 Remove the bolt in order to remove the crankcase drain access cover which is in the crankcase guard Illustration 177 1 drain valve 2 shutoff valve 3 drain valve elbow A Left view B Rear view 2 Install a drain hose not shown onto drain valve elbow 3 3 Open shutoff valve 2 Allow the oil to drain into a suitable container 4 When the oil has completed draining from th
226. ink 121SR system and the Product Link 522 523 system can be changed WEBM1000 Data Broadcasts Data concerning this machine the condition of the machine and the operation of the machine is being transmitted by Product Link to Caterpillar and or Cat dealers The data is used to serve the customer better and to improve upon Caterpillar products and services The information transmitted may include machine serial number machine location and operational data including but not limited to fault codes emissions data fuel usage service meter hours software and hardware version numbers and installed attachments Caterpillar and or Cat dealers may use this information for various purposes Refer to the following list for possible uses Providing services to the customer and or the machine Checking or maintaining Product link equipment Monitoring the health of the machine or performance Helping maintain the machine and or improve the efficiency of the machine Evaluating or improving Caterpillar products and services Complying with legal requirements and valid court orders Performing market research e Offering the customer new products and services Caterpillar may share some or all of the collected information with Caterpillar affiliated companies dealers and authorized representatives Caterpillar will not sell or rent collected information to any other third party and will exercise reasonable efforts to keep the inf
227. is ripper three function hydraulic Display Settings From the Display Setup menu use the arrow buttons to highlight the desired parameter Then press the OK button This exercise will allow access to that parameter screen Then follow the screen prompts in order to adjust the parameter All the parameters in this category relate to the operator preferences in regard to the monitoring system display The following parameters may be adjusted Language Select a language Units Select one of the following options Metric English and Imperial Display Backlight Select the amount of brightness for the digital display window Contrast Select the desired degree of contrast for the digital display window Machine Settings From the Machine Setting menu use the arrow buttons to highlight the desired parameter Then press the OK button This exercise will allow access to that parameter screen Then follow the screen prompts in order to adjust the parameter Duration Timer Lighting Select the amount of duration time for the lights to remain on WEBM1000 79 WEBM1000 Operation Section D6T LGP OEM Machine Operation Service Menu SERVICE MENU View List Expanded Diagnostics _ _ 3 _ of Events and Details of Diagnostics Each Line Blade Raise Blade Tilt Slowly Move Implements Senice m Limp Home Implements ECM Summary i 1 IF
228. ith a 1U 5718 Vacuum Pump Note Do not use the drain stream method to obtain a sample of the final drive oil A stream of dirty oil from the bottom of the compartment will contaminate the sample Likewise never dip an oil sample from an oil container or pour a sample from a used filter 145 Maintenance Section D6T LGP OEM Final Drive Oil Sample Obtain 3 Install oil filler plug 2 4 Repeat Step 1 to Step 3 in order to sample the oil in the other final drive Reference Refer to Lubricant Viscosities in the Maintenance Section of this manual for the correct fluid for your machine Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining a sample of the final drive oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the final drive oil Front Idler Position Check SystemOne Undercarriage The following check is for Caterpillar SystemOne Undercarriages that have the center tread idler Illustration 188 Elevated undercarriage system 1 Park the machine on a hard flat surface Make sure that the bottom track is tight and that the measured grouser lies directly below the track idler shaft 2 Measure the height A B from the flat ground surface to the grouser tip that is centered below the track idler shaft 3
229. ittings with a hand operated lubrication pump or a suitable grease gun Use of pressure operated lubricating equipment damages the seals NOTICE Before and after the equalizer bar end pin is filled with gear oil seal 1 must be flush with the equalizer bar If the seals are not flush damage to the seals can result by overfilling Illustration 182 F x i A N Illustration 183 1 Clean the areas that are around the end pin with a high pressure wash Inspect the condition of the seal 1 2 Check the area for oil leakage Be sure that the seal is in a neutral position 3 Remove plug 2 4 Check the oil level Oil level 4 should be at the top of the hex head on the fitting 143 Maintenance Section D6T LGP OEM Equalizer Bar End Pins Oil Level Check 5 Ifthe oil level is low apply the gear oil through fitting 3 until the gear oil reaches oil level 4 at the top of the hex head on the fitting Remove any excess oil This exercise will maintain a volume of air The gear oil must be applied with a 7H 1680 Lubrication Hand Pump Refer to Operation and Maintenance Manual Lubricant Viscosities for the correct oil The gear oil has excellent load carrying capacity 6 Be sure that seals 1 are not pushed out Push back the seals if the seals are pushed out 7 Install plug 2 Note MPGM GREASE IS ALLOWED ONLY FOR A FAILED SEAL THE SEAL SHOULD BE REPLACED AS SOON AS POSSIBLE THE COMBIN
230. ket that remains on the filter element mounting base 5 Install the new pilot filter element by hand Note Instructions for the installation of the filter are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Illustration 211 3 Hydraulic tank sight glass 6 Maintain the hydraulic oil to the FULL mark in the sight glass 7 Install hydraulic tank filler cap 2 8 Close access door to the pilot filter Hydraulic System Oil Filters Replace At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure WEBM1000 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regula
231. kup Alarm Backup Alarm The alarm sounds when the transmission direction selector is in the REVERSE position The alarm alerts the people behind the machine that the machine is backing up The backup alarm is on the rear of the machine on the right side of the machine Operation Information To prevent injury make sure that no maintenance work is being performed on the machine or near the machine Keep the machine under control at all times in order to prevent injury Reduce the engine speed when you maneuver the machine in tight quarters or when you break over a rise Select the speed range that is necessary before you start the downgrade Do not change speeds when you are going downhill When you drive down a grade use the same speed that is used for driving up a grade Operating The Machine 1 Adjust the operator seat 2 Fasten the seat belt Illustration 129 3 Push down on service brake pedal 1 in order to prevent the machine from moving 4 Start the engine 5 Raise all attachments enough to clear any unexpected obstacles WEBM1000 Illustration 130 Differential steering control and transmission direction selector 6 Release the parking brake by pushing down on parking brake switch 3 This action unlocks the parking brake the transmission control and the steering lever Note When the pa
232. lable for downloaded from the internet at www plmcat com Read study and keep this manual with the machine Whenever a question arises regarding your machine or this publication please consult PipeLine Machinery International for the latest available information Machine Description The sideboom equipment is attached to a Caterpillar D6T LGP tractor The primary use of this machine is for petroleum product pipeline construction in the 20 to 30 510 to 765 mm pipeline range The operator should read understand and follow both the tractor and the pipelayer operating and maintenance instructions The operator must comply with all pipelayer procedures regulations and safety precautions This equipment is to be operated by qualified personnel only The daily service inspection procedure should be performed before start up Operate all pipelayer controls with no load until familiar with machine operation Note Refer to the Caterpillar operation manual for detailed information on the specific operation of the tractor unit Safety The section entitled Pipelayer Attachment Kit of this manual contains a safety section and the section entitled D6T LGP OEM contains a safety section The safety sections list basic safety precautions In addition these sections identifie the text and locations of warning signs and labels used on the machine Read and understand the basic precautions listed in the safety s
233. ld result in excessive fuel usage and or shortened engine component life NOTICE Measure the valve clearance with the engine stopped To obtain an accurate measurement allow at least 20 minutes for the valves to cool to engine cylinder head and engine block temperature Check the valve bridge before setting the valve lash Ensure that the valve bridge is seated equally on both valve stems NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure WEBM1000 Equalizer Bar Center Pin Lubricate NOTICE Apply lubricant to the fittings with a hand operated grease gun only Use of pressure operated lubricating equipment damages the seals Illustration 180 8F 9866 Grease Gun Illustration 181 Remote Fitting Lubricate the equalizer bar center pin through the remote fitting The remote fitting is located on the frame on the left side of the machine The fitting is located below the dipstick The proper lubricant for the center pin is the Desert Gold NLGI 2 grease Refer to Operation and Maintenance Manual SEBU6250 Lubricating Greases for more information WEBM1000 Equalizer Bar End Pins Oil Level Check NOTICE Apply gear oil through the f
234. le Push the decelerator pedal until the desired speed is reached 2 When this desired speed is reached push the top of switch 18 and hold for 2 seconds This movement will electronically set the engine speed as the maximum operating speed 3 The decelerator will function normally in order to reduce engine speeds below this maximum speed 4 In order to return to high idle as maximum speed press the top part of switch 18 An optional method performs in the following manner 1 Press and hold the top of throttle switch 18 for 2 seconds a The engine speed will ramp up until the switch is released b The engine speed will ramp up until the high idle point is reached 2 Press and hold the bottom of throttle switch 18 for 2 seconds a The engine speed will ramp down until the switch is released or the low idle speed is reached Hydraulic Lockout Control 19 Note Disengage the locking tab on the switch to use the hydraulic lockout control The hydraulic lockout control is designed to deactivate the control levers Press the top of switch 19 to the lock position in order to deactivate the control levers Deactivate the control levers before you exit the seat or before you service the machine The control levers should always be deactivated when the machine is left unattended Press the bottom of switch 19 to the unlocked position in order to activate the control levers 61 Operation Section D6T L
235. lead Sheave Lubricate Hook and Wire Cable Inspect Hydraulic System Oil Level Check Sheave Block Bearings Lubricate Boom Stop Valve Check operation Tractor Operation Refer to the tractor operation and maintenance manual for the specific procedures regarding complete Tractor Operation Hydraulic Oil Temperature Refer to the tractor operation and maintenance manual Gauges for the specific procedures regarding hydraulic oil temperature indication and operating temperature 199 Operation Section Pipelayer Attachment Kit Before Operation 200 Operation Section Pipelayer Attachment Kit Before Operation Pipelayer Operation Illustration 271 Controls for pipelayer Speed Lockout Control Lever 1 The speed lockout control lever has three positions that controls the speed range of the hook winch and prevents accidental actuation of the pipelayer controls while not in use ee HIGH SPEED MODE WINCH CONTROLS UNLOCKED Push the speed lockout control lever forward for the hook winch at high speed range the maximum hook winch pull is reduced the boom winch speed is unaffected WEBM1000 046 05 63 2004 G LOCKED MODE WINCH AND CONTROLS LOCKED To prevent accidental actuation of the hook and boom winch controls while not in use move the speed lockout control lever to the centre position and flip the speed lockout control lock to engage the lever 2 and lock it in position In this
236. ler Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Note Obtaining a Coolant Sample Level 1 is not necessary if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval That interval is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This sampling includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat Diesel Engine Antifreeze Coolant DEAC e Commercial heavy duty coolant antifreeze Testing the coolant can be done at your Caterpillar dealer Caterpillar S O S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system S O S Coolant Analysis is a program that is based on periodic samples Perform a Coolant Analysis Level 1 at 250 hours for systems that do not contain extended life coolant ELC Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic
237. lity 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 various machine systems These machine systems are needed for machine control Note Safe operation on steep slopes may require special machine maintenance Excellent skill of the operator and proper equipment for specific applications are also required Consult the Operation and Maintenance Manual sections for the proper fluid level requirements and intended machine use Engine Stopping Do not stop the engine immediately after the machine has been operated under load This can cause overheating and accelerated wear of engine components After the machine is parked and the parking brake is engaged allow the engine to run for two minutes before shutdown This allows hot areas of the engine to cool gradually 29 Safety Section D6T LGP OEM Engine Stopping Equipment Lowering with Engine Stopped Before lowering any equipment with the engine stopped clear the area around the equipment of all personnel The procedure to use will vary with the type of equipment to be lowered Keep in mind most systems use a high pressure fluid or air to raise or lower equipment The procedure will cause high pressure air hydraulic or some other media to be released in order to lower the equipment Wear appropriate personal prot
238. lso be checked while the engine is running at low idle and the oil is at operating temperature Maintain the oil level in the operating area on the engine oil level gauge The operating area is between the ADD mark and the FULL mark Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the engine oil level gauge a i Illustration 173 4 Remove the oil filler cap If necessary add oil 5 Clean the oil filler cap and install the oil filler cap 6 Close the access cover WEBM1000 Engine Oil Sample Obtain Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of the engine oil as close as possible to the recommended sampling interval
239. lt 00 0 0 cece 49 Relief Valve Setting 0 108 Removing the Spark Plug ccccceeeeeeee 125 230 Index Section Reporting a Problem ece 83 Restricted Visibility 0 0 ceeeeeeeeteeeeeees 26 Restrictions to Application and Configuration 34 195 Rollover Protective Structure ROPS Inspect 165 Rollover Protective Structure ROPS Falling Object Protective Structure FOPS or Tip Over Protection Structure TOPS ma ae e a iiaa 33 Rotating Shaft eaoin t aai 11 Running Engine 107 S S O S Information 120 SE a E E E AAE T I A EN 4 Safety Messages ncr 6 Safety Messages 72H Pipelayer 55 180 Safety Section D6T LGP OEM ee 6 Safety Section Pipelayer Attachment Kit 180 DEAL ENS E AEE E E bvedadd esfiehadncas E S 44 orl me A T E a ae 9 47 48 Seat Belt Inspect cece n 165 Seat Belt Replace 0 0 cc eeteeeeeee 165 Seat Belt Adjustment for Non Retractable Seat Bels wissen atest ad ten ade ed Sin Aan aes 48 Seat Belt Adjustment for Retractable Seat Belts 49 Secondary Filter 0 00 0 cccc ccc eeceeceteeeeeeeees 137 Selecting the Viscosity 0 cceceecceeeeeeees 113 Service Brake Control ae 53 Service Hour Meter errereen 63 Service Menu cccccceceeeceeeeeteeetneeeeeteeees 79 Settings MENU occ ccc ceeeeeeeenteeeeeeens 76 Severe Environmental Factors 0 ccccce 121 Severe Operating Conditions 0 c ee 121 Severe S
