D5N Track-Type Tractor - Safety
Contents
1. PX WARNING Illustration 2 g01211654 SEBUT7418 08 7 Safety Section Safety Messages Ld AA WARNING A Illustration 3 g01211659 There are several specific safety messages on this machine The exact location of the hazards and the description of the hazards are reviewed in this section Please become familiarized with all safety messages Make sure that all of the safety messages are legible Clean the safety messages or replace the safety messages if you cannot read the words Replace the illustrations if the illustrations are not visible When you clean the safety messages use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the safety messages Solvents gasoline or harsh chemicals could loosen the adhesive2. General Information Specifications SMCS Code 1000 7000 101815795 The basic machine specifications are listed below Table 1 SEBU7418 08 Table 2 D5N FTC LGP Track Type Tractor Shipping Weight 12975 kg 28606 Ib Operating Weight 2 13252 kg 29217 Ib Operating Weight with Ripper three teeth 14258 kg 31435 Ib Length of Machine 3720 mm 12 3 ft Length of Machine with VPAT Bulldozer blade 5064 mm 16 5 ft Length of Machine with VPAT Bulldozer blade and Ripper 5882 mm 19 3 ft D5N FTC XL Track Type Tractor Width of Machine across Tracks 2760 mm 9 1 ft Shipping Weight 12541 kg 27647 Ib Height of Machine with OROPS 3036 mm 10 0 ft Operating Weight 2 12818 kg 28258 Ib Operating Weight with Ripper three teeth 13824 kg 30476 Ib Height of Machine with EROPS 3039 mm 10 0 ft Length of Machine 3544 mm 11 6 ft Length of Machine with VPAT Bulldozer blade 4555 mm 14 9 ft Length of Machine with VPAT Bulldozer blade and Ripper 5373 mm 17 6 ft Width of Machine across Tracks 2330 mm 7 7 ft Height of Machine with OROPS 2992 mm 9 8 ft Height of Machine with EROPS 2995 mm 9 8 ft 1 The machine shipping weight includes the EROPS cab the air cleaner the lights the Power Angle Tilt blade the powershift transmission arrangement
3. amp Illustration 7 g01056162 Safety Message 4 is located inside both track roller frames at the end of the tube for the roller frame WARNING g01211683 WARNING Personal injury or death can result from grease under pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is es caping Watch the track or track adjustment cylin der 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 901211685 WARNING Personal injury death can result from pressed recoil spring being released suddenly us ing incorrect disassembly procedures A recoil spring that is still held in compression can result in the recoil spring being released un expectedly 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 tubu lar section that has separated from the front of the frame assembly when 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 10 Sa
4. 103860832 Parking SMCS Code 7000 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 to NEUTRAL position and the speed control to LOW IDLE position Engage the parking brake switch Lower all attachments to the ground Activate any control locks Stop the engine Turn the engine start switch key to OFF position and remove the key Always turn the battery disconnect switch to the OFF position before leaving the machine If the machine will not be operated for a month or more remove the battery disconnect switch key SEBU7418 08 102624835 Engine Stopping SMCS Code 1000 7000 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 101329161 Equipment Lowering with Engine Stopped SMCS Code 7000 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
5. 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 additional safety measure keep a fire extinguisher on the machine Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Follow the recommendations on the instruction plate Consider installation of an aftermarket Fire Suppression System if the application and working conditions warrant the installation SEBU7418 08 i01834364 Fire Extinguisher Location SMCS Code 7419 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 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 otrap the mounting plate to a leg of the ROPS in order to mount the fire extinguisher as neede
6. the drawbar the fuel tank the radiator guards the engine enclosure the four valve hydraulic control the ES track the lubricants the coolant and 5 fuel 2 Shipping weight plus an operator and a full fuel tank 1 The machine shipping weight includes the EROPS cab the air cleaner the lights the Power Angle Tilt blade the powershift transmission arrangement the drawbar the fuel tank the radiator guards the engine enclosure the four valve hydraulic control the ES track the lubricants the coolant and 5 fuel 2 Shipping weight plus an operator and a full fuel tank SEBU7418 08 Identification Information 102063047 Plate Locations and Film Locations SMCS Code 1000 7000 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 Illustration 31 g00650398 The machine PIN is located at the rear of the machine on the left side of the transmission housing Machine PIN 000650411 Illustration 32 The service information number plate SIN is located behind the seat of the machine Service Information Number Plate SIN 31 Product Information Section Identificat
7. Link If equipped This safety message is located near the product link module not shown The product link module is installed with specific requirements See your Caterpillar Dealer for proper installation WARNING g01211824 This machine is equipped with a Caterpillar Product Link radio communication device which must be deactivated within 6 0 m 20 ft of a blast zone Failure to do so could result in serious injury or death 104010649 General Hazard Information SMCS Code 7000 Illustration 17 g00104545 SEBU7418 08 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 Ay WARNING Operating the machine while distracted can result in the loss of machine control Use extreme cau tion when using any device while operating the machine Operating the machine while distracted can result in personal injury or death Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles Be aware of high voltage power lines and power cables that are buried If the machine comes in contact with these hazards serious injury or death may occur from electrocution GO 98 Illustration 18 g0070
