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Parts Catalogue - Barloworld Equipment

1. _ _ Advanced Ef FICYEMET Negligible impact on contaminant holding capacity The Cat Advanced Oil Filter provides improved filtration efficiency with little effect on dirt holding capacity Therefore the condition of the oil as determined by SeOeS Services analysis and not filter capacity is the major factor in determining the recommended oil change interval The bar graph below illustrates the relative dirt holding capacity of the Advanced Filters and corresponding Standard Efficiency Filters CATERPILLAR ADVANCED HIGH EFFICIENCY OIL FILTER DIRT HOLDING CAPACITY PERFORMANCE 60 Z gt qu 5 c 80 TO C NO c 1R 1807 1R 1808 Improved efficiency with minimal loss in reserve capacity and no impact on recommended change interval 1R 0739 1R 0716 Cat Ultra High Efficiency Fuel Filters Maximum engine performance maximum engine life Cat Ultra High Efficiency UHE fuel filters provide unsurpassed contamination control to ensure that only clean fuel reaches your engine Clean fuel is important because diesel engines now have advanced designs and emissions reduction technologies that use fine tolerances between parts and pressures up to 30 000 psi Under these conditions even smaller micron sized con taminates can cause premature component wear reduced performance and or emissions com pliance Issues Unsurpassed component
2. c du T E continually expanding our Cat equipment model t 1 coverage if Because Cat hydraulic components are designed to be remanufactured we can often award credit even when you think a component has no value left Contents 1 4 6 Cat Flexport Tyres 1 4 9 Cat LED Work Lights 1 4 9 Cat Machine Security System GENERAL USAGE Cat Flexport Tyres Designed specifically for skid steer loaders and compact small and medium wheel loaders Created with operator comfort in mind Flexport tyres use a series of elliptical shaped ports moulded through the outer ring of the sidewalls The ports increase tyre flexibility to produce a smoother more cushioned ride on any surface from waste and scrap to quarry and glass The ports won t crush under the weight of a full bucket and the innovative design also improves ma chine stability when lifting and carrying To meet demanding and diverse operating environments Cat Flexport tyres are available in three different tread patterns e Construction e Smooth Iread and e OTR Off the Road Construction Tread The Flexport construction tread design is the right choice for maximum performance in your toughest environments It is designed for smaller machine applications where better traction is required FLEXPORT Features and Benefits e Patented sidewall ports make the ride more comfortable for operators e
3. e Includes Bronze Kit 4 Fe d e 6 pistons liners wrist pins rings retainers 4 4 e Rodless unassembled cylinder pack Benefits e Basic rebuild e Where Reman is not a preference e Similar consist to aftermarket kits e Additional engine components can be ordered as needed Features e Includes Bronze Kit e Includes 6 Cat Reman cylinder pack assemblies Benefits e Basic rebuild e Cat Reman cylinder packs are preassembled with connecting rods pistons rings wrist pins and liners saving four to six hours of labour during engine rebuild e deal for repair before failure e Additional engine components can be ordered as needed PLATINUM LEVEL The Platinum Level is the most complete rebuild option designed to maximise the built in second and third life of your engine Features e Bronze Kit e Cat Reman cylinder packs e Cat Reman injectors or fuel nozzles e Cat Reman complete cylinder head water pump and oil pump Benefits e More complete engine rebuild option e Preassembled Reman cylinder packs and cylinder head will save additional labour hours during engine rebuild e Maximises the built in second or third life of your engine e Additional engine components can be ordered as needed Firing on all Cylinders Continued BRONZE LEVEL 1 2 gt Lu CC Lu 2 ALL YOU NEED TO DO IT RIGHT Precious Metals Engine Ki
4. m Discover the D iffe rence The values shown are typical values and should not be used as quality contro parameters to either accept or reject product Specifications are subject to change without notice Cat FDAO is developed tested and approved by Caterpillar to meet the same high standards as Genuine Cat Parts e Used as standard factory fill for Cat off RECOMMENDED DRAIN 6000 highway trucks and large track type INTERVALS tractors Cat Final Drives for Off 5000 e Extended drain intervals Allows Highway Trucks for double length drain intervals 4000 in off highway truck final drives as compared to 4 commercial oils 3000 e Minimal foaming formulated to protect against the damaging effects of air 2000 mm 2000 1000 Possible with SeOeS Services 0 TDTO FDAO PREVENTATIVE MAINTENANCE AND FLUIDS Oils Cat TDTO Transmission and drive train oil for Cat transmissions final drives and wet brake compartments SAE 10W SAE 30 SAE 50 Recommended Use Tested Beyond Industry Standards e The preferred lubricant for Cat power shift transmissions and most final drives and wet brake compartments The TO 4 specification defines a minimum standard of e Cat machine compartments where TO 4 and TO 4M performance for transmissions and drive train oils but Cat specification oils are recommended TDTO is required to pass five additional Caterpillar tests e Other manuf
5. Retrofit Cabs For Cat 988G Wheel Loaders More Cab Less Time Caterpillar is pleased to announce the availability of cost effective alternative solutions for cab rebuilds and replacement cabs for certain Cat 988G large wheel loaders These new retrofit cabs are designed as plug and play kits and they can be installed in a matter of hours Further modifications might be needed if any additional attachments need to be transferred from the current machine cab Cat Retrofit Cabs offer value by upgrading to newer technologies and assuring ROPS integrity On board is the Cat Comfort Seat with patented three point harness for improved operator ergonomics helping to reduce fatigue and improve alertness and general productivity The upgraded cab has all necessary certification labelling including ROPS certification Features include AJC LED indicators in dash EMS III CB ready HID lighting Extended root Deluxe radio with USB port Two 10 Amp Converters Blade Fuses E bay Additional features include exterior paint schemes similar to current production cabs folding mirrors and rear laminated glass For further information please contact your Barloworld Equipment customer service representative 114 5145 e 346 3845 upgrade cab Large wheel loader customers around the world are targeting longer service life from their Cat machines A complete upgrade cab satisfies the cust
6. Electric Power and Marine Cat Certified Engine Rebuilds 3300 3400 3500 3600 Engine Family Series An investment in productivity A Cat engine is the best investment in productivity you can make But eventually every piece of equipment reaches the end of its useful life Through the Cat Certified Engine Rebuild programme a member of the Cat 3300 3400 3500 or 3600 engine family can be rebuilt for a second life at a fraction of the cost of an engine replacement Rebuild specifications meet all Caterpillar standards providing the kind of quality you have grown to expect Parts are built to exact tolerances and undergo rigorous testing to ensure reliable performance These Cat Certified Engine Rebuilds also come with extended service coverage options the latest required updates and optional performance enhancement upgrades which could result in e mproved fuel consumption e Reduced emissions e Solutions for governmental or international regulations SOLAS Reg number 15 2 9 SOLAS Reg number 15 2 10 SOLAS Reg number 15 2 11 e Reduced owning and operating costs e Technology upgrades like EIS Technology G3600 ESS to ADEM III G3500A Gas Compression EIS to ADEM III Inspection Evaluation This vital first step is a thorough process during which we develop a customised rebuild plan and cost estimate for you Disassembly Once the rebuild plan is established your engine will be completely disassembled
7. Colour Boiling protection with 15 psi 1 bar radiator cap 6096 Cat ELC A096 water ELC concentrate added 6096 Cat ELC A096 water ELC concentrate added The values shown are typical values and should not be used as quality control parameters to either accept or reject product Specifications are subject to change without notice Hed CAT DEAC Cat Supplemental Coolant Additives Every 250 Hours or 25 000 km 3 000 Hour Life or 333 000 km CAT ELC Machines and Commercial Engines Cat Extender Every 6000 Hours 12 000 Hour Life or 6 Years whichever comes first CAT ELC Truck Engines Cat Extender Every 500 000 km 1 000 000 km or 6 Years whichever comes first Or one half of the coolant service life These coolant change intervals are only possible with annual SeOeS Level 2 coolant sampling and analysis SeOeS Services for early problem detection Protect your investment with Cat SeOeS Coolant Analysis the ultimate detection and diagnostic tool for your equipment We recommend SeOeS Level 1 Coolant Analysis according to the engine s Operation and Maintenance Manual and Level 2 Coolant Analysis annually for all your Cat equipment Cat ELC Extender for Longer Life Exceeds Cat EC 1 performance requirements Protects against cylinder liner block pitting and cavitation erosion Should be added at 500 000 km for Cat powered on highway trucks and 6 000 hours for commer
8. KEEP IT REAL KEEP CONTENTS 04 Repair Indicators 0 8 Undercarriage 2 3 Ground Engaging Tools GET A 9 Engines 6 7 Preventative Maintenance and Fluids 9 7 Filters Braking Systems 1 3 Drive Train 1 Bearing Maintenance 1 2 Hydraulics 1 4 5 General Usage l 5 Cabs and Accessories 1 5 9 Contact Us CONTENTS REPAIR INDICATORS Quick Reference Guides Engine Drive Train and Hydraulic Repair Indicators Machine life cycle management should combine preventative and predictive maintenance strate gies to achieve optimal results Planned Indicators SeOeS M Services Experience SeOeS Services provide the best insight into internal component wear and potential failure Each machine s Operating and Maintenance Manual gives general guidelines for servicing based on service meter hours e Observation and Discussion Site Operations Maintenance Advisor SOMA provides component life estimates SOMA is a software that assesses customers operating and maintenance practices The following quick reference guides provide a useful checklist for identifying potential problems and their possible Cat Engine Excess black smoke at full load hot unburned fuel Increased fuel consumption Blue smoke oll consumption White smoke steam water in combustion chamber White smok
9. e Greater bushing retention e Increased strength e More press fit area e Increased retention e press fit area e Increased retention Wear life enhancement Link rail 2096 more wear material e Extended link roller system life SALT stands for Sealed and Lubricated Track Comparison percentages based on D6H System Management Undercarriage Optimisation The Importance of Track Adjustment Incorrectly adjusted track can cost you money both in accelerated undercarriage wear and downtime If the track is too tight damaging non productive loads are placed on the undercarriage and its manual components Tight track accelerates track wear and reduces tractor drawbar horsepower Adjustment procedures take only a few minutes and require only one person When adjusting your track on any Cat machine Always adjust the track in the working area Do not try to squeeze any packing material from in between the track Never loosen the relief valve more than one turn Grease and oil are under extreme pressure and can penetrate the body causing serious injury Operating Checklist Always use the narrowest shoe possible which still allows adequate flotation Minimise high operating speeds in non productive situations especially in reverse Alternate turning direction since turning only in one direction wears out one side of the machine faster than the other Rotate the track from side to side if you or
10. 15 9 0 750 19 1 1 000 25 4 1250 31 8 1 500 38 1 256 1390 12 000 50 8 5 8358 2 000 50 8 XT 6 ES HOSE EXCEEDS SAE 100R15 STANDARDS 238 8343 0 375 9 5 0 500 12 7 0 750 19 1 1 000 25 4 1250 31 8 1 500 38 1 222 4844 2 000 50 8 4 000 4 000 4 000 4 000 4 000 3 000 2 500 2 500 5 000 _ 6 000 6 000 28 000 28 000 28 000 28 000 28 000 21 000 17500 17500 5 000 34 474 34 474 41 370 41 370 12 50 318 25 98 660 Custom Hydraulic Service For peak performance and profitability Custom Hydraulic Service CHS is a detailed inspection programme available through Barloworld Equipment that is designed to keep today s hydraulics intensive machines operating at peak per formance Studies show that hydraulic system efficiency can fall off by as much as 20 before being detected by operators Today s hydraulic systems operate with higher pressures and SOS Fluids Analysis tighter tolerances that demand attention to contamination e Extraction of oil sample from the hydraulic compartment control Dirt and other contaminants allowed to enter the e Analysis of oil sample to determine contamination level system accelerate parts wear Along with higher service physical properties and wear material count costs premature wear can also cause a loss of performance that may go undetected for a long time Corrective action recommendations e Anal
11. Cat NGEC demonstrated its superior ability to protect compared to competitive heavy duty coolants Drain Interval When used in Cat natural gas engines and properly maintained with Cat SCA Cat NGEC has a drain interval of three years Refer to the Operation and Maintenance Manual of your specific machine engine for drain intervals based on service hours Coolants and Antifreeze SeOeS Fluid Analysis Services for Early Problem Detection Protect your investment with Cat SeOeS Coolant Analysis the ultimate detection and diagnostic tool for your engines Refer to the Caterpillar Operation and Maintenance Manual for the recommended intervals of SeOeS Level 1 Coolant Analysis e g every 250 hours Level 2 Coolant Analysis is recommended at least annually for all Cat engines and machines Testing Nitrite Levels Field testing of coolant nitrite levels can be performed using the 4C 9301 test kit Results are immediate and SCA additions can be made as needed Coolant Maintenance Resources For in depth information on coolant maintenance refer to your Barloworld Equipment customer service representative ASTM Specification ASTM D6210 Silicon in the form of silicates 50 solution values shown are typical values and should not be used as quality control parameters to either accept or reject product Specifications are subject to change without notice Higher levels of glycol reduce the heat transfer
12. The parts will be inspected and measured against our strict reusability guidelines Those parts that do not meet our high standards will be replaced with new Cat parts Reconditioning This phase of the process addresses equipment needs not typically included an engine overhaul Engineering updates During reassembly your engine will receive any required updates and your choice of optional performance enhancement upgrades that have occurred since your engine was originally manufactured Reassembly Our professional technicians will carefully and completely reassemble your engine 7 ENGINES Testing and validation AVAILABLE COVERAGE Following the original commissioning procedures of the rebuild process the engine will be retested and re commissioned Repainting Your engine will perform like new and look like new after a paint job A Cat Certified Engine Rebuild decal will also be issued New Cat Certified Engine Rebuild identification numbers A new Cat Certified Engine Rebuild number identifies your engine and entitles you to Caterpillar extended service coverage options Customer evaluation The rebuild process is not considered complete until your operators are satisfied with the performance of your engine in Its working environment Model coverage Contact our Cat Certified Engine Rebuild team for 3300 3400 3500 3600 Engine family serial number specific data Cat Certified
13. e ncoming air is now filtered through a separate breather allowing for cleaner fuel e Closed vent lowers the risk of fuel spilling during severe operations side slope and rollover conditions Reduced Costs and Maintenance Time e Eliminates pressure in the fuel tank e Fast refuelling rates up to 150 GPM Fills in 1 10th of the time over standard gravity fill rates e Minimises fuelling downtime e Eliminates need to drain fuel tank for receiver servicing e mproved vent performance resulting in less risk of fuel leaks Safer Work Environment e Ground level fuelling eliminates dangerous climbs to reach the fuel cap on the top of the tank e Fuel tank is not pressurised during nozzle shut off e Shut off levels are consistent Durable Components e Vent and inlet valve have a long life e Receiver connects to industry standard fuel nozzles KEEP IT REAL KEEP IT For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Models Off Highway Truck Tractor 7690 773E 776D 777D Articulated Truck 725 730 730 Ejector 735 740 740 Ejector Excavator 385B 385C 5090B 5110B 5130B Quarry Truck 7
14. e Steel crown for heat resistance and higher cylinder pressure e Aluminium skirt for weight reduction Cat Liners e Inside surfaces feature a uniform cross hatch pattern for faster ring seating proper ring seal uniform oil distribution and long life GENUINE CAT PARTS Comprehensive service and support When your engine needs service our professional technicians have the training and tools to get you back to work quickly We provide off the shelf component availability backed by Caterpillar s worldwide parts network a ph ye Pa a Tr aa TES TTEN TAYA i m B m ih E e Flanges are roll burnished in the radius for increased strength and resistance to cracking e Heat treated high grade gray iron construction provides exceptional strength and long life e Controlled flange head thickness guarantees a precise match with the block and head e Precise manufacturing tolerances ensure perfectly round bores for efficient oil control and proper fit in Cat engine blocks Cat Rings e Precise plasma or chrome plating guarantees exceptionally long wear life e Proper surface finish provides smooth operation and long wear life Barrel faced top ring maintains the proper oil film thickness on the cylinder liner for reduced liner damage and oil consumption Durable heat treated ductile iron construction resists breaking and impa
15. forestry landfills farming military and more Debris types Expels all types of mixed debris including mud Snow rain leaves sawdust chaff dust etc Debris laden applications may require an optional Heavy Debris Basket Screen FILTERS Cat Turbine Precleaner Continued Online savings calculator Make your own cost saving case study with the Cat Turbine PreCleaner online Savings Calculator www cat com parts precleaner Enter your own data and costs to see how much time and money the Cat Turbine PreCleaner can save you each year eL How it works Step 1 Air and debris pass through a pre screen on the underside entering the unit through recessed vanes underneath the particle accelerator blades 09000909090000000909000000900090000000900000000900000090000000000909000009000000000090909000000009009000009009000000900000000009090000909 Step 2 The curved particle accelerator blades force air and debris into the sidewall Step 3 Strakes angled fins along the interior surface move heavier than air debris towards the ejection slot where it is expelled back into the atmosphere Step 4 Clean air continues to spin upward until it is compressed and folded The clean air
16. 10W 30 performance when used in conjunction with the SeOeS Services oil analysis programme e Proven Performance Tested thoroughly in Cat diesel engines including Cat engines with ACERT Technology to ensure excellent engine life and performance e Long Lasting Protection Improved soot control and enhanced shear stability enable oil to maintain proper viscosity for longer operating periods in Cat engines with ACERT technology especially those equipped with HEUI Systems Recommended Use e Cat earthmoving commercial marine and on highway truck diesel engines e Low emission diesel engines including Cat engines with ACERT technology e Heavy duty diesel engines made by other manufacturers that recommend API 4 4 or CG 4 classification oil Please refer to the Typical Characteristics table for more information e Automotive gasoline engines that require API SL classification oils Excluding 3126 3116 MUI Marine diesel engines The 3116 and 3126 MUI Marine diesel engines with closed crankcase ventilation systems should use Cat SAEOTM Discover the Difference Cat DEO is developed tested and approved by Caterpillar to meet the same high standards as all Genuine Cat Parts e Used as standard factory fill for Cat machines e Increased Engine Life Resists oxidation and prevents build up of deposits on pistons and rings e Extended Drain Intervals Extends oil drain intervals
17. Base edge scalloping The base edge is the primary support for the entire bucket system When it wears thin or cracks it weakens the whole bucket structure The bottom and sides of the bucket can warp and bend Also cracks may develop in the weld areas of the bucket All this means expensive repair and downtime Downtime that could have been reduced through a programme of planned repair and maintenance You can reduce base edge scalloping by using either bolt on edge segments or weld on half arrow edge segments between the teeth Edge segments protect the base edge from scalloping and bolt on edge segments have the added benefits of being reversible and easily replaced Conservation your answer to lower costs Conservation is one of your best defences against rising maintenance costs The following conservation practices have been tested and proven e Always replace worn edges with the latest Cat edges e Rotate bucket tips from the ends to the centre and from the centre to the ends e Turn bucket tips over The results are a re sharpened tip and extra wear life e Reuse rings and pins Also inspect hardware for reuse and discontinue the practice of automatically burning it off e Minimise ground contact with the bucket Some operators lower the bucket to the ground long before they are ready to enter the stockpile This extra scraping unnecessarily wears the bucket bottom e Protect the bucket bottom with bolt on or weld o
18. Caterpillar specs for blanking tooth shaping and broaching can create improper fit resulting in premature failure and damage to the mating part Stress relieving Lack of or improper stress relieving can cause premature wear warping of the separator plate and damage to the mating part Surface finish and cleaning Improper surface preparation can result in poor bond strength with the core resulting in partial or complete separation from the core plate Poor surface finish can result in accelerated wear on the friction disk as well as noise creep drag and reduced coefficient of friction Failure to remove loose material can clog fluid filters and affect fluid flow resulting in poor lubrication and higher running temperatures _ 4 a performance Real world validation delivers better Caterpillar invests millions of dollars to design test and develop friction material for each machine application a process that can take years All friction material must undergo a stringent certification process to ensure it performs to Caterpillar specs Cat elastomeric friction materials for example feature an exclusive material designed by Caterpillar that is moulded and bonded to a core for use in transmissions and load clutches in off highway trucks and wheel loaders Choosing Cat friction material is your assurance of safety and reliability the result of real world validation quality assurance and experi
19. Contents 130 134 139 140 143 Cylinders and Rods Advanced Surface Technology Cylinder Rod Seals Hydraulic Cylinder Reseal Service Hydraulic Cylinder Seal Kits Hoses and Couplings Hose Service Couplings No Skive and XT Onsite Hose and Coupling Container Service Toughguard Hydraulic Systems Custom Hydraulic Service O Rings and Seals Cat optional high temperature FKM seals Pumps and Motors Pump and Motor Service Reman Cat Advanced Surface Technology For off highway truck suspension and hoist cylinders Reman rods with Cat AST available to support Cat F Series off highway trucks Introduced on the Cat F Series off highway trucks Cat Advanced Surface Technology AST coated rods offer several advantages over traditional chrome plated rods Benefits e They can last up to three times as long in the same application e Offer better wear resistance e Are more environmentally friendly Superior wear characteristics and improved component durability mean longer seal life reduced downtime and improved machine availability and productivity Because many of these rods are compatible to earlier models Caterpillar is offering an upgrade to AST option Owners of older Cat trucks interested in upgrading to Cat AST Reman Rods will receive core credit for their existing rods How Cat AST works Here s how the Cat Advanced Surface Technology process works e Salvaged components undergo straightenin
20. Engine Rebuild Extended Service Coverage Inspection Evaluation The Cat Certified Engine Rebuild programme doesn t end with the rebuild process The value of your engine is further increased with new engine extended service coverage options Ask your Barloworld Equipment Customer Service representative for details on additional extended service coverage options available through the Cat Certified Engine Rebuild programme Available coverage e 2 year or 12 000 service hours e 2 year or 16 000 service hours e 3 year or 18 000 service hours e 3 year or 24 000 service hours You have to push every day To meet tomorrow s deadline To secure the next contract To stay ahead of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILT IN For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission B d 7 Equipment Engine Bearings e Aluminium Alloy Bearings Bi metal e Aluminium Alloy Bearings with overlay e Copper Lead Bearings Built to