240. lt a Caterpillar dealer for disassembly instructions 13 Safety Section D6T LGP OEM Safety Messages High Pressure Cylinder 11 Safety message 11 is located on the access cover on both track roller frames AN LL A WARNING Personal injury or death can result from grease under pressure Grease coming out of the relief valve under pressure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is escaping Watch the track or track adjustment cylinder to see if the track is being loosened Loosen the relief valve one turn only If track does not loosen close the relief valve and contact your Caterpillar dealer 14 Safety Section D6T LGP OEM Additional Messages Compressed Recoil Spring 12 Safety message 12 is located inside both track roller frames The safety message is located on the front frame of the rear track roller frame Ye Personal injury or death can result from a compressed recoil spring being released suddenly using incorrect disassembly procedures A recoil spring that is still held in compression can result in the recoil spring being released unexpectedly with extreme force which could cause serious injury or death Make sure that the correct disassembly procedure is used if a front track roller frame that has a crack in the parent metal or weld connection or a tubular section that has separated from the front of the frame assembly w
241. lue for an enclosed cab The cab was properly installed and maintained The test was conducted with the cab doors and the cab windows closed 30 Safety Section D6T LGP OEM Sound Information and Vibration Information The European Union Physical Agents Vibration Directive 2002 44 EC Vibration Data for Track Type Tractors Information Concerning Hand Arm Vibration Level When the machine is operated according to the 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 track type tractors Note Vibration levels are influenced by many different parameters Many items are listed below e Operator training behavior mode and stress e Job site organization preparation environment weather and material e Machine type quality of the seat quality of the 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 estimated with the information in Table 3 in order to calculate the daily vibration exposure A simple evaluation of the machine application can be used Estimate the vibration levels for the three vibration directions For typical operating conditions use the average vibration levels as the estimated level With an exp
242. ly This self testing feature is 3 seconds long If the action alarm does not sound during this test or machine monitoring displays are not functioning do not operate the machine until the cause has been corrected Machine operation with faulty action alarms or displays could result in injury or death as any Warning Category 3 notifications will not be relayed to the operator During the self test all status indicators light WEBM1000 e The action light stays illuminated e The action alarm sounds once The monitoring panel is then in the normal operating mode Action Lamp Illustration 87 Monitoring system display lamps One action lamp 1 is on the gauge cluster The other action lamp is located on the right console The rearward action lamp is viewed when the operator is facing rearward Oo Action Lamp 1 There are two action Gauges Hydraulic Oil Temperature 2 The gauge indicates the temperature of the hydraulic oil in the hydraulic oil sump for the steering and implement circuits If the gauge needle enters the red zone the hydraulic system oil is approaching 95 C 203 F The monitoring system display will display a warning If necessary reduce the load that is on the machine until the hydraulic oil temperature decreases Engine Coolant Temperature 3 The water temperature regulator regulates the coolant temperatures If the gauge needle just enters the red zone the coolant
243. m operation and adjustment lubricate boom stop valve roller and ac tuator Lightly lubricate wire rope with recommended engine or hydraulic oil Every 500 Service Hours Hydraulic System Oil Sample Obtain 225 Every 500 Service Hours or 3 Months Hydraulic System Oil Filter Replace 223 Hydraulic System Case Drain Filter Replace Every 2000 Service Hours or 1 Year Hydraulic System Oil Change 221 Accumulator This system contains high pressure gas Failure to follow the instructions and warnings could cause an explosion resulting in possible injury or death Do not expose to fire Do not weld Do not drill Do not remove any hydraulic system lines taps or parts until pressure has been relieved Relieve pressure before discharging See Operation and Maintenance Manual Accumulator Relieving Charge See Operation and Maintenance Manual Accumulator for charging and discharging See your Dealer for tools and detailed information Accumulator must be charged with dry nitrogen N2 gas by qualified personnel only The accumulator must be at the same temperature as the surrounding air before being checked or charged Charge the accumulator depending on the ambient air temperature according to the table below Access the accumulator to charge from the rear of the tractor above the tow winch drive 213 WEBM1000 Maintenance and Lubrication Section Pipelayer Attachment Kit REM
244. machine components Refer to the Operation and Maintenance manual Boom Stop Valve Adjustment for correct operation and adjustment Check its function daily WEBM1000 Counterweight Control 5 NOTICE In order to prevent machine damage check to make sure the counterweight lock lever is not locked in the extended position before you operate this control lever Refer to Operation and Maintenance manual Safety Section Hold When the operator releases the counterweight control from any position the control will return to the HOLD and the counterweight will remain in position Out Move the counterweight control to this position in order to move the counterweight outward When the counterweight control is released the returns to the HOLD position and the counterweight will remain in position Refer to the Operation and Maintenance Manual Counterweight Lock Lever for the procedure to mechanically lock the counterweight in the fully extended position when you service the machine In Move the counterweight control lever to this position in order to move the counterweight inward When you release the counterweight control lever the lever returns to the HOLD position and the counterweight will remain in position Counterweight Control Lockout Lever 6 Use the counterweight control lockout lever 6 to lock the counterweight control 5 in the HOLD position in order to avoid accidental actuation of the counterweight Mov
245. mp sleeves etc Small amounts of debris may be found in the filter element This could be caused by friction and normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar could result in severe damage This could result in larger particles in unfiltered oil These particles could enter the system and cause damage 226 Maintenance and Lubrication Section Pipelayer Attachment Kit Sheave Block Bearing Lubricate Sheave Block Bearing Lubricate 5 035 20 30 007B Illustration 303 Rigging Grease Nipples 1 Lubricate 1 in the luff block Illustration 304 Rigging Grease Nipples Tail Block 2 Lubricate fitting in the pins for boom luff block 2 amp 3 and load sheave block 3 Lubricate pin 4 in load sheave block and the pin 5 in the hook sheave block 4 Lubricate pin 6 on tail block WEBM1000 Tractor Maintenance Refer to the tractor s operation and maintenance manual for the specific procedures regarding complete Tractor Maintenance Indexa Accumulator Relieving Charge 0605 202 ACtION LAMP Sa eia dias A AT ene 66 Active Faults mira anoe S ER 80 Additional Messages ee 14 Additional Operator Controls 00cccccceeee 62 Adjustable Armrests c 51 Adjusting the Angle of the Back of the Seat
246. n 04 6683 Nipple 5P 8018 Adapter Union 8M 0547 Elbow and 5P 2909 Plug Plug the pressure hose at the connection with a 5P 2909 Plug The components are indicated by shaded area A 2 Turn the handle of bypass valve 5 to the closed position 3 While you are pumping handle 4 observe the opening pressure of relief valve 3 4 Adjust the opening pressure of the relief valve Set the pressure to 3030 70 kPa 440 10 psi 5 Turn the handle on bypass valve 5 to the open position in order to relieve the pressure in the pump and in the hose WEBM1000 Connection for the Pump Z S Illustration 144 1 Remove the components that were used to plug the pressure hose The components are 9J 6190 Adapter Union 04 6683 Nipple 5P 8018 Adapter Union 8M 0547 Elbow and 5P 2909 Plug The components are indicated by shaded area A Illustration 145 1 Pump adapter 7 Brake release adapter 2 Connect FT1973 Adapter 1 to the pump pressure hose The adapter will be downstream from the relief valve 109 Operation Section D6T LGP OEM Towing Information l ae gi
247. n Pipelayer Attachment Kit Lubricant Viscosities for Ambient Temperatures Table 31 Lubricant Viscosities for Ambient Temperatures Compartment or System Oil Type and Classification Oil Viscosities C F Min Max Min Max Caterpillar HYDO SAE 0W20 Caterpillar DEO 40 40 40 104 Caterpillar TDTO SAE 0W30 40 40 40 104 Caterpillar MTO SAE 5W30 30 40 22 104 Global DHD 1 SAE 5W40 30 40 22 104 API CH 4 SAE 10W 20 40 4 104 Hipdiaulie System API CG 4 SAE 30 10 50 50 122 API CF 4 SAE 10W30 20 40 4 104 API CF SAE 15W40 15 50 5 122 commercial TO 4 Caterpillar MTO 25 40 13 104 Caterpillar TDTO TMS Biodegradable Caterpillar Biodegradable Hydraulic Oil Hydraulic Oil HEES 1 40 43 40 110 HEES 4 commercial BF 1 1 TDTO TMS 2 20 50 4 122 1 Commercial Biodegradable Hydraulic Oil S O S Information HEES must meet the Caterpillar BF 1 specification S O S Services is a highly recommended process for Caterpillar customers to use in order to minimize Capacities Refill owning and operating cost Customers provide oil samples coolant samples and other machine Table 32 information The dealer uses the data in order to provide the customer with recommendations for APPROXIMATE REFILL CAPACITIES management of the equipment In addition S O S Compartment Liters USgal Imperial Services can help determine the ca
248. n changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not loosen the fuel lines at the fuel manifold The fittings may be damaged and or a loss of priming pressure may occur when the fuel lines are loosened 147 Maintenance Section D6T LGP OEM Fuel Priming Pump Replace NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over disconnected fuel system component Prime the fuel system in order to fill the fuel filter and prime the fuel system in order to purge trapped air The fuel system should be primed under the following conditions e The injector has been changed e The fuel filter has been changed e The fuel system is dry 1 Turn the engine start switch to the ON position Leave the engine start switch in the ON position for 2 minutes Illustration 192 2 Verify that the water separator is full o
249. n pipe with a side mounted boom Restrictions to Application and Configuration Maximum approved operating weight is 29484 kg 65000 Ib The maximum lift capacity is 40820 kg 90 000 Ib The maximum fore and aft slope is 45 degrees or a 100 percent grade for the proper lubrication of the pipelayer components Refer to the tractor operation and maintenance manual for additional restrictions 195 Product Information Section Pipelayer Attachment Kit General Information Lifting Capacities The machine may tip and personal injury may occur if the maximum load capacities are exceeded Load capacities assume that the machine is stationary on a level concrete surface with the counterweight extended Lift capacities will decrease on slopes or soft ground i D 19 05mm 0 75in 261 56 kN 58 800 LBS 6 1m 20 Ft 7 3m 24 Ft ANSI ASME B30 14 ISO 8813 SS Illustration 267 Lifting Capacities 196 Product Information Section Pipelayer Attachment Kit General Information kgx LBx 1000 1000 4o 80 yol wH T 60 50 20 40 C 30 10F a 20 10 ok Ft ANSI ASME 830 14 12 m ISO 8813 Illustration 268 Lift capacity chart Note Do not exceed the lifting capacity that is shown in the chart in illustration above The lift capacity chart is located on the right hand winch guarding to the front of the controls T
250. n the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure 1 Slowly remove the hydraulic tank filler cap in order to relieve the system pressure 2 Open the access door that is located on the right side of the machine next to the filler cap 223 Maintenance and Lubrication Section Pipelayer Attachment 224 Maintenance and Lubrication Section Pipelayer Attachment Kit WEBM1000 Hydraulic System Oil Filter Replace 046 60 71 31 2A l PeT TRANSMISSION FILTER 046 6071 3114 1 RELOCATED TO REAR OF TRACTOR Illustration 298 Filter locations Illustration 299 Filter locations Illustration 300 Filter location 1 Transmission oil filter 2 Hydraulic system filter 3 Hydraulic Tank filler cap 4 Case drain filter pipelayer WEBM1000 Kit 3 Remove filter 1 2 and 4 Note Remove case drain hydraulic filter 1 Discard the used filter Filter 1 must be removed for access to hydraulic system filter 2 Replace both of the filters at the same time 4 Inspect the seal on the filter housings for filter 1 2 and 4 If the seals are damaged or worn install new seals Install a new filter element into the filter housing for 1 2 and 4 Hydraulic System Oil Level Check At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal injury Do not
251. ncorporate a shunt design cooling system it is mandatory to always operate the engine with a thermostat Depending on load failure to operate with a thermostat could result in either an overheating or an overcooling condition NOTICE If the thermostat is installed incorrectly it will cause the engine to overheat 5 Install a new seal in the thermostat housing Install the new thermostat and the new gasket Install the thermostat housing on the engine cylinder head 6 Install clamp he elbow and the hose Tighten the hose 7 Close the right engine compartment 8 Replace the coolant that was drained from the system Refer to Operation and Maintenance Manual Capacities Refill Diesel Particulate Filter Clean Replace Consult your Cat dealer when the DPF needs to be cleaned The approved Caterpillar DPF maintenance procedure requires that one of the following actions be taken when the DPF needs to be cleaned e The DPF from your machine can be replaced with a new DPF e The DPF from your machine can be replaced with a remanufactured DPF e The DPF from your machine can be cleaned by your local authorized Cat dealer or a Caterpillar approved DPF cleaning machine and reinstalled WEBM1000 Note In order to maintain emissions documentation the DPF that is removed from the machine when the DPF is cleaned must be reinstalled on the same machine Note A specific ash service regeneration
252. nd Maintenance Manual Accumulator for charging and discharging See your Dealer for tools and detailed information Precharge only with dry nitrogen gas WEBM1000 Free Fall Active Do Not Operate 5 Safety message 5 is located on the right side on the pipelayer control box LA a WARNING Dropping load hazard The free fall control remains live for several hours after the engine has been stopped Operation of the free fall control could cause a sudden uncontrolled drop of any supported load Do not operate the free fall control when personnel are near a suspended load even with the engine stopped See Operation and Maintenance Manual Pipelayer Operation for complete description of control operation WEBM1000 Boom Stop Operation and Adjustment Do Not Operate 6 Safety message 6 is located on the left side of the crossmember support at the front on the boom stop valve access panel The Boom Stop system stops the boom winch from hauling in when the boom is vertical preventing overloading of key machine components Defeating the boom stop valve could result in serious equipment damage personnel injury or even death The boom stop function must be check and verified daily Do not Operate until it has been checked and properly adjusted See the Operation and Maintenance Manual Boom Stop Valve 185 Safety Section Pipelayer Attachment Kit Safety Messages 72H Pipelayer Tipover Hazard 7