8. Obtain the complete and most current information before you start any job Cat dealers have the most current information available WARNING When replacement parts are required for this product Caterpillar recommends using Cat re placement parts or parts with equivalent speci fications including but not limited to physical dimensions type strength and material Failure to heed this warning can lead to prema ture 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 A 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 Some photographs or illustrations in this publication show details or attachments that can be different from your machine Guards and covers might have been removed for illustrative purposes Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication Read study and keep this manual with the machine Whenever a question arises regarding your machine or this publication pl
9. Relieve all pressure in the air system in the oil system in the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiator and all lines to the heaters or to the engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained 19 Safety Section Burn Prevention 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 e
10. a fire should occur Clean all accumulations of flammable materials such as fuel oil and debris from the machine Do not operate the machine near any flame Keep shields in place Exhaust shields if equipped protect hot exhaust components from oil spray or fuel spray in case of a break in a line in a hose or in a seal Exhaust shields must be installed correctly Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material Empty and purge the lines and tanks Then clean the lines and tanks with a nonflammable solvent prior to welding or flame cutting Ensure that the components are properly grounded in order to avoid unwanted arcs Dust that is generated from repairing nonmetallic hoods or fenders may be flammable and or explosive Repair such components in a well ventilated area away from open flames or sparks Use suitable Personal Protection Equipment PPE Inspect all lines and hoses for wear or deterioration Replace damaged lines and hoses The lines and the hoses should have adequate support and secure clamps Tighten all connections to the recommended torque Damage to the protective cover or insulation may provide fuel for fires SEBU7418 08 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 Il
11. and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids 18 Safety Section Crushing Prevention and Cutting Prevention Inhalation SU p 5 d f rial ipa df MISC v zi EE DE d 74 mena Illustration 20 g02159053 Exhaust Use caution Exhaust fumes can be hazardous to your health If you operate the machine in an enclosed area adequate ventilation is necessary Asbestos Information Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free Caterpillar recommends the use of only genuine Cat replacement parts Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris Use caution Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers Inhaling this dust can be hazardous to your health The components that may contain asbestos fibers are brake pads brake bands lining material clutch plates and some gaskets The asbestos that is used in these components is bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present there are several guidelines that should be followed e Never use compressed air for cleaning e Avoid brushing materials that contain asbestos e Avoid grinding materials that co
12. 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 e Cracking e Discoloration e Cuts on insulation e Other damage Make sure that all clamps guards clips and straps are reinstalled correctly This will help to prevent vibration rubbing against other parts and excessive heat during machine operation 22 Safety Section Fire Prevention and Explosion Prevention 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 25 g00687600 Check lines tubes and hoses carefully Wear Personal Protection Equipment PPE in order to check for leaks Always use a board or cardboard when you check for a leak Leaking fluid that is under pressure can penetrate body tissue Fluid penetration can cause serious injury and possible death A pin hole leak can cause severe injury If fluid is injected into your skin you must get treatment immediately Seek
13. right side of the machine WARNING STRUCTURAL DAMAGE AN OVERTURN MODIFICA TION 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 CONSULT A CATERPILLAR DEALER TO DETERMINE THIS STRUCTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION ROLLOVER ROPS AND FALLING OBJECT FOPS PROTECTIVE STRUCTURE CERTIFICATION THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE WHICH IS NOT ALTERED TO EXCEED THE CERTIFICATION TEST MASS MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J397 OCT95 SAE J1040 MAY94 ISO 3164 1995 ISO 3471 1994 SAE J231 JAN81 150 3449 1992 LEVEL II CERTIFICATION TEST MASS MODEL NO kg LB D5N XL DSN LGP 15 920 35 100 CATERPILLAR INC PEORIA ILLINOIS USA g01211698 Structural damage an overturn modification al teration or improper repair can impair this struc ture s protective capability thereby voiding this certification Do not weld on or drill holes in the structure Consult a Caterpillar dealer to deter mine this structure s limitations without voiding its certification SEBU7418 08 Laser If your machine is equipped with the AccuGrade Laser System this safety message is located on each leg of the tripod for the laser g01211700 WARNING Movement of the transmitter could cause unex pected blade movement Death or serious injury c
14. treatment from a doctor that is familiar with this type of injury Replace the affected parts if any of the following conditions are present End fittings are damaged or leaking 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 End fittings are displaced SEBU7418 08 Make sure that all clamps guards and heat shields are installed correctly During machine operation this will help to prevent vibration rubbing against other parts excessive heat and failure of lines tubes and hoses Do not operate a machine when a fire hazard exists Repair any lines that are corroded loose or damaged Leaks may provide fuel for fires Consult your 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 well ventilated areas Do not smoke while you are replacing an ether cylinder or while you