21. Management System 4 0 VIMS The cabs are equipped with VIMS 4 0 for better monitoring of truck operations and payloads e he Cat Comfort Seat with patented three point harness e A full size buddy seat Cat Retrofit Cabs offer value by upgrading to newer technologies and assuring ROPS integrity Retrofit cross reference chart The information in this chart will helo match the Retrofit Cab Upgrade Part Number to the truck application by machine sales model and serial number prefix These Upgrade Retrofit cabs replace same series machine cabs These cabs are not intended to upgrade from a lower series model The Retrofit Cabs that are compatible with Hydraulic Automatic Retarder Control ARC are 785C and 789C series The Retrofit Cabs that are compatible with the Air ARC are 785B 789B 793B and 793C Large OHT Serial Number The plug and play design requires less than a day for installation minimising downtime New Retrofit Cab Part Original Cab Part 250 6898 174 0523 159 Lubumbashi 00243 992 901 300 CONTACT US Our Southern African Footprint SAO TOME amp PR NCIPE DRC KATANGA PROVINCE DRC Joint Venture with ANGOLA Tractafric E ZAMBIA ZIMBABWE NAMIBIA E S BOTSWANA g E m SWAZILAND HN Hb m H O m LESOTHO SOUTH AFRICA MALAWI MOZAMBIQUE Q Main Branches m Dep
22. Repair Indicators section in this handbook Understanding differential steering Differential steering uses three planetary gear sets and a hydraulic motor to change the speed of each track This system delivers uninterrupted power to both tracks during turns Power from the transmission is delivered through the bevel gears to three planetary gear sets then to the final drives and tracks By adding power to one of the planetary gear sets the motor adds or redistributes power to the steering differential and by its direction of rotation speeds up one track and slows down the other to make turns By rotating one direction it makes a right turn and by rotating the other direction it makes a left turn Thus the hydraulic motor determines the direction and degree of the turn The results are turns of any degree from slight to sharp without interruption in power The operator turns reverses direction and changes speed ranges using one hand on a single tiller This Caterpillar patented steering system 15 available in the Cat D6R through DOR and Challenger tractors Causes of premature bearing failure In order to maximise bearing life it is important to eliminate the four primary causes of premature failure Improper installation bearings are not properly installed with the correct pre load Improper tolerances width tolerances are incorrect for the application Overload fatigue resulting from ma
23. Right Now Get more for your money Pre packaged kit options feature improved pricing and contain everything you need for a cost effective repair solution Count on quality Genuine Cat engine components are manufactured to precise specifications and engineered for a reliable rebuild boosting productivity and minimising downtime They work together as a system to give your machine new life Save time and effort Because there s no need to select individual parts for the repair you always get exactly what you need no more no less That simplifies ordering and handling shortens turnaround time and reduces the chance for errors O Mo 6 Firing on all Cylinders Continued FIND THE LEVELTHAT S RIGHT FOR YOU Features Basic building block for all higher levels e Includes additional value add components such as rod bearings e Includes components you might not think of replacing but that could lead to unplanned downtime and costly failures such as exhaust manifold sleeves e Includes required gaskets and seals to reassemble the engine out of frame rebuild kit Benefits e Includes all parts necessary for low cost repair option e deal for repair before failure Building from the Bronze Level a cost effective option for a basic rebuild the Silver Level includes new pistons liners wrist pins rings retainers and a rodless unassembled cylinder pack Bo AL 2 42 Features L iS IE TI
24. SAE standard sizes won t perform well Packaged to save you time and money Caterpillar offers several O ring seal kits saving you time and up to 15 percent off the cost of ordering O rings individually Available alongside the Cat refillable kit option is Caterpillar s comprehensive range of resealable O ring packets Caterpillar now offers 67 different O Ring packages to match the most common types of hydraulic adapters and hose fittings each available in a convenient contamination free poly bag seven different kits are available for hydraulic fittings and air conditioning systems Contact your Barloworld Equipment customer service representative for more information on the range of Cat O rings available for your Cat equipment and other applications For order enquiries please contact your Barloworld Equipment customer service representative or any one of our Parts Counters nationwide Cat Refillable O Ring Seal Kits When you replace Cat hoses and tubes it s important to have the right O rings at your fingertips which is where Cat refillable O ring seal kits prove invaluable Stored in durable carry cases Cat seal kits have individual compartments to store a variety of seal sizes Highly Saturated Nitrile Caterpillar offers two types of application specific seals Buna Rubber Standard Nitrile NBR and Fluorocarbon FKM rubber made specifically for high performance Ca
25. a crucial part of machine management Oil sampling at scheduled intervals validates your maintenance procedures tracks what is going on inside of the equipment and forecasts wearrelated problems Our SeOeS Oil Analysis programme is well recognised for its ability to detect potential failures before they occur Each SeOeS Services test is designed to reveal specific information about the condition of Cat products The four types of analysis are below e Wear Metal monitors and tracks metal wear particles contaminants and oil additive package elements e Oil condition compares used oil to new oil to see if it is providing adequate lubrication and protection e Oil Cleanliness determines if abrasive contaminants are causing accelerated wear e Oil Contamination detects water glycol or fuel in oil Control Contamination reduce overall operating costs Dirt sand grit and even the finest dust can cause problems when they find their way into the differential They cause parts to wear faster making them more prone to premature failure There are four ways contamination can get into machine systems 1 Contaminants can be built in during manufacturing and assembly operations 2 Contaminants can enter during servicing and maintenance procedures 3 Contaminants can enter with new fluid 4 Contaminants can enter during operation through pitted shafts broken breathers worn seals and other trouble spots Fortunately there ar
26. and over fuelling This harms performance and fuel economy Contaminants also result in hard starts and increased emissions Larger contaminants can actually clog orifices e Injector plungers and barrels Abrasive particles cause wear between an injector s plunger and barrel Contaminants scuff metal surfaces causing metal to metal contact and eventual injector seizure e Control valves contaminants damage valves that control fuel pressures eroding mating parts of the valves This excessive wear causes leaks and eventual loss of engine power Size of Contamination A particle five microns across can damage fuel systems A micron is one millionth of a metre To give you an idea of how small that is an average human hair is 80 microns in diameter Tolerances in Cat fuel injectors are 1 20th the diameter of a human hair It s easy to understand how even small contaminants can damage today s fuel systems Sources of Contamination e Inthe fuel Contaminants can enter during storage or transportation of fuel A reliable supplier filtered dispensing and periodic sampling and testing ensure consistent quality During operation Airborne particles can be drawn into your fuel tank through the vent tube A fuel tank vent can ingest dust when it is not properly sealed e External Contamination can enter during maintenance and service even when changing filters Filtering Contamination The precision components in today s fu
27. and inactive periods such as disarming the system during regular work hours so that a standard key can be used and then reverting to security keys after hours e Program security keys to expire at a specific period of time e One security key can be programmed to operate any machine in your fleet Cat Machine Security System The Cat Machine Security System is superior to more basic add on theft deterrent devices because it Is integrated into the electronics of the machine This makes it virtually impossible to defeat Key Management Programming the Cat Machine Security System is simple An authorised Barloworld Equipment technician can quickly program your machine to start with a new key or make changes for existing keys A machine can be programmed to accept many unique security keys Availability e Factory available for many models e be field installed on your entire fleet both Cat and competitive machines e Works on both 12 and 24 volt systems To find the field installation kit part number for your model please contact your Barloworld Equipment customer service representative MACHINE SECURITY SYSTEM KEY DASH LIGHT ENGINE OR TRANSMISSION ELECTRONIC CONTROL MODULE MACHINE SECURITY SYSTEM ELECTRONIC CONTROL MODULE The Cat Machine Security System is superior to more basic add on theft deterrent devices because it is integrated into the electronics of the ma
28. buttons roll bars and wear blocks This wide variety of product designs and sizes allows for maximum wear protection in virtually any type of environment or application plates can be quickly replaced without hammering or welding making installation quick and easy Reduced Downtime and Maintenance In two minutes or less the wear plates can be changed reducing downtime and maintenance Extended Wear system s patented compression retainer is positioned low in the base plate allowing for a greater percentage of the wear plate to be worn away before replacement MAWPS Systems Versatility he weld on base plate can be welded onto virtually any flat or moderately curved surface that requires wear protection The solid Mechanically Attached Wear Plate System provides a hammerless method for installation and removal of wear plates MAWPS are available in variety of sizes Each size 15 also available in two different thicknesses standard and heavy duty Wear Indicator Inspections are quick and easy When the holes become exposed in one or more corners it is time to change the wear plate Each part features two layers which are bonded together through a copperbrazing process ij _ Chrome White Iron CWI Heat treated ASTM Class 2 Type The solid MAWPS is designed B with a minimum hardness of Rockwell C 60 for high wear for extended wear protection 77 resistance in a variety of areas such as b
29. can also view SeOeS Oil Analysis results on line Record keeping By developing an accurate machine record keeping system you can identify high cost or problem areas track work flow control costs and increase machine resale value An accurate record keeping system documents drive train history by detailing component life and cost information We can help you set up manual record keeping and work order systems or we can help you install computer software programs to perform scheduling checklists and other record keeping functions Final Drive Maintenance A Management Guide Final drives play a crucial role within a machine s drive train by transferring power to the tyres or tracks while providing speed reduction and torque increase Final drives are closed components and thus hidden from view and for this reason it is easy to overlook routine maintenance requirements In response effective system management will lead to fewer failures less downtime and better machine resale value This guide discusses preventive maintenance repair management options and highlights the main components that wear and fail in final drive systems By understanding these topics you could minimise your owning and operating costs while maximising your productivity Overview Cat final drive components must endure incredible torque high impact loads and frequent direction and gear changes In fact the final drive is where the highest t
30. cap the ends of hoses to help prevent contaminant ingress prior to installation The benefits One part number makes ordering hoses for Cat Certified Clean equipment quick and easy Certified Crimp Hoses are assembled to original specifications by While you wait service for Cat and other equipment trained Barloworld Equipment technicians brands Use of superior Cat hose products On site support for remote sites Barloworld Equipment technicians pneumatically clean hoses with foam projectiles to remove contaminants that can damage hydraulic system components Work hard Play hard Visit our Cat clothing store for a wide range of quality Cat clothing shoes and merchandise For more information call 011 929 0067 or email pselebi barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission i i Barloworld AD Equipment be No Skive Couplings Added Flexibility When Caterpillar first announced its decision to move away from the Cat reusable coupling sys tem and introduce the No Skive coupling se ries many people were apprehensive about the change After all Cat reusable couplings have been around since the late 605 they have also been the only high pressure reusable couplin
31. common factor in premature bearing failure Overloading causes the to generate heat which affects the oil viscosity Heat will cause the oil viscosity to decrease and make the lube film thin allowing contact between the rolling components and raceway The contact can cause damage similar to the damage caused by insufficient lubrication Caterpillar s Solution Caterpillar bearings are designed as an integral part of the total machine system By always using genuine Cat parts you will ensure the integrity of those systems and provide high performance and long life especially under high load applications 2 Improper Lubrication As mentioned before proper lubrication is vital to high quality bearing performance and service life Insufficient lubrication allows for metal to metal contact of the major elements and especially of the roller end against the rib producing scoring in these areas Heat has the ability to turn various elements and roller ends dark blue or perhaps in extreme cases black Caterpillar s Solution n applications where inadequate lubrication is a concern Caterpillar uses a proprietary bearing technology called textured bearings Texturing allows for better oil retention on the contact surfaces which leads to longer bearing life especially in high load slow speed applications 3 Contamination Contamination is any foreign substance that has the ability to damage a bearing Moisture dirt sa
32. equipped with the standard via SIS Web to reduce ladders The diagonal stairway kits must be ordered as an installation down time Dn optional retrofit kit Retrofit stairway kits and associated Cat 777D REHS5075 cem pem dme serviceable components are available through the Barloworld Installation of the Ladder Equipment parts system Please contact your customer Gp and Catwalk As service representative for further information Components individually serviced and backed by Upgrade Kit standard Caterpillar parts Part Number service and warranty 356 8750 Ease of access is an important factor in ensuring overall operator safety Safety Tip It should be noted that with the newly installed diagonal stairway upgrade kit Caterpillar instructs that individuals face the direction of travel when using the stairs maintain a minimum of gos two points of contact at x gt 124 Js all times and always have one hand in contact with the handrail New Cat 777D Series machines are equipped with ladders as standard Cat Cabin Air Filters A cleaner more comfortable cab environment Two high efficiency filters the Cat Dust Reduction and the Cat Dust and Odour Reduction Cabin Air Filter improve ventilation and or odour reduction in enclosed operator cabs Advanced filtra tion technology reduces airborne irritants creating a cleaner and more comfortable
33. for no skive products an XT press for all reusable coupling changes a fully ventilated hose cutter a workbench with vice The purpose built 40 foot high rise container comes equipped a contamination control cupboard storage shelving and hose with the latest Caterpillar technologies and is manned and reel racking managed on site by Barloworld Equipment Parts Department personnel that include trained hose assemblers Ongoing The container s easy portability also means that the unit can inventory management ensures that replacement parts are be loaded onto a truck and moved from site to site when always available required Standard for each container configuration are features that include an air conditioning system an office area and ISO electrical points with lock out Each purpose built 40 foot high rise container comes equipped with the latest Caterpillar technologies 4 Cat XT ES Enhanced Spiral hos an exclusive cover which is form 26 and manufactured by Caterpillar to provide up to 20 times more abrasion resistance than industry standard hose Cat Toughguard Hose The standard in hose performance Cover abrasion is the leading cause of hydraulic hose failure which in turn has downstream impacts on machine availability and productivity Caterpillar s research and development team has responded Besides helping to increase machine uptime Cat ToughGuard with the ToughGuard series designed for XT ES Enha
34. forces are exaggerated when using wide shoes in high impact applications causing pressed track joints to open up This may lead to loss of lubricant internal wear and replacement or reconditioning of track joints sooner than expected 4 UNDERCARRIAGE Shoe breakage severe turning resistance in extreme conditions and bending forces may cause wide shoes to break Your parts and service representative can help determine the best shoe width for your underfoot conditions Control the operation of your machine One of the best ways to protect your machine against unnecessary wear is to make sure it is used properly All of the following can cause additional wear on the components of your undercarriage e Slipping the track reduces production and increases wear on all undercarriage components especially on grouser bars e Avoid unnecessary reverse operations Non productive reverse operation compounds bushing and sprocket wear If the machine must be taxied from one location to another reverse operation will cause more bushing wear regardless of speed e Operating the machine at a non productive high speed may cause link tractor roller and idler tread wear Wear increases proportionally to speed e Always turning the machine in one direction may cause link side rail track roller flange and idler flange wear Wear Increases on one side of the machine because of the greater horsepower and distance travelled Keepi
35. gray security key can start the machine when the system is armed The Cat Machine Security System gives you many options to help you manage your equipment Each security key is unique SO Operators can be restricted to certain machines or hours of operation he system can also be programmed to allow use of the standard black key during active periods and then for after hours automatically rearm Benefits e Theft protection e Restrict machine access to only known operators e Easily installs on all Cat equipment e Caterpillar designed and machine integrated e Potential insurance savings e also be used on competitive equipment How the Cat Machine Security System works Each yellow or gray security key has a unique identification number When a key is inserted into the ignition switch the Cat Machine Security System electronic control module checks that key against the preapproved list If the key is an unauthorised security key or a standard black key the machine will not start Controlling Machine Access The Cat Machine Security System is programmable to give you the protection that best fits your needs By limiting operators to specific machines which prevents access by untrained operators or unauthorised personnel thereby reducing damage and injury risks e Controlling the days and hours equipment may be started which guards against unauthorised Weekend use of equipment e Programmable for active
36. help you keep your costs and machine downtime to a minimum We even offer Cat Classic pumps an economical new part alternative for older Cat equipment Disciplined contamination control procedures help to keep your hydraulic systems clean and operating at peak efficiency Pumps and motors we service are performance tested before they leave our workshop to make sure they meet factory specifications Va Pis e More options save you time and money Gear type Pumps and Motors Reseal Rebuild section kit Cat Reman pump New pump motor Cat Classic pump ne type Pumps and Motors Reseal Cat Reman cartridge Cat Reman pump motor New cartridge New pump motor ton type Pumps and Motors Reseal Rebuild Precision lapping Cat Reman barrels port plates and piston assemblies Cat Reman pump motor New pump motor HYDRAULICS Cat Remanufactured Hydraulic Components e Deliver the same performance and life as new Cat components e Are backed with a same as new parts warranty Caterpillar incorporates the latest e Offer the broadest line of remanufactured hydraulic engineering updates into all Cat PO PORE remanufactured hydraulic components e Area fraction of the price of new The difference is in the details Reman hydraulic cylinders and rods 7 e Piston slippers and pistons are reconditioned or replaced e Barrel assembly faces are re machined and bu
37. is important to protect bucket corners from unnecessary wear Cat corner protectors are cast using DH 2 steel and are through hardened for longer wear life These corner protectors have two bolt holes so they can be placed in the same location as 2 bolt corner adapters They are compatible with all Cat bolt on cutting edges The sharper profile increases penetration and production by funnelling loose material into the centre of the bucket Bucket corner configurations Former buckets with 1 bolt corners can be re worked to accept corner protectors by replacing the bucket corner with a 2 bolt corner piece Be sure to follow appropriate welding procedures with adequate pre heat when working on hardened base edges sidebars Penetrates better Funnels material flow into the bucket Increases productivity Increases wear protection Eliminates gaps between sidebar protectors and corner guards Cat corner protectors NEW SHARPER CORNER PROTECTORS FOR 924 988 LOADERS are designed to protect bucket corners from wear when bolt on cutting edges are used 9805 980G 980H 9886 988H J400 J460 Caterpillar s new corner protectors feature extra wear material to make them last even longer Increases in wear material range from 19 the J300 size to 86 in the J400 460 size The new design for the J400 J460 adapter size allows for greater sidebar protection by eliminating the gap between the sidebar protector and cor
38. is then forced down into the engine air inlet pipe Case Studies Five times filter life with concrete dust Location Ready mix plant FL USA Machine Medium wheel loader Test period 5 000 hours Front End Loader Before precleaner Filter Change Interval installation filters were blown out every 250 hours not recommended and changed every 500 hours in accordance with the planned maintenance schedule Before After After precleaner installation only two filters were used during 5 000 hours of operation The filters were never blown out and were only changed when the restriction gauge indicated a change was necessary Four times filter life improvement with quarry dust and debris Location Machine Rock quarry in England 7770 large mining truck with dual air filters Test Period 2 000 operating hours Mining Truck Filter Change Interval Before precleaner installation both filters were changed every 150 hours and blown out every 60 hours Filters were changed when the restriction light came on After precleaner installation both filters were changed at 610 hours even though there was no restriction indicated by the signal light Before After p E E LZ ND P r 1 B LI Contents 1 Cat Friction Material 1 Cat Extended Life Friction Material N gt o x ct cc co BRAKING SYSTEMS C
39. kit depending on engine sales model and kit manufacturer Remanufactured Engines and Engine Components As good as new as strong as ever At Barloworld Equipment we stock Cat Reman engines engine overhaul kits and engine compo nents so we can get you back in operation quickly affordably and reliably Factory Remanufacturing Remanufacturing is more than rebuilding It is a process of returning engines and components to their original performance specifications through the use of state of the art salvage techniques strict reuse guidelines advanced manufacturing systems and unequalled quality control Restoring original performance is possible since new Cat engines and engine components are built to be remanufactured for a second life This attention to detail ensures that Cat Remanufactured engines and engine components provide like new quality and reliability Engines Cat Reman engines are remanufactured using only Cat parts many of them new Engines are upgraded to include critical design improvements Plus each engine is dynamometer tested for operational and performance indicators This ensures that Cat Reman engines meet the same performance specifications as new Cat engines All blocks are tested electronically to ensure consistent quality and long life Generators Reman generators provide an off the shelf solution which helps customers avoid the lengthy processing time required by a generator rewind sho
40. oil change period Worn gears bearings Disc disintegration REPAIR INDICATORS Quick Reference Guides Engine Drive Train and Hydraulic Repair Indicators continued Cat Differential Repair Indicators Cat Hydraulic Repair Indicators Bent or Damaged Lines _Worn gears bearings Ring and pinion need adjustment _ Dirt in entryway Low fluid level Worn differential case assembly Worn spiders Worn spider gears Gear failure Spider failure Differential failure Bearing failure Contamination entry dirt debris Extended oil change period Wrong oil used Worn gears bearings i Worn damaged seals pinion differential Worn bearings Wrong oil used _ Low fluid level Worn or damaged seals Unusual Noises when travelling straight Unusual Noises when turning Plug Overheating Leaks Excessive cylinder drift Loose cylinder joints Blisters or abrasions in hose Excessive hose movement System pressure too high Scored or bent cylinder rod Failed or incorrect seals Improperly torqued hose connection Worn or damaged hoses tubes and fittings Missing guards Valve adjustment needed Scored cylinder Failed seal or seals Scored valve Contaminated oil Engine performance Faulty Valve _ Low fluid level Worn system components Contaminated oil Engine performance _ Low fluid level Restriction i