253. nd the action lamp flash The monitoring system display will display a level III warning above 3000 RPM Do not allow the engine to exceed 2900 rpm Severe engine damage may result Warning Categories The operator will be warned of immediate problems with a machine system or impending problems with a machine system by digital display window The monitoring system display provides three warning categories The first category requires only operator awareness The second warning category informs the operator of the machine that the operator should change machine operation The third warning category states that the machine must be shut down immediately 69 Operation Section D6T LGP OEM Machine Operation The monitoring system display will show a text message for the current highest level active event 70 Operation Section D6T LGP OEM Machine Operation WEBM1000 Table 9 WARNING OPERATION Status Indicators Action Lamp Action Monitoring Warning Flashes Alarm System Display Category Sounds Operator Action Required Possible Result 1 x No immediate action is No machine damage required The system needs occurs Minor attention soon reductions in machine performance may occur 2 x X Change machine operation or Severe damage to perform maintenance to the components can occur system 3 x x 9 X Immediately perform a safe Injury to the operator or engine shutdown
254. nd while the machine is operated In order to determine the proper oil viscosity grade refer to the Min column in the table This information reflects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine Refer to the Max column in the table for operating the machine at the highest temperature that is anticipated Unless specified otherwise in the Lubricant Viscosities for Ambient Temperatures tables use the highest oil viscosity that is allowed for the ambient temperature 113 Maintenance Section D6T LGP OEM Lubricant Viscosities and Refill Capacities Machines that are operated continuously should use oils that have the higher oil viscosity in the final drives and in the differentials The oils that have the higher oil viscosity will maintain the highest possible oil film thickness Refer to General Information for Lubricants article Lubricant Viscosities tables and any associated footnotes Consult your Cat dealer if additional information is needed NOTICE Not following the recommendations found in this manual can lead to reduced performance and compartment failure Engine Oil Cat oils have been developed and tested in order to provide the full performance and life that has been designed and built into Cat engines Cat DEO ULS or oils that meet the Cat ECF 3 specification and the API CJ 4 are required for use in the applications listed below
255. ne and apply the parking brake With the engine at low idle initiate a manual regeneration Engine power will be slightly derated if the machine continues to operate Illustration 85 After a certain period if no action is taken to regenerate an action alarm will activate After 5 minutes with the action alarm active the engine will automatically be taken to low idle A manual regeneration is required at this time A complete regeneration will unlock the forced low idle speed Cycling the engine start switch key will unlock the forced low idle speed Once the engine has been in the forced low idle strategy for approximately 10 minutes regeneration will be locked out At this time a regeneration can only be done through Caterpillar Electronic Technician ET by an authorized Cat dealer After a certain amount of time engine will automatically shut down Engine can be restarted but will only run for 30 seconds before shutting down again WEBM1000 Finally if the engine is still allowed to run through multiple forced engine shutdowns all types of regenerations are locked out The DPF must be replaced Consult your local Cat dealer if the DPF needs to be replaced Key Off Regeneration The use of the Key Off Regeneration feature and the Delayed Engine Shutdown feature allows the engine to run for a time when the engine start switch is turned to the OFF position The key may be removed Note There may be regulations t
256. ng Charge To relieve the accumulator charge with no load on the hook and the engine stopped move the hook control lever from HOLD to RAISE 10 times Boom Control 4 i HOLD The lever self centres to this position whenever it is released In this position the boom winch brake will set and the boom will stop and remain at the position it is in f LOWER Move the lever to this position to lower the boom The further the lever is pushed away from HOLD the faster the boom will lower The closer the lever is toward HOLD the slower the boom will lower When the lever is released it will return to the HOLD position and the boom will stop and remain at the position it is in Boom winch line speed varies with engine throttle setting Boom control is smoothest at engine speeds faster than idle RAISE Move the lever to this position to raise the boom The further the lever is pulled away from HOLD the faster the boom will raise The closer the lever is toward HOLD the slower the boom will raise When the lever is released it will return to the HOLD position and the boom will stop and remain at the position it is in Boom winch line speed varies with engine throttle setting Boom control is smoothest at engine speeds faster than idle Boom Stop Valve The Boom Stop valve is a safety device that is intended to automatically stop the boom winch from hauling in when the boom is vertical preventing overloading of key
257. ng the machine while distracted can result in the loss of machine control Use extreme caution when using any device while operating the machine Operating the machine while distracted can result in personal injury or death Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles Be aware of high voltage power lines and power cables that are buried If the machine comes in contact with these hazards serious injury or death may occur from electrocution Gan Cov X 98 3 BES Illustration 15 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 18 Safety Section D6T LGP OEM General Hazard Information Do not smoke when you service an air conditioner Also do not smoke if refrigerant gas may be present Inhaling the fumes t
258. nterval is performed all maintenance from the previous interval must be performed Perform the following servicing at EVERY interval they occur for example the 10 hour and 50 hour service are also performed at the 200 hour interval etc When Required Boom Line Install aerer 214 Hook Load Line Install oo ee 220 Every 10 Service Hours or Daily Controls for proper operation of boom and hook Check Boom Stop operation Check adjust if POQUINE P EE E eel iy 214 Boom Pivot Pins Lubricate 00 ee 217 Counterweight Cylinder Bearings Lubricate 218 Counterweight Hinge Pins Lubricate 218 Fairlead Sheave Lubricate cece 219 Hook and Wire Cable Boom and Hook lines In SPECiala raria tremor e AR 219 Hydraulic System Oil Level Check 0 0 225 Hoses and fittings for leaks Check Sheave Block Bearings Lubricate 226 Pipelayer structures and components for loose bolts cracks damage etc Inspect Inspect the hook for any distortion bends twists etc Inspect the hook for any wear cracks nicks or gouges Refer to American National Standard Insti tute ANSI ASME B30 14 Blocks and yokes for wear or damage Inspect Ensure that area between tractor tracks and pipelay er tractor attachment structures are free from dirt debris ice snow etc Inspect WEBM1000 Every 50 Service Hours or Weekly Thoroughly check Boom Stop syste
259. nto FORWARD gear If the cancellation of the Purge Cycle occurs after 15 seconds of purge time the purge interval timer is kept at zero Then the system is able to purge the cooling system and the purge cycle starts automatically at the next time After three successive attempts fail to complete more than 15 seconds of purge time the purge interval timer is reset to the purge interval The purge interval timer is reset upon full completion of every purge cycle regardless of an automatic start or manual start The reverse fan function is disabled when the hydraulic oil temperature is below 0 C 32 F The fan purge cycle will not operate when the engine coolant temperature equals 109 C 228 2 F or the engine coolant exceeds that temperature Throttle Control Switch 18 Illustration 78 Throttle control switch 18 is located on the right hand console High Idle For high idle press the P throttle control switch on the top of switch 18 if equipped The engine speed immediately moves to high idle Your machine has a high idle engine speed of 2000 rom Low Idle For low idle press the throttle control switch on the bottom of the switch 18 The engine speed immediately moves to low idle Engine speed may also be reduced by pushing down on decelerator pedal 7 WEBM1000 Set the maximum operating speed at a point less than high idle in one of the following manners 1 Set the engine speed to high id
260. nuous WEATHER Operation Multiple Cat TDTO SAE 30 40 0 40 32 Sy Cat TDTO TMS commercial TO 4 Cat TDTO TMS 40 0 40 32 Special Applications Cat Synthetic GO is an SAE 75W 140 viscosity grade oil 117 WEBM1000 Maintenance Section D6T LGP OEM Lubricant Viscosities and Refill Capacities Table 21 Lubricant Viscosities for Ambient Temperatures 7 C oF Compartment or nati Oil Type and avi n Application Artha Oil Viscosities System pp Classification Min Max Min Max SAE 75W 90 30 40 22 104 End Pin Joints for Cat GO SAE 75W 140 30 45 22 113 the Equalizer Bar Cat Synthetic GO Bogie Cartridge Normal ynt LAPI GL SAE 80W 90 20 40 4 104 Pins and Track commercia A T Pins 5 gear oil SAE 85W 140 10 50 14 122 SAE 90 0 40 32 104 SAE 0W20 40 10 40 50 SAE 0W30 40 20 40 68 Cat TDTO SAE 5W30 30 20 22 68 h araic dne Normal Cat TDTO TMS y commercial TO 4 SAE 10W 20 10 4 50 SAE 30 0 43 32 110 Cat TDTO TMS 10 35 14 95 SAE OW 20 40 0 40 32 SAE 0W 30 40 10 40 50 Track Roll SAE 5W 20 35 0 31 32 rack Roller Frame bara TNE SAE 10W 30 0 22 32 Recoil Spring Normal Cat Arctic TDTO Pivot Shaft ial TO 4 SAE 30 20 25 4 77 Bearings commercia SAE 40 10 40 14 104 SAE 50 0 50 32 122 Cat TDTO TMS 25 25 13 77
261. ny compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Replace the thermostat on a regular basis per the maintenance interval schedule This action reduces the chance of unscheduled downtime and of problems with the cooling system A new thermostat should be installed after the cooling system has been cleaned Install the thermostat while the cooling system is drained or while the cooling system coolant is drained to a level that is below the thermostat housing NOTICE Failure to replace the engine s thermostat on a regularly scheduled basis could cause severe engine damage Note If you are only installing a new thermostat drain the cooling system coolant to a level that is below the thermostat housing 1 Open the right engine compartment Illustration 167 136 Maintenance Section D6T LGP OEM Diesel Particulate Filter Clean Replace 2 Loosen the hose clamp and remove the hose from the elbow Disconnect the hose assembly from the thermostat housing assembly 3 Remove the bolts from the elbow Remove the elbow and the thermostat housing assembly 4 Remove the gaskets the thermostat and the seal from the thermostat housing NOTICE Since Caterpillar engines i
262. oil pressure reaches the normal operating range and the temperature gauge begins to move you may operate the machine at full load 4 Monitor lights and gauges 4 frequently during operation 5 Check oil levels in the power train the engine and the hydraulic systems when the oil is at operating temperature Maintain the oil levels to the FULL marks Engine and Machine Warm Up NOTICE Keep engine speed low until the engine oil pressure registers on the gauge or the engine oil pressure indicator light goes out If it does not register or the light 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 Always run the engine at low idle for at least ten minutes before performing any other operations in cold conditions to protect your engine and to protect your transmission The engine may automatically change speeds when the machine is stationary and idling in cold ambient temperature for an extended time This action is to WEBM1000 e Maintain desired coolant temperature e Maintain desired operation of engine systems e Maintain desired operation of the regeneration system During extended idling in cold ambient conditions engine speed may operate between 1000 rom and 1600 rpm Operation at 1600 rom is minimal and will only last for up to 20 minutes The high exhaust system temperature indicator may also illuminate during
263. om the welder to the component that will be welded Place the clamp as close as possible to the weld Make sure that the electrical path from the ground cable to the component does not go through any bearing Use this procedure in order to reduce the possibility of damage to the following components e Bearings of the drive train e Hydraulic components e Electrical components e Other components of the machine 4 Protect any wiring harnesses and components from the debris and the spatter which is created from welding 5 Use standard welding procedures in order to weld the materials together 121 Maintenance Section D6T LGP OEM Maintenance Support Severe Service Application An engine which operates outside of normal conditions is operating in a severe service application An engine that operates in a severe service application may need more frequent maintenance intervals in order to maximize the following conditions e Reliability e Service life The number of individual applications cause the impossibility of identifying all of the factors which may contribute to severe service operation Consult your Caterpillar dealer for the unique maintenance that may be necessary for your engine An application is a severe service application if any of the following conditions apply Severe Environmental Factors e Frequent operation in dirty air e Frequent operation at an altitude which is above 1525 m 5000 ft
264. on Pipelayer Attachment Kit Lubricant Viscosities General e Follow tractor manufacture s maintenance and lubrication instructions for tractor service as required e Follow tractor and or winch manufacture s lubrication instructions for the pipelayer hydraulic system e To prevent corrosion damage to the winch interiors if not used regularly cycle the winches up and down several times at least once every two weeks Selecting the Viscosity The proper oil viscosity grade is determined by the minimum outside temperature This is the temperature when the machine is started and when the machine is operated In order to determine the proper oil viscosity grade refer to the Min column in the table This information reflects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine Refer to the Max column in the table in order to select the oil viscosity grade for operating the machine at the highest temperature that is anticipated Use the highest oil viscosity that is allowed for the ambient temperature when you start the machine Machines that are operated continuously should use oils that have the higher oil viscosity in the final drives and in the differentials The oils that have the higher oil viscosity will maintain the highest possible oil film thickness Consult your dealer if additional information is needed WEBM1000 211 WEBM1000 Maintenance and Lubrication Sectio
265. on the menu or the submenu that is selected Then the display will show the information in the system system status and operator warnings Five buttons on the right of the Monitoring System Display are the user interface Use the buttons for the following purposes navigation selection menu and data information Left Button Up Down D This button is used for the following purposes navigation data information and a decrease in a setting value Right Down Up Down D This button is used for the following purposes navigation data information and an increase in a setting value OK E This button is used to make selections on the screen Also use this button to confirm a password entry or use the button to save an 74 Operation Section D6T LGP OEM Machine Operation operator profile Back button F This button is used to return to the previous screen Navigate to operator menu G This button is used to return to the operator menu Return to main menu H This button is used to return to the main menu Use the arrow buttons to highlight the desired selection in order to navigate through the menus and submenus Then press the OK button Also use the arrow buttons to highlight a mode or parameter setting Then press the OK button in order to select that option Note When the diagnostic message is acknowledged a predetermined length of time passes before the message screen will appear