15. 1806 Illustration 13 This safety message for the air conditioner has the appropriate information for the following services the air conditioner lubricant the refrigerant charge and the refrigerant capacity Read the service manual before you perform any service to the air conditioner Belt Mounting 2 This safety message is located inside the right engine compartment on the upper flange of the alternator guard Illustration 14 g01211808 SEBU7418 08 When an air conditioner is present this message identifies the serpentine belt as the drive belt for the air conditioner compressor also e The serpentine belt can be inspected for looseness and fraying e The serpentine belt is self adjusting Reference See Operation and Maintenance Manual Maintenance Interval Schedule for all maintenance recommendations Do Not Weld on FOPS 3 SAEXXXX MAYXX ISOXXXX 1969 ISOXXXX 1994 FOPS SAEJISOXXXX APRXX LEVEL XX I8C39000C 1989 ISOXXKXX 1992 LEVEL Il Operater Protectlve Guard WCB GXXX Kg LB KXXX XXXX Illustration 15 g01211813 S N AGG903 Up S N AKD802 Up oafety Message 4 is located on the FOPS SEBU7418 08 A WARNING STRUCTURAL DAMAGE AN OVERTURN MODIFICA TIUN ALTERATION OR IMPROPER REPAIR CAN IMPAIR THIS STRUGTURE S PROTECTION CAPABILITY THEREBY VOIDING THIS GERTIFICATION DQ NOT WELD OR DRILL HOLES IN THE STRUCTURE CONSULT A CATERPILLAR DEALER DETE
16. 2020 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 SEBU7418 08 Do not smoke when you service an air conditioner Also do not smoke if refrigerant gas may be present Inhaling the fumes that are released from a flame that contacts air conditioner refrigerant can cause bodily harm or death Inhaling gas from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death Never put maintenance fluids into glass containers Drain all liquids into a suitable container Obey all local regulations for the disposal of liquids Use all cleaning solutions with care Report all necessary repairs Do not allow unauthorized personnel on the equipment Unless you are instructed otherwise perform maintenance with the equipment in the servicing position Refer to Operation and Maintenance Manual for th
17. 23 2 Illustration 46 g00995393 Consult your Caterpillar dealer with any questions that concern the operation of the MSS in a specific country Product Link This message is located on the electronic control group of the Product Link module Orbcomm Type Approval 146KME CAT 08880 IC 216701105A AYAA001 1 J98 0601 D 231 1403 Illustration 47 g01057253 Consult your Caterpillar dealer with any questions that concern the installation or the operation of the Product Link SEBU7418 08 35 Product Information Section Identification Information i01834458 Emissions Certification Film SMCS Code 1000 7000 7405 Emission Certification Film CATERPILLAR INC IMPORTANT ENGINE INFORMATION 2000 JDMooo001 CAT ENGINE MODEL 3116 DISPLACEMENT 6 6L VALVE LASH O 38mm INTAKE O 64mm EXHAUST MAXIMUM MAXIMUM MAXIMUM MAX FUEL RATE MAXIMUM EXHAUST ENGINE ADVERTISED RATED LOW IDLE GMAXIMUM INITIAL TIMING EMISSION 1 FAMILY kW HP SPEED RPM SPEED RPM mni STROKE DEGREES BTDC CONTROL SYSTEM XCPXLO6 6MRB 164 220 2600 875 104 11 5 EM DI TC SPL CAC THIS 3116 ENGINE CONFORMS TO DIRECTIVE 97 68 EC FOR NON ROAD ENGINES EC TYPE APPROVAL NO elRL 97 68AA 0001 00 THIS 3116 ENGINE CONFORMS TO 2000 U S EPA AND CALIFORNIA REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES THIS ENGINE IS CERTIFIED TO OPERATE ON COMMERICIALLY AVAILABLE DIESEL FUEL DATE OF MANUFACTURE MONTH 08 8050 01 CATERPILLAR INC INF
18. 6S8L12345 66 o Illustration 1 g00751314 Where 1 Caterpillar s World Manufacturing Code characters 1 3 2 Machine Descriptor characters 4 8 5 Foreword 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 SEBU7418 08 Safety Section Safety Messages Safety Section Safety Messages D5N Track Type Tractor SMCS Code 7000 7405 A WARNING A WARNING A WARNING Ff
19. GP 15 920 35 100 CATERPILLAR INC PEORIA ILLINOIS USA 173 1634 Illustration 43 900921851 Safety Message 4 is located on the right rear post of the FOPS cab 34 Product Information Section Identification Information Structure certification ROPS 5 ROPS SAEJ1040 MAY94 1503471 1994 Kg LB DSN XL DSN LGP 16150 35 610 CATERPILLAR INC PEORIA ILLINOIS Illustration 44 g01056122 S N AGG903 Up S N AKD802 Up A WARNING STRUCTURAL DAMAGE AN OVERTURN MODIFICA TION ALTERATION OR IMPROPER REPAIR CAN IMPAIR THIS STRUCTURE S PROTECTION CAPABILITY THEREBY VOIDING THIS GERTIFIGATION DO NOT WELD ON OR DRILL HOLES IN THE STRUCTURE CONSULT A CATERPILLAR DEALER DETERMINE THIS STRUCTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION FALLING OBJECT F PS PROTECTIVE STRUCTURE CERTIFICATION THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J231 JANS1 150 3449 1992 LEVEL II MODEL NO D5N XL LGP CATERPILLAR INC PEDRIA ILLINOIS USA 173 1635 3 Illustration 45 g00921852 oafety Message 5 is positioned on the vertical support of the outside right ROPS post Machine Security System This message is located on the control group for the machine security system The control group is located in the engine compartment SEBU7418 08 FCC ID PQMMSS1 CANADA 4071104478A Cc 0888 021747 Ez 212 42
20. H CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS PROP ER CARE IS YOUR RESPONSIBILITY SEBU7418 08 Improper Connections for Jump Start Cables 2 44 WARNING Illustration 5 g01211667 Safety Message 2 is in the battery compartment IMPROPER JUMPER CABLE CONNECTIONS CAN CAUSE EXPLOSION RESULTING IN PERSONAL INJURY BATTERIES MAY BE LOCATED IN SEPA RATE COMPARTMENTS WHEN USING JUMPER CABLES ALWAYS CONNECT POSITIVE CABLE TO POSITIVE TERMINAL OF BATTERY CONNECTED TO STARTER SOLENOID AND NEGA TIVE CABLE FROM EXTERNAL SOURCE TO STARTER NEGATIVE TERMINAL IF MACHINE NOT EQUIPPED WITH STARTER NEGATIVE TERMINAL CONNECT TO ENGINE BLOCK FOL LOW PROCEDURE IN THE OPERATION MANUAL 001211675 WARNING Improper jumper cable connections can cause an explosion resulting in personal injury Batteries can be located in separate compartments When using jumper cable always connect positive ca ble to positive terminal of battery connected to starter solenoid and negative cable from exter nal source to starter negative terminal If not equipped with starter negative terminal connect to engine block SEBU7418 08 High Pressure Cylinder 3 A WARNING Illustration 6 g01211678 Safety Message 3 is attached to the cover for each recoil spring compartment WARNING 9 Safety Section Safety Messages Compressed Recoil Spring 4 N