41. particularly accelerates wear on the idlers For information on how to adjust your track see Track Adjustment Procedures Undercarriage repair options Maximise the life of your undercarriage and reduce your cost per hour by taking advantage of these undercarriage repair options e Wet bushing turn e idler resurfacing e Track shoe regrousering Barloworld Equipment 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Track Adjustment Procedures 5 F i d gt qut Elevated Sprocket Tractors 1 Move the tractor forward and let it coast to a stop without applying the brakes Make sure slack is between the sprocket and front idler Then park the machine and turn off the engine Place a tight line over the grouser tips from the sprocket to the front idler For machines without carrier rollers measure the distance from the line to the grouser tip at the lowest point of sag Refer to Chart 1 to determine the correct sag for each model For machines with carrier rollers measure the distance from the line to the grouser tips in two places at the lowest point of sag between the front idler and carrier roller A and between the carrier roller and sprocket B Then ave
42. performance of the coolant For optimum performance Caterpillar recommends a 50 50 percent mix of Cat NGEC and water unless additional freeze protection is required Formulated to meet or exceed the following ASTM standards D3306 04985 06210 RP302 and TMC RP329 Cat ELC Coolants and Antifreeze Extended Life Coolant for Cat and original equipment manufacturer OEM diesel and gasoline engines 50 50 Premix Recommended Use Cat ELC meets or exceeds the requirements of the following specifications and guidelines e Cat EC 1 e TMC RP 329 e TMC RP 338 ASTM D 3306 ASTM D 6210 e SAE J1034 Cat ELC also meets the performance requirements of Cummins Detroit Diesel International Mack and Volvo Discover the Difference Cat ELC is developed tested and approved by Caterpillar to meet the same high standards as all Genuine Cat Parts e Used as standard factory fill for all Cat machine cooling systems e Lower Maintenance Costs Reduces engine coolant and additive costs by as much as 50096 compared to conventional coolants It eliminates the need for supplemental coolant additives extends coolant change out intervals and reduces disposal requirements e Advanced Metal Protection Incorporates an advanced formula technology with organic acid additive corrosion inhibitors such as a combination of mono and dicarboxylates for maximum protection of copper solder brass steel cast iron and aluminium
43. preventive maintenance include quality oils and filters regular S O S Oil Analysis and contamination control Preventive maintenance e Allows you to schedule downtime and plan for maintenance and repair costs e Helps prevent major failures including failure of related parts e Saves you money because you can often repair before failure e Reduces total downtime e parts reusability e Optimises equipment life to keep your machine productive and on the job e Increases machine resale value Proper oil use The three main functions of oil are to provide cleaning cooling and lubrication Modern Cat drive train systems feature new metals elastomers and paper disc materials which may have advanced lubrication needs requiring you to change oil regularly properly and use the right drive train oil to achieve top performance DRIVE TRAIN Use the right drive train oil Cat final drives axles and differentials experience high gear and bearing loads and temperatures In these conditions it is important that gears and bearings are protected Final Drive and Axle Oil FDAO is the preferred lubricant for Cat final drives and axles not containing friction materials FDAO is used where 4 was previously specified but should not be used in compartments that contain friction material because this oil does not generate a sufficient friction coefficient to satisfy the requirements of most brakes and clutche
44. protection With the ability to capture particles four microns in size and smaller Cat UHE fuel filters trap and hold contaminates to provide the protection necessary to achieve the designed life of components Maximise engine performance High filtration efficiency 15 important because contaminated fuel can rob your engine of Its rated power and cause hard starts Easier serviceability Cat UHE fuel filters have a positive stop so they can t be overtightened and in most cases can be changed without the need for tools Less maintenance time means more uptime Lower cost The filter housing is reusable so only the cartridge needs to be changed Less waste is created which reduces disposal costs CAT FUEL WATER SEPARATOR x FH The Cat Fuel Water Separator removes more than 98 of the particles 10 microns in size and larger while removing virtually all the free water and 8796 of the dispersed water This is important because with the fine tolerances between parts in today s engines diesel fuel acts as a lubricant Removing the water also eliminates the biggest source of pitting damage to fuel injectors Sub ten micron efficiency Reusable housing Integrated seals Easy disposal element Reusable Housing A reusable housing reduces waste and disposal costs Clean Drain Valve The patented Clean Drain Valve lets you drain the fuel before removing the filter The valve also locks the filter in place an
45. software into MCS Print them when each level of maintenance is due Good scheduling means maintenance inspections and planned repairs are done on time so you can prevent any transmission failures caused by overlooked maintenance Record keeping An accurate record keeping system documents drive train history by detailing component life and cost information We can help you set up manual record keeping and work order systems or we can help you install computer software programs such as the Preventive Maintenance Planner PMP or the Maintenance Control System MCS These programs perform scheduling checklists and other record keeping functions By developing an accurate machine record keeping system you can identify high cost or problem areas track work flow control costs and increase machine resale value Maximise the life of your transmission For any machine to be safe reliable and productive regular preventive maintenance Is vital Itis the most cost effective way to keep your transmission operating at peak performance If you take care of your transmission then gears and shafts can last through multiple rebuilds and the overall transmission life increases Take a proactive approach by planning for scheduled downtime maintenance and repair costs When you plan you save money and time and who couldn t use more of each For more information contact our call centre on 0800 21 22 48 or visit
46. specialised bearings Some bearings are imprinted with the manufacturer s code that supplies information on the bearing s general dimensions Cat bearings are made specifically for Cat products Therefore they have no stamped dimensions In some cases even though a bearing might portray the same identification code as a standard bearing it might be unique and have the ability to provide longer life in certain applications For example a bearing could have a particular surface finish or heat treat or possibly include a different roller crown or cage design It is vital that you avoid using a standard bearing when a special bearing is specified Selecting the incorrect bearing will shorten the life and can create further damage Detect then correct If you correctly maintain your bearings they will not incur premature failure However they will eventually fail due to rolling contact stress fatigue A premature failure happens when bearings fail at low hours for causes beyond normal material fatigue If you identify any signs of possible bearing failure such as excessive noise and vibration excessive heat lubricant loss or shaft resistance to turning refer to the troubleshooting chart on the following page This chart may help you determine the indicators causes and proper repair options If the recommended maintenance options do not correct the problem disassemble the bearing and try to recognise the cause again Keep in mind de
47. system Brushless design for harsh environments Barloworld 22 Equipment d CAT CATERPILLAR their respective logos trade dress as well as corporate and product f Caterpillar and may not be used without KEEP IT REAL KEEP IT For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com Barloworld i Equipment AT 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission UM DIESE eye FUIS E ee LF ipe ciem 1 f CT RES E IM uc 3 box 1 E A Y 1 T 4 1 1 t nS 4222 9 TEL H FAL P ah T s ic m 5 H 1 i K F L E p F 3 4 E E 1 Tz d T i i A T amp ij j r m m n E Li t 7 n T a j 4 i i E i a 8 2 ul T i r k Ys TE ML L gt 7 1 H j Fg au g ron ROME i l C eee E _ 7 Bii wow Follow us on Facebook Barloworld Equipment Southern Africa Follow
48. the machine reducing waste element can be incinerated after use And because the correct filter is used change after change your machine continues to operate at its designed levels of performance FILTER STRUCTURE THE ESSENTIAL INGREDIENTS Prefill deterrent top end cap prevents dirty fuel from entering the clean side of the fuel system even during prefill Integrated seals A number of integrated filter seals maintain a tight separation between the clean and dirty sides of the fuel system Non metallic centre tube Centre tubes are made out of fibreglass reinforced nylon that is 30 stronger than typical metal tubes to help prevent collapse during pressure spikes and cold starts Non metallic centre tubes also eliminate a common source of metal contamination e d i m Advanced filter media A layer of cellulose synthetic media is combined vo 9 with a second layer of melt blown polypropylene media to increase dirt holding capacity and take filtration efficiency of the secondary filter to the sub four micron level Spiral roving fibreglass spiral roving is used to prevent the pleats from flexing This keeps contaminants locked in the filter Acrylic beads Pleat spacing is rigidly maintained by acrylic beads that prevent bunching and provide maximum filtration surface area throughout the life o
49. the necessary wear material for long life abrasive conditions It features e Redesigned links pins and bushings for enhanced strength durability and retention e 20 additional rail wear material for extended system life Results may vary material has been added to the links for increased wear life Combined structural and wear life enhancements result in lower owning and operating costs through e Enhanced track joint retention and sealability e Stronger components e that resist cracking and e breakage e e Extended system wear e life Innovative design Heavy Duty Track is more than an enhancement of conventional Sealed and Lubricated Track It is a completely new design engineered to match the requirements of medium size H Series machines It features redesigned links pins and bushings that significantly offset the effects of high impact loads and stresses Additionally 2096 more wear Structural enhancements Expect longer life In most underfoot conditions you can expect Heavy Duty Track to extend undercarriage system life an average 20 The greatest benefits are realised in aggressive high impact applications such as Logging reforestation Side sloping work Rocky conditions Any uneven terrain with wide track shoes specifically LGP machines Wider pin boss Wider bushing strap Longer track pin and bushing More rail wear material
50. to high temperatures Easy installation FKM ORFS and STORS seals are coated with a light blue coloured polytetrafluoroethylene PTFE dry lubricant which makes seal installation easier It reduces seal twisting and helps prevent cutting during installation NBR seals can experience hardening and a subsequent loss of sealing capability with prolonged exposure to excessive operating temperatures above 100 C near mufflers aftercoolers and turbochargers Cat Hydraulic Pump and Motor Service Here are just a few reasons why you can trust us to provide the best value in pump and motor service Control costs and maximise uptime Trained technicians Caterpillar Parts Reuse Guidelines Comprehensive repair options Commitment to contamination control Performance testing Nobody knows Cat hydraulics like our trained technicians They have the parts tooling and expertise to diagnose and resolve problems quickly and accurately Caterpillar provides us with comprehensive Parts Reuse Guidelines developed from decades of Cat dealer repair data Because we don t replace parts unnecessarily you contain repair costs and realise the full value from your Cat equipment investment We offer the industry s most comprehensive repair options More choices means you won t pay for or wait for repairs you don t really need Off the shelf Cat Reman products section kits and precision lapping are just a few of the options we offer to
51. us on Twitter Barloworldequip 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission C WE el LL T 68 69 1 72 73 74 9 76 78 79 o0 ol 92 94 85 Contents Fuel Contamination Control An Introduction Bulk Fuel Filtration Cat Fuel Water Separators and Primetime Priming Pumps Cat Non Pressurised Fast Fill Fuel Kits Fast Fuel Conversion Kits Oil Safe Containers Cat GO Cat DEO Cat DEO Monograde Cat MTO NGEO Advanced 40 Cat FDAO Cat TDTO Cat NGEC Cat ELC PREVENTATIVE MAINTENANCE AND FLUIDS Fuel Management Fuel Contamination Control An Introduction Contamination control is increasingly important for maximising performance and service life in fuel systems Some Cat fuel systems exceed pressures of 30 000 psi in order to deliver more horsepower better fuel economy and fewer emissions This necessitates tolerances smaller than five microns between parts These tolerances and injection pressures make fuel systems more vulnerable to wear and abrasion e Injector nozzles Contaminants move quickly in high pressure systems causing damage eroding orifices and resulting in incomplete atomisation of fuel
52. working en vironment for the operator An optional replacement for the standard filter no equipment modification is needed for installation Dust Reduction Filter Benefits e Higher efficiency for better dust reduction e Direct replacement for standard filter e Fits current filter housing e Easier to clean Dust and Odour Reduction Filter Benefits in addition to the above e High performance activated charcoal ensures a fast rate of absorption e Higher capacity extends life and reduces maintenance costs e Superior particle removal efficiency reduces eye nose and throat irritants e There is no adverse effect on air flow heat or air conditioning performance Please note that dust reduction and odour reduction cabin filters are not intended for filtering hazardous materials Both Cat Dust Reduction and Odour Reduction Air Filters can be cleaned with compressed air to extend life They should not be cleaned if the dust odour reduction capability is diminished if the filter is damaged or has been used for 12 months of longer Machine coverage Integrated tool carriers Track loaders Track type tractors Off highway trucks Pipelayers Soil compactors Wheel loaders Wheel tractors The Cat Dust Reduction Cabin Air Filter can be used anywhere excessive cab dust exists KEEP IT REAL KEEP IT For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipme
53. www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission What are some of the subtle signs that you may have transmission problems Overheating slippage or jerky shifting can signify a problem with a transmission component If this occurs carry out a thorough machine inspection and take an S O S sample What are some of the primary causes of transmission failure and or reduced power output or performance Low oil pressure can cause clutch slippage Check your transmission filter and oil levels in the transmission They may need replacing Incorrect pressure may cause transmission failure or reduced power output or performance Transmissions are designed to run at around 200 lbs of pressure Check all pressures to ensure correct levels Contamination from other failing parts can cause plugged filters Check all parts for contamination Are oil additives usually recommended Cat doesn t recommend any additives they are already in the lubricant What have been the major technological changes to transmission design in recent years and how have these affected the maintenance and upkeep of transmissions As the expectations of life and durability of machines increase Caterpillar engineers have responded by ma
54. 073 0 Joa dap 943 939 D9 D8 983 7 8 250 50 Ib ft 340 70 N m 2220 260 Ib ft 3000 350 D11T D11R D11N Nm Conventional Shoe and Link The number one cause of shoe loosening is improperly tightened shoe hardware Use the following procedure to tighten your track bolts 1 Lubricate the bolt threads and bolt washer faces with 5P3931 Anti seize Compound 2 Install Self Locking Track Nuts with the rounded corners against the link 3 Tighten the bolts to the specified initial torque shown in the chart below 4 Give each bolt an additional 1 3 turn Initial torque draws the parts together tightly An additional 1 3 turn gives the bolt correct stretch for good retention This ensures that the bolt s maximum clamping force is used D7H 067 D6R DEN D6M D6H 527 517 D8T D8R D8N D8L D8T SystemOne 1100 110 Ib ft 1500 150 D117 D11R DTIN Nm Low Sprocket Track Initial Torque for fastening shoes and split master links DAK D4G DAC D3K 361036109 0512039 D5K D5G D5C D5 D4 953 943 941 938 9 6 65 15 Ib ft J0 20 Nm 400 50 Ib ft 540 70 N m Excavator Front Shovel Track Initial Torque for fastening shoes 225 215 213 211 205 5 8 130 30 Ib ft 175 40 Nm 521522 TK TK722 TK741 319 319 320 3200 32 9 650 50 Ib ft 870 70 N m Split Master Link The importance of correctly assembling and torquing
55. 140 Cat GO is a multi grade API GL5 classification gear oil intended for extreme pressure applica tions such as the following Differentials and final drives on Cat wheel tractorscrapers specific articulated trucks wheel excavators and backhoe loaders Cold Planer direct drive transmissions differentials and final drives Drum bearings on vibratory soil compactors Discover the Difference Cat GO is tested and approved by Caterpillar to meet the same high standards as Genuine Cat Parts e Longer gear and bearing life superior thermal stability and oxidation resistance reduce deposits and wear e Extreme pressure performance provides extra protection for improved performance and life in extreme load conditions e Simplified maintenance multi purpose capability reduces number of gear lubricants needed for maintenance e Wide temperature range provides excellent stability at high temperatures and superior performance at low temperatures for easier start ups TYPICAL CHARACTERISTICS The values shown are typical values and should not be used as quality control parameters to either accept or reject product Specifications are subject to change without notice KEEP IT REAL KEEP IT CAT Barloworld Equipment PREVENTATIVE MAINTENANCE A AND DROS Oils Cat DEO Diesel engine oil for world wide application except North America SAE 15W 40 SAE
56. 2 48 or visit www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Barloworld At Equipment Cat Air Filter Service Indicator Getting the longest life from your air filters Equipment filters working in low dust conditions last longer Since it is not possible to visually determine when a filter reaches capacity changing air filters too soon can result in unnecessary labour and filter costs Conversely in highly contaminated air you may need to change filters ear lier than scheduled to ensure full airflow and engine power You ll know exactly when to change your air filters when you use the Cat Air Filter Service Indicator In applications where there is a high percentage of fine dust particles or high amounts of exhaust soot Cat UHE Arr Filters will improve early filtration and provide longer engine life Accurate and easy to read e Reduced engine wear Particles collect on the filter s surface layer of very fine fibres quickly building a cake that It is impossible to visually allows less dust to reach the engine determine when a filter has e Higher efficiency filters are at peak efficiency when reached capacity Instead brand new T
57. 22 48 owist www barloworld equipment cm 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Barloworld Y Equipment DAT 4 5 Side Cutters For Series Buckets For Cat 320 to Cat 390D L hydraulic excavators Caterpillar s new side cutters feature an innovative design that offers a sharper profile helping the bucket cut through tough material with less resistance whilst staying sharper for longer Additionally the new side cutter profile increases heaping which can help the bucket load more material These improvements in penetration and heaping promote a significant Increase in productivity in nearly all digging and loading applications It is estimated that bucket performance may increase up to 496 with the use of the new side cutters As with all Cat GET side cutter components are warranted against breakage for the normal wear life of the product However Caterpillar will not provide warranty coverage under the breakage terms of the warranty statement if the wear plates are worn beyond the wear indicators on the wear plate KEEP IT REAL KEEP IT You have to push every day To meet tomorrow s deadline To secure the next contract To stay ahead
58. 7 87in 200mm 275 5444 0 70 in thick 8 15 12 2 1 77 18mm 207 mm x 310 mm x 45 mm 5 35 2 43 kg 18 3 Ib 8 4 kg Not recommended for convex radii smaller than those specified in this chart ES m WE gi For more information i f Follow us on Twitter p Barloworldequip p g IE 7 5H LTD dae Sl era gr cris Cleese CATE HaT te D HUMBLE LIEU eel opii tacui nip cal f a ur muy oct ba uad AB nur EH Uy lic m aded mni a Times oj B Ampat ONE Chk Of iis Shes Lh a mim T Lire ER gt LIS goba h Bio E 13 ji iB GET WEAR PLATES Heavy Duty Wear Plates Quarrying and Industrial Buckets Abrasion Resistant Material Benefits For tough applications Caterpillar s top mounted wear plates with ARM Abrasion Resistant Material provide added durability for straight spade rock and HD heavy duty quarry buckets These plates are used with bolt on half arrow segments Wheel Loader Models e Cat 988 HD Quarry Bucket e Cat 990 992C 992D and 992G HD Quarry Straight and Spade Rock Buckets ARM plates protect the bevel and top part of the base edge between the adapters wh
59. 71D 775E Wheel Dozer 844 844H 854G 814F Wheel Loader 980H 988G 988H 990 Series Il 990H 992G 994F 994D Barloworld i Equipment CAT Fuel Management Fast Fuel Conversion Kits Flange mounted receivers reduce fuel leaks and contamination It s now faster and easier to change fast fuel receivers That s because Caterpillar offers kits to convert Cat or Wiggins fast fuel threaded receivers to flange mounted units 5o now many old or new Cat machines equipped with fast fuel systems can benefit from greatly simplified field changes and a reduced risk of fuel leaks e Less thread damage because threaded receivers can be installed and removed several times a year the tank port threads can become worn or damaged his results in both fuel leaks and fuel contamination With flange mounted fast fuel receivers worn receivers can be changed without replacing the reusable steel adapter and without damaging the tank port threads e No special tools a common Allen wrench easily removes and installs four bolts to change flange mounted fast fuel receivers e Two conversion kits one conversion kit is available for threaded receivers on Cat fast fuel systems and another kit is designed for threaded receivers on Wiggins fast fuel systems Installation just got easier e Easy access 10 mm Allen wrench removes the four bolts holding the two split flanges so removal and installation can be performed with l
60. CARRIAGE Hardware Requirements Track Roller and Idler Caps Inadequate clamping of the track roller and idler caps can result in broken retaining bolts and damage to the frame or bogie bore To install roller and idler hardware 1 Lubricate the bolt threads with 5P3931 Anti seize Compound 2 Align the shaft and cap dowel holes to ensure proper Sprocket Segment bearing lubrication and shaft movement 3 Completely tighten the bolt bolts on the side having metal principal cause of segment loosening and subsequent contact loss and or damage to other parts is incorrect segment 4 Completely tighten the bolt on the side that has a gap hardware installation 5 Tighten the bolts to the specified torque shown in the charts below To install segment hardware Elevated Sprocket Roller Hardware Torque Requirements 1 Lubricate the bolt threads and the washer face of the nut with 5P3931 Anti seize Compound 2 Tighten all nuts on any one segment to the specified initial D4H 943 with caps 9 8 torque shown in the chart This draws the mating parts together tightly 3 Tighten each nut an additional 1 3 turn This stretches the bolt properly for good retention Elevated Sprocket Sprocket Segment Hardware Initial Torque D6T D6R D6N D6M 5 87 130 30 Ib ft 175 40 Nm D5N DSMD5H D4H 1650 150 Ib ft 2200 200 DAK D3K D4G DAC 36309657935 D6K D5K D6 056 D5C
61. E TROUBLESHOOTING CHART Excessive Noise and Vibration Insufficient lubrication Excessive Heat Lubricant Loss Shaft Resistant to Turning Leakage between bearings caps and housing Fill with correct amount of proper lubricant Determine what is misaligned housing shaft or bores Shaft may be bent or housing bores not aligned Replace shaft or housing Chrome plate or metalise shaft or bore and regrind to specification replace bearing if seating surfaces are worn Determine what is misaligned housing shaft or bores Shaft may be bent housing bores not aligned Replace shaft or housing Use less lubricant or use a lower viscosity lubricant Be sure to use recommended lubricant Either inner or outer race is sliding around its seated surface Use proper sized components Grease to proper level Replace seal Check shaft for scratches or burrs that may have damaged Seal If new installation remove bearing and clean mating Surfaces Reinstall bearing if not damaged Replace gasket You should always work with clean recommended approved tools Do not use a wooden mallet Also work in clean surroundings such as on a metal or a metal covered bench Always handle the bearings with clean dry hands or even clean canvas gloves Never hold a bearing with dirty or moist hands as contamination can easily be transmitted to the bearing W