266. on will always shift into the second physical gear Use the autoshift button on the dash to cycle through the three autoshift modes and the ON OFF The switch cycles in order from the top setting to the bottom setting in the table below i woe Pst Illustration 71 Bidirectional Keypad A Arrow that adjusts the FORWARD gear B Arrow that adjusts the REVERSE gear The Message Display on the instrument module changes with a hand control keypad with up down arrow keys The arrow keys will be used to adjust the Bidirectional Autoshift settings The up arrow will adjust the forward gear in the up arrow on the LCD screen The down arrow will adjust the reverse gear in the down arrow on the LCD screen 58 Operation Section D6T LGP OEM Machine Operation The Message Display on the instrument module with the hand control keypad will scroll through a set of gears The scrolling feature for gears will be cyclical The diagrams below show the scrolling feature for gears for MVP Active status and MVP Inactive status 3 5F 5 a 1 5R AN 3 0F f Set of reverse 2 0R Set of forward gears ard x gears 2 5R es D sie b 4 way p 3 0R directional op keypad Illustration 72 Scrolling feature with an MVP active status 1R Set of reverse gears 2R Set of forward gears 4 way directional 4F 3R keypad Illustration 73 Scrolling feature
267. operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Cooling System Conditioner contains alkali Avoid contact with skin and eyes Illustration 162 Rear view 1 Open radiator access door 1 on the top right side of the radiator guard 2 Filler cap 2 is located inside the radiator access door on the top right side of the radiator guard Loosen the radiator cap slowly in order to relieve pressure Remove the radiator cap 3 Drain some coolant from the radiator so that Extender can be added to the cooling system if necessary 132 Maintenance Section D6T LGP OEM Cooling System Coolant Level Check Note Always discard drained fluids according to local regulations 4 Add 1 20 L 41 oz of Extender to the cooling system 5 Start the engine Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes Check for leaks 6 Maintain the coolant level above the sight gage in the coolant tank to area 3 Adding coolant above this area will cause the coolant to overflow the cooling system If you need to add coolant daily check the cooling system for leaks 7 Inspect filler cap 2 and the filler cap seal for
268. ormation about the engine aftertreatment system is displayed Illustration 93 Performance 1of 5 Soot level DPF filter The soot level of the aftertreatment regeneration device ARD displays the level of active soot WEBM1000 P y OFF Automatic Regen Mode Machine Hour 103 5 Hr Fuel Level 100 Illustration 94 The aftertreatment regeneration device system is set to the automatic regeneration mode Reference See Operation and Maintenance Manual Diesel Particulate Filter Regeneration for additional information on aftertreatment regeneration Delayed Engine Shut Down N gt i OFF Engine Cooldown D ACTIVE Illustration 95 This message display alerts the operator that an engine cooldown is active The engine key start switch is in the OFF position WEBM1000 Emergency Shutdown Override a gt a S 25 nB a Operator Override 4 Hot Shutdown saaal Illustration 96 This message alerts the operator that a hot engine shutdown has occurred The engine key start switch is in the fourth position A level III warning is active for 15 seconds after the engine shutdown Note The operator may allow the engine system to cool by restarting Engine Idle Shutdown This function shuts down the engine after the operator is not operating the machine for a configured time This function does shut down other electrical systems such as the A C air con
269. ormation secure Caterpillar recognizes and respects customer privacy For more information please contact your local Cat dealer Operation in a Blast Site If the machine is required to work within 12 m 40 ft of a blast site then Product Link 121SR system or the Product Link 522 523 system should be disabled in compliance with applicable legal requirements One of the following are suggested methods in order to disable the Product Link 121SR system or the Product Link 522 523 system a Install a Product Link disconnect switch in the machine cab that will allow the Product Link 121SR system or the Product Link 522 523 system module 87 Operation Section D6T LGP OEM Machine Operation to be shut off Refer to Special Instruction REHS2365 An Installation Guide for the Product Link PL121SR and for the PL300 and Special Instruction REHS2368 Installation Procedure For Product Link PL522 523 Cellular for more details and installation instructions Or b Disconnect the Product Link 121SR system or the Product Link 522 523 module from the main power source by disconnecting the wiring harness at the Product Link module The following Product Link 121SR system and the Product Link 522 523 system specifications are provided in order to aid in conducting any related hazard assessment and to ensure compliance with all local regulations e The transmit power rating for the Product Link 121SR transmitter is 5 to 10 W
270. oroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over disconnected fuel system component Illustration 193 1 Element 2 Bowl 3 Drain Bowl 2 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly WEBM1000 2 Close drain 3 NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system Fuel System Secondary Filters Replace Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on
271. oss the slope When possible operate the machine up the slopes and operate the machine down the slopes Place the heaviest end of the machine uphill when you are working on an incline Mounted equipment Balance of the machine may be impeded by the following components equipment that is mounted on the machine machine configuration weights and counterweights Nature of surface Ground that has been newly 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 machine s stability Rocky surfaces may promote side slipping of the machine Slippage due to excessive loads This may cause downhill tracks or downhill tires to dig into the ground which will increase the angle of the machine WEBM1000 Width of tracks or tires Narrower tracks or narrower tires further increase the digging into the ground which causes the machine to be less stable Implements attached to the drawbar This may decrease the weight on the uphill tracks This may 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 working loads are in higher positions the stability of the machine is reduced Operated equipment Be aware of performance features of the equipment in operation and the effects on machine stabi
272. other slippery material will prevent the machine from slipping in transit NOTICE Obey all state and local laws governing the mass width and length of a load Observe all regulations governing wide loads Illustration 140 1 Place blocks under the trailer wheels or under the rail car wheels before loading as shown 2 Lower all attachments to the floor of the transport machine Move the transmission control lever to the NEUTRAL position 3 Engage the parking brake switch 4 Stop the engine by turning the engine start switch key to the OFF position Remove the key 5 Engage the parking brake switch in order to lock the parking brake 6 Turn the battery disconnect switch to the OFF position Remove the key 7 Lock the door and lock the access covers Attach any vandalism protection WEBM1000 8 Install the tie downs at several locations and block the tracks in the front and in the rear 9 Cover the opening for the engine exhaust Rotation of the turbocharger without engine operation can result in damage to the turbocharger Consult your Cat dealer for shipping instructions for your machine Lifting and Tying Down the Machine Improper lifting and improper tie downs can allow the load to shift or fail and cause injury or damage Use only properly rated cables and slings with lift and tie down points provided Follow the instructions in Operation and Maintenance Manual Lifting and Tying Down th
273. ow idle Idling the engine at a higher RPM ensures good engine lubrication Stopping the Engine if an Electrical Malfunction Occurs If the engine does not stop after turning the engine start switch key to the OFF position perform the following procedure 1 Turn the key to the Emergency Shutdown Override position in the event of a Delayed Engine Shutdown DES or Key Off Regeneration KOR is active 2 Apply the parking brake 3 Lower the implement if necessary 4 Dismount the machine Illustration 138 5 Open the access door on the left side of the cab At the Ground Level Service Center toggle the Engine Shutdown Switch upward in order to stop the engine WEBM1000 SSS eon ru A Srana N l je i ye e anit Po T el Selh Pal J e te E I EE i i i i a PNN A jeoe Ng loa oj lllustration 139 Rear view 6 Ifthe engine remains operating locate the fuel shutoff valve The fuel shutoff valve is under the fuel tank at the center rear of the machine 7 Close the red handle of the fuel shutoff valve in order to shut off the fuel supply to the engine Note Do not operate the machine until the malfunction has been corrected Leaving the Machine 1 Park on a level surface If you must park on a grade block the machine 2 Apply the service brake in order to stop the machine Move the speed range selector to the NEUTRAL position Use the throttle switch
274. own Mode Automatic auto kickdown mode allows the transmission to downshift automatically After a manual upshift the auto kickdown is prevented for 2 seconds The operator can make manual shifts at any time Auto Kickdown OFF Push switch 14 and release switch 14 until the auto kickdown indicator is off The manual shift mode is active if no autoshift indicators are on Auto Kickdown LOW This mode utilizes the low shifting points Auto Kickdown MEDIUM This mode utilizes the middle shifting points Auto Kickdown HIGH This mode utilizes higher downshift points The higher downshift points result in a quicker response as load is applied Engine Start Switch 15 Illustration 74 WEBM1000 OFF 1 Inserting the engine start O switch key and removing the key must only be done from the OFF position In the OFF position there is no power to most electrical circuits in the cab The cab lights the panel lights the tail lights and the dome light are operational even when the start switch is in the OFF position Turn the start switch key to the OFF position in order to stop the engine ON 2 Turn the start switch key clockwise to the ON position in order to activate all cab circuits clockwise to the START position in order to crank the engine Release the key after the engine starts The key will return to the ON position Emergency Shutdown Override 4 Turn the engine start switch k
275. p slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Cat dealer Level 1 Analysis NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers 133 Maintenance Section D6T LGP OEM Cooling System Coolant Sample Level 1 Obtain NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dea
276. parking brake switch is disengaged the parking brake indicator on the dashboard turns off A direction is ready to be chosen Do not use the parking brake to stop the machine Engaged Push switch 2 away from P the operator in order to engage the parking brake The steering control is electronically locked Also the transmission controls are electrically disabled The transmission will be locked in NEUTRAL Disengaged Push switch 2 toward the operator in order to disengage the parking brake Differential Steering Control 3 Steering control lever 3 allows the steering system and the transmission system to be simultaneously controlled Push down on parking brake switch 2 in order to disengage the parking brake and allow movement of the steering and transmission controls The steering lever is electronically locked by the parking brake The transmission controls are electronically disabled Illustration 60 Steering Control The machine can be steered with the power train in the NEUTRAL position NOTICE When the steering lever is moved with the transmission in NEUTRAL or in gear and the engine is running the machine will turn Engage the steering control lock by engaging the parking brake in order to prevent machine movement 52 Operation Section D6T LGP OEM Machine Operation Illustration 61 When the machine is moving forward push the steering control forward for a left turn When
277. pean Union Physical Agents Vibration Directive 2002 44 EC for complete information noting that the Information Concerning Whole Body Vibration Level will not be greater than the typical operating activity values given for dozing Guards There are different types of guards that are used to protect the operator 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 WEBM1000 Product Information Section Pipelayer Attachment Kit General Information Components Load Block Na ral Hook or Load line Hook Block 035 05 05 020B Winch Drawworks Boom winch upper Winch Drawwaorks Hook Winch Lower Right hand frame 193 Product Information Section Pipelayer Attachment Kit General Information Counterweight frame with counterweights Boom Luff Black Boorn line Tail Block aa _ aa SH a 035 0505 0195 194 Product Information Section Pipelayer Attachment Kit WEBM1000 General Information Illustration 265 Component Identification Specifications 035 05
278. pics for correct replacement instructions e Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace e Operation and Maintenance Manual Engine Air Filter Secondary Element Replace Required Engine Oil 4 This message is located on the engine oil filler tube 16 Safety Section D6T LGP OEM Additional Messages CAT DEO ULS API CJ 4 ACEA E9 Illustration 8 Refer to Operation and Maintenance Manual Lubricant Viscosities The engine must be shut off before any maintenance is performed Use a wand in order to clean debris from the fan and baffle assembly Product Link 5 This message is located beneath the left window inside the cab Illustration 9 The Product Link System is a communication device that transmits information regarding the machine back to Caterpillar and Caterpillar dealers and customers All logged events and diagnostic codes that are available to the Caterpillar Electronic Technician ET on the CAT data link can be sent to the receiving station Information can also be sent to the Product Link System The information is used to improve Caterpillar products and Caterpillar services The Product Link is also available in cellular format Refer to Operation and Maintenance Manual Product Link for more information WEBM1000 Reference See Operation and Maintenance Manual Maintenance Interval Schedule for all maintenance
279. proper specification Refer to Specifications Spark Plug for the proper torque specification 3 Connect the wiring harness 4 Close the right engine access door Backup Alarm Test The backup alarm is on the rear of the machine In order to test the alarm for proper functioning turn the engine start switch to the ON position Apply the service brake Release the parking brake Move the speed range selector to the REVERSE position 126 Maintenance Section D6T LGP OEM Battery Inspect The backup alarm should start to sound immediately The backup alarm will continue to sound until the speed range selector is moved to the NEUTRAL position or to the FORWARD position Battery Inspect 1 Open the battery access covers The battery access covers are located on the left side of the machine outside the operator compartment 2 Tighten the battery retainers Clean the top of the batteries with a clean cloth Keep the terminals clean and coated with petroleum jelly Install the terminal covers after you coat the terminals 3 Close the battery access covers Belt Inspect Replace Your engine is equipped with a serpentine belt 1 that drives the alternator 5 the water pump 3 and the a c compressor 4 if equipped Inspect the Belt 1 Park the machine on level ground Lower the dozer blade to the ground Move the transmission control to the NEUTRAL position and engage the parking brake Shut off t