21. ORMATION IMPORTANTE SUR LE MOTEUR MOD LE MOTEUR 3116 6 61 JEU SOUPAPES 0 38 mm ADMISSION 0 64 mm CHAPPEMENT Kw HP MAXI MAXI MAXI D BIT D INJ MAXI CALAGE FAMILLE MAXI REGIME R GIME PUIS MAXI INITIAL D INJ DISPOSITIF DE MOTEURS PUBLI S NOMINAL tr mn RALENTI tr mn mm3 STROKE PISTON DEGR S AVANT PMH ANTI POLLUANT XCPXLOS 6MRB 164 220 2600 875 104 11 5 EM DITC SPL CAC CE MOTEUR 3116 EST CONFORME AUX DIRECTIVES 97 68 EC POUR LES MOTEURS NON ROUTIERS NO APPROBATION TYPE EC e RE 97 68AA 0001 00 MOTEUR 3116 EST CONFDRME AUX R GLEMENTATIONS 2000 DE L AGENCE AM RICAINE DE PROTECTION DE L ENVIRONNEMENT EPA ET DE LA CALIFORNIE POUR LES GROS MOTEURS NON ROUTIERS A COMPRESSION CONTAGT CE MOTEUR EST HOMOLOGUE POUR FONCTIONNER AVEC LE CARBURANT DIESEL DU COMMERCE DATE DE FABRICATION MOIS tiquette d homologation anti pollution Illustration 48 g00937112 The emission certification film is located on the engine typical example 1 English 2 French
22. RMINE THIS STRUGTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION FALLING OBJECT F PS PROTECTIVE STRUCTURE CERTIFICATION THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J231 81 ISO 3449 1992 LEVEL II MODEL D5N XL LGP CATERPILLAR INC PEORIA ILLINOIS USA g01211814 Ay WARNING Structural damage an overturn modification al teration or improper repair can impair this struc ture s protection capability thereby voiding this certification Do not weld on or drill holes in the structure Consult a Caterpillar dealer to deter mine 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 label 15 Safety Section Additional Messages Do Not Weld on ROPS 4 SAEXXXX MAYXX ISOXXXX 1969 ISOXXXX 1994 FOPS SAEJISOXXXX APRXX LEVEL XX ISOXXXX 1989 ISOXXKX 1992 LEVEL Il Operator Protectlve Guard WCB GXXX Kg LB KXXX XXXX XX XXX XXX CATERPILLAR INC PEORIA UAA AAX AXXX Illustration 16 g01211818 S N AGG903 Up S N AKD802 Up oafety Message 5 is positioned on the vertical support of the ROPS on the right side of the machine WA
23. RNING STRUCTURAL DAMAGE AN OVERTURN MODIFICA TION 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 CONSULT A CATERPILLAR DEALER TO DETERMINE THIS STRUCTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION ROLLOVER ROPS AND FALLING OBJECT FOPS PROTECTIVE STRUCTURE CERTIFICATION THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE WHICH IS NOT ALTERED TO EXCEED THE CERTIFICATION TEST MASS MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J397 OCT95 SAE J1040 MAY94 ISO 3164 1995 ISO 3471 1994 SAE J231 JAN81 ISO 3449 1992 LEVEL II CERTIFICATION TEST MASS MODEL NO kg LB D5N XL D5N LGP 15 920 35 100 CATERPILLAR INC PEORIA ILLINOIS USA g01211821 WARNING Structural damage an overturn modification al teration or improper repair can impair this struc ture s protective capability thereby voiding this certification Do not weld on or drill holes in the structure Consult a Caterpillar dealer to deter mine this structure s limitations without voiding its certification 16 Safety Section General Hazard Information 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 label Product
24. SAFETY Operation and Maintenance Manual Excerpt 2010 Caterpillar All Rights Reserved CATERPILLAR Q 8 7418 08 CATERPILLAR November 2010 Operation and Maintenance Manual DSN Track Type Tractor 103991620 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 WARNING The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involv
25. Structure Other Guards If Equipped Protection from flying objects and or falling objects is required for special applications Logging applications and demolition applications are two examples that require special protection A front guard needs to be installed when a work tool that creates flying objects is used Mesh front guards that are approved by Caterpillar or polycarbonate front guards that are approved by Caterpillar are available for machines with a cab or an open canopy On machines that are equipped with cabs the windows should also be closed Safety glasses are recommended when flying hazards exist for machines with cabs and machines with open canopies If the work material extends above the cab top guards and front guards should be used Typical examples of this type of application are listed below Demolition applications SEBU7418 08 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 29 Safety Section Guards 30 Product Information Section General Information Product Information Section
26. aily 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 21 Safety Section Fire Prevention and Explosion Prevention Discoloration Cuts on the insulation of the cable e Fouling Corroded terminals damaged terminals and loose terminals Replace damaged battery cable s and replace any related parts Eliminate any fouling which may have caused insulation failure or related component damage or wear Ensure that all components are reinstalled correctly An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface A battery cable short produces heat from the battery current which may be a fire hazard An exposed wire on the ground cable between the battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes into contact with a grounded surface This may result in an unsafe condition for servicing the machine Repair components or replace components before servicing the machine 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