62. EASY TO INSTALL PUMP Protect your fuel system and Electric priming pump works with the flip of a switch extend the life of priming in two to six minutes unit fuel injectors un dissolved water Resilient mounting extends pump life and absorbs ne some of the shock load quantities greater 0 Primary fuel filter removes more than 98 of debris 10 than 1 can cause microns and larger major damage Water separator removes virtually all free water and 87 of dissolved water from diesel fuel Reusable water collection bowl has capacity of 90ml is transparent for easy monitoring and drains in less than one minute 9 PREVENTATIVE MAINTENANCE AND DUDE GS Fuel Management Cat Non Pressurised Fast Fill Fuel Kits Faster safer more accurate filling Now there are non pressurised fast fill fuel kits available for Cat and non Cat equipment These easy to install kits do not depend on a traditional pressure sensing nozzle to shut off fuel flow but instead rely on a valve to control fuel shut off Cat Non Pressurised Fast Fill Fuel Kits can be used to retrofit existing pressurised fast fill systems or added to machines without fast fill provisions Better technology for better results Environmentally Friendly e Prevents over underfilling of tank does not rely on the automatic nozzle for shut off e Provides tank fill with greater accuracy e Improves contamination control through a closed loop system
63. EEE a 7V4188 9V6574 7V0909 Bolt plate Thickness 1 7 8 48 mm 1 7 8 48 mm 1 7 8 48 mm 1 7 8 48 mm Cat J800 Retrofit A hammerless tip option for Cat 994 wheel loaders and 385 hydraulic excavators Incorporating Caterpillar s groundbreaking Cap sure retention design the Cat J800 Retrofit system greatly simplifies the replacement of bucket tips As an alternative to conventional pin driven GET retention options Caterpillar s Capsure innovation makes a major difference when it comes to faster serviceability and safer tool changeover times on specified Cat models A retrofit pin and washer inserted in the J800 adapter mates with the hammerless tip design without introducing the need for special tools The tip and retainer are one integral system All maintenance crews need is a 180 degree anti or clockwise turn with a 19 mm 34 inch ratchet to either loosen or secure the Capsure locking system when replacing GET tips A positive stop is cast into the tip and protector to prevent overrotation The tip locks and unlocks using approximately 136 Nm of torque The locking system placement is on the side of the tip reducing exposure to wear which results in easier change outs CapSure correct incorrect locking sequence TIP STYLES Heavy Duty Penetration highly abrasive _ materials i Easy to penetrate Heavy Duty Abrasion highly abrasive materials Long _ General
64. Elliptical ports won t collapse under heavy loads reducing stress points for longer wear life Greater machine stability when carrying maximum loads Deep tread delivers long wear life and excellent traction on any surface Tread pattern handles tough terrain and allows easy smooth transitions from unimproved to improved surfaces Highest quality rubber compound manufactured to Caterpillar specifications means durability for longer wear life and a consistent product Puncture proof design puts an end to fixing flats One piece tyre and rim design reduces tyre servicing costs Off the Road OTR The OTR design has a block pattern that provides a degree of traction in applications where debris is not an issue Smooth Tread The Flexport smooth tread design is ideal for special applications where debris Is an issue like scrap yards recycling centres and some waste transfer stations Cat Flexport tyres are available on new machines and from Barloworld Equipment as service parts Contact your Barloworld Equipment customer service representative for advice on Flexport tyre sizes to suit your machine and working application Flexport tyres for skid steers and compact wheel loaders Cat Flexport tyres for skid steer loaders are a 1 piece tyre rim design and are available in directional construction smooth and OTR tread patterns For most applications the machine width can be customised by altering th
65. GE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Barloworld AT Equipment PREVENTATIVE MAINTENANCE AND FLUIDS Oils Cat DEO Monograde Monograde Diesel Engine Oil for Cat 3600 Series Diesel Engines SAE 30 SAE 40 Recommended Use e Cat DEO Monograde is the only oil approved by Caterpillar for use in 3600 series diesel engines operating on distillate diesel fuels e Cat DEO Monograde is recommended for older Cat engines equipped with pre combustion fuel injection systems that permit the use of American Petroleum Institute CD or CF oll e Cat DEO Monograde can be used with low sulphur diesel fuel and protects Cat engines operating on higher sulphur diesel fuels 3600 series engines operating on fuel containing up to 1 3096 sulphur and pre combustion engines operating on fuel containing up to 0 06596 sulphur fuel Discover the Difference Cat DEO Monograde is developed tested and approved by Caterpillar to meet the same high standards as Genuine Cat Parts e Used as standard factory fill for Cat 3600 series diesel engines e Increased engine life Resists oxidation and prevents build up of deposits on pistons and rings e Longer intervals Extends oil drain intervals while providing excellent engine protection and performance SAE Viscosity Grade The values shown are typical values and should not be us
66. Management Bulk Fuel Filtration Strategies Understanding the importance of coalescence During laboratory analysis of a diesel engine injector valve seat the results of poor fuel manage ment practices are clearly discernable under microscopic conditions Here the evidence of inad equate contamination control procedures is exposed in the form of moderate to severe scouring damage caused by water and debris ingress Left unchecked this invisible threat will steadily erode individual machine and overall fleet performance increasing downtime and pushing up owning and operating costs Some Cat fuel systems for example exceed pressures of 30 000 psi in order to deliver more horsepower better fuel economy and fewer emissions which necessitates tolerances smaller than five microns between parts Where contamination is present these tolerances and injection pressures make fuel systems more vulnerable to wear and abrasion However this potentially underlying problem can be countered efficiently by installing a bulk filtration system that forms part of a strict contamination control programme since clean dry fuel is essential in order to achieve long injector life As part of its solutions offering Caterpillar supplies bulk fuel filtration plants in various litre flow rate configurations that are designed to help maintain fuel to 18 16 13 per ISO 4406 or below 4 micron These bulk filtration units are positioned along the supply p
67. Oil exposed to air immediately becomes contaminated Poorly stored fluids will become contaminated and will lead to accelerated component wear like e Shortened component and fluid life e Catastrophic failures and costly downtimes and repairs and e Reduced productivity System efficiency can drop 20 before the operator detects a problem That s a loss of one day per week Features and Benefits Available in 5 sizes 1 5L 2L 3L 5L and 10L Interchangeable lids and drums Sold separately or in a kit Vent control with button in handle Quick twist spout Is easy to open and close it controls flow rate and keeps dirt out Semi transparent cylinder with graduated markings makes liquid levels easy to see Durability tested Withstands extreme temperatures ranging from 40 F io 176 IF Flash Point at 340 C gt Manufactured from High Density Polyethylene HDPE incorporating anti static agents and ultraviolet UV Stabilisers For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Oils Cat GO Gear oil for Cat manual transmissions differentials and final drives SAE 80W 90 SAE 85W
68. This cast end bit offers more wear material easier installation and decreased change out times as It is shipped ready to install The new D11 cast end bit is recommended for low to Cutting Edge Supports An Integral System moderate impact and low to high abrasive applications When Component installing the new EEWL cast end bits it is recommended that EWL or EEWL cutting edges be installed to ensure a balanced system life The cutting edge support is an integral part of the blade structure to which the cutting edges and end bits are bolted Tie EEUULend bik fas 232 Together they ensure guaranteed dimensional accuracy versus the EWL Extended Wear Life end bit with 1479 lbs These cutting edge support plates are available for factory The mounting surface of bulldozer blades on D6R through D11R track type tractors the end bit which attaches to the blade support has been machined for optimum flatness The mounting surface should be flat to ensure that maximum clamping force can be obtained which allows better bolt retention Having good bolt retention keeps the end bit tight against the blade support greatly reducing the chances of end bit cracking and or breakage The cutting edge support consists of a one piece element for Straight Angle and Carrydozer blades The Universal and Semi U blades use a three piece cutting edge support system that consists of one support in the cen
69. Tyres with elliptical shaped ports e Flexport s elliptical ports are designed not to crush when compressed by heavy weight e Because the ports don t crush this reduces stress points and increases wear life gt SS 2 NN AAW Flexport Warranty Cat tyres have a separate warranty statement covering defects in material and workmanship For more information on Flexport tyres contact your Barloworld Equipment customer service representative Transfer Station Comfortable stable and durable Cat LED Work Lights Light Emitting Diode LED technology eliminates lights maintenance When youre working against the clock or at night it can be costly to shut down a machine to change a light bulb Thats why more more machine owners are upgrading their equipment to Cat LED Work Lights Unlike halogen lights Cat LED Work Lights do not have a filament that will burn out so there are no bulbs to replace or unexpected downtime These lights also have a greatly extended life more than 50 000 hours and deliver bright illumination that improves operator safety and performance ouitable for a wide range of light and heavy duty equipment applications Cat LED Work Lights feature a common two pin connector that permits easy change outs of most same sized halogen lights on Cat and other brands of equipment CONSIDERTHE ADVANTAGES Power Consumption Q 0 6 amps 28 Volts i LED lights
70. acturers machines that recommend 4 or TO 4M or specification oils for their transmissions final It is only through these tests and thousands of hours of field drives and wet brake compartments Please refer to the experience that Caterpillar is confident in saying Cat TDTO will Typical Characteristics table deliver long life and excellent performance when used in Cat transmissions and final drives Discover the Difference Cat TDTO is developed tested and approved by Caterpillar to meet the same high standards as Genuine Cat Parts e Used as standard factory fill for Cat machine compartments where TO 4 oils are specified Longer Clutch Life Prolongs clutch disc life up to 45 Optimum Wear Life Ensures long life and excellent performance for gears bearings and friction disc material e System Matched Formula Engineered as an integral part of Cat power shift transmissions most wet brake compartments and hydrostatic systems SAE Viscosity Grade The values shown are typical values and should not be used as quality control parameters to either accept or reject product Specifications are subject to change without notice Follow us on Facebook Barloworld Equipment Southern Africa Follow us on Twitter Barloworldequip 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and pro
71. al is to help keep your undercarriage operating cost per hour or per km as low as possible That s why we developed Custom Track Service CTS Our parts and service representatives Dozing and push loading usually shift the machine weight e Have the best training and tools to manage your toward the front causing faster wear rates on the front rollers undercarriage system and idlers e Regularly inspect and measure wear on your undercarriage Ripping and drawbar shift the weight toward the back e Prepare reports with maintenance and repair alternatives increasing wear on the rear rollers idlers and sprockets SO you can make informed decisions to reach the lowest possible cost perhour or per km of operation Loading as with a carry dozer shifts the weight from the rear to the front of the machine as it changes from digging to While there is no substitute for Custom Track Service you carrying Wear will occur more on the front and rear rollers also play an important role in maintaining undercarriage life than the centre ones The following pages describe conditions and situations that affect undercarriage and highlight ways you can help slow or Excavating shifts the weight to the side where the digging is reduce wear being done Spreading dumped material tends to create more wear on the undercarriage side where the operator hits the Factors Affecting Wear a due to the material entering the undercarriage from the Appli
72. ants can enter during operation through pitted shafts broken breathers worn seals and other trouble spots Fortunately there are steps you can take to prevent fluid contamination An effective contamination control programme is made up of many small steps that help maintain fluid cleanliness and reduce opportunities for contaminants to get in machine systems Caterpillar recommends a four part contamination control programme consisting of 1 Clean fluids 2 Clean components 3 Clean facilities 4 Clean shop repair processes By following these steps you will be better prepared to control contamination reduce overall operating costs and keep your Cat equipment performing at its best Filters Control contamination inside your final drive system through the use of Cat fluid filters By changing filters regularly and properly and by selecting the right filters you maintain system cleanliness reduce component wear and lower costs The final drive is where the highest torque increase occurs Change filters regularly In order to keep your drive train system running clean and at peak performance it is important to change the filters regularly This reduces the chance of contamination which causes component wear and system failure We recommend changing fluid filters at least every 500 hours This change interval will vary with application environment and type of filter being used Change filters properly It is im
73. at had a two point restraint new riser must be installed with the new Cat Comfort Seat with three point restraint Order 153 4001 _in addition to the specified Seat If the original machine seat had a two point restraint a new riser must be installed With the new Cat Comfort Seat with three point restraint Order 144 4184 _in addition to the specified Seat 2529713 If the original machine seat had a two point restraint new riser must be installed with the new Cat Comfort Seat with three point restraint Order 144 4184 in addition to the specified Seat 244 2803 Retrofit Cabs for Large Off Highway Trucks A lot more cab in a lot less time How do you keep large off highway trucks in operation while at the same time upgrading their capabilities The Cat Retrofit Cab is a rebuild or replacement option that can help do both by pro viding upgrades and cutting installation time Rebuild time for an outdated cab is normally meas ured in weeks but Cat Retrofit Cabs can be installed in less than a day The fully assembled cabs are available for Cat 785 789 and 793 B and C Series off highway trucks with an exterior paint scheme and markings similar to current production cabs Each Cat Retrofit Cab includes e All new components including Electronic Control Modules ROPS and cab mounting hardware e New updated wiring harnesses e New Vital Information
74. at Friction Material The type of friction material your equipment requires is based on machine size and application Heavy load applications like mining for example require friction material with different functional properties than cycling applications like construction Caterpillar engineers match the characteristics of friction Built to perform in Cat machines material to the function it performs the equipment in which it operates and the fluids and other components used in that Components made with Cat friction material allow proper fluid system flow and heat dissipation resulting in longer life and lower maintenance costs than other brands That s why it s critical to Total system design helps ensure safe performance balanced select Cat components when it s time to choose replacement component life and maximum parts reusability brake transmission and steering parts Only Cat friction material is proven to deliver long reliable performance in Cat machines Caterpillar provides reusability guidelines so you know what is required for servicing another way we help you manage your owning and operating costs Separator Plate Extended Life Elastomeric Paper Bronze FRICTION MATERIAL USES Bronze Elastomeric Extended Life Wheel loaders Separator Plate All machines All applications Using genuine Cat friction material ensures your parts are designed for the best performance safety and reliability Built
75. bolts and nuts are greater than the standard specifications However after a short period of operation the mating surfaces will seat more uniformly and the bolt torque will reduce to approximately standard values During dozing avoid excessive speed Slow steady prying force is more desirable than high speed impact when a boulder or other tough obstacle is encountered Speed also accelerates track wear and imposes potentially damaging loads on dozer frames drive train and hydraulics You have to push every day To meet tomorrow s deadline To secure the next contract To stay ahead of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILT IN For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission WHEREVER YOU ARE WE ARE THERE KEEP IT REAL KEEP IT CAT Barloworld AL Equipment DAT GET BUCKETS Bucket Corner Protectors Even the toughest buckets undergo severe punishment normal applications That s why it
76. broken or welded e Fully assembled and complete e No non operational damage mishandling excessive rust corrosion or pitting e Acceptable part number Cat part Core refund criteria vary by component and are subject to change Partial core refunds are available for some Cat Reman components Contact you Barloworld Equipment customer service representative for more information Warranties protect your investment Cat Reman Engines We have various warranties depending on the sales model and application Cat Reman engine components Cat backs Reman engine components with a same as new warranty honoured worldwide Good for the environment Generous core acceptance reduces cost reduces waste keeping non renewable resources in circulation for multiple lifetimes Cat Starters and Alternators Built to meet your engine s demands New and remanufactured Cat starters and alternators are built to work together meeting the demands of your engine and operating environment A large amp alternator for a Cat 140K motor grader Starters Cat starters are designed specifically to handle the high current experienced during the cranking of Cat engines They are built to work hard and deliver reliable performance even in tough dirty environments Caterpillar starters with the PRELUB system Cat starters with the PRELUB system help to prevent the wear caused by dry starts This innovative starter combines an oi
77. c drive Iransmissions rely on the engagement of gear groups to provide the transfer of power to your machine components Caterpillar designs all parts including these gear groups to fall under three levels of wear By understanding that different components are intended to wear faster than others you can inspect for signs of wear and keep your transmission running smoother for longer For example gears and shafts if properly maintained are designed to last through multiple transmission rebuilds But components such as friction material seals gaskets and bearings are faster wearing To increase productivity and prevent downtime it s vital to make sure that all drive train components are constantly monitored Look at their condition to ensure contamination Isn t entering their systems and to check that correct operating techniques are being used This section focuses on how to identify problem indicators and how to maximise the performance and life of your transmission Scheduled Oil Sampling is a crucial part of machine management Oil sampling at scheduled intervals validates your maintenance procedures tracks what is going on inside the equipment and forecasts wearrelated problems The Caterpillar S O S Oil Analysis programme is well recognised for its ability to detect potential failures before they occur Each S O S Services test is designed to reveal specific information about the condition of Cat products The follow
78. cannot be overemphasised Follow these steps for both new and used split master links 1 Before installing the track the point of connection for the master link must be clean and undamaged Remove all paint from points of connection 2 Use 4C5593 Lubricant or 5P3931 Antiseize Compound on master bolt threads 3 Put master links together and check alignment of holes for master bolts Install one master bolt in each link The bolts must turn easily by hand in the threads 4 Remove the bolts Install the master track shoe and all four master bolts Turn the master bolts by hand 5 Tighten the master bolts to the specified initial torque shown in the chart 6 Give each bolt an additional 1 2 turn Give a 1 3 turn for D6T D6R D6H D7H SandL DSL DSI DSR DSN DOL D9T D9R D9N D10T D10R DION 589 578 245 235 GROUND ENGAGINC Contents 24 Understanding Bucket Wear 2 6 BLADES Dozers Carry Dozer Edge Systems for the Cat D11 Extreme Extended Wear Cast End Bits for Dozers 3 BUCKETS Wheel loaders Corner Protectors Cutting Edges Bolt On for Cat 966 to 972 CGS Buckets Hammerless Tip Protection J800 Retrofit for Cat 9945 High Abrasion Buckets for the Cat 990 Half Arrow Segments and Top VVear Plates Side Cutters K Series Buckets Wear Plates for Wheel Loaders 3 6 Mechanically Attached Wear Plates VVear Plates for Total Protection A 1 Motor Graders ML 4 3 Cat Mo
79. carbon edges will not withstand the impact of a DH 2 edge and care should be taken to choose an application with very low impact Caterpillar utility edges are heat treated DH 2 edges that offer an economical option for Cat 24H 24m motor graders These edges are intended for use in highly abrasive applications where high impact and breakage are not an Issue Cat Moldboard Components Cat moldboard end bits overlays repair plates and hardware help you protect maintain and repair moldboards and working edges for longer life and lower total costs Overlay End Bits Overlay end bits are recommended for applications such as ditching that cause severe wear on the cutting edge and moldboard corners They add strength and limit corner wear which extends cutting edge life when an edge would otherwise be thrown away due to excessive wear at the corners When worn on one side overlay end bits can be rotated for a second wear life Moldboard End Bits Cat moldboard end bits are recommended for all applications Made of through hardened DH 2 steel for added strength and service life they protect moldboard edges from wear Moldboard Repair Plates Most moldboard damage can be avoided through routine monitoring of cutting edge wear and timely edge replacement But when unexpected damage occurs repair plates provide a cost effective way to extend moldboard life Excessive down pressure can dramatically shorten edge life Hard
80. cation Packing During operation materials can stick to and pack between mating components such as rollers links sorocket teeth and bushings Packing prevents parts from engaging correctly This can cause higher loads and increased wear rates Packing is inevitable in many applications However there are things you can do to reduce the effects of packing The type of job the machine is doing and the type of materials it is working in can affect the rate of wear on different components The following situations all assume level terrain e Use centre punched shoes in certain situations to help relieve extrudable materials such as wet sand clay or Snow e Clean out your undercarriage as often as possible Garbage twigs stones and demolition debris cannot be extruded through the centre punched shoes e Use roller guards only when necessary because they may trap debris and increase the effects of packing They are designed primarily for use in high impact underfoot conditions Terrain Most of the time you can t control the terrain you are working in However it is important to understand how contours and slopes affect undercarriage wear Working uphill shifts the weight and load balance to the rear causing higher wear on rear rollers and increasing forward drive side sprocket and bushing wear Working downhill shifts weight and load balance forward causing a relatively higher wear rate on front track rollers and idlers W
81. chine s Li a 1 ir A E i J 4 4 we D UIT TI l h S3IH0SS322V ANY SdV The Cat Operator Environment Employing the best operators starts with keeping them happy You can have the most productive machines on earth but it doesn t count for much unless you have people who know how to get the most out of them That is why Caterpillar makes operator satisfaction a top priority designing cabs with improved visibility and heating cooling as well as decreasing noise vibration and fatigue with state of the art ergonomic designs It all adds up to operator environment that s safer and more comfortable helping make your operators workday easier and more productive Choose from a wide range of options Air Conditioning e Retrofit kits are easy to install e These systems are designed to provide maximum cooling efficiency in the most rugged operating conditions e And they are engineered to fit like a factory installed system TEL Cabs e Two types of replacement cabs are available original equipment and retrofit upgrades e Original equipment cabs look and perform like new e Upgraded retrofit cabs are designed to include the latest engineering productivity and comfort updates Lights e High Intensity Discharge lights provide twice the light and las