280. r any person engaged in the business of repairing servicing selling leasing or trading engines or machines to remove alter or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations 40 CFR Part 89 Certain elements of the machine and engine such as the exhaust system fuel system electrical system intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar 5 Foreword Machine Capacity Additional attachments or modifications may exceed machine design capacity which can adversely affect performance characteristics Included would be stability and system certifications such as brakes steering and rollover protective structures ROPS Contact your Caterpillar dealer for further information Caterpillar Product Identification Number Effective First Quarter 2001 the Caterpillar Product Identification Number PIN has changed from 8 to 17 characters In an effort to provide uniform equipment identification Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard Non road machine PINs are defined by ISO 10261 The new PIN format will apply to all Caterpillar machines and generator sets The PIN plates and frame marking will display the 17 character PIN The new format will look lik
281. r for the replacement of the seat belt and the mounting hardware Note The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts Seat Belt Replace The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 166 Maintenance Section D6T LGP OEM Torque Converter Scavenge Screen Clean ej 0 Illustration 232 Typical Example 1 Date of installation retractor 2 Date of installation buckle 3 Year of manufacture tag fully extended Web 4 Year of manufacture underside buckle Consult your Cat dealer for the replacement of the seat belt and the mounting hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should
282. r injects the engine air intake This action will occur during the engine starting procedure The indicator light indicates that the relay for the ether aid is being activated For starting below the approximate temperature of 1 C 30 F the use of the ether starting aid is automatic Continue the procedure for Engine Starting For starting below 18 C 0 F the use of the cold weather starting aids is recommended Lighter Illustration 134 viscosity fluids a jacket water heater a fuel heater or the heavy duty starter may be required 2 Move direction selector 2 to the NEUTRAL position 3 Engage parking brake 1 98 Operation Section D6T LGP OEM Engine Starting At temperatures below 23 C 10 F consult your Caterpillar dealer For information on starting the engine in cold weather refer to the Operation and Maintenance Manual SEBU5898 Cold Weather Recommendations for all Caterpillar Machines Subsequent Engine Starting Procedures NOTICE Keep engine speed low until the engine oil pressure registers on the gauge or the engine oil indicator light goes out If it does not register or the light 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 1 Allow acold engine to warm up at low idle for at least 5 minutes 2 You can begin to operate the machine with a reduced load 3 When the
283. r more information about vibration This publication uses data that is measured by c Controls hydraulic system and linkages international institutes organizations and manufacturers This document provides information 3 Keep the terrain in good condition about the whole body exposure of operators of earthmoving equipment Refer to Operation and a Remove any large rocks or obstacles Maintenance Manual SEBU8257 The European Union Physical Agents Vibration Directive 2002 44 b Fill any ditches and holes EC for more information about machine vibration levels c Provide machines and schedule time in order to maintain the conditions of the terrain The Caterpillar suspension seat meets the criteria of ISO 7096 This represents vertical vibration level 4 Use a seat that meets ISO 7096 Keep the seat under severe operating conditions This seat is maintained and adjusted tested with the input spectral class EM6 The seat has a transmissibility factor of SEAT lt 0 7 a Adjust the seat and suspension for the weight and the size of the operator The whole body vibration level of the machine varies There is a range of values The low value is b Inspect and maintain the seat suspension and 0 5 meter per second squared The machine meets adjustment mechanisms the short term level for the design of the seat in ISO 7096 The value is 1 61 meter per second squared 5 Perform the following operations smoothly for thi
284. r sensor sol solenoid spd speed sts status std standard str steering sw switch tc torque converter tco torque converter output temp temperature term terminal trans transmission V volt Table 16 Abbreviation and Term for Monitoring System Display Additional Term Abbreviation Term Aftrmt Aftertreatment Alt Alternator ARD Aftertreatment Regen Device Auto Man Auto Manual Bal Balance Bar Barometric Batt Battery Brk Brake Chrg Charge Cnsmp Consumption Cntl Control Cnvtr Converter Crank Crankcase DC Direct Current Dec Decrement Decel Decelerator Dem Demand Diff Differential Dir Direction Div Divrtr Diverter DPF Diesel Particulate Filter ECU Electronic Control Unit EGR Exhaust Gas Recirculation Enbl Enable Exh Exhaust Fitr Filter Fwd Forward Grd Grade Hndl Handle ID MOD Identification Number Module Ignt Ignition Imp Implement In Inlet IN Intake Inc Increment 86 Operation Section D6T LGP OEM Machine Operation Abbreviation and Term for Monitoring System WEBM1000 Abbreviation and Term for Monitoring System Additional Term Abbreviation Term Rkr Rocker Rng Range Rs Raise Scndry Secondary Sec Secondary Sel Selector Shnk Shank Shtdn Shutdown Shtdwn Shutdown Srv Service Tmg Timin
285. r to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations for additional information Maintaining the system as ELC is preferred See the sections Coolant Recommendations and ELC Cooling System Maintenance Illustration 164 Rear view 2 If additional coolant is necessary open radiator access door 1 Remove filler cap 2 slowly in order to relieve the pressure 3 Maintain the coolant level above the sight gage in the coolant tank to area 3 Adding coolant above this area will cause the coolant to overflow the cooling system If you need to add coolant daily check the cooling system for leaks WEBM1000 4 Inspect filler cap 2 and the filler cap seal for debris for foreign material or for damage Clean filler cap 2 with a clean cloth Replace the radiator cap if the filler cap is damaged 5 Install the filler cap 6 Inspect the radiator core for debris Clean the radiator core if necessary Use compressed air high pressure water or steam to remove dust and debris from the radiator core However the use of compressed air is preferred Cooling System Coolant Sample Level 1 Obtain Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler ca
286. r will illuminate when the soot level reaches 90 This lamp turns off during an active regeneration High Exhaust System Temperature HEST lamp indicates that a regeneration cycle using the Aftertreatment Regeneration Device ARD is active 60 Operation Section D6T LGP OEM Machine Operation Regeneration Disabled The display will indicate when a regeneration cycle is disabled Reference See Operation and Maintenance Manual Diesel Particulate Filter Regeneration for additional information Engine Fan Reverse Switch 17 If equipped If the machine is equipped with the reverse fan function attachment the fan can reverse the direction of air flow from forward to the rearward direction This function enables the fan to purge debris from the radiator aftercooler cores and engine access doors The purge cycle will begin automatically when the purge interval expires or the purge cycle can begin manually with a switch 17 on the left dash Reversing Fan Control 17 In order to initiate the fan purge cycle press fan control switch 17 while the machine is in NEUTRAL and the parking brake is released or when the machine is in REVERSE In order to initiate the continuous purge cycle press fan control switch 17 while the machine is in NEUTRAL and the parking brake is ON and hold for 3 seconds The fan will remain in a continuous purge cycle until the switch is pressed again or the parking brake i
287. r you get on the machine and whenever you get off the machine Maintain a three point contact with the steps and with the handholds Note Three point contact can be 2 feet and one hand Three point contact can also be 1 foot and two hands Do not mount a moving machine Do not dismount a moving machine Never jump off the machine Do not carry tools or supplies when you try to mount the machine or when you try to dismount the machine Use a hand line to pull equipment onto the platform Do not use any controls as handholds when you enter the operator compartment or when you exit the operator compartment WEBM1000 Illustration 35 Location of the ground level service center After daylight hours end or in periods of darkness use the platform access lighting This light illuminates the entrance way to the cab Open the access door to the ground level service center Illustration 36 Ground level service center Access Lighting Use the toggle switch for the lighting in order to mount the machine Note When the switch in the ground level service center is activated the lights remain on for 10 minutes The time limit of the lights is programmable in the Monitoring System Display with Machine Setup in the Settings Menu Toggling the switch a second time will deactivate the lights The toggling of the switch will also turn off the lights if the lights were activated from the cab while exiting the machine W
288. radual steady machine movement will be more effective WEBM1000 All situation requirements cannot be listed Minimal towing machine capacity is required on smooth level surfaces Maximum towing machine capacity is required on inclines or on surfaces that are in poor condition Consult your Caterpillar dealer for the equipment that is necessary for towing a disabled machine Running Engine If the engine is running the machine can be towed for a short distance under certain conditions The power train and the steering system must be operable Tow the machine for a short distance only For example pull the machine out of mud or pull the machine to the side of the road The operator on the towed machine must steer the machine in the direction of the tow line Carefully follow all instructions that are outlined in the Towing Information Ensure that the instructions are followed exactly Stopped Engine or Drive Line Defect You can move the machine when the engine is not operable You must use a brake release pump or you must remove the axle shafts You can use a brake release pump or you can remove the axle shafts in order to tow the machine if the engine is stopped and if the driveline is not damaged If an internal transmission or a driveline failure is suspected remove the axle shafts For the first method remove the axle shafts You may remove the axle shafts from the final drives in order to tow the machine T
289. re more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced 10 hydraulic oil is used the hydraulic oil change interval will change The normal interval of 2000 hours is extended to 3000 hours S O S services may extend the oil change even longer Consult your Cat dealer for details When Required Engine Air Filter Primary and or Secondary Element Glean Mepla onrera in e A O R 136 Engine Air Precleaner Clean issie 138 Ether Starting Aid Cylinder Replace s s s 143 Front Idler Position Check n 145 Fuel System Prime s an 147 Fuses and Circuit Breakers Replace Reset 152 Oil Filter INSPEChevccsissreweedssaiiees cdesveveecends dtgccedent 161 Radiator Core Clean eere 162 Radiator Pressure Cap Clean Replace 162 Window Washer Reservoir Fill l 174 Windows CIean noenssinnei siei aa eS 175 Every 10 Service Hours or Daily Backup Alarm Test ccccccccccccccesececeseseseseeseeeees 125 Brakes Indicators and Gauges Test 05 127 Cab Filter Fresh Air Clean Inspect Replace 128 Cooling System Coolant Level Check 4 132 Engine Oil Level Check cc eeeeceeeeetteeeeee 138 Fuel System Primary Filter Water Separator Drain se oesahscrec titrant ie tai sts Met ere tas eames amaeeteen as cndname ey waco 148 Hydraulic System Oil Level
290. re red for correct identification 8 Connect the positive jump start cable to the positive cable terminal of the discharged battery 9 Batteries in series may be in separate compartments Use the terminal that is connected to the starter solenoid Trace this cable in order to make sure that the cable is connected to the starter 10 Connect the positive jump start cable to the positive terminal of the electrical source Use the procedure from Step 149 in order to determine the correct terminal 1 _ Connect one end of the negative jump start cable to the negative terminal of the electrical source 12 Make the final connection Connect the negative cable to the frame of the stalled machine Make this connection away from the battery the fuel the hydraulic lines or moving parts WEBM1000 13 Start the engine on the machine that is the electrical source Also you can energize the charging system on the auxiliary power source 14 Allow the electrical source to charge the batteries for 2 minutes 15 Attempt to start the stalled engine Refer to Operation and Maintenance Manual Engine Starting See the beginning of this topic Allow the electrical source to charge the batteries for 2 minutes 16 Immediately after the stalled engine starts disconnect the jump start cables in reverse order 17 Conclude with a failure analysis on the starting charging system Check the stalled machine as required
291. red for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including but not limited to physical dimensions type strength and material Failure to heed this warning can lead to premature failures product damage personal injury or death 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 Table of Contents Safety Section D6T LGP OEM Safety Messages oe eeeceteeetteeeteetteeeeettteeettteeen 6 Additional Messages ou ceeeteccctttteeeetteteeeees 14 General Hazard Information eee 17 Crushing Prevention and Cutting Prevention 19 BUN PrEVENUOM yeri inia a a 20 Fire Prevention and Explosion Prevention 21 FOS BIST reye A C 24 Fire Extinguisher Location ecic 24 Track INformation erectae 24 Electrical Storm Injury Prevention issie 25 Before Starting Engine cceecceeeeesteeeeeee 25 Engine Starting e a oy aimee acacia aves does 25 Before Operation ececccccccceeeeeeeeeeeeeseeeeeeeees 25 Visibility INformation oo ccc ceceeeee se ee neers 25 Restricted Visibility 00 cccccceceeceeeceesseetteteeeeees 26 OPELAUGM ROEE TEATE ETEEN EEA TTS 26 PAKO a eo Gea a eet AAT A A E 28 Slope Operation eeccccceeeeeecceeeeeeseeeeeeeeeeteenees 28 Engine Stopping esseeeseeesseessrerrssrrsrerrrerrreerrserrsse
292. rking brake is set the transmission defaults to NEUTRAL When the parking brake is released the transmission will stay in NEUTRAL To select the direction of machine travel return direction selector 4 to neutral 7 Then move direction selector 4 to the desired direction Use speed range selector 5 to select the desired speed 8 Release service brake pedal 1 in order to allow the machine to move Illustration 131 The throttle control switch is located on the right side console 9 To select high idle push in on the top of the throttle control switch and release The engine speed immediately moves to high idle 10 To select low idle push in on the bottom of the throttle control switch and release The engine speed immediately moves to low idle WEBM1000 11 Select an intermediate speed in the following manner a Set the engine speed to high idle b Select the desired engine speed with the decelerator 2 c Push in on the throttle control switch and hold for 3 seconds in order to lock in the engine speed This speed is now the maximum operating speed 12 Change an intermediate speed in the following manner a Push in the top part of the throttle control switch and hold for 3 seconds Then release the switch The rom ramps up from the current setting b Push in the bottom part of the throttle control switch and hold for 3 seconds Then release the switch The rom ramps down from the curr