27. ation 10 g01211691 oafety Message 7 is located on the FOPS A WARNING STRUCTURAL DAMAGE AN OVERTURN MODIFICA TION ALTERATION OR IMPROPER REPAIR CAN IMPAIR THIS STRUCTURE S PROTECTION CAPABILITY THEREBY VOIDING THIS CERTIFICATION DQ NOT WELD ON OR DRILL HOLES IN THE STRUCTURE CONSULT A CATERPILLAR DEALER TO DETERMINE THIS STRUCTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION FALLING OBJECT FOPS PROTECTIVE STRUCTURE CERTIFICATION THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J231 JANG1 150 3449 1992 LEVEL II MODEL NO D5N XL LGP CATERPILLAR ING PEORIA ILLINOIS USA g01211693 Ay WARNING Structural damage an overturn modification al teration or improper repair can impair this struc ture s protection capability thereby voiding this certification Do not weld on or drill holes in the structure Consult a Caterpillar dealer to deter mine this structure s limitations without voiding its certification 12 Safety Section Safety Messages Do Not Weld On ROPS 9 SAEXXXX MAYXX ISOXXXX 1969 71994 FOPS SAEJISOXXXX APRXX LEVEL XX I803000C 1989 0 1992 LEVEL Il Dperator Protectlve Guard WCB GXXX Kg LB KXXX 20000 XX CATERPILLAR ING PEORIA UAA AAX AXXX Illustration 11 g01211695 oafety Message 8 is positioned on the vertical support of the ROPS on the
28. d 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 Consult your Caterpillar dealer for the proper procedure for mounting the fire extinguisher i01329108 Track Information SMCS Code 7000 Track adjusting systems use either grease or oil under high pressure to keep the track under tension 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 It is possible to burn the fingers if there is more than brief contact with these components i01122596 Electrical Storm Injury Prevention SMCS Code 7000 When lightning is striking in the vicinity of the machine the operator should never attempt the following procedures 23 Safety Section Fire Extinguisher Location 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 i01896223 Before Starting Engine SMCS Code 1000 7000 Start the engine only from the operator s c
29. e 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 personal 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 17 oafety Section General Hazard Information Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine
30. ease consult your Caterpillar dealer for the latest available information Safety The safety section lists basic safety precautions In addition this section identifies the text and locations of warning signs and labels used on the machine Read and understand the basic precautions listed in the safety section before operating or performing lubrication maintenance and repair on this machine Operation The operation section is a reference for the new operator and a refresher for the experienced operator This section includes a discussion of gauges switches machine controls attachment controls transportation and towing information 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 SEBU7418 08 Maintenance The maintenance section is a guide to equipment care The Maintenance Interval Schedule MIS lists the items to be maintained at a specific service interval Items without specific intervals are listed under the When Required service interval The Maintenance Interval Schedule lists the page number for the step by step instructions required to accomplish the scheduled maintenance Use the Maintenance Interval Schedule as an index or one safe source for all maintenance procedu
31. ed The message that appears under the warning explains the hazard and can be either written or pictorially presented A non exhaustive list of operations that may cause product damage are identified by NOTICE labels on the product and in this publication Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use including site specific rules and precautions applicable to the worksite If a tool procedure work method or operating technique that is not specifically recommended by Caterpillar is used you must satisfy yourself that it is safe for you and for others You should also ensure that 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
32. fety Section Safety Messages No Step 5 Illustration 8 g00936182 This safety message is located on both the blade angle cylinders This area may be oily and slippery A WARNING g01211686 WARNING Falling Hazard Area may be oily and slippery Do not step on angle blade cylinders Serious injury or death could occur from a fall SEBU7418 08 Hot Coolant Under Pressure 6 WARNING Illustration 9 g01211688 Safety Message 5 is located under the access door to the radiator cap AXWARNING 000782457 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure SEBU7418 08 Seat belt 7 oafety Message 6 is located on the left side of dash panel A WARNING SS g01211690 A seat belt should be worn at all times during ma chine operation to prevent serious injury or death in the event of an accident or machine overturn Failure to wear a seat belt during machine opera tion may result in serious injury or death 11 oafety Section oafety Messages Do Not Weld on FOPS 8 ROPS SAEXKXX MAYXX ISOXXXX 1959 ISOXXXX 1994 FOPS SAEJ ISOXXXX APRXX LEVEL XX I300000C 1989 80 1992 LEVEL Il Operator Protective Guard WCB GXXX Kg LB XXXX XXXX XX XXX CATERFILLAR INC PEORIA ILLINOIS URA XXXIG000 Illustr
33. fore you start the engine at temperatures below 23 C 10 F consult your Caterpillar dealer or refer to Special Publication SEBU5898 Cold Weather Recommendations 101963896 Before Operation SMCS Code 7000 Clear all personnel from the machine and from the area Remove all obstacles from the path of the machine Beware of hazards such as wires ditches etc Be sure that all windows are clean Secure the doors and the windows in either the open position or the 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 26 Safety Section Operation Reference Refer to Operation and Maintenance Manual Daily Inspection in this manual Fasten the seat belt securely 103721461 Operation SMCS Code 7000 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 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 Check for proper operation of a