82. chine overloading or long hours of use Contaminated lube oil which causes accelerated surface pitting and premature failure Causes of premature gear failure There are five primary causes of premature gear failure Pitting from surface normal end of life failure mode however consistent overloading accelerates this scenario Contaminated lube oil causes accelerated surface pitting and cracking Gear tooth bending fatigue the result of severe gear overloading Improper alignment creates unbalanced loading and contact on gears Improper lube oil which increases surface wear 00909000090909000090900000900000090900009090000000909000090000000000090909000900000000000900900009009000009000000009000000000000909000090900099 Bearings and gears How they work Bearings are used in the differentials to maintain position and alignment of gears and shafts and to minimise friction heat and wear They also carry the weight of the vehicle and payload subjecting them to very high loads and temperatures Cat bearings have precision surfaces that are separated by a film of lube oil It is critical that the surface of the contact areas retains an adequate oil film thickness to prevent metal to metal contact with the mating part Loads are transferred through gears by gear teeth pushing against each other Gears used in the differentials are put through a carburising and hardening process This creates a durable outside surface e
83. cial engines Extender is only necessary once during the life of the coolant Ensures Cat ELC performance to 1 000 000 km or 12 000 hours Cat ELC Extender and Flush Intervals Cat ELC Extender should be added after 6 000 hours or 500 000 km of operation and the system should be drained and flushed with clean water after 12 000 hours or 1 000 000 km No cleaning agents are needed If SeOeS Services are used regularly safe operation with Cat ELC may extend beyond 12 000 hours epu eic Contents 9 9 Air Filters Cat UHE Air Filters Cat Air Filter Service Indicator 9 0 Engine Oil Filters 9 2 Fuel Filters 5 Radial Seal Air Filters 6 Transmission Filters Turbine Precleaners Cat UHE Air Filters Early filtration efficiency provides longer engine life Cat UHE Ultra High Efficiency air filters feature a unique surface that extends filter life up to six times that of standard filters and benefits engine life Caterpillar engineers its UHE air filters to provide best protection for your engine components So called dirty filters can be more efficient than new ones because dust cake build up on the surface actually increases filtration Designed with this concept in mind UHE air filters feature a unique media This media has a very fine synthetic surface layer that covers the entire outside diameter of the filter Here s how it works e Fine particles dust heavy carbon coal du
84. ct loading e Precise fit with grooves ensures proper oil control and sealing between the crankcase and combustion chamber for efficient operation long wear life and reduced blow by Chrome Ceramic Ring e Coating of several layers of hard chromium for higher scuffing resistance e Anetwork of tiny micro cracks on each layer for better thermal fatigue properties e Ceramic particles embedded into each layer of chrome Improve consistency properties over the entire coating depth e Normal chromium wear exposes new ceramic particles resulting in less surface cracking ring flaking reduced wear of both ring and cylinder bore significant life improvement and better spalling resistance Fractured Rod e Perfectly matched joint surfaces allow rods to accept higher loads e Fractured uneven surface helps locate the rod end and cap eliminating the need for a locating dowel e Automatic bolt insertion and fastening equipment ensures the cap and rod stay together eliminating the possibility of a mismatched cap and rod during material handling REMAN CYLINDER PACKS Remanufacturing transforms used Cat components to new parts standards When you need repairs Cat Reman Cylinder Packs will get you back to work quickly reliably and affordably Completely remanufactured to include all critical engineering updates and design improvements Cat Reman Cylinder Packs provide same as new performance and long life Strict remanufacturing pr
85. cutting inner races or shrinking outer races with weld bead if possible Using these practices can result in uncontrolled heat that can damage housings or shafts When the removal process is complete bearings should always be cleaned before inspection Follow Cat s recommended guidelines to ensure the bearings are not damaged Only use petroleum solvents that are suggested for washing It is important to remember that most solvents are flammable and toxic when inhaled or absorbed into the skin Handle with caution BEARING MAINTENANCE To prevent contamination clean bearings in a container that is large enough for the bearings to be splashed around without contacting the bottom where the dirt settles Allow the bearings to soak for an extended period of time to loosen grease and dirt possibly several hours or overnight Use a short bristled brush that will not lose or break off its bristles After visually inspecting the bearing to see that all dirt has been removed rinse the bearing in a container of clean solvent next dip the bearing in oll When drying the bearing notice you should not use compressed air to spin it dry This can cause a non lubricated bearing surface to be damaged To dry the bearing hold both inner and outer races together to avoid spinning and blow air through the bearing After the bearing has gone through the cleaning process examine it thoroughly for cracks in the race dented seals and damaged or bro
86. d keeping functions Maximise the life of your final drives For any machine to be safe reliable and productive regular preventive maintenance is vital It is the most cost effective way to keep your final drives operating at peak performance If you take care of your final drives then gears and shafts can last through multiple rebuilds and the overall final drive life increases Take a proactive approach by planning for scheduled downtime maintenance and repair costs When you plan you save money and time and who couldn t use more of each 23 Barloworld Equipment CAT DRIVE TRAIN Transmission Maintenance A Management Guide The transmission Is a critical part of a machine s power train Its function is to take the output from the engine and manipulate it to control speed direction and torque Following a planned maintenance programme and Caterpillars recommended maintenance guidelines can help en sure longer life for your transmission and reduce machine downtime Because of the wide variety of work they do Caterpillar products use several transmission types including planetary powershift countershaft powershift direct drive and hydrostatic Each is designed to convert engine power into the exact combination of speed direction and torque required for the particular application Transmissions do this by various means such as hydraulic clutches or a hydrostatic hydrauli
87. d makes it possible to change the filter without using tools Reliable emissions reduction performance Cat engines are equipped with after treatment devices that lower emissions levels Filters are an important part of this emissions treatment process The primary and secondary fuel filters work together to remove nearly all contaminates and water before combustion It is important to use the correct filter for each and every change because using the wrong filter can jeopardise the performance of the emissions reduction system taking your engine out of emissions compliance as a result Fuel systems are sensitive to damage by contaminates carried in diesel fuel To minimise this type of damage Cat UHE fuel filters are designed to maintain a tight separation between the dirty and clean sides of the filter All the fuel is forced through the media where more than 9896 of the particulates four microns in size and larger are captured before entering the clean side CAT SECONDARY FUEL FILTER Next the Secondary Fuel Filter removes more than 9896 of the remaining particles down to four microns in size Testing has shown that the filter remains highly efficient with particles below four microns in size as well Sub ten micron efficiency Reusable housing Integrated seals Easy disposal element Supporting Sustainable Progress Cat Filters help support your sustainability efforts The filter housing was designed for the life of
88. duct identity used herein are trademarks of Caterpillar and may not be used without permission PREVENTATIVE MAINTENANCE AND FLUIDS Cat NGEC M Natural Gas Engine Coolant Premix 50 50 Prevents Freezing While Providing Superior Component Protection Cat NGEC Natural Gas Engine Coolant is a heavy duty cooling system fluid designed to prevent freezing and boiling while providing superior component protection NGEC is approved for use in all Cat natural gas and diesel engines as well as in most diesel gas or natural gas engines made by other manufacturers when following OEM recommendations Benefits Performance Cat NGEC protects the cooling system of your natural gas engine over a temperature range of 37 C to 129 C Additional freeze protection can be gained when the coolant concentration is raised to 60 Cat NGEC contains inhibitors that provide superior protection for metal components especially aluminium against pitting and corrosion The formulation of Cat NGEC minimises the formation of foam Ready To Use Cat NGEC is premixed with de ionised water and embitterment No supplemental coolant additive is needed Cat NGEC Provides Top Component Protection Aluminium can be a very difficult metal to protect from corrosion and cavitation boiling damage Cat NGEC is formulated to provide excellent protection for all metals used in cooling systems In testing ASTM D2809 with aluminium water pumps
89. e 138 0043 138 0007 same 275 5444 108inx787inx2 5in 275 mm x 200 mm x 75 mm 41 21b 18 7 kg 50 Series 994 5230 other 138 0050 138 0052 21380007 4725in 1200 mm 275 5444 similar sizes 1 14 in thick 29 mm 11 81inx9 8inx295 in 2 minimum 13 41b 6 08 kg 300 mm x 250 mm x 75 mm B525lb 25 08 kg Heavy Duty same same 138 0053 138 0007 same 22 275 5444 1181inx98inx3 93in 300 mm x 250 mm x 100 mm 83 151b 37 75 kg ET EET ET TTT ET ET ET EEE EPEELEEPEPEEPEPEEEEP PET EET EPET EP EEE UTEP ETE UTEPEPEUPETEPET PET EPETEETEPEPEEPETEPEEPETEREEP ETE EET TEP ETED EEE UPEPEPETEEPEPLT EP EEEEPEPTT EP EEELPEPEEEPEEPET EP EP ETP EPEELEEEPUTETEPETEEPETET EET UPEPEE ET EP EEPEPEPET ETP ETETEEEEPEP EP EPELPEPEP ETE EPET EP EEE UTEP EPL TP EPETEPEEPETEPEEEUTEDEPEUPETEPET PET EPEP EE EE PEPE EE ETT ET EEE Skeletal Mechanically Attached Wear Plate System Standard Highway Trucks 138 0020 138 0024 138 0006 275 5444 0 70 in thick 8inx122inx1 38in 18 202 mm x 310 mm x 35 mm 535Ib 243kg 12 9 Ib 5 9 kg Heavy Duty Off Highway Trucks 138 0020 138 0025 138 0006
90. e on start up unburned fuel Increased oll consumption excess blow by Dirty primary secondary air cleaner Operating in too high a gear Over fuelling Overloading Malfunctioning fuel nozzles injectors Malfunctioning turbocharger _ Dirty air cleaner Improper set point Fuel leak Worn turbocharger seals Worn rings liners Worn valve guides Hours on engine Cracked head and or liners _ Leaking head gasket Incorrect starting procedure _ Incorrect fuel injection timing Faulty injector Worn broken rings liners Worn turbocharger seals Worn valve guides Hours on engine Causes Repair Indicators Unusual Noises Lack of power Overheating Malfunctioning fuel nozzles injectors Malfunctioning turbocharger Worn piston pin bushings Worn rod main bearings Too much valve lash Incorrect adjustment of governor linkage Malfunctioning fuel nozzles injectors Slipping torque converter Improper set point Dirty fuel filter Dirty air cleaner Low quality fuel Malfunctioning temperature regulator Incorrect adjustment or worn belts pulleys Incorrect operator technique Plugged radiator core external and internal Low coolant level Dirty air cleaner Cat Engine Repair Indicators continued Malfunctioning fuel nozzles injectors Improper starting technique Worn fuel injector pump Slipping torque converter Low cranking speed Low quali
91. e kits simplify Cat cylinder repairs e Convenience One part number gets you all the right seals for your application no more no less Quality Cat seal kits contain genuine Cat hydraulic cylinder seals matched to specific applications for durability and long wear life Protection Careful packaging helps ensure seals are protected from contaminants that can reduce hydraulic system performance Value Available off the shelf for most cylinder applications Cat seal kits cost less than ordering the seals individually To ensure correct seal kit selection locate the cylinder group part number and engineering change level on the outside of the cylinder 4 HYDRAULICS Cat Hose Service Fast Dependable Certified Clean Superior Cat hose products Barloworld Equipment hydraulics centres build hoses from their large inventory of Cat high medium and low pressure hoses and couplings These products are designed built and tested as a system by Caterpillar to exceed industry requirements Certified Crimp Our hydraulics technicians visually and dimensionally check crimps to make sure they meet specifications Over and under crimped hoses can be detrimental to both hose performance and safety Certified Clean We use a state of the art process to remove contaminants created during the cutting and crimping of hoses If left inside hoses these contaminants can damage cylinders pumps and other hydraulic system components We also
92. e placement of the rim on the machine Applications uilding amp Framing Industrial Waste Pavement Profiling Demolition Flexport Construction Flexport Smooth Tread Flexport CICI ajaj Quarry Cleanup afa or afa emn Flexport tyres for small and medium wheel loaders Cat Flexport tyres for small and medium wheel loaders are a 2 piece tyre rim design and are available in smooth and OTR tread patterns Installation of a Cat Flexport tyre on either a small or medium wheel loader requires the use of an adapter plate and hardware Please note In certain small and medium wheel loader configurations Cat Flexport tyres may cause the machine to exceed the Roll Over Protection Structure ROPS capacity To be certain that the machine does not exceed ROPS the machine should be weighed to verify that the ROPS limits would not be exceeded with Flexport tyres The ROPS capacity can be found on the cab of the machine HEAD TO HEAD COMPARISON RESULTS Caterpillar s Flexport elliptical design far superior to round design Other tyre companies manufacture tyres with round holes e The round design easily collapses into a flat shape under a load which creates corners that cause pinch or Stress points e Stress point damage will typically result in cracking and chunking of a tyre SS 2 S S SS TY Caterpillar designed Flexport
93. e relative wear life of Cat S 3 is Extended Life Friction Material is to four times greater gt than the Cat standard paper material and is twice as resistant t to glazing This resistance to glazing which occurs during c 2 periods of high temperature braking provides consistent braking power It may also lessen audible brake noise 1 0 Glazing Resistance Wear Resistance Failure M ode FRICTION MATERIAL COST COMPARISON m Fewer Final Drive Friction Disc Final Drive Friction Disc Final Drive Labour Hours Application Friction Discs Overhaul Replacement Only Overhaul Replacement Only Overhaul x Savings Consumed Light 33 C O 40 64 102 Severe 57 128 204 Q Cat Extended Life Q Standard Cat Disc Percentages reflect fewer friction discs consumed final drive overhaul cycles using the Cat Extended Life Discs over Standard Discs Labour hour savings based on brake replacements performed outside of normal overhaul cycle and may vary based on machine type Models 777 789 Brake life better matched to final drive life cycle The chart above illustrates the potential reduction in the number of friction discs required and labour hours saving over the life of final drive overhaul cycles for off highway trucks using Cat Extended Life Friction vs Cat standard friction discs Contents 1 04 Differential Maintenance An Introduction Preventative Maint
94. e steps you can take to prevent fluid contamination An effective contamination control programme is made up of many small steps that help maintain fluid cleanliness and reduce opportunities for contaminants to get in machine systems Caterpillar recommends a four part contamination control programme consisting of 1 Clean fluids 2 Clean components 3 Clean facilities 4 Clean shop repair processes By following these steps you will be better prepared to control contamination reduce overall operating costs and keep your Cat equipment performing at its best DRIVE TRAIN Filters Control contamination inside your differential through the use of Cat fluid filters By changing filters regularly and properly and by selecting the right filters you maintain system cleanliness reduce component wear and lower costs For further information on selecting the correct fluid filters consult your machine s Operation and Maintenance Manual or contact your Barloworld Equipment customer service representative Repair management Repair indicators Repair management is only one factor that influences your owning and operating costs You should also address operating technique and application as well as preventative maintenance In the area of operating technique Avoid high speed direction changes Avoid backing over obstructions Avoid extreme braking Operators should adequately warm up the machine Pay attention to war
95. eaner as the first stage of an air intake system prevents nearly all of the heavier than air particles from entering the system which results in longer air filter life more efficient engine performance and decreased maintenance expenses Benefits Significantly lower owning and operating costs e Lowers cost per operating hour because cleaner air means longer filter life e Lowers air restriction which increases useable horsepower and improves fuel economy e Three times filter life with a reduction in labour parts and downtime No routine maintenance requirements e Debris is immediately ejected from the unit so no cleaning Is required Built to last e Rugged polymer construction gives the strength of steel with the light weight of plastic e Sealed bearing cavity eliminates wear due to moisture or corrosion e No spot welds that will break over time Features Pre screen eliminates clogs inlet pre screen on the underside eliminates clogs and jams by preventing any debris larger than the ejection slot from entering the precleaner Internal strakes angled fins on sidewall catch debris in outer orbits and channel the debris horizontally to the ejection slot Toroidal dome shape enhances the separation process by preventing debris from being sucked in through the ejection port Debris is ejected and clean air continues to rise until the dome shape folds it and sends it into the engine air intake Ro
96. ed as quality control parameters to either accept or reject product Specifications are subject to change without notice Can be used in applications where the obsolete CD classification oil is recommended when used in conjunction with the SeOeS Services oil analysis programme e Proven performance Tested in Cat 3600 series diesel engines worldwide Sulphur level compatibility Cat DEO Monograde provides excellent performance and protection for the following Cat engines operating at or below these fuel sulphur levels e 3600 Series Direct Injection 1 3096 e Pre combustion 0 65 For higher fuel sulphur content SeO S Services oil analysis programme 15 recommended to optimise oil drain intervals Tested Beyond Industry Standards The large bore medium speed Cat 3600 engines require oils that meet a unique standard not defined by any industry classification Cat DEO Monograde meets that proprietary Caterpillar standard other brands of lubricant are used instead of Cat DEO the manufacturer must demonstrate that the oil meets the same standard SeOeS Services for early problem detection Protect your investment with Cat SeOeS Service the ultimate detection and diagnostic tool for your equipment SeOeS helps you detect potential problems before they can lead to major failures and costly unscheduled downtime Cat Filters Complete protection for your equipment Combine Cat Fluids with Cat Fi
97. ed without permission UNDERCARRIAGE UNDERCARRIAGE Contents 09 10 11 12 15 20 Positive Pin Retention Track Heavy Duty Track System Management Operating and Maintenance Tips Custom Track Service Factors Affecting Wear Track Adjustment Procedures Elevated Sprocket Tractors with and without Carrier Rollers Low Sprocket Tractors and Loaders Hydrostatic Loaders Hydraulic Excavators Hardware Requirements 12 12 1 18 19 a gt i aet scm uev cU 09 DEN S as sum e M RR 4 T E E a 4 wm gt T me s x i 4 4 Doe i Cat Undercarriage is designed to work and wear as a system to reduce your operating costs You make daily decisions that impact undercarriage wear and costs This guide can help you and your operators understand how undercarriage works and how to reduce wear and save money Although wear can t be halted we are committed to helping you make each undercarriage system last with correct operation and maintenance Positive Pin Retention Track Resists link end play and increases sealability for maximum track life Designed for high impact and high loading applications such as mining heavy construction dem and waste disposal Positive Pin Retention Track is an exclusive Caterpillar design that mechanically locks the link to t
98. ee of the track then remove the pin Close the hydraulic relief valve Using the grease gun extend the hydraulic track adjuster until the rear edge of the idler bearing assembly aligns with the mark on the roller frame The resulting sag should be about 50 mm Operate the machine in forward and reverse then reinspect track adjustment 6 and 7 UNDERCARRIAGE Hydrostatic Loaders 1 Move the machine forward and let it slowly come to a stop Then park the machine and turn off the engine Place a tight line over the grouser tips from the sprocket to the front idler Measure the distance from the line to the grouser tips at the lowest point of sag Proper track tension is about 50 mm 4 2 f the track requires adjustment remove the cover for the adjusting mechanism Connect the grease gun to the fitting Add grease to move the idler forward until the track Is tight 3 Using a straight edge make a mark on the rod even with the recoil housing 4 Place a second mark on the rod 10 mm from the first mark in the direction of the idler On the Cat 973 place the mark on the rod 13 mm in the direction of the idler 9 5 Open the relief valve and let the idler drift back until the second mark is behind the recoil housing Then close the relief valve Using a grease gun move the idler forward until the second mark is even with the recoil housing The resulting sag should be about 50 mm Operate the machine in forward and rev
99. eel move at a faster speed than the inside wheel allowing for easier turning and less wear on tyres or tracks The gears in the differential also provide speed reduction and torque Increases In order to get the productivity and life you demand it is important to maximise the life of these components by properly managing and maintaining them The key components of the differential are e The differential assembly which turns the spider and pinion gears that mesh with the side gears turning the axle shafts e Pinion gears which transmit power from the spider to the side gears that are attached to the axle shafts e Side gears which are splined to the axles and driven by the pinion gears e The spider which serves as the mounting for the pinion gears and rotates with the differential assembly e The bevel pinion gear driven by the drive shaft e The bevel ring gear which meshes with the bevel pinion gear and is mounted to the differential assembly DIFFERENTIAL CROSS SECTION Side Gear Spider The key functions of a differential are Transterring power coming from the transmission to the left and right axle shafts Balancing the power according to the demand of each wheel To transmit the power to the wheels while allowing them to rotate at different speeds Gears in the differential further reduce speed and increase torque to drive the rear wheels Bevel Ring Gear There are four types of Pinion Gears diff
100. ekeeping in the shop using proper oil storage and transfer methods Premature clutch wear from spinning Leaks or premature wear Premature bearing wear or bearing failure Premature gear wear Store oil drums on their sides Use drum covers Use the kidney loop system Use high efficiency filters for extra filtration Repair and assembly e Place covers over open compartments e Ensure that the root cause of failure has been identified and repaired e Use standard parts kits for all component installations Particle count monitoring e Strive for oil cleanliness e Test oil in new machines after field assembly or after adding new attachments e Test oil before and after service repairs Thorough inspection keeping parts packaged during handling and storage cleaning components thoroughly during repair and assembly and performing particle count monitoring Good housekeeping practices e Sweep floors daily Clean up spills immediately e Keep workbenches uncluttered and free of debris Limit use of floor storage Proper oil storage and transfer methods A good inspection programme combines your daily inspections with our periodic in depth analysis By combining both you can e Locate potential problems before they become major repairs e Schedule transmission maintenance and service e Plan and control your operating costs and downtime Your daily visual inspection routine should include a co
101. el Water Separators Diesel fuel acts as a lubricant in unit injectors The film strength of diesel fuel prevents metal to metal contact between the plunger and barrel Water can compromise film strength resulting in scuffing and eventual seizure Cat fuel water separators have best in class water removal capabilities essential for better protection of unit injectors Cat fuel water separators also deliver longer secondary fuel filter life These Cat fuel water separators e Remove more than 98 of debris 10 microns and larger e Virtually eliminate free water in fuel e Remove 87 of dissolved water PrimeTime Priming Pump Cat PrimeTime priming pumps are easily installed on the frame or engine as retrofits They prime the filter and fuel system with a flip of the switch The benefits e No need to pre fill the filter and risk debris reaching injectors e Primes the fuel filter in two to six minutes e No time consuming difficult manual pumping While these two products are available separately you will get the best results when they are used together Retrofit Information Axial seal filters are designed to retrofit engines in the field while radial seal filters have an exclusive Cat design for improved sealing performance on new engines Both will upgrade the durability and water removal performance over 1 previous Caterpillar offerings and other brands 1 Check the collection bowl daily and drain as needed