293. rmation and Vibration Information 191 GUAS Sazccsth heel Sophos ear a e e Meese 192 Product Information Section Pipelayer Attachment Kit General Information uo cece ee ces eeeeeees 193 Operation Section Pipelayer Attachment Kit Before Operation rreren 197 Maintenance and Lubrication Section Pipelayer Attachment Kit Lubricant Viscosities eee 210 Maintenance Interval Schedule MIS 212 NIEK aai ete el On ee 227 4 Foreword Foreword Literature Information This manual should be stored in the operator s compartment in the literature holder or seat back literature storage area This manual contains safety information operation instructions transportation information lubrication information and maintenance information The information contained in the section entitled Pipelayer Attachment Kit of this manual is limited to the pipelayer attachment and specific modifications made to the tractor unit Refer to the section entitled D6T LGP OEM for complete information regarding the tractor unit Some photographs or illustrations in this publication show details or attachments that can be different from your machine Guards and covers might have been removed for illustrative purposes Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication The latest version of this publication is avai
294. rofile must be inactive in order to delete the profile Using Operator Preferences Upon the next restart the user will be prompted to recall a saved profile Press the OK button within 15 seconds in order to recall the profile settings If 15 seconds pass by the start up no profile settings are applied If the message display fails to apply any settings included in the operator profile a message communicating Operator XXXXX Settings Error will be displayed Where XXXXxX is the name of the profile being applied The following information indicates the typical procedure for start ups if the operator has saved a set of preferences by Name Illustration 100 75 Operation Section D6T LGP OEM Machine Operation 1 Turn the key ON Highlight the Name 1 in order to use the saved preferences Then press the OK button If you do not select the Name 1 within 15 seconds no profile setting will activate Note The Default profile name 2 is a selection that allows the most appropriate settings for the machine and the recent working conditions 2 You have now selected the Operator Profile with the set of preferences that was previously saved 76 Operation Section D6T LGP OEM WEBM1000 Machine Operation Settings Menu Auto Shift Bi dir FORWARD REVERSE S ETTI N G S M E N U Auto Kickdown gt Low Medium High Power Train oa mp pE eae REV Enter
295. rsonal injury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Lower the bulldozer and the ripper to the ground 157 Maintenance Section D6T LGP OEM Hydraulic System Oil Filter Pilot Replace Illustration 208 Right side of cab 2 Slowly remove hydraulic tank filler cap 2 in order to relieve the system pressure Illustration 210 158 Maintenance Section D6T LGP OEM Hydraulic System Oil Filters Replace Note The pilot filter is located in the compartment in front of the hydraulic tank on the right side of the machine 3 Remove the filter element with a strap type wrench 4 Clean the filter element mounting base Remove any part of the filter element gas
296. s 45 Feet WEBM1000 While In Transit Near High Voltage Power Lines Normal Voltage Phase to Phase Minimum Clearance Required 0 Volts to 75 kVolts 1 22 Meters 4 Feet Over 75 kVolts to 50 kVolts 1 83 Meters 6 Feet Over 50 kVolts to 345 kVolts 3 05 Meters 10 Feet Over 345 kVolts to 750 kVolts 6 10 Meters 20 Feet Over 750 kVolts to 1000 kVolts 7 62 Meters 25 Feet Parking Park on a level surface If you must park on a grade use blocks to prevent the machine from rolling Apply the service brake in order to stop the machine Move the transmission control lever to NEUTRAL position and move the engine speed switch to the LOW IDLE position Engage the parking brake Lower any load to the ground and fully retract the counterweight Refer to the tractor s operation and maintenance manual for the specific procedures regarding engine shut down and or other implement attachments Slope Operation Machines that are operating safely in various applications depend on these criteria the machine model configuration machine maintenance operating speed of the machine conditions of the terrain fluid levels and tire inflation pressures The most important criteria are the skill and judgment of the operator A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability Operator training provides a
297. s further increase the digging into the ground which causes the machine to be less stable Implements attached to the drawbar This may decrease the weight on the uphill tracks This may 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 working loads are in higher positions the stability of the machine is reduced Operated equipment Be aware of performance 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 various machine systems These machine systems are needed for machine control 191 Safety Section Pipelayer Attachment Kit Equipment Lowering with Engine Stopped Note Safe operation on steep slopes may require special machine maintenance Excellent skill of the operator and proper equipment for specific applications are also required Consult the Operation and Maintenance Manual sections for the proper fluid level requirements and intended machine use Note Refer to the tractor s operation and maintenance manual for further specific requirements for safe operation on steep slopes Equipment Lowering with Engine Stopped Before lowering any equipment with the engine s
298. s machine a Steer Guidelines for Reducing Vibration Levels on Earthmoving Equipment b Brake Properly adjust machines Properly maintain machines Operate machines smoothly Maintain the Gr AORelelate conditions of the terrain The following guidelines can help reduce the whole body vibration level di Shitting gears 1 Use the right type and size of machine Be Move the ave pmenssineainly equipment and attachments 7 Adjust the machine speed and the route in order 2 Maintain machines according to the manufacturer s recommendations to minimize the vibration level a Drive around obstacles and rough terrain 32 Safety Section D6T LGP OEM Operator Station 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 Track Type Tractors c If no ride control system is available reduce speed in order to prevent bounce d Haul the machines between workplaces 9 Less operator comfort may be caused by other risk factors The following guidelines can be effective in order to provide better operator comfort a Adjust the seat and adjust the controls in order to achieve good posture b Adjust the mirrors in order to minimize twisted posture c Provide breaks in order to reduce long periods of sitting d Avoid jumping from the cab
299. s released The setting range for the duration of the fan purge cycle is 5 60 seconds The setting range for fan purge interval is 5 120 minutes If the purge interval expires a purge cycle will begin when the track type tractor is in a REVERSE gear or in NEUTRAL and the parking brake is released If the purge interval expires and the track type tractor is in a FORWARD gear starting a purge cycle is prevented If the purge interval expires and the track type tractor is in NEUTRAL with the parking brake engaged starting a purge cycle is prevented A purge cycle is prohibited until there is a shift into REVERSE gear or the parking brake is released in NEUTRAL If the purge button is manually depressed a purge cycle will begin when the track type tractor is ina REVERSE gear or in NEUTRAL and the parking brake is released If the purge button is manually depressed the request for a purge cycle will be ignored when the track type tractor is in a FORWARD gear or in NEUTRAL and the parking brake is engaged WEBM1000 When a purge cycle is in progress and the cancellation of the purge cycle is set to OFF the indicator light for the reverse fan function in monitoring system display 10 will light After a purge cycle begins the purge cycle is canceled if there is a shift to forward gear When a purge cycle begins and the cancellation of the Purge Cycle is set to ON the purge cycle will stop automatically once the machine is put i
300. se or after the engine is restarted unintentional drawworks operation Hook Control 3 8 HOLD The lever self centres to this position whenever it is released In this position the load winch brake will set and the hook will stop and remain at the position it is in Component failure Re engaging the free fall while the load is dropping causes shock loads which could cause component structural failure resulting in possible personnel injury or death 201 Operation Section Pipelayer Attachment Kit Before Operation Emergency Lower Free Fall l Move the hook control lever to this position to lower the load fast in an emergency The load winch s free fall brake will release and the hook will move down under the weight of the load The lever will return to the HOLD position when released the load winch s free fall brake will upon activating the free fall function the load will drop and must be allowed to fall to its end travel without re engagement NOTICE The Free Fall is used for a full release of a suspended load up to the maximum lift capacity of the hook winch Upon activating the free fall function the load will drop and must be allowed to fall to its end travel without re engagement Note Free Fall is only available in pipelayer HIGH or LOW SPEED modeeeWinch Controls Unlocked bi LOWER Move the lever to this position to lower the hook with controlled winch power The further the lever
301. section Illustration 241 Some components are removed for clarity 3 Raise the front of the machine with the hydraulics of the dozer Place the block under the inside edge of the same track grouser Lower the machine onto the block 169 Maintenance Section D6T LGP OEM Track Roller Frame Guides Inspect Illustration 242 4 Puta mark on the tubular section of the front roller frame This mark should correspond with the mark on the rear roller frame Measure the distance between the two marks on the front roller frame If the distance between the two marks is greater than 4 5 mm 18 inch inspect the track roller frame guides for wear Repeat the entire procedure for the other side of the machine NOTICE Never build up the track roller frame guides with hard face welding This will cause serious wear damage to the guide slots in the front track roller frame Illustration 243 If dimension X is less than 45 3 mm 1 78 inch replace the track roller frame guides Consult your Caterpillar dealer for information or for service 170 Maintenance Section D6T LGP OEM WEBM1000 Transmission Breather Clean Replace Transmission Breather Clean Replace Replace Replace the transmission breather if the breather is Clean no longer capable of cleaning Illustration 246 1 The transmission breather is located on the bulk head bracket
302. severe damage to components can occur 1 The active status indicators are marked with an X 2 This is the possible result if the operator takes no action Some level warnings will be logged only The front action lamp flashes amber The rear action lamp flashes red Both action lamps flash red 3 4 6 6 The action alarm sounds 7 immediately This action reduces the engine speed immediately If a fault indication occurs the message will override any screen that was displayed on the monitoring system display For example a steering malfunction is indicated on the message display The message display prompts the operator with the Limp Home Mode screen in order to continue to move the machine with limited operation to a safe place Reference See Systems Operation KENR8246 D7E Track Type Tractor Monitoring System for more information Monitoring System Display Illustration 89 The monitoring system display is located in the front operator console Engine overspeed does not require engine shutdown Engine overspeed requires applying the travel control pedal in order to reduce the track speed The monitoring system display monitors the machine operations diagnostic events and modes of operation The monitoring system display is used to change the preferred operator inputs and operation parameters This exercise allows additional means for the operator to
303. should be positioned so that the machine may be lifted in a level plane The spreader bars should be wide enough to prevent contact with the machine Locations for Tie downs e Use the eye of the front tie down e Use the inside edge of the track shoe for the side tie downs e Use the drawbar the ripper or the outer edge of the track shoe for the rear tie downs Check the state laws and the local laws that govern the following load characteristics e Weight e Width e Length e Height 105 Operation Section D6T LGP OEM Transportation Information Consult your Cat dealer for shipping instructions for your machine 106 Operation Section D6T LGP OEM Towing Information Towing Information Towing the Machine 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 blocked Personal injury or death can result from worn wire rope cable Worn or frayed cable could break causing injury Check the wire rope cable If cable is worn or is frayed install a new cable When the final drive sun gears are removed the machine has NO parking brakes The machine can roll and cause personal injury or death Block the tracks securely so that the machine cannot move The towing connection must be rigid or towing must be done by two machines of the same size or larger than the towed ma
304. smission oil temperatures After the work on the severe slopes has been completed drain the excessive oil quantity from the bevel gear case 3 If necessary add oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities in this manual 4 Clean the filler cap and install the filler cap 5 Close the access cover Transmission Scavenge Screen Clean When you change the transmission oil clean the scavenge screen 174 Maintenance Section D6T LGP OEM Transmission System Oil Sample Obtain Illustration 255 1 Remove the cover from the rear of the transmission The scavenge screen is located behind the cover 2 Wash the screen in a clean nonflammable solvent 3 Inspect the seal If the seal is damaged replace the seal 4 Install the screen and the cover Transmission System Oil Sample Obtain Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and cont
305. structions that are provided by the supplier of the filter 7 Open the fuel shutoff valve Refer to illustration 194 8 Prime the fuel system See the Topic Fuel System Prime in this manual 9 Close the engine access door Fuel System Water Separator Element Replace Personal injury or death may result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filter with fuel before installing the fuel filter Contaminated fuel causes accelerated wear to fuel system parts NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 150 Maintenance Section D6T LGP OEM Fuel Tank Cap Filter and Strainer Replace Clean Illustration 196 1 The fuel shutoff valve
306. suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 200 The drain valve is under the fuel tank at the rear of the machine 1 Open the drain valve Allow the water and the sediment to drain into a suitable container 2 Close the drain valve 152 Maintenance Section D6T LGP OEM Fumes Disposal Filter Element Replace Fumes Disposal Filter Element Replace Open Crankcase Ventilation OCV Filter Illustration 201 The filter for the open crankcase ventilation system is located toward the rear of the left side of the engine A filter that has been used may contain a small amount of engine oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations
307. t 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 8 Safety Section D6T LGP OEM Safety Messages Replace any safety message that is damaged or missing If a safety message is attached to a part of the machine that is replaced install a safety message on the replacement part Any Caterpillar dealer can provide new safety messages WEBM1000 Do Not Operate 1 Safety message 1 is positioned on the upper ledge of the left hand console of the operator station Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual Failure to follow the instructions or heed the warnings could result in injury or death Contact any Cat dealer for replacement manuals Proper care is your responsibility WEBM1000 Seat Belt 2 Safety message 2 is located on the right console to the right of the dozer control 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 9 Safety Section D6T LGP OEM Safety Messages Do Not Weld on the ROPS 3 Safety message 3 is positioned on the vertical s