34. gaged in the business of repairing servicing selling leasing or trading engines or machines to remove alter or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations 40 CFR Part 89 Certain elements of the machine and engine such as the exhaust system fuel system electrical system intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar Machine Capacity Additional attachments or modifications may exceed machine design capacity which can adversely affect performance characteristics Included would be stability and system certifications such as brakes steering and rollover protective structures ROPS Contact your 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 like the following CAT0789BG
35. 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 19 g00687600 Always use a board or cardboard when you check for a leak Leaking fluid that is under pressure can penetrate body tissue Fluid penetration can cause serious injury and possible death A pin hole leak can cause severe injury If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component 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
36. hydraulic or some other media to be released in order to lower the equipment Wear appropriate personal protective equipment and follow the established procedure in the Operation and Maintenance Manual Equipment Lowering with Engine Stopped in the Operation Section of the manual 102399549 Sound Information Vibration Information SMCS Code 7000 The measurement for operator sound pressure level Leq was obtained with the procedures that are specified in ANSI SAE J1166 OCT 98 The procedure specifies the requirements of the work cycle to use while the measurement is obtained The operator sound pressure level is 84 dBA for the cab that is offered by Caterpillar This reading is correct under the following conditions proper installation of the cab proper maintenance of the cab closed cab doors and closed cab windows 27 Safety Section Engine Stopping Hearing protection may be needed during operation with an open operator station Hearing protection may be needed during operation with a cab that has not been maintained properly Hearing protection may be needed during operation with open doors or with open windows The exterior sound pressure level for the standard machine is 84 dBA This measurement was obtained with the test procedures that are specified in SAE J88 Jun 86 The measurement was obtained under the following conditions distance of 15 m 49 2 ft machine in middle speed range and mov
37. in an enclosed area vent the exhaust to the outside 24 Safety Section Engine Starting Air Inlet Heater Use the following procedure to start the engine WARNING This machine is equipped with an air inlet heater AIH for cold weather starting Do not use aerosol can types of starting aids such as ether Such use could result in an explosion and personal injury An air inlet heater is installed in the air inlet manifold The air inlet heater is an electrical device which provides heated inlet air for cold weather starting Note Startability is improved at temperatures below 16 C 60 F with the air inlet heater This helps reduce white smoke and misfire during start up in cold weather The operation of the air inlet heater is fully automatic on the 3126B Engine that is installed in the D6N Track Type Tractor The Engine ECM controls the inputs according to the prevailing condition Illustration 26 900926403 1 Turn the battery disconnect switch to the ON position The battery disconnect switch is inside the access door that is on the left side of the machine SEBU7418 08 Illustration 27 g00100360 Finger Tip Control NEUTRAL 2 Verify that the transmission direction control lever is in the NEUTRAL position Illustration 28 g00100361 3 Use parking brake switch key 1 in order to operate the parking brake Engage parking brake switch 2 Illustration 29 g00861458 Implement lever
38. ing Sound Performance for Machines that are Offered in European Union Countries and in Countries with the EU Directives The operator sound pressure level is 76 dBA The measurement was taken according to the static test procedure and conditions that are specified in ISO 6394 1998 The labeled sound power level for this machine was measured according to the test procedure and conditions specified in 2000 14 EC for fan drive with continuous variable speed The labeled sound power level is measured at 70 percent of maximum speed Vibration Level The hands and arms are exposed to a weighted root mean square acceleration that is less than 2 5 m s The whole body is exposed to a weighted root mean square acceleration of 0 6 m s Measurements are obtained on a representative machine that is using the procedures that are in the following standards ISO 2631 1 ISO 5349 e SAE J1166 Cab Internal Clearance If a machine is equipped with a cab the position of the operator conforms to industry standards These standards are SAE J154 and ISO 3411 An item should not protrude into the space of the cab The following items should not protrude into the cab e Radio 28 Safety Section Operator Station e Fire extinguisher e Lunch box Objects in the cab should be secured The objects must remain in place during operations in rough terrain The objects must remain in place during a
39. ion Information Illustration 33 g00863172 The serial number plate for the transmission is located at the rear of the machine to the right of the transmission housing Transmission Serial Number g00860883 Illustration 34 The engine serial number is located on top of the engine valve cover Engine Serial Number 32 Product Information Section Identification Information CAT CATERPILLAR rey CAT CATERPILLAR CATERPILLAR INC PEORIA IL 61629 l PARTS MADEIN ORDER 801057200 Illustration 35 D5N S N AGG903 Up D5N S N AKD801 Up e PIN 1 e Bar code 2 e Engine Serial Number 3 e Transmission Serial Number 4 CE plate 5 e Country of Manufacture 6 g00650427 Illustration 36 The serial number plate for the bulldozer is located at the rear of the bulldozer on the left side Bulldozer Serial Number SEBU7418 08 Illustration 37 g00942536 Ripper Serial Number The serial number plate for the ripper is located on the right tower of the ripper carriage Mark for European Union PIN 5 7 7 MODEL kW kg CATERPILLAR INC PEORIA IL 61629 117 5874 Illustration 38 g00039984 PIN Model e Power kW e Weight kg SEBU7418 08 Illustration 39 g00650430 This plate is positioned on the front side of the left fender Note Thi