102. el systems require specially designed fuel filters Cat advanced high efficiency fuel filters use exclusively designed filtration media to remove more than 9896 of particles four microns in size and larger These Cat fuel filters feature e Spiral roving and acrylic beads to maintain pleat stability and spacing to better trap and hold contaminants e A non metallic centre tube for strength and to prevent metal contamination Measuring Contamination Contamination is measured by counting particles and reported by comparing those results to an International Standards Organisation ISO code This ISO standard refers to the number of particles in three different size categories contained in a one millilitre sample The first number refers to the number of particles that are greater than 4 microns the second number refers to particles that are greater than 6 microns and the third number refers to particles that are greater than 14 microns An 150 level of 18 15 13 would mean that a one millilitre sample of fuel contains ISO Code 18 or between 1300 2500 particles greater than 4 microns ISO Code 15 or between 160 320 particles greater than 6 microns and ISO Code 13 or between 40 80 particles greater than 14 microns If the contamination level is allowed to rise one ISO Code the amount of particles for that size will double OTHER BRANDS OF FILTERS CAT FILTERS 50 efficiency 98 efficiency 4 micron particle Fuel
103. enance Contamination Control Differential Steering Bearings Gears Key Components Component Durability hepair Options Scheduling and Record Keeping 1 Final Drive Maintenance Preventive Maintenance SeOeS Services Contamination Control Repair Management Repair Indicators Repair Options A Look at the Key Components Bearings Gears Duo Cone Seals Key Steps to Improve Component Durability Scheduling and Record keeping 1 1 6 Transmission Maintenance Importance of SeOeS Fluid Analysis Preventative Maintenance Thorough Inspections Transmission DOs and DON Ts Training scheduling and record keeping 104 105 105 106 107 107 108 109 110 111 112 112 113 114 114 115 117 118 Hg 120 120 DRIVE TRAIN DRIVE TRAIN Differential Maintenance An Introduction This guide discusses preventative maintenance repair management options and highlights the components that wear and fail in the differential By understanding these topics machine owners can minimise owning and operating costs while maximising on site productivity Understanding how differentials work The differential plays a critical role within a machine s drive train by changing the direction of the power coming from the transmission 90 degrees to allow the axles to be driven They also allow speed and torque differences between the left and right axles When a machine is turning the differential lets the outside wh
104. ence gained by millions of hours of operation Other brands may not be subjected to such extensive validation Optimum drive train performance depends on the right friction material BRAKING SYSTEMS Cat Extended Life Friction Material Purpose designed for off highway trucks and large wheel loaders Caterpillar offers a friction material that provides extended life and increased heat resistance in wet brake systems In certain applications friction material may no longer be the limiting factor in the life of a final drive This follows the development of Cat Extended Life Friction Material which uses an innovative carbon paper for braking A unique bonding process adds strength and helps prevent premature failures A significant step forward in braking technology the relative wear life of Cat Extended Life Friction Material is up to four times greater than the Cat standard paper friction material and 15 twice as resistant to glazing This resistance to glazing which occurs during periods of high temperature braking is especially well suited to heavy load applications like mining Brake Kits Cat Extended Life Friction Material is available in brake kits for selected models Give us a Call for details on availability RELATIVE LIFE OF BRAKE FRICTION MATERIALS Results May Vary Depending on Application amp Severity Cat Extended Life Standard Cat Disc 4 This graph demonstrates that th
105. ere wear can be significant in moderate to high abrasive dense material applications Top plates are made from through hardened DH 2 steel section for optimum strength and wear life Plates are divided into three separate parts Centre Left Hand and Right Hand to match the shape of the spade bucket Straight base edges require only the centre top plate As an added benefit the life of the top wear plate is intended to match the wear life of the half arrow so that maintenance is minimised Genuine parts Find them on line Keep it Real Keep it Cat For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com d Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos B Id i tity used h trademarks of Caterpillar and t be used without permissi AD artowor CA Identity use are trademarks and may not be used without permission Eq i p ent Motor Graders Choosing the right Cat Ground Engaging Tools makes a difference in motor grader performance and productivity From the Cat GraderBits System to a range of moldboard components and more than 200 available cutting edges Cat Ground Engaging Tools for motor graders are built to deliver superior performance and long wear life Each provides certain benefits when
106. erentials e Standard as shown e Limited Slip e No Spin Differential Assembly Locking Bevel Pinion Gear Preventative maintenance Optimise equipment life The key components in differential preventive maintenance include quality oils and filters regular SeOeS Oil Analysis and contamination control Proper oil use The three main functions of oil are to provide cleaning cooling and lubrication Modern Cat drive train systems feature new metals elastomers and paper disc materials which may have advanced lubrication needs requiring you to change oil regularly properly and use the right drive train oil to achieve top performance Use the right drive train oil Cat differentials experience high gear and bearing loads and temperatures In these conditions it is important gears and bearings are protected It is essential that components be run in the correct Always consult your Operations and Maintenance Manual for the specific oil needed Cat Transmission Drive Train Oil is specially formulated to increase the life and performance of your Cat drive train components This oil e Reduces transmission slippage e Controls brake chatter e Provides greater machine rimpull e Increases friction material life up to 45 percent Cat TDTO surpasses the TO 4 specification requirement and is specified as factory fill for all Caterpillar machine compartments where TO 4 is the primary recommenda
107. erse then reinspect the track I 6 As wear increases on the track link and rolling Ur a components the distance between the piston and Wh ia recoil housing will increase Consult a Caterpillar 6 _ _ T Service Manual or contact us when the distance exceeds j 50 on 943 and 953 track loaders and 60 mm on 963 and 973 track loaders c ndi LIE Hydraulic Excavators 1 Operate the machine in the direction of the Idlers 2 Stop with one track pin directly over the front carrier roller Park the machine and turn off the engine 3 Place a tight line or straight edge on top of the grousers 3 between the front carrier roller and idler bz vESS s C m 7m Measure the distance from the straight edge to the grouser tip at the lowest point of sag midway between the front carrier roller and idler Refer to the chart below to determine the correct sag for each model 4 fthe track is too tight loosen it by opening the relief valve and allowing grease to escape Tighten track by adding grease at the hydraulic fill and relief valve Travel in forward and reverse to equalise tension throughout the track Then reinspect adjustment Proper Track Sag All 200 Family series excavators All E Family series excavators All 300 Family series excavators All 500 and TK Family series excavators 5080 5090B 5130 5130B 5110B UNDER
108. ess clearance There s no more need for large cumbersome wrenches in tight conditions as is the case when changing threaded receivers Compatibility Cat flange mounted fast fuel receivers compatible with existing Wiggins and other brands of fuel system nozzles without degradation of fuel flow or fuel nozzle shut off valve performance The fuel tank adapter accepts Cat flange mounted fast fuel receivers and mounting flanges where space permits Convert Cat or Wiggins fast fuel threaded receivers to flange mounted receivers KEEP IT REAL KEEP IT For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Barloworld Equipment CAT PREVENTATIVE MAINTENANCE AND FLUIDS Oil Safe Containers Protect fluid quality reduce contamination Recognise this Poorly stored fluids can become contaminated and will lead to accelerated component wear robbing equipment of efficiency Oil Safe Way Protects fluids from contamination Prevents spills from open containers Reduces accidents Allows easy access to hard to reach locations Durable Manual flow rate control Fluid Contamination
109. ew performance and carry the same warranty as new components at a lower cost Aftertailure overhaul is recommended when large pieces of metal are discovered during magnetic plug inspections when failure occurs or when broken parts are discovered during before failure procedures It includes removal and replacement of the entire axle group and a complete rebuild of final drives the differential and brakes Understanding how final drives work wear is the key to maximising component life Final drive repair parts can be broken up into three groupings They are Level I fastest wearing parts not reusable e Anti friction bearings e Seals and gaskets e Duo cone seals Level slower wearing parts possibly reusable e Plates e Discs e Gears e Shafts Level Ill longest life designed not to be replaced e Housings hubs and carriers In order to correctly identify failure modes for final drives it Is necessary to understand how the component works the causes of its premature wear or failure and the maintenance steps that can be taken to minimise the causes of wear and failure How they work Bearings are used in the drive train system to mai
110. excavation _and loading Penetration 2 Hard to penetrate Hard to penetrate low abrasion materials Tips stay sharp with What to consider when choosing tips Cat bucket tips come in diverse shapes and sizes your selection will be determined by three factors namely impact penetration and wear Impact Choose tips with the ability to withstand penetrating shocks extensive digging and extreme breakout forces Penetration Make sure the tips will penetrate tough material whether it s rocky hard packed or frozen It s important to remember that sharp tips should only be used when penetration is more important than wear life Wear Select the tip that will withstand wear gouging and abrasive action associated with material handling A retrofit pin and washer inserted in the J800 adapter mates with the hammerless tip design without introducing the need for special tools Choosing the right tip for the job site will increase safety Very good penetration and uptime long life ensured by _ heavy wear pad Long life ensured by heavy wear pad Good combination of penetration strength and wear material Very good penetration A heavy duty abrasion tip fitted with the CapSure locking use system High Abrasion Buckets Cat 990 New wider half arrow segments and top wear plates for Cat 990 high abrasion rock buckets field
111. f the filter FILTERS Cat Radial Seal Air Filters Larger capacity longer service life and lower costs This rugged filter has all of the outstanding fea tures of other Cat air filters and more Get 100 of filter life Use the Cat Air Filter Service Indicator to get an accurate continuous reading of how much life remains in your filter The easy to understand graduated readings let you change the filter only when needed Overservicing and underservicing are eliminated so you get the lowest possible cost per hour Contact your Barloworld Equipment customer service representative about retrofit options on most Cat machines It provides up to 5096 more capacity for longer service life and one piece urethane end caps for a more consistent bond to the filter media A more reliable seal permits quick servicing with no tools required Radial seal filters feature a special adapter ring that can be easily retrofitted to most existing equipment Once the ring is in place installation is fast and easy so you spend less time on routine maintenance Cat radial seal filters are the best value on the market with standard filter elements for normal duty and ultra high efficiency elements for extremely dusty and high soot conditions Air filter structure and benefits Radial seal design No tools are required SO Service times and maintenance costs are minimised e All steel adapter ring Most new Cat mac
112. fe Better Material Cat hydraulic cylinder rod seals feature a proprietary urethane material that delivers improved performance over the material used in previous seals This proprietary material provides e Better compression set Compression set measures a material s ability to rebound to its original shape after compression Cat urethane material offers up to a 2596 improvement in compression set capabilities over previous materials without sacrificing tensile strength or seal hardness levels Wider temperature application Cat hydraulic cylinder rod seals can work in a wider range of operating temperatures than previous designs without seal degradation Better Value At Barloworld Equipment s service centres resealing hydraulic cylinders involves more than installing new seals To help you get the full life of the new seals we light hone cylinder tubes We also practice contamination control have tooling for proper disassembly and assembly reassemble to Cat specs and have pressure test capability Cat wiper U Cup and buffer seals are designed to work together to provide optimum sealing performance in Cat hydraulic systems HYDRAULICS Hydraulic Cylinder Reseal Service Count on our expertise to stop leaks and maximise system performance Our Barloworld Equipment service team 15 committed to resealing hydraulic cylinders quickly and correctly the first time That means using proper disassembly and assembl
113. following Vickers 35 TYPICAL CHARACTERISTICS The values shown are typical values and should not be used as quality control parameters to either accept or reject product Specifications are subJect to change without notice Combine Cat fluids and Cat filters for the highest level of contamination control and protection for your machine 69 2542 MER e PREVENTATIVE MAINTENANCE AND FONDS Oils NGEO Advanced 40 For natural gas engines requiring low ash oil SAE 40 Cat NGEO Advanced 40 oil is designed for specifications that provide superior lubrication per formance in low emission high output fourcycle engines using natural gas fuel Cat NGEO Ad vanced 40 has been tested and approved by Caterpillar to meet the same high standards as Genuine Cat Parts Customer Benefits TYPICAL CHARACTERISTICS Reduced Piston and Cylinder Wear Anti oxidant and anti nitration properties prevent deposit buildup to minimise scuffing scoring and wear e Increased Spark Plug and Valve Life Excellent detergent and dispersant additives protect against deposits and damage Corrosion Protection Acid neutralisers protect parts from rust and copper corrosion e Extended Drain Intervals Provides extended oil drain capabilities when using the Cat S O S Services oil analysis programme e Comparable viscometric properties as Cat NGEO EL 250 and EL 350 All are SAE 40 grade o
114. g e New and salvaged components undergo grit blasting to prepare and clean the surface for the thermal spray e Hot combustion gases near 2 760 C are channelled and combined with a fine metal powder and accelerated through a nozzle at more than three times the speed of sound This forms a stronger mechanical bond than chrome plating e surface is ground to like new specifications e A final grinding operation gives the surface a superfine polish Superior wear characteristics Because the metal alloy coating created by Cat AST is harder than chrome plating it provides greater resistance to scratching and therefore helps prevent contaminants from entering the system The Cat AST surface is also denser allowing it to extend component life The process is good for the environment as Cat AST byproducts can be recycled or reused y Y E Suspension Cylinder Rods Hoist Cylinder Rods Hoist Cylinder Groups Models e 69 771D 770 772 773 775F 777F el OHI 785 797 Hydraulic Cylinder Rod Seals When it is time for repairs you should not overlook any part regardless of size Even parts as small as seals have a big impact on machine performance contamination control and operating costs hat s why selecting the right seals is so important and why Caterpillar is dedicated to de signing the best performing seals in the industry Cat rod seals are designed to work together to de
115. g system on the market for many years Once seen in operation though customers soon appreciate that this latest Caterpillar R amp D innovation is designed with the express purpose of improving efficiencies still further No Skive Designed to lower inventory holdi No Skive couplings satisfy the requirements for Cat XI 3 5 and oiaings 6 5 and ToughGuard hoses Cat XT No Skive couplings provide several benefits a key one being lower inventory requirements That s because each No Skive coupling satisfies the requirements for Cat 3 XF5 coupling results in more consistent torque readings and easier and XI 6ES and ToughGuard hoses hose assembly installation Additionally as the name implies No Skive couplings Previously you could only use an coupling on an XT eliminate the need for the hose to be skived prior to 3ES hose and the same applied with Caterpillar 5 5 and assembly In addition to reducing labour and assembly time XT GES hoses This meant having to carry one coupling for it also reduces the chance for installation error and system each pressure hose Now however with the new No Skive contamination from rubber particles innovation one coupling will fit on all three hose pressure ratings XT No Skive couplings can be pushed on by hand in the Dash 6 and Dash 8 sizes while maintaining enough grip to ensure In addition to the No Skive series Barloworld Equipment s orientati
116. g life of bucket teeth GraderBits are inserted into the adapter and are individually replaceable Each bit is held in place with a snap ring Different sizes of GraderBits can be used in combination to create edge patterns that deliver optimum performance in a wide variety of surfaces from rough haul roads to paved roads with compacted ice and snow Advantages Over Conventional Edges GraderBits penetrate to the desired depth immediately even on highly compacted surfaces so shaving and scuffing are eliminated Fines and gravel flow through the gaps between bits and don t end up wasted in windrows At the same time subsurface gravel is brought back to the surface for reuse greatly reducing the expense of spreading new gravel As a result most road maintenance jobs can be accomplished in a single pass Other advantages include e 6 10 times longer life than standard flat 1 x 10 through hardened edges e Less time required on blade and edge maintenance e More distance covered in less time means lower overall cost per mile kilometre e Significantly less new road material required e Better water retention helps control dust and erosion Caterpillar also offers high carbon edges for those light duty applications where impact is extremely low High carbon edges have a relatively high surface hardness and will provide good life in high abrasion applications or in finish work It is important to realise that high
117. ge life Slivering can also create a tyre hazard value may be a narrower and or thinner cutting edge This reduces costs by minimising the amount of usable iron thrown away Edge thickness Penetration requirements determine how thick your edge should be Harderto penetrate materials call for the use of a thinner edge In easierto penetrate materials the edge can be thicker to extend wear life MOTOR GRADERS Flat Edges are usually wider and thicker than curved edges because they are designed for more demanding applications including road maintenance and pioneering In general flat edges provide better abrasion and impact resistance Curved Edges are usually narrower and thinner than flat edges They provide the superior penetration and rolling action necessary for fine grading and finish work The quality of a moldboard cutting edge is usually judged on three factors Hardness e Wear resistance e Breakage resistance Cat Tungsten Carbide Edges are available in all three basic shapes for use in areas of high abrasion and low to medium impact Cat Tungsten Carbide Cutting Edges combine the toughness of Cat DH 2 steel with the wear resistance of tungsten carbide They provide extended life in highly abrasive conditions to lower operating costs Tests show that tungsten carbide edges can provide up to 20 times the life of a standard DH 2 edge Features e Curved edge improves penetration a
118. gears by gear teeth pushing against each other Gears used in the final drives are put through a carburising and hardening process This creates a durable outside surface enabling them to carry very high loads for thousands of hours The gears are machined and precision ground to exact tolerances making it crucial for the lubricating oil to be at its proper level to avoid metal to metal contact The heat treatment material and machining processes used on gears are based upon the specific application Causes of premature gear failure There are five primary causes of premature gear failure e Pitting from surface fatigue normal end of life failure mode however consistent overloading accelerates this factor e Contaminated lube oil causes accelerated surface pitting and cracking e Gear tooth bending fatigue the result of severe gear overloading e Improper alignment creates unbalanced loading and contact on gears Improper lube oil increases surface wear Duo Cone seals are metal faced seals used to provide oil sealing in extreme or abrasive rotating applications involving high speed and load They use two large flexible toric rings to apply force to the opposing metal sealing rings to hold them together These seals carry the important function of keeping contaminants dirt and debris out of the drive train and oil in Causes of premature Duo Cone seal wear There are four primary causes of premature seal wear e I
119. gine operation to protect them from damage The consistent wall thickness of Cat bearings ensures that the film Cat engine bearings e Feature consistent wall thickness to distribute oil properly Have precise crush height to ensure proper clearance and oil flow Are made of the correct material to optimise performance under varying cylinder pressures of oil is the proper thickness helping prevent the friction and metal to metal contact that can cause excessive wear and premature failure Precise crush height Cat bearings feature precise crush height which helps ensure proper clearance and contact pressure between the bearing and bore Our comprehensive support helps you lower costs Contact your Barloworld Equipment customer service representative for more information on Cat engine bearings With Cat parts you receive the correct bearings to match your system together with the right technical support for dependable engine system operation Engine Bearings Aluminium alloy bearing with overlay Aluminium alloy bearing bi metal Alumini uminium Steel back allo j y material Aluminum Steel back alloy Lead tin copper overlay Copper lead bearing Copper lead alloy Lead tin copper overlay 4 ENGINES Cat Pistons Rings Liners and Rods Built to meet your engine s demands Pistons rings liners and rods form the heart of your engine control
120. has high service hours it is suggested to go with a replacement This is a precaution due to the fact that the bearing might possibly fail and destroy other critical systems Remember that many times it is challenging to determine If a bearing is reusable just by visually inspecting it Rolling contact stress fatigue originates beneath the surface and cannot be seen When choosing whether to replace or reuse a bearing consider the load application and the number of service hours In most situations it is more economical to replace a bearing that is in severe applications under heavy load or has high service hours Note that if you are not planning on reinstalling the inspected bearing immediately perform the following steps oil the bearing wrap it in clean oil proof paper place it in a box and store it in a dry dust free place These precautions will help avoid corroding and shortening of the bearing life Hints on replacement Any time during inspection you decide to replace a bearing be sure you replace it with a genuine Cat bearing Only then are you assured of the proper performance and long life of your machine Bearings must be compatible with the machine in the areas of lubrication fit surface and load carrying ability Many times a bearing will look like an original yet it might not be a correct replacement Bearings that are not compatible in all areas can fail prematurely Cat equipment requires the use of many
121. have an extremely long life These lights may dim following extensive use but they will never turn off LED benefits explained e No bulb replacement or unexpected downtime e Extremely long life LED Bright illumination lights may dim following lt WU di dL improves operator safety extensive use but will never and performance turn off ti e be used in a wide range of Cat and other equipment applications e Bright illumination is closer to daylight lessening eye strain and operator fatigue e Easy connection use two pin Deutsche DT series connector e One fourth the current draw of halogen lights minimises the need for a larger alternator e Environmentally safe free of mercury lead and heavy metals e Extremely efficient with no filaments LED lights do not cause heat buildup which can damage other parts e Reliable no moving parts eliminate wear and limit friction e Durable LED lights are completely waterproof and vibration resistant e 3 inch x 3 inch spotlight and floodlight options available The key to theft deterrence Theft and unauthorised use of equipment are big concerns The Cat Machine security System keeps your equipment safe by giving you control over both who can operate your machines and when Integrated into the electronics of Cat equipment the Cat Machine Security System guards the starting system engine and transmission Only a yellow or