308. t frame For machines that are compliant to 2006 42 EC the following information is stamped onto the CE plate 2 on eRe E gre E EN t E t t I E 4 E i i Wek ove ee Cua oo BB t CE Kw KW kg Illustration 30 CE plate For quick reference record this information in the spaces that are provided below e Engine Power of primary engine kW _ 37 Product Information Section D6T LGP OEM Identification Information e Engine Power for additional engine kW if equipped _ e Typical operating weight of machine for European market kg _ e Year of construction _ e Machine Type _ For machines that are compliant to 1998 37 EC the following information is stamped onto the CE plate CAT CATERPILLAR NUMBER CAT CATERPILLAR PRODUCT poco cece rrr eH HHH He CATERPILLAR INC PEORIA IL 61629 USA PARTS MADEIN ORDER z z J 239 6006 1 Illustration 31 For quick reference record this information in the spaces that are provided below e Engine Power of primary engine kW _ e Typical operating weight of machine for European market kg _ e Year _ Structure certification ROPS Structural damage an overturn modification alteration or improper repair can impair this structure s protection capability thereby voiding this certification Do not weld on or drill holes in the
309. t mode at 1F 2R and a directional shift is requested the machine will shift directly from third gear forward to second reverse gear If another directional shift is requested the machine will shift from second reverse gear to first gear forward When the machine powers up and the autoshift function is previously enabled the mode selection always begins in the default OFF mode Bidirectional Shift 13 The bidirectional autoshift function allows selection from two fixed settings and one configurable setting Table 7 Autoshift Mode 1F 3 0R 1F 2R 2F 2R OFF 1 Active setting 2 Configurable setting in the monitoring system display For the best results change the options with the transmission in NEUTRAL WEBM1000 1F 3 0RConfigurable setting This active setting can be configured with the Monitoring System Display for use in directional shift mode with first speed forward to reduced Eco Reverse 1F 2R This setting is the active setting when first speed forward to second reverse speed is the directional shift mode 2F 2R This setting is the active setting when second speed forward to second reverse speed is the directional shift mode The lights will display the desired mode For the best results change the options with the transmission in NEUTRAL If the autoshift functions are not desired the machine can be operated in the manual mode The modes of
310. tallation tool does not damage the filter 5 be Lg Illustration 179 11 Open the left engine access door 12 Clean the area around oil filler cap 4 before you remove the oil filler cap Clean the area around oil level gauge 5 before you remove the oil level gauge Remove the oil filler cap Fill the crankcase with new oil See the topic Operation and Maintenance Manual Refill Capacities and Lubricant Viscosities in this manual 13 Clean oil filler cap 4 and install oil filler cap 4 14 Start the engine and allow the oil to warm Check the engine for leaks 142 Maintenance Section D6T LGP OEM Engine Valve Lash Check Adjust 15 Check the oil level If necessary add oil To ensure that the correct amount of oil was added always measure the oil level with the engine oil dipstick 5 Refer to Operation and Maintenance Manual Engine Oil Level Check for more information 16 Stop the engine Close the engine access doors Engine Valve Lash Check Adjust To prevent possible injury do not use the starter motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before measuring valve clearance Electrical shock hazard The electronic unit injector system uses 90 120 volts NOTICE Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency This reduced efficiency cou
311. tch to the OFF position Remove the key when you exit the machine for an extended period of time Turning the battery disconnect switch to the OFF position will provide the following benefits WEBM1000 e Prevent battery discharge that is caused by a battery short circuit e Prevent battery discharge that is caused by some of the components e Prevent battery discharge that is caused by vandalism Slope Operation Machines that are operating safely in various applications depend on these criteria the machine model configuration machine maintenance operating speed of the machine conditions of the terrain fluid levels and tire inflation pressures The most important criteria are the skill and judgment of the operator A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability Operator training provides a person with the following abilities observation of working and environmental conditions feel for the machine identification of potential hazards and operating the machine safely by making appropriate decisions When you work on side hills and when you work on slopes consider the following important points Speed of travel At higher speeds forces of inertia tend to make the machine less stable Roughness of terrain or surface The machine may be less stable with uneven terrain Direction of travel Avoid operating the machine acr
312. tem Coolant ELC Change Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting turn the battery disconnect switch to the OFF position and remove the key If the machine is not equipped with a battery disconnect switch disconnect the battery cables from the battery and tape the battery clamps Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on NOTICE Make sure you read and understand the information in the topics Safety and Cooling System Specifications for all information pertaining to water antifreeze and supplemental coolant additive requirements before you proceed with maintenance of the cooling system NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Drain the coolant whenever the coolant is dirty or whenever foaming is observed The filler cap is located inside the access door in the top right side of the radia
313. tem components are cooled The maximum run time is 10 minutes Note To override delayed engine shutdown and stop the engine turn the engine start switch to the STOP position Overriding delayed engine shutdown may reduce engine and machine system component life A warning message and or audible alarm will be initiated and a fault code will be logged for improper engine shutdown 66 Operation Section D6T LGP OEM Machine Operation Illustration 86 Note At any time during a delayed engine shutdown the engine start switch may be turned to the ON position The machine may be placed back into service Monitoring System The monitoring system informs the operator of the status of the machine systems The monitoring system informs the operator of problems or of an impending problem Functional Test When the engine key start switch is turned ON the monitoring system will conduct a self test The self test consists of the following characteristics full sweep of the gauge needles from the minimum position to the maximum position activation of all indicators and activation of the audible alarm for level three warnings for one second The operator must observe the self test to verify that the monitoring system is working properly The self testing feature verifies that the modules of the monitoring system are properly operating The operator must observe the outputs in order to determine if the modules are operating proper
314. temperature is 112 C 234 F Increased temperatures will sound the warning alarm Continued operation of the machine during the sounding of the warning alarm or the gauge needle in the red zone may damage the engine Stop the machine in a safe place and investigate the cause WEBM1000 Fuel Level 4 The fuel level gauge indicates the amount of fuel that remains in the fuel tank A gauge needle in the red zone indicates a low fuel level This proceeding indicates a remaining fuel level of approximately 10 percent NOTICE Running out of fuel can cause engine damage Do not continue to operate the machine when critically low on fuel Torque Converter Oil Temperature 5 This gauge indicates the temperature of the oil in the torque converter If the gauge needle reaches the red zone increased temperatures will sound the warning alarm Continued operation of the machine during the sounding of the warning alarm or the gauge needle in the red zone may damage the transmission and or the torque converter Reduce the load that is on the machine until the torque converter oil temperature decreases 67 Operation Section D6T LGP OEM Machine Operation 68 Operation Section D6T LGP OEM Machine Operation Status Indicators ECO S U 18 17 im Illustration 88 Eco Reverse Mode reverse travel 6 This indicator is illuminated when the fuel economy mode is active during reverse travel in the unlo
315. the REVERSE position will always shift to the third physical gear or operator configured gear This mode allows a direct shift from the FIRST SPEED FORWARD position to the THIRD SPEED REVERSE position With the transmission in the NEUTRAL position the display for the transmission indicates N Speed shifting is manual Use the thumb roller for upshift requests and downshift requests When MVP is active the autoshift mode 1 5F 3 0R is active or the operator selected mode is active 57 Operation Section D6T LGP OEM Machine Operation First speed forward to second reverse directional shift mode fixed setting B Push the button for the autoshift function 13 twice When you shift the transmission to the FORWARD position the transmission will always shift into the first physical gear When you shift the transmission to the REVERSE position the transmission will always shift into the second physical gear The speed shift mechanism is manual Use the buttons in order to upshift or use the buttons in order to downshift When MVP is active the autoshift mode 2 5F 2 5R is active Second speed forward to second reverse directional shift mode fixed setting C Push the button for autoshift function 13 three times When you shift the transmission to the FORWARD position the transmission will always shift into the second physical gear When you shift the transmission to the REVERSE position the transmissi
316. the boom Remove the old wire rope 3 Unroll the new wire rope from the spool Note Weld the cable ends in order to prevent fraying NOTICE Unroll all of the cable from the spool Lay the wire rope on a flat surface Never lift the wire rope off the spool in coils 215 Maintenance and Lubrication Section Pipelayer Attachment Illustration 285 nstalling boom line cable anchor assembly 4 Install the cable 1 into the small slot and through the larger slot in the drum for the boom Make sure that 2 to 4 threads of capscrew 2 are engaged into the cable anchor assembly 4 Start with the capscrew and insert the cable anchor assembly into the longer slot as far as allowed Make sure that the lip of retainer 3 faces the top edge 5 of the small slot in order to hold the retainer in place Make a loop with the end of the wire rope and insert the end into the slot past the cable anchor assembly Pull the wire rope until the wire rope and anchor assembly are securely seated inside the slot Tighten the capscrew to a torque 6 of 44 3N m 32 2 Ib ft 5 Wind one half of the wire rope on the drum 7 Wind the wire rope evenly across the drum 216 Maintenance and Lubrication Section Pipelayer Attachment Kit WEBM1000 Boom Line Install Illustration 286 nstalling boom line A Wire rope from the winch B Detail B 6 Install the wire rope from the winch to sheave 8 in the upper sheave block
317. the counterweight The locking mechanism will hold the counterweight in position in the event of a hydraulic failure 205 WEBM1000 Operation Section Pipelayer Attachment Kit Before Operation Equipment Lowering with Engine Stopped 046 05 63 3004 Illustration 276 Controls for Equipment lowering with engine stopped e Unlock the Speed Lockout Control Lock 2 and NOTICE move the Speed Lockout Control Lever 1 to LOW Before lowering any equipment with the engine SPEED MODE WINCH CONTROLS UNLOCKED stopped clear the area around the equipment of all or to HIGH SPEED MODE WINCH CONTROLS personnel The procedure will cause immediate UNLOCKED rapid lowering of the load Refer to Operation and Maintenance Manual Hook Control for complete a e Move the hook control 3 to control function description e Emergency Lower Free Fall If the machine does not have engine power in order to lower the equipment follow these steps e Emergency Lower Free Fall 206 Operation Section Pipelayer Attachment Kit Before Operation e The accumulator will provide pilot pressure that will allow the hook to be immediately lowered fast under the weight of the load e Do not release the hook control to re engage the Free Fall until the load is completely lowered Transportation Information Shipping the Machine Investigate the travel route for overpass clearances Make sure that there is adequate clearance for the m
318. the ignition source in the event of an electrical short Disconnecting the battery will eliminate a second ignition source if electrical wiring is damaged by the fire resulting in a short circuit Notify emergency personnel of the fire and your location If your machine is equipped with a fire suppression system follow the manufacturers procedure for activating the system Note Fire suppression systems need to be regularly inspected by qualified personnel You must be trained to operate the fire suppression system Use the on board fire extinguisher and use the following procedure 1 Pull the pin 2 Aim the extinguisher or nozzle at the base of the fire WEBM1000 3 Squeeze the handle and release the extinguishing agent 4 Sweep the extinguisher from side to side across the base of the fire until the fire is out Remember if you are unable to do anything else shut off the machine before exiting By shutting off the machine fuels will not continue to be pumped into the fire If the fire grows out of control be aware of the following risks e Tires on wheeled machines pose a risk of explosion as tires burn Hot shrapnel and debris can be thrown great distances in an explosion e Tanks accumulators hoses and fittings can rupture in a fire spraying fuels and shrapnel over a large area e Remember that nearly all of the fluids on the machine are flammable including coolant and oils Additionally plasti
319. the use of the Product Link communication network have been satisfied In the event that a machine outfitted with Product Link is located in or relocated to a location where i legal requirements are not satisfied or ii transmitting or processing of such information across multiple locations would not be legal Caterpillar disclaims any liability related to such failure to comply and Caterpillar may discontinue the transmission of information from that machine Consult your Cat dealer with any questions that concern the operation of the Product Link ina specific country 89 WEBM1000 Operation Section D6T LGP OEM Machine Operation EC DECLARATION OF CONFORMITY OF MACHINERY Manufacturer CATERPILLAR INC 100 N E ADAMS STREET PEORIA IL 61626 U S A Person authorised 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 amp Regulations Manager Caterpillar France S A S 40 Avenue Leon Blum B P 55 F38041 Grenoble Cedex 9 I the undersigned Michael R Verheyen hereby certify that the construction equipment specified hereunder Description Generic Denomination Earth moving Equipment Function Asset Management Model Type PL121SR Commercial Name Product Link Fulfils all the relevant provisions of the following Directives Directives Notified Body 2004 108 EC lee NA vaoo PLA21SR PEO101 1990 5EC few NA wen E
320. tion Before you start the machine perform a walk around inspection in order to ensure that there are no hazards around the machine While the machine is in operation constantly survey 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 examples of visual aids are Closed Circuit Television CCTV and mirrors Before operating the machine ensure that the visual aids are in proper working condition and that the visual aids are clean Adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual If equipped the Work Area Vision System shall be adjusted according to Operation and Maintenance Manual SEBU8157 Work Area Vision System 26 Safety Section D6T LGP OEM Restricted Visibility It may not be possible to provide direct visibility on large machines to all areas around the machine Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area Examples of job site organization include the following e Safety instructions e Controlled patterns of machine movement and vehicle movement e Workers that direct traffic to move when it is safe e Restricted areas e Operator training