40. lectrolyte 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 104090611 Fire Prevention and Explosion Prevention SMCS Code 7000 J Illustration 22 g00704000 General All fuels most lubricants and some coolant mixtures are flammable 20 Safety Section Fire Prevention and Explosion Prevention To minimize the risk of fire or explosion Caterpillar recommends the following actions Always perform a Walk Around Inspection which may help you identify a fire hazard Do not operate a machine when a fire hazard exists Contact your Cat dealer for service Understand the use of the primary exit and alternative exit on the machine Refer to Operation and Maintenance Manual Alternative Exit 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
41. ling Object Protective Structure FOPS or Tip Over Protection Structure TOPS The ROPS FOPS Structure if equipped on your machine is specifically designed tested and certified for that machine Any alteration or any modification to the ROPS FOPS Structure could weaken the structure This places the operator into an unprotected environment Modifications or attachments that cause the machine to exceed the weight that is stamped on the certification plate also place the operator into an unprotected environment Excessive weight may inhibit the brake performance the steering performance and the ROPS The protection that is offered by the ROPS FOPS 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
42. ll controls and protective devices while you operate the machine slowly in an open area Before you move the machine make sure that no one will be endangered Do not allow riders on the machine unless the machine has the following equipment e additional seat e additional seat belt e Rollover Protective Structure ROPS Never use the work tool for a work platform Note any needed repairs during machine operation Report any needed repairs Carry attachments close to the ground approximately 40 cm 15 inches higher than ground level 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 SEBU7418 08 e Turn the machine downhill Be careful to avoid any condition which could lead to tipping Tipping can occur when you work on hills banks and slopes Also tipping can occur when you cross ditches ridges or other unexpected obstructions Whenever it is 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 devices are adequate Never straddle a wire cable or allow other personnel to straddle a wire cable Know the maximum dimensions of your machine Always keep the Rollover Protective Structure ROPS installed during machine operation
43. lustration 23 g00704059 Use caution when you are fueling a machine Do not smoke while you are fueling a machine Do not fuel a machine near open flames or sparks Always stop the engine before fueling Fill the fuel tank outdoors Properly clean areas of spillage Follow practices for safe fueling that are described in the Operation section of the Operation and Maintenance Manual section and follow local regulations Never store flammable fluids in the operator compartment of the machine SEBU7418 08 Battery and Battery Cables Illustration 24 902298225 Caterpillar recommends the following in order to minimize the risk of fire or an explosion related to the battery Do not operate a machine if battery cables or related parts show signs of wear or damage Contact your Cat dealer for service Follow safe procedures for engine starting with jump start cables Improper jumper cable connections can cause an explosion that may result in injury Refer to Operation and Maintenance Manual Engine Starting with Jump Start Cables for specific instructions Do not charge a frozen battery This may cause an explosion Gases from a battery can explode Keep any open flames or sparks away from the top of a battery Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter in order to check the battery charge D
44. ntain 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 SEBU7418 08 e Use exhaust ventilation on permanent machining jobs 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 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 21 g00706404 Improperly disposing of waste can threaten the environment Potentially harmful fluids should be disposed of according to local regulations Always use leakproof containers when you drain fluids Do not pour waste onto the ground down a drain or into any source of water i01359664 Crushing Prevention and Cutting Prevention SMCS Code 7000 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 SEBU7418 08 Unless yo
45. off turn the engine start switch key to the start position in order to start the engine 25 Safety Section Before Operation 7 Turn the engine start switch key to the START position Crank the engine When the engine starts release the engine start switch key NOTICE If the engine start key switch is turned to the OFF position before the engine is started or if the engine does not start allow the air inlet heater to cool for two minutes before the next attempt to start the engine Do not crank the engine for more than 30 seconds Al low the starter to cool for two minutes before cranking the engine again Turbocharger damage can result if the engine speed is not kept low until the engine oil in dicator light or the engine oil gauge verifies that there is sufficient oil pressure 8 Allow the engine to idle for three to five minutes or allow the engine to idle until the water temperature indicator begins to rise The engine should run at low idle smoothly before increasing to high idle Allow the white smoke to disperse before proceeding with normal operation 9 Operate the engine at low load until all systems reach operating temperature Check the gauges during the warm up period When you are starting the engine at temperatures below 18 0 F the use of additional cold weather starting aids is recommended A coolant heater a fuel heater an oil heater or extra battery capacity may be required Reference Be
46. ompartment 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 free of personnel 102412758 Engine Starting SMCS Code 1000 7000 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 Move all hydraulic controls to the HOLD position before starting the engine Move the transmission control to NEUTRAL position 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 well ventilated area If you are