122. he best performing seals in the industry That s why we reseal hydraulic cylinders with genuine Cat seals and money saving seal kits Cat seals are specifically designed to handle the increasing pressures and temperatures of today s hydraulic cylinders Don t risk poor performance or leaks use seals that carry the Caterpillar name Quality assurance We pressure test each hydraulic cylinder before returning it to you helping ensure reliable on the job performance Other ways our hydraulic service can save you time and money Resealing hydraulic cylinders quickly and effectively is just one of the many ways we can help you lower your operating costs and improve your hydraulic system s performance We ll show you our wide range of repair options including Cat Reman components and explain how we can help you get maximum machine productivity at the lowest possible cost Hydraulic Cylinder Seals Kits It s frustrating to open a seal kit and find it contains too many too few or the wrong seals Cat hydraulic cylinder seal kits are designed to provide the exact seals you need The key is ordering the right seal kit Occasionally Caterpillar changes the design of a cylinder group in production Sometimes these changes result in a new cylinder group part number Other times the part number stays the same and a new engineering change level is assigned This makes it possible for multiple seal kits to service the same cyl
123. he front of the seat for easy operator reach As durable as itis e Benefits comfortable The Dual Retractor Belt System keeps the operator in the seat for a secure ride e Rip resistant tight e Meets SAE J386 and SAE J2292 specifications weave fabric e Bright orange shoulder belt is easily visible when properly e Asphalt black worn and latched e Slip resistant material e Six vertical adjustment positions provide optimum fit for a e Special backing is wide range of operator heights fused not sewn to e Emergency Locking Restraint ELR the shoulder belt the underside of the functions sense and lock when conditions demand material allowing the e Lap belt comfort with Automatic Locking Restraint ALR material to stretch the lap belt automatically locks into position but still without sagging allows operator movement without cinching Proven Toggle Link Air Suspension system ensures a smooth ride Optimal Ride Zone positioning is accomplished by adding or removing air to the proven Toggle Link Air Suspension An indicator gauge makes it easy for the operator to see that the correct amount of air has been added to the system Once adjusted the seat will maintain the correct setting with no further adjustment until a shift change The Toggle Link Air Suspension system has proven extremely durable in the most rugged applications with over 10 000 hour life expectancy Cushions add to the comfort A negat
124. he pin This system e Resists end play generation and link movement on the pin and e Increases joint sealability in applications where end play growth can exceed the capacity of the seal Standard DOI D10T D11R and optional on D8T elevated sprocket tractors Positive Pin Retention helps maximise undercarriage wear life and minimise your owning and operating costs Current D11R link assemblies also contain Sleeve Bearing Track Exclusive design maximises track life Positive Pin Retention Track features specially machined links and pins that allow for the use of a metal retaining ring This ring is pressed into the groove between the pin and link locking the joint to a predetermined factory end play specification This in turn e Prevents end play generation the outward movement of the links on the pin and e Ensures seal to bushing face contact oil retention on sealed and lubricated track This exclusive Caterpillar design is recommended for mining heavy construction demolition and waste disposal applications conditions that generate high loading and impact twist the track chain and cause end play Positive Pin Retention Track features specially machined links and pins that allow for the use of a metal retaining ring Machines equipped with wider shoes Extreme Service shoes or Super Extreme Service shoes should also consider Positive Pin Retention Track Undercarriage management lower
125. hen you are finished handling the bearing lay the bearing out on a clean surface To clean a bearing you should use uncontaminated solvents and flushing oils If it is necessary to wipe the bearing only use clean lint free rags It is important to note that you should never use cotton waste or dirty rags to wipe a bearing Further never use the same container for both cleaning and final rinse of used bearings To dry a bearing hold both the inner and outer races together and blow air through the bearing You should never spin any bearing with compressed air When storing a bearing remember the most important factor is protecting the bearing from dirt and moisture You should be sure to keep the bearing wrapped in oil proof paper Be sure that you do not scratch or nick bearing surfaces while handling and storing the bearing When installing a new bearing install the bearing as it comes from the package without washing if it was received in a clean container When installing used bearings you should thoroughly clean the inside of the housing prior to the installation process Lubricants are a critical aspect of bearing maintenance It Is vital that you always keep lubricants clean when applying them and cover the containers when not in use Further always use the correct type and amount of lubrication as this will play a key role in bearing wear life Ten factors causing premature failure Overloading is an especially
126. hines leave the factory with Radial Seal Air Filters installed Most older machines can be easily converted with a retrofit adapter ring It quickly bolts into position to accept the new filter design e One piece moulded urethane end caps Forms a tough reliable corrosion proof bond to paper media Up to 3096 more seal contact area for a seal that is more reliable than conventional elements e Densely pleated filter paper Large media area provides superior capacity without impeding airflow e Built in pleat support and positive pleat spacing Prevents pleat bunching and ensures optimum filter media surface area e Heavy duty metal inner and outer wrap Increases structural strength and durability e Baked on enamel outer filter wrap Creates a corrosion resistant filter wrap Change filters without tools and take advantage of up to 50 more capacity with Cat radial seal air filters Radial seal filters feature a special adapter ring that can be easily retrofitted to most existing equipment KEEP IT REAL KEEP IT For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com Follow us on Facebook Barloworld Equipment 4 Barloworld CAT Southern Africa AL Equipment Follow us on Twitter 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Barloworldequip Caterpillar 9 pective log 3 identity used herein are
127. his surface particle cake is more porous the Cat Air Filter Service than dust coated media fibres causing less restriction Indicator accurately reads a throughout the filter life filter s condition e Better engine performance and fuel economy lower restriction allows the engine to breathe more This reading indicat easily and fuel economy improves because it takes less Checking for n ilic 2 Accuracy mge may power to pull In air vary with system design e Longer filter life unique surface helps extend air filter life up to six times as long as standard filters limiting filter The air filter service changes and the chance of contamination during service indicator will help you avoid changing filters too frequently which wastes filter life costs money and Limits Filter Changes and Saves Money unnecessarily introduces contaminants make sure the service indicator IS operating properly Caterpillar recommends changing it once a year It should be checked Number of Changes every 250 hours in normal As the filter element fills A Cat Air Filter Service Indicator can often save eight filter changes when in a cleaner environment for 6 000 operating hours conditions or daily if dust iS with dust and soot the Severe indicator moves up the calibrated gauge to show There are two steps to the exact percentage of check the operation filter life remaining e Rese
128. identify good and bad operator techniques Avoid e High speed direction changes e Backing over stumps or off a lowboy e Operating with a frozen undercarriage e Extreme braking Implement e Adequate warm up e Periodic and proper shifting e Attention to warning signs e Daily walk around inspections Drive train life is also impacted by the applications in which a machine operates throughout the year Key factors include the operating environment and the layout of the jobsite Operating environment e Seasonal temperatures often affect fluid choices change intervals inspection and operating practices e Operating in water increases the chance of water entering and contaminating the transmission fluid system and may cause a loss of braking ability Job site layout e Well paved and maintained haul roads reduce the Jarring impact on the drive train and other machine systems e Repetitive and high speed load and carry applications can cause brake overheating Scheduling We can help you develop an effective scheduling system by providing you with time and cost record booklets or software programs Use Maintenance Control System MCS software to schedule your maintenance and record machine operating costs and time usage This software allows you to download S O S reports from Trend Analysis Module TAM software You can also bring customised checklists from the Planned Maintenance Planner PMP
129. identity used herein are trademarks of Caterpillar and may not be used without permission e O IR e 572 49 GET UNDERGROUND LOADERS lt gt Underground Loaders More life from new weld on bucket protection system Caterpillar s new weld on GET for underground mining loaders is designed to be more productive than the previous half arrow system and offers more wear material to maximise wear life and bucket protection This new weld on system also reduces downtime Traditionally corners wear faster than edge segments causing the machine to be idled twice for maintenance The new design was developed for an even wear rate between corners and edge segments allowing both to be replaced at the same time The new system consists of four new parts a right and left corner along with two lengths of centre edge segments 850 and 1150 mm long Centre edge segments are offered in two lengths to minimise waste when cutting and fitting the parts Improved wear material for corner components ranges from 73 to 9596 and centres between 14 and 2896 depending on the GET model match Cat model match Please note that only centre edge segments should be used on Cat R1300 machines due to the narrower width of their buckets using the corner segments reduces the spade profile Machines larger than R1300s should use the corners with centre edge segments For complete
130. ific oil needed The Importance of 5 5 Oil Analysis 5 5 analysis is a crucial part of machine management Oil sampling at scheduled intervals validates your maintenance procedures tracks what is going on inside of the equipment and forecasts wearrelated problems Our S O S oil analysis programme is well recognised for its ability to detect potential failures before they occur Each 5 5 Services test is designed to reveal specific information about the condition of every Cat product The four type of analysis are listed below e Wear Metal monitors and tracks metal wear particles contaminants and oil additive package elements e Oil Condition compares used oil to new oil to see if it is providing adequate lubrication and protection e Oil Cleanliness determines if abrasive contaminants are causing accelerated wear e Oil Contamination detects water glycol or fuel in oil Advantages of using 5 0 5 Services Surveys have shown that there are many benefits to using our S O S oil analysis programme e Experts can provide analysis and interpretation of trends and can forecast any excessive wear concerns e Test results are available within 24 hours after receipt of the sample e Easy to understand test reports call for specific action and or makes carefully outlined recommendations e Saves time and money by identifying trouble spots before they become major failures S O S Services help you avoid complete fai
131. ils Recommended Uses The oil may be used in engines that use high sulphur gas provided that shorter drain intervals are employed NGEO Advanced 40 is formulated from select base stocks blended Values shown are typical values and should not be used as quality with special additives to provide control parameters to either accept or reject product Specifications e Excellent anti oxidation nitration properties are subject to change without notice e Thermal stability e Reduced carbon and sludge formation Oils Cat FDAO Final drive axle oil for off highway trucks large track type tractors pipe layers and track skidders SAE 60 TYPICAL CHARACTERISTICS Recommended Use 22 2 esses preferred lubricant for Cat off highway truck front wheels differentials and final drives Recommended drain intervals are at around 4 000 hours for off highway trucks UII ON OMNI ORIUNTUR CROCI UNS E as determined by SeOeS Services Mead Arcam Md Rust e uta Preferred lubricant for Cat large track type tractor pipe layer and track skidder final drives steel tracked machines with elevated final drives except the DSM D6M and P M M PH MM M U ARM up 561M Compatible with Cat final drives and axles that previously specified TO 4 lubricants and do not contain friction material MCN Par Lume CNIS ae
132. inder group Therefore when ordering a seal kit you need to know both the cylinder group part number and its engineering change level Speak to your Barloworld Equipment customer service representative for expert advice Contents and packaging help ensure quality and ease of use Cat hydraulic cylinder seal kits contain genuine Cat seals many of which feature proprietary urethane material and patented designs for superior compression set and broader temperature applications All are matched to your application helping ensure top performance and long wear life Kits themselves are carefully packaged to keep contamination out and they include a list of the contents installation instructions and the engineering change level For more information contact us today or visit the Cat website www cat com Light honing optimises seal performance and life Restoring the proper geometry and surface to the cylinder bore can keep you from replacing seals earlier than necessary That s why before we install new cylinder seals in our workshop we perform a simple procedure called light honing Light honing detects and corrects minor damage to the cylinder bore that left unchecked wears out internal seals and eventually causes leaks inside the system VVith Cat hydraulic cylinder seal kits you receive all the seals you need and only the right ones for your application There s no waste or confusion saving you time and money Easy to us
133. ing wear table outlines transmission failures and their common indicators identified by using the S O S Service S 0 S TRANSMISSION FLUID ANALYSIS INDICATORS Y Si Cu Pb friction materials v Cu Pb and or Sn bronze _ bushing or thrust washer Cr rolling element _ bearing Fe rolling element bearing shaft iron housing v Oxidations caused by overheating the oil Y ncorrect fluid difficult to identify Y Fe separator plates gears Y Cu Pb Sn bronze bushings or thrust washers v Oxidation caused by overheating the oil EY Ro o MER I What do these S O S indicators mean If excessive amounts of silicate 51 and aluminium Al are found in the transmission fluid it means the oll is contaminated with dirt The S O S experts might recommend you change your oil right away and to change it more frequently in the future High levels of copper Cu iron Fe and lead Pb would indicate abnormal wear of the bronze friction discs and steel separator plates Recommendations would include stopping the machine and inspecting the transmission Also you would be advised to cut open and inspect the oil filter for large particles What tests are done by S O S Services The 5 0 5 Oil Analysis consists of four standard analysis tests Component Wear Rate determination of which components are wearing and at what rate e Oil Contamination What contami
134. installation instructions contact your Barloworld Equipment customer service representative 5 Cat 3516B Engine Upgrade Cat 793 Off Highway Trucks 5 1 Electric Power and Marine Cat Certified Engine Rebuilds 5 3 Engine Bearings 5 A Piston Rings Liners and Rods 5 7 Precious Metal Engine Rebuild Kits 6 1 Reman Products for Engines 6 3 Starters and Alternators Cat 3516B High Displacement Engine Upgrade For Cat 793B and 793C mining trucks The Cat 3516B High Displacement HD engine upgrade delivers substantial savings by using less fuel extending time between repairs and lowering the overall cost per tonne The Cat 3516B HD gets its improved performance from a 1396 increase in displacement compared to previous standard stroke SS engines Owners of Cat 793B and 793C mining trucks can upgrade their equipment by purchasing an HD Reman engine and conversion parts package and returning their old 3516 short stroke cores 7 896 Less Fuel Used compared to the SS engine versus the HD Longer Longer Time to Time to Overhaul Overhaul 55 HD So HD SS HD Performance May vary depending on application load factors and other variables HD Advantage Features e 13 more displacement e New turbos e Extended repair and maintenance intervals Benefits Significantly less fuel consumption Better response Lower repair and maintenance costs and lower cost per tonne ab Acto
135. ion Rotatable drive housing allows flexible mounting Brush holder provides constant spring pressure for even wear ENGINES occa dia Cat Starters and Alternators Continued Strict remanufacturing processes Components are stripped down to the piece parts New O rings seals bushings and bearings are installed Rewound coils are sealed with new insulation Heat sink compounds are replaced All components that cannot be remanufactured to Caterpillar specifications are replaced with new parts e Each part is checked individually and the finished product is performance tested to ensure it meets like new specifications Coverage and availability Cat Reman starters and alternators are available off the shelf for nearly all Cat engine applications Coverage includes Cat Reman starters with the PRELUB system as well as a wide amperage range of alternators up to 145 amps Fully warranted low cost repair options Cat Reman starters and alternators are priced at 40 5096 of the cost of new parts and provide same as new performance and long life To prove it Caterpillar backs Reman starters and alternators with a same as new parts warranty AN ASY W AY TO INCREASE EFFICIENCY CERTIFIED USED For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com Caterpillar Alternators e Built in electronic voltage regulators High efficiency cooling
136. ipeline between the fuel storage tank and fuelling station They have the capacity to remove 396 continuous free waterin fuel by volume to less than 01 at the rated flow of the unit At the heart of the Cat bulk filtration process is the coalescer vessel which contains multiple elements Pre filter elements remove dirt and particulate debris the coalescer elements then strip water from the fuel Due to the high flow rate of fuel through the coalescer elements flow forces will cause some small water droplets to be washed off the coalescer s hydrophilic filter fibres The separator canisters fit over the coalescer elements and prevent these droplets from escaping to the outlet of the coalescer vessel so there is no chance of water contamination Naturally these filtration systems are not designed to clean heavily contaminated fuel a good portion of water and dirt can routinely be removed from supply fuel by using proper storage tank settling and draining practices Most of the remaining water and dirt can then be removed by using Cat bulk filtration or adding filtration and water separation capacity to each machine in the fleet Failure to maintain clean fuels that meet or exceed 18 16 13 per ISO 4406 will lower fuel system reliability and engine performance The Cat bulk fuel filtration system is intended for use in any application where users store fuel for machines or engines Smaller Cat filtration units are intended f
137. ive rake feature enables cushion tilt adjustment even while the operator is in the seat Side bolsters on the upper cushion help keep the operator in the seat in rough applications Cushion density designed for shift long comfort Cushions use a waterproof foam in place technology that Is easily cleaned Upper and lower cushions are individually replaceable _5SS 5TR 6XZ AGY AGC DCB 2YW 3PR FKR 244 2803 COMMITMENT TO BRING YOU THE BEST ALL DAY EVERY DAY First class equipment First class solutions First class support An easy choice for a hard place The new E Series hammers feature a symmetrical housing that can be rotated 180 degrees to compensate for wear extending the life of the housing giving you greater uptime Sound suppression for greater operator comfort On the ground service backup Our work tools generally have a high resale value giving you a better return on your investment What s more using them in combination with Cat machines gives you the perfect performance match Uninterrupted productivity And a single point of contact Work with confidence use hydraulic hammers from Barloworld Equipment For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com Follow us on Facebook Barloworld Equipment Southern Africa or err morc 1m rr x Follow us on Twitter Barloworldequip If the original machine se
138. ked corners can cause other bucket components to wear faster The widest range of mining machines from one solution You have to push every day To meet tomorrow s deadline To secure the next contract To stay ahead of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILT IN For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com Follow us on Facebook Barloworld Equipment Southern Africa Follow us on Twitter Barloworldequip f Barloworld Equipment CAT 2013 Caterpillar All Rights Res m CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE dress as well as corporate and product identity us rademarks of aid and may not be clita out permission Never run a bare bucket always use d either bucket teeth or bolt on edges Worn and missing tips and adapters Much of your bucket s penetration capability depends on teeth Even one or two missing teeth will reduce your bucket s digging ability A missing tooth also speeds up base edge wear Tips also protect the more expensive adapters A worn tip is almost as bad as not having any tips at all Blunt or broken tips cut the bucket s digging ability making it work harder to do the same amount of work
139. ken separators balls or rollers If a brownish blue or bluish black colour appears it means the bearing has been overheated At this point replace the bearing If the bearing has a seal or shield inspect it for damage or wear If the seals are damaged or worn you must replace the complete bearing worn or damaged seal will permit dirt and moisture to enter the bearing minimising its wear life Check separable bearings for pitted scratched or flaked balls rollers or races If any of these signs are visible replace the bearing Inspect the inner surfaces and rolling components in a non separable bearing by shining a flashlight between the balls and rollers If you notice any pits scratches or surface damage replace the bearings Further scan the outer race for proper wear patterns such as wear tracks that are centred without pits or scratches If you do not visually notice any signs of wear or damage lightly lubricate the bearing and slowly turn the outer race Never spin it If a clicking or sticking is observed clean the bearing again If the condition still exists after cleaning you will need to replace the entire bearing A thrust bearing or tapered roller bearing can be tested the same way but place the bearing on a clean surface lightly apply hand pressure and turn the bearing If no signs of wear or damage are indicated and the bearing has low service hours it can be reused after cleaning However if the bearing
140. king many mechanical and electrical changes that allow increased productivity and longer life of your product However these changes require smaller tolerances and increases in pressure in your machine that make maintenance and the upkeep of your transmission essential Because these mechanical and electrical changes are advanced they often require unique testing and repair that only Barloworld Equipment can provide accurately When a company with a diverse fleet uses just one or two lubricating oils what is the effect Using the incorrect lubricating oil can cause incorrect pressure faster wear or slippage Are shared oil reserves with implement cylinders vane or gear pumps a problem Shared oil reserves can cause cross contamination Newer machines are being designed without them Do different types of equipment wear out transmissions at different times For example how does a transmission wear in load and carry operations vs stay at home operations Transmissions do wear out at different intervals due to the applications they are in If you are constantly shifting from gear to gear or from forward to reverse your clutches and gears may wear out faster Can cutting open a filter help you diagnose a problem Yes Cutting open a filter is very important to determine the root cause of a problem By finding pieces of metal in the filter you can determine what is failing Refer to the filter discussion under the Planned Maintenance secti