321. tions and mandates 1 Lower the bulldozer and the ripper to the ground rani Illustration 212 Right side of cab 2 Slowly remove hydraulic tank filler cap 2 in order to relieve the system pressure 3 Remove retaining nut 1 Hydraulic Tank i f WW f RM VILLI lt N LLLLLLL CZ aa U th rue A Illustration 213 WEBM1000 Remove the cover and remove oil filter 4 from the filter housing Perform the following steps Properly dispose of the filter element Apply a thin coat of oil to the seal on the new filter element Install the filter element into the filter housing Replace the cover and install retaining nut 1 Lif S NANNANANAANANNNANRRNNANNR Se Illustration 214 5 6 Remove retainer ring 5 from the oil filler tube Remove strainer 6 from the oil filler tube Wash the screen in a clean nonflammable solvent Inspect seal 7 on the filler cap Replace the seal if the seal is worn or if the seal is damaged Install the strainer the retainer ring and filler cap 2 Illustration 215 3 Hydraulic tank sight glass 10 Maintain the hydraulic oil to the FULL mark in the sight glass 159 Maintenance Section D6T LGP OEM Hydraulic System Oil Filters Replace Steering Charge Filter Illustration 216 1 Open the access door on the le
322. topped clear the area around the equipment of all personnel The procedure will cause immediate rapid lowering of the load Wear appropriate personal protective equipment and follow the established procedure in the Operation and Maintenance Manual Equipment Lowering with Engine Stopped in the Operation Section of the manual Sound Information and Vibration Information Sound Level Information Hearing protection may be needed when the machine is operated with an open operator station and an open cab for extended periods or in a noisy environment Hearing protection may be needed when the machine is operated with a cab that is not properly maintained or when the doors and windows are open for extended periods or in a noisy environment Sound Performance for Machines that are Offered in European Union Countries and in Countries that Adopt the EU Directives The operator sound pressure level is 87 dB A when ISO 6394 2008 is used to measure the value for an open operator station The sound power level that is labeled on the machine is 110 dB A The measurement of the sound power level was made according to the static test procedures and conditions that are specified in ISO 6393 2008 and the criteria per 2000 14 EC 192 Safety Section Pipelayer Attachment Kit WEBM1000 Guards The European Union Physical Agents Vibration Directive 2002 44 EC Refer to the tractor operation and maintenance manual The Euro
323. tor Diesel Particulate Filter DPF indicator Force Regeneration switch Disable Regeneration switch 40 Product Information Section D6T LGP OEM WEBM1000 Identification Information Declaration of Conformity Table 5 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 amp Regulations Manager Caterpillar France S A S 40 Avenue Leon Blum B P 55 38041 Grenoble Cedex 9 France I the undersigned hearby certify that hte construction equipment specified hearunder Description Generic Denomination Earthmoving Equipment Function Steel track dozer Model Type D6T2 Serial Number Commercial Name Caterpillar Fulfills
324. tor guard 1 Slowly loosen the filler cap in order to relieve system pressure Remove the filler cap 130 Maintenance Section D6T LGP OEM Cooling System Coolant ELC Change Table 25 Required Tools Part Tool Number Part Description Qty Mobile Transmission Jack A 1U 7505 Low Lift 1 Illustration 158 2 Use Tooling A and a suitable block to support the front bottom guard Note The front bottom guard weighs 75 kg 165 Ib 3 Remove nuts 1 and the washers 4 Remove bolts 2 and the washers Lower Tooling A and remove the front bottom guard from the machine 5 Direct the hose on the drain valve pipe into a suitable container 6 Open the drain valve Allow the coolant to drain into a suitable container 7 Close the drain valve Fill the system with a solution which consists of clean water and of cooling system cleaner The concentration of the cooling system cleaner should be 6 to 10 percent 8 Start the engine Run the engine for 90 minutes Stop the engine Drain the cleaning solution into a suitable container 9 While the engine is stopped flush the system with water Flush the system until the draining water is clear 10 Close the drain valve WEBM1000 Illustration 159 11 Use Tooling A and a suitable block to install the front bottom guard 12 Install the front bottom guard on the machine with the four bolts 2 the washers an
325. uctions and use the disable regeneration function when appropriate General All fuels most lubricants and some coolant mixtures are flammable To minimize the risk of fire or explosion the following actions are recommended 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 dealer for service Understand the use of the primary exit and alternative exit on the machine Refer to Operation and Maintenance Manual Alternative Exit Do not operate a machine with a fluid leak Repair leaks and clean up fluids before resuming machine operation Fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire A fire may Cause personal injury or death Remove flammable material such as leaves twigs papers trash and so on These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine Keep the access doors to major machine compartments closed and access doors in working condition in order to permit the use of fire suppression equipment in case a fire should occur 21 Safety Section D6T LGP OEM Fire Prevention and Explosion Prevention Clean all accumulations of flammable materials such as fuel oil and debris from the machine Do not operate the machine near any flame Keep shields in place Exhaust shields if equipped protect hot e
326. unt the machine Before you mount the machine clean the step and the handholds Inspect the step and handholds Make all necessary repairs Face the machine whenever you mount the machine and whenever you dismount the machine Maintain a three point contact with the step and with handholds Note Three point contact can be two feet and one hand Three point contact can also be one foot and two hands Do not mount a moving machine Do not dismount a moving machine Never jump off the machine Do not try to mount the machine when you carry tools or supplies Do not try to dismount the machine when you are carrying tools or supplies Use a hand line to pull equipment onto the platform Do not use any controls as handholds when you enter the operator compartment or when you exit the operator compartment 197 Operation Section Pipelayer Attachment Kit Before Operation 198 Operation Section Pipelayer Attachment Kit Before Operation Illustration 270 Daily inspection walk around For maximum service life of the machine perform a daily walk around inspection Note Watch closely for leaks If leaking is observed find the source of the leak and correct the leak If leaking is suspected or leaking is observed check the fluid levels more frequently Inspect the machine for the following items e Inspect the hydraulic system for leaks Repair any hydraulic system leaks Inspect the hoses the seals and the flanges
327. upport of the outside left ROPS post ROPS SAEJ1040 MAY94 1S03471 1994 Structural damage an overturn modification alteration or improper repair can impair this structure s protection capability thereby voiding this certification Do not weld on or drill holes in the structure This will void the certification Consult your Cat dealer to determine this structure s limitations without voiding its certification This machine has been certified to the standards that are listed on the certification 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 A typical example of the certification plate is shown above Refer to Operation and Maintenance Manual Guards Operator Protection for more information 10 Safety Section D6T LGP OEM Safety Messages Improper Connections for Jump Start Cables 4 Safety message 4 is located on the bottom side of the battery box cover Explosion Hazard Improper jumper cable connections can cause an explosion resulting in serious injury or death Batteries may be located in separate compartments Refer to the Operation and Maintenance Manual for the correct jump starting procedure WEBM1000 Electrical Shock Hazard 5 Safety message 5 is located on the inside of the fuse panel door that is inside the battery box on the left side of the machine WA
328. use of an or System gallon existing product problem Refer to Caterpillar Special Publication SEBU6250 Caterpillar Hydraulic Oil 76 20 16 65 Machine Fluid Recommendations for detailed Tank only 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 Consult your dealer for complete information and assistance in establishing an S O S program for your equipment 212 Maintenance and Lubrication Section Pipelayer Attachment Kit Maintenance Interval Schedule MIS Maintenance Interval Schedule MIS Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive i
329. ustration 127 Trimble Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 FCC Declaration of Conformity Trimble Navigation Limited declares under sole responsibility that the following product s conforms to FCC Part 15 Subpart B Section 15 109 Product Name Trimble MTS523 Caterpillar 523 Trimble MTS522 Caterpillar 522 Trimble MTS521 Product Description Telematics with M2M cell and GPS Receiver This device complies with Part 15 class B of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference 2 This device must accept any interference received including interference that may cause undesired operation This document is maintained under Trimble part number 78356 00 DC and the technical file is maintained under Trimble part number 78356 00 CE at Manufacturer Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 3642 USA Declaration Approved ay a r Ze my CMe fe EP etna CE Dect fag haha Signature Date Name Chuck Maniscalco Title Director of Engineering Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale CA 94085 3642 USA Telephone 408 481 8000 Trimble MTS500 FCC DoC Rev A WEBM1000 WEBM1000 Illustration 128 93 Operation Section D6T LGP OEM Trimble Navigation Limited 935 Stewart Drive Post Office Box 3642 Sunnyvale
330. utient a A AENG AAAA 149 Fuel Tank Cap Filter and Strainer Replace CISA E E E TEET 150 Fuel Tank Water and Sediment Drain 151 Fumes Disposal Filter Element Replace 152 Functional TeSt cccccceecseeeceeeteeeeetettteeeeennaees 66 Functional Test of the Monitoring System DISPLAY steno esoc EEE tl Skat oil gates 127 FUSES a AEE OEE nc thant EERE ANE 153 Fuses and Circuit Breakers Replace Reset 152 G Gauges eo en e E E NE A 66 Gauges and Indicators 0 0 0 0 cccccceeeeeeeees 53 General ereere tation drs inde ki heir N 21 General Hazard Information o a 17 General Information 34 193 GIG ASO or tee siateon rt eh hal fae owt alacant tat 117 Ground Level Service Center ou 62 GUANO presser aon staes tc sinsuit sa edelan sae azi iene Sots 192 Guards Operator Protection 0 ccee 32 Guidelines for Reducing Vibration Levels on Earthmoving Equipment saae 31 H Hand Arm Vibration Level e eee 30 High Pressure Cylinder i s 13 High Pressure Recoil Spring isese 13 Hook Control re 201 HO a e a a seated elen 62 Horn location moved l 203 Hot Fluid Under Pressure 12 Hydraulic Accumulator 0 183 184 Hydraulic Lockout Control i 61 Hydraulic Oil Temperature a cece 199 Hydraulic System Accumulator 0 ccceee 12 Hydraulic System Oil Change a a 155 Hydraulic System Oil Filter Pilot Replace 157 Hydraulic System Oil Filters
331. ve to battery negative Jump start only with an energy source with the same voltage as the stalled machine Turn off all lights and accessories on the stalled machine Otherwise they will operate when the energy source is connected 111 Operation Section D6T LGP OEM Engine Starting Alternate Methods NOTICE When starting from another machine make sure that the machines do not touch This could prevent damage to engine bearings and electrical circuits Turn on close the battery disconnect switch prior to the boost connection to prevent damage to electrical components on the stalled machine Severely discharged maintenance free batteries do not fully recharge from the alternator after jump starting The batteries must be charged to proper voltage with a battery charger Many batteries thought to be unusable are still rechargeable This machine has a 24 volt starting system Use only the same voltage for jump starting Use of a welder or higher voltage damages the electrical system Refer to Special Instruction Battery Test Procedure SEHS7633 available from your Caterpillar dealer for complete testing and charging information Use of Jump Start Cables When the auxiliary start receptacles are not available use the following procedure 1 Determine the failure of the engine to start Reference Refer to Special Instruction SEHS7768 on the use of 6V 2150 Starting Charging Analyzer Use this procedure
332. watch the relief valve to see if grease is escaping Watch the track or track adjustment cylinder to see if the track is being loosened Loosen the relief valve one turn only If track does not loosen close the relief valve and contact your Caterpillar dealer 1 Move the machine forward Allow the machine to coast to a stop without the use of the service brakes Adjust the tracks while you are in the machine typical operating conditions If packing conditions prevail on the workplace the tracks should be adjusted without removing the packed material 2 To measure the sag in the track stretch a string over the grousers that are between the sprocket and the front idler Take the measurement from the string to the top of the grouser at the maximum measurement Dimension A is the maximum distance between the string and the grouser 167 Maintenance Section D6T LGP OEM Track Check Adjust Illustration 236 The machine is equipped with a carrier roller Calculate the average of dimension A and dimension B The correct average value is 55 10 mm 2 2 0 4 inch Loose Track Adjustment Illustration 237 NOTICE Do not attempt to tighten track when dimension C is 150 mm 5 9 inch or more Contact your Caterpillar dealer for track service or instructions 1 Remove the access cover 168 Maintenance Section D6T LGP OEM Track Pins Inspect
333. xhaust components from oil spray or fuel spray in a break in a line in a hose or in a seal Exhaust shields must be installed correctly Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material Empty and purge the lines and tanks Then clean the lines and tanks with a nonflammable solvent prior to welding or flame cutting Ensure that the components are properly grounded in order to avoid unwanted arcs Dust that is generated from repairing nonmetallic hoods or fenders may be flammable and or explosive Repair such components in a ventilated area away from open flames or sparks Use suitable Personal Protection Equipment PPE Inspect all lines and hoses for wear or deterioration Replace damaged lines and hoses The lines and the hoses should have adequate support and secure clamps Tighten all connections to the recommended torque Damage to the protective cover or insulation may provide fuel for fires Store fuels and lubricants in properly marked containers away from unauthorized personnel Store oily rags and flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Illustration 20 22 Safety Section D6T LGP OEM Fire Prevention and Explosion Prevention Use caution when you are fueling a machine Do not smoke while you are fueling a machine Do not fuel a machine near open flames or sparks Always stop the engine before fu
334. y cause product damage are identified by NOTICE labels on the product and in this publication Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use including site specific rules and precautions applicable to the worksite If a tool procedure work method or operating technique that is not specifically recommended by Caterpillar is used you must satisfy yourself that it is safe for you and for others You should also ensure that the product will not be damaged or become unsafe by the operation lubrication maintenance or repair procedures that you intend to use The information specifications and illustrations in this publication are on the basis of information that was available at the time that the publication was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes can affect the service that is given to the product Obtain the complete and most current information before you start any job Cat dealers have the most current information available When replacement parts are requi

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