47. ould occur Turn off the transmitter before you move the transmitter or before you adjust the transmitter SEBU7418 08 i02424775 Additional Messages SMCS Code 7405 EU L i 1 8 40 2959 Illustration 12 There are several specific messages on this machine The location of the messages and the description of the messages are reviewed in this section Please become familiarized with all messages 13 Safety Section Additional Messages g01211803 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 secures the messages Loose adhesive will allow the messages to fall 14 Safety Section Additional Messages Replace any message that is damaged or missing lf a message is attached to a part that is replaced install a message on the replacement part Any Caterpillar dealer can provide new messages Air Conditioner 1 This safety message is located on the left side of the instrument panel Xx R134a kg 5 PAG 4C 2959 25 90121
48. res 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 SEBU7418 08 It is prohibited for any person en
49. rollover of the machine 103634321 Operator Station SMCS Code 7000 Any modifications to the inside of the operator station should not project into the operator space or into the space for the companion seat if equipped The addition of a radio fire extinguisher and other equipment must be installed so that the defined operator space and the space for the companion seat if equipped is maintained Any item that is brought into the cab should not project into the defined operator space or the space for the companion seat if equipped A lunch box or other loose items must be secured Objects must not pose an impact hazard rough terrain or in the event of a rollover i03656846 Guards Operator Protection SMCS Code 7000 7150 7325 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 SEBU7418 08 Rollover Protective Structure ROPS Fal
50. s plate is on machines that are going into the European Union 225 4148 5 Illustration 40 g01057231 D5N S N AGG903 Up D5N S N AKD801 Up Power 1 kW e Weight 2 kg e Date of Manufacture 3 Year The CE plate is located on the PIN Plate See illustration 35 Certification Protective structure certifications are located on the machine 33 Product Information Section Identification Information 2 Illustration 41 g01057492 Structure certification FOPS 4 FOPS SAEJASO3449 APR98 LEVEL Il 1503449 1992 LEVEL Il D5N XL DSN LGP CATERPILLAR INC PEORIA ILLINOIS USA Illustration 42 g01056125 S N AGG903 Up S N AKD802 Up A WARNING STRUCTURAL DAMAGE AN OVERTURN MODIFICA TION 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 CONSULT A CATERPILLAR DEALER TO DETERMINE THIS STRUCTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION ROLLOVER ROPS AND FALLING OBJECT FOPS PROTECTIVE STRUCTURE CERTIFICATION THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE WHICH IS NOT ALTERED TO EXCEED THE CERTIFICATION TEST MASS MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J397 OCT95 SAE J1040 MAY94 ISO 3164 1995 ISO 3471 1994 SAE J231 JAN81 ISO 3449 1992 LEVEL II CERTIFICATION TEST MASS MODEL NO kg LB D5N XL D5N L
51. that secures the safety message Loose adhesive will allow the safety message to fall Replace any safety message that is damaged or missing If a safety message is attached to a part of the machine that is replaced install a safety message on the replacement part Any Caterpillar dealer can provide new safety messages 8 Safety Section Safety Messages Do Not Operate 1 A WARNING DO NOT OPERATE OR WORK ON THIS EQUIPMENT UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS PROPER CARE I YOUR RESPONSIBILITY Illustration 4 g00930652 Safety Message 1 is positioned 230 mm 9 05 inch above the bottom of the left post A WARNING 00 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 ANY CATERPILLAR DEALER FOR REPLACE MENT MANUALS PROPER CARE I YOUR RESPONSIBILITY g01211662 Ay WARNING 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 IN JURY OR DEAT
52. u are instructed otherwise never attempt adjustments while the machine is moving or while the engine is running Never jump across the starter solenoid terminals in order to start the engine Unexpected machine movement could result Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement Stay clear of all rotating and moving parts If itis 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 loose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pin Chips or other debris can fly off an object when you strike the object Make sure that no one can be injured by flying debris before striking any object i01329099 Burn Prevention SMCS Code 7000 Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine
53. with implement control linkage HOLD D5NFTC S N AGG1 902 AKD1 800 D6N FTC S N ALH1 398 ALR1 377 SEBU7418 08 pL ELT Illustration 30 g01061586 Implement lever with hydraulic pilot control HOLD DSNFTC S N AGG903 Up AKD801 Up D6N FTC S N ALH399 Up ALR378 Up 4 Verify that the implement control levers are in the HOLD position NOTICE Do not engage the starting motor when flywheel is turning Do not start the engine under load If the engine fails to start within 30 seconds release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again 5 Turn the engine start switch key to the ON position The system performs an automatic self diagnosis When you turn on the engine start switch key the test is performed If the test is complete without any faults proceed to the next step If the system detects a fault check the electrical system Complete all of the necessary repairs before you start the engine Air inlet heater starting aid 6 The indicator for the air inlet heater is positioned on the upper digital display window The indicator for the air inlet heater will come on during the next cycle before engine start up a When the indicator light is on the air inlet heater is in the ON position or in the preheat cycle Do not attempt to start or crank the engine until the light turns off b When the indicator light goes
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