141. l pump with the body of a conventional starter The pump automatically draws engine oil from the sump and pressurises the engine before allowing the starter to crank the engine Cat starters with the PRELUB system can be easily retrofitted to your machine PRELUBS is a registered trademark of RPM Industries Alternators Cat alternators are divided into two categories brush type and brushless Brush type alternators use one piece brushes and constant pressure springs for even brush wear Brushless alternators feature tighter air gap tolerances and superior sealing for longer life in dusty dirty environments Both alternator types are superior high output charging systems that are quiet compact and lightweight Starters crank your engine to starting RPM while alternators supply electrical power to operate electrical attachments and or accessories a me F A starter motor for a Cat D10T dozer Cat Reman starters and alternators reduce downtime and costs When you need repairs Cat Reman starters and alternators get you back to work quickly reliably and affordably Completely remanufactured to include the latest engineering updates Cat Reman starters and alternators provide same as new performance and long life Caterpillar Starters Power and Reliability Positive engagement shift mechanism ensures precise pinion to ring gear engagement Seamless one piece solenoid case protects against corros
142. ldboard Components E A 9 Underground Loaders 26 28 30 al 32 33 34 35 36 Understanding Bucket Wear A worn bucket costs you money every day you run your machine It means your loader or exca vator works harder to accomplish less Your productivity is cut and in most cases downtime for patch up repairs Is increased That s why regular bucket inspections are so important to ensure that signs of worn parts and structural damage are identified early before they can rob equipment owners of valuable production time Bucket bottom and end plates The best way to reduce this kind of wear on general and multi purpose buckets is with the Cat Corner Guard System The bucket bottom is an area that receives much abuse As the bucket scrapes along the ground the bottom wears thin For buckets with teeth a bolt on corner adapter and tip resulting in cracked wear plates and weld areas When wear protect the bucket from excessive corner wear and protect patterns develop on bucket bottoms replace the wear plates the bucket bottom For buckets with bolt on edges the Corner before other bucket parts are affected Corner wear Guard System uses bolt on end bits to protect the corners For rock buckets you can weld a tooth in the corner to reduce corner wear A two strap adapter will protect the bucket bottom The most critical wear point in your bucket is the corner It receives the most abuse Severely worn or crac
143. ling the combustion pro cess and transferring mechanical energy to the crankshaft To protect your engine from harsh conditions Cat pistons rings liners and rods are e Designed to work and wear as a system in your Cat engine for smooth efficient operation and long life e Manufactured and tested to close tolerances to ensure top engine performance e Heat treated to deliver strength and durability during engine operation Quality materials and controlled manufacturing processes also mean Cat piston crowns and connecting rods can be remanufactured for a second life Cat Reman Cylinder Packs offer same as new performance long life and quick turnaround all at a fraction of new prices New Cat pistons rings liners and rods are designed and manufactured using quality materials and controlled processes for maximum performance and durability One Piece Pistons e Improved structural capability of the single piece forged steel piston simplifies assembly and eliminates the number of parts e New oil jet with higher oil velocity provides more concentrated cooling e Reduces thermal expansion and allows piston fit to be tighter for a reduction in cavitation e Reduction in surface area provides less friction and helps improve fuel consumption Two Piece Pistons e Two piece articulated design for reduced piston slap better combustion and reduced emissions due to rings located closer to the top of the piston
144. liver optimum sealing performance and lower operating costs in Cat hydraulic systems something you risk when purchasing other brands of seals All Cat rod seals wiper U cup and buffer feature a proprietary urethane material and patented designs When you need new hydraulic cylinder rod seals don t install doubt Turn to us for genuine Cat seals Discover the difference better designs and better material make Wiper Seal Cat wiper seals feature a patented double lip design that provides optimum contact with the rod to keep out contaminants Also vents moulded into the radius of the internal lip help prevent these seals from unseating themselves during operation U cup Seal Cat U cup seals also feature a double lip This design ensures uniform contact of the oil sealing lip helping deliver top performance and wear life Cat U cup seals work together with the buffer seals to optimise sealing performance while minimising pressure build up Buffer Seal Cat buffer seals last longer because they are designed to be pressure activated Unlike compression buffer seals these Cat seals exert pressure on the rod only when necessary And because vents provide a passage for high pressure to be relieved back into the cylinder Cat buffer seals minimise pressure build up reducing U cup failure Better Design Cat wiper U cup and buffer seals feature design improvements that enhance performance reduce leakage and increase seal li
145. longer life i BEEN AEN nl A filtration efficiency matched to the needs of E 40 transmission applications 3 BE Ad Reduced pressure drop across the media o 20 Better cold weather performance Fewer instances of filter bypass i Improved protection for sensitive electronic s i uid e iis p p Flow GPM control valves Did you know That Cat oils have specially formulated additives that play multiple roles in protecting diesel engine systems These additives act as A detergent keeping all hot parts of the engine clean A dispersant keeping undesired particle elements in suspension until the next scheduled oil drain interval An anti wear system protecting main components against wear caused by friction A rust inhibitor to protect against corrosion caused by sulphur elements An anti corrosion barrier to avoid corrosion of metallic parts An anti oxidant to counter potential oxidation of the oil A Vl improver to keep viscosity stable when temperatures change An anti foaming agent to avoid foam in the oil All oils are not equal and don t perform in the same manner It s important to make sure the right fluid is in the engine both type and brand Cat Turbine Precleaner Three times the filter life means less maintenance downtime Air filter life is directly related to the amount of debris ingested through the engine air intake Installing a Cat Turbine PreCl
146. lters for the highest level of contamination control and protection for your equipment We recommend Cat Filters for all Cat equipment applications Cat MTO Oils Tractor oil for multi application use in older Cat backhoe loader rear axles and Cat Challenger tractors Recommended Use Recommended for older Cat backhoe loader rear axles and Cat Challenger tractors Cat MTO can also be used in the following applications e Cat components and systems recommending multipurpose tractor fluid that meet Ford New Holland M2C134D specification e Most Cat hydraulic systems e Other manufacturers machines and components Please refer to the DEM Compatibility table Discover the Difference Cat MTO is developed tested and approved by Caterpillar to meet the same high standards as Genuine Cat Parts e Improved braking and clutching Where approved for use MTO enhances control and extends life in clutches and wet brakes e Lower maintenance costs Exceptional anti wear properties extend equipment and component lives Cold weather operation Can be used in temperatures as low as 25 C Simplified maintenance Can be used in multiple compartments reducing inventory and the chance of using the wrong oll e Long lasting performance Offers high thermal stability and oxidation resistance for long service life In severe applications OEM COMPATIBILITY Cat MTO can be substituted in applications that require the
147. lures Often an adjustment or replacement of a single part based on 5 5 Services findings can prevent a small problem from growing into a major repair S O S Oil Analysis is different from other oil analysis programmes because it focuses on component condition not just oil condition Since only Caterpillar knows the exact design of your Cat drive train system we can help you analyse S O S reports determine what additional tests need to be performed and recommend the proper corrective action Particle count Particle count is another way of assuring oil cleanliness When used in conjunction with fluid analysis particle counting can be a valuable tool in reducing failures in final drive systems The particle count instrument counts the number of particles in several different size ranges from as small as two microns to over 100 microns It measures both metallic and non metallic particles and provides an early warning of abnormal component wear and contaminant ingestion Dirt sand grit and even the finest dust can cause problems when they find their way into the final drive system They cause parts to wear faster making them more prone to premature failure There are four ways contamination can get into machine systems 1 Contaminants can be built in during manufacturing and assembly operations 2 Contaminants can enter during servicing and maintenance procedures 3 Contaminants can enter with new fluid 4 Contamin
148. ly difficulties The minimisation of defects is a result of the extreme cleanliness of bearing steels and stringent quality control measures used in manufacturing facilities that supply Caterpillar bearings Note that usually only a metallurgist can characterise these types of defects from other causes of premature failures Caterpillar s Solution Caterpillar bearings are manufactured to the highest material quality standards in the industry and will always provide for the optimum performance and component life of Cat machines 9 Improper Servicing Techniques It is critical to always follow the manufacturer s recommendations summarised in your service manual Further this means using the proper tools Using inappropriate tools and procedures when removing installing and handling bearings can cause damage and possibly failure zi Caterpillar s Solution Always refer to your Cat equipment s Operation and Maintenance Manual and other service literature for proper procedures and servicing techniques 10 Electrical Current Bearings pass electrical currents that initiate an arcing and burning at the points of contact between the races and rollers This may produce a single burn or multiple grooves called fluting A burned bearing Ll A allows for excessive noise and will need to be replaced X Caterpillar s Solution Be sure to find and repair the root cause of the electrical ground to avoid damage to the new bearing
149. m Oi GET MOTOR GRADERS CATERPILLAR CURVED HIGH CARBON STEEL CUTTING EDGE SIZES B TE eee 9w2339 9W2341 711638 7T1625 7116277 REPLACEMENT PARTS FOR SCARIFIERS 70 4501 General Purpose DH 2 195 7234 Migh Temperature ov 3230 Uses 6B 3260 tool for driving scarifier tips off shanks HARDWARE Except 14G 16G and H Series 140H 143H 160H 163H 14G 2 bolt part numbers for 16H and 166 with 16 blade 2 bolt part numbers for 24H 4 9058 112 4521 0 75 19 mm 9W2305 9W2307 MOLDBOARD END BITS 9301 9302777 94880 1 4F7827 6 NOTE For machines equipped with power blade arrangement refer to the appropriate parts book for the correct moldboard end Dit Use 8E5531 End Bits on the following machines 126 61M11716 UP 1206 87V08135 UP 1306 74V02293 UP 1406 72V09829 UP 9W2945 is 1 8 3 mm thicker than 7D2052 and is recommended for use when installing overlay end bits a Use larger 5F8933 bolt where rear moldboard reinforcing plates are used MOLDBOARD REPAIR PLATES Use 8W5266 for larger radius moldboards Radius is 16 25 413 mm Use 8W5265 for larger radius moldboards Radius is 16 25 413 mm Blank Plate without Bolt Holes 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product
150. mplete visual and operational check of your transmission The following chart summarises planned and problem indicators e Filter new oll CAT TRANSMISSION REPAIR INDICATORS S O S Services Service Meter Hours Operator Discussion S O S Services provide the best insight into internal transmission wear and potential failure Our dealers use service meter hours as a repair indicator Talking with your machine operator can reveal many potential transmission problems Hesitation Slippage Unusual Noises Overheating Debris in Filter on Magnetic Screen Damaged Lines that are associated with the transmission Worn plates and disks Linkage out of adjustment Low fluid level Linkage not free Incorrect pressure settings Wrong oil used Technical Analysis Inspection Repair Determination Inspection 5 0 5 Services Customer Dealer Discussion Technical Analysis Inspection Repair Determination Inspection 5 0 5 Services Customer Dealer Discussion Technical Analysis Inspection Repair Determination Inspection S O S Services Customer Dealer Discussion Worn gears bearings Dirt entry i Aeration cavitation Low fluid levels Bent shaft drive Gear failure Bearing failure Wrong oil used Plugged radiator Worn pump pressure relief valve Worn or damaged seals Low fluid level Worn or dirty co
151. mproper installation caused by uneven or excess seal face load or handling damage Polishing housing surfaces allows toric rings to slide rather than roll resulting in inadequate loading of the metal sealing faces Contaminated lube oil abrasive particles accelerate wear of metal seal rings Toric ring compression set from overheating overheating lube oil causes the toric ring to lose its ability to apply the correct load to the seal faces Clean lube oil By far the most common and preventable cause of component failure is due to contaminated lube oil To ensure components run in clean lube oil it should be built clean installed clean and operated clean Correct lube oil It is essential to the components life to be run in high quality lube oil such as Cat FDAO Using the correct lube oil will improve component wear life up to 4096 in some applications Proper installation and assembly Components are built with specific tolerances and preloads Proper installation and assembly practices are absolutely essential to component life Avoid overload and fatigue Two factors that dramatically accelerate subsurface fatigue and component life are excessive loads and rolling resistance Replace parts before failure Final drive piece parts do not have an infinite life After being run for thousands of hours at high loads and temperatures the material will eventually fatigue Thoroughly inspecting the components res
152. n system Aeration Worn system components Faulty relief valve Faulty oil cooler _ Low fluid level Plugged filter Worn system components Faulty relief valve Wrong viscosity or contaminated oil Restriction in system Poor operator habits Worn rod or cylinder eye trunnion Poor lubrication Improper PM schedule Pinhole leaks in liner material Poor hose routing External damage System overheating Improper clamping or routing of hose Aeration cavitation Parts Service backup far bette 1 with one solution KEEP IT REAL KEEP IT You have to push every day To meet tomorrow s dead line To secure the next contract To stay ahead of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILT IN For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com Follow us on Facebook Barloworld Equipment Southern Africa Follow us on Twitter Barloworldequip Barloworld gt Equipment CAT 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be us
153. n wear plates They can prevent expensive structural damage to the bucket resulting in longer bucket life and e Lubricate the bucket linkage pins or install sealed linkage pins where possible D11 Carrydozer Edge Systems Along with the new fully reversible line of dozer cutting edges Caterpillar supplies a line of one way dozer cutting edges for the D11 carry dozer The Cat reversible cutting edge system Is avail able in three styles for Cat D11 carry dozers in either a 45mm thick 60mm thick or 60mm thick with ARM Abrasion Resistant Material configuration on a standard 19 inch wide plate Compared to an unsymmetrical edge of similar style equipment owners will experience around a 31 reduction in GET cost per hour by using the reversible cutting edge system When installing this system always bolt the cutting edge to the blade utilising the upper row of bolt holes One way cutting edges Along with the new fully reversible line of dozer cutting edges Caterpillar has introduced a new line of one way dozer cutting edges for the D11 carry dozer These 406mm 16 inch thick edges offer less throw away than previous generation Cat unsymmetrical edges translating into a 16 reduction in GET cost per hour GET BLADES Cat EEWL Extreme Extended Wear Life Cast End Bits EEWL cast end bits are designed for Cat D11 and other selected track type tractors that utilises a semi U Blade or Universal Blade
154. nabling them to carry very high loads for thousands of hours The gears are machined and precision ground to exact tolerances making it crucial for the lubricating oil to be at its proper level to avoid metal to metal contact The heat treatment material and machining processes used on gears are based upon the specific application Caterpillar bearing design is application driven which means Caterpillar offers the correct bearing for the application Key components Component durability 000000000000000000009000000000000900000009000000900000000000000000000000000000000000000000000000009000000000900000000000000900000009 A look at the key components Understanding how differentials work and wear is the key to maximising component life Differential repair parts can be broken up into three groupings They are Level I Fastest wearing parts not reusable e Anti friction bearings e Seals and gaskets e Duo cone seals Level Il Slower wearing parts possibly reusable e Plates e Discs e Gears Level Ill Longest life designed not to be replaced e Housings and axles In order to correctly identify failure modes for differentials it is necessary to understand how the component works the causes of its premature wear or failure and the maintenance steps that can be taken to minimise the causes of wear and failure DRIVE TRAIN Key steps to improving component durability Clean lube oil By far the most common a
155. nates are showing up in the oil e Oil Condition Is the correct transmission oil being used Has the oil been exposed to excessive heat e Oil Identification Is there coolant or water leaking into the oil Is the right oil being used Consult your Barloworld Equipment customer service representative for further information about the Barloworld Equipment Condition Monitoring Centre in Boksburg which incorporates the S O S laboratory 10 1 is a common payback ratio when comparing the amount saved on repair costs to the amount invested 5 5 Services DRIVE TRAIN Regular preventive maintenance is the most cost effective way to keep your transmission operating at peak performance Preventive maintenance focuses on transmission and drive train oils filters 5 5 and contamination control Preventive maintenance e Allows you to schedule downtime and plan for maintenance and repair costs e Helps prevent major failures including failures of related parts e Saves you money because you can often repair before failure e parts reusability e Optimises equipment life to keep your machine on the job e Increases machine resale value Proper oil use Oil helps to perform three main functions cleaning cooling and lubricating the transmission Today s transmissions feature new metals elastomers and paper disc materials that require advanced lubrication You must use the right oil and change it
156. nced hose significantly reduces material and labour costs Spiral hose Engineered to meet the toughest working associated with other hose protection options applications ToughGuard covers provide up to 20 times more abrasion resistance than industry standard hose as confirmed More flexibility by ISO abrasion resistance testing This ISO test requires a 5ON steel tool to be cycled back and forth along the length Cat XT ES hose works at half of the SAE s bend radius of the hose until the cover wears away to the point of wire allowing tighter routing without sacrificing cold flex capability exposure These attributes plus superior reliability make Cat XT ES hose the preferred choice in a variety of machines and applications ToughGuard built to last Each ToughGuard hose features a polyethylene exterior that provides increased resistance to abrasion caused by hoses rubbing together or against other abrasive materials Additionally this cover e Eliminates the need for nylon or plastic add on protection in most applications e Does not sacrifice minimum bend performance e Offers protection against chemicals and weathering e 5 compatible with both Cat XT No Skive and Cat XT ES Reusable Couplings e Uses existing clips and grommets e Has been tested to two million abrasion cycles without failure Cat Toughguard Hose Continued XT 3 ES HOSE EXCEEDS SAE 100R12 STANDARDS 238 8337 0 375 9 5 0 500 12 7 0 625
157. nd UP AFM AEM D6T D6R LGP 8LN529 and UP 9PN1579 and UP ACJ ADE D6T XL XW LG D6R XL AMN504 and UP 5LN2766 and UP DAH 561H M Low Sprocket Tractors and Loaders Move the machine forward and let it coast to a stop without applying the brakes Then park the machine and turn off the engine Place a tight line over the grouser tips from the sprocket to the front idler Track sag should be about 50 millimetres If your track requires adjustment complete the following steps Connect the grease gun to the fitting at the track adjustment mechanism located under the inspection plate B is the front idler bearing assembly Add grease to extend the hydraulic track adjuster until the idler is at maximum forward position The relief valve should remain closed After adding grease the track should be almost straight between the front carrier roller and idler On machines with one carrier roller per side place a mark on the track roller frame 10 mm behind the rear edge of the front idler bearing assembly On machines with more than one carrier roller per side mark the track roller frame 13 mm behind the rear edge of the assembly Open the hydraulic relief valve Place a track pin or drawbar pin between the sprocket teeth near the link assembly Travel in reverse until the idler backs up at least 13 mm 5 Move the machine forward until the pin is fr
158. nd or any type of abrasive material will cause premature bearing breakdown It is important to be able to recognise symptoms of contamination such as scratching scoring brushing pitting grooving bruising matte or satin finish or rust Several causes of contamination involve debris manufactured into the system cracked housings or hoses dirt access through failed seals minute metal particles and contaminated lubricant Caterpillar s Solution When contamination is an issue Caterpillar offers debris resistant bearings These bearings utilise a combination of specialised material and heat treat to produce bearings that are extremely resilient to debris and contaminants in the 128 BEARING MAINTENANCE di 4 Distortion When the housing or shaft is out of round the bearing roller components are forced together where there is a minimum amount of clearance The heightened pressure can result in the race and other rolling elements to incur surface flaking something that typically happens with normal fatigue Caterpillar s Solution see Improper Fit 5 Misalignment To maximise bearing life the supporting seats and shoulders must meet manufacturer s specific limits If the misalignment is beyond those particular limits the load on the bearing will be intense on only a segment of the roller and races causing excessive stress and premature failure at that single point Caterpillar s Solution Caterpillar s specialised roller profile
159. nd preventable cause of component failure is due to contaminated lube oil To ensure components run in clean lube oil it should be built clean installed clean and operated clean Correct lube oil It is essential to the components life to be run in high quality lube oil Using the correct lube oil will improve component wear life up to 4096 in some applications Proper installation and assembly Components are built with specific tolerances and preloads Proper installation and assembly practices are absolutely essential to component life Avoid overload and fatigue Two factors that dramatically accelerate subsurface fatigue and component life are excessive loads and rolling resistance Replace parts before failure Differential piece parts do not have an infinite life After being run for thousands of hours at high loads and temperatures the material will eventually fatigue Thorough inspection of the components results in early detection of defect and deterioration before parts fail completely and damage other vital components Repair options Scheduling and record keeping Selecting the right repair option Selecting the right repair option is a way to lower owning and operating costs Before failure repairs Repairing before failure gets your machine back to work sooner and costs two to three times less than afterfailure repairs Our before failure repair options e Help prevent major failures and failure of related part
160. nd rolling action e rapezoid shaped tungsten carbide tile on leading edge stays sharp as it wears for improved penetration and longer wear life e Available in 609 mm and 914 mm sections for easy handling e Smaller easierto handle edges allow rotation substantially reducing downtime and crowning e Reversible DH 2 overlay end bits are available to protect end sections from damage Developed for high abrasion low to medium impact ap plications such as e Unimproved earthen material roads e Public sand and gravel roads e Mining or logging haul roads Caterpillar GraderBits System The Cat GraderBits System is a flexible high production road maintenance edge system that saves time and money How Cat GraderBits Work The GraderBits System starts with adapters bolted onto the moldboard in place of a conventional cutting edge Like a row Serrated Edges are designed to loosen hard to penetrate materials such as packed gravel frozen earth and ice Because of their ability to penetrate quickly serrated edges may last longer in some applications For the most severe impact conditions they can be installed over a 6 152 mm edge for improved resistance to tooth breakage Cat GraderBits are part of the revolutionary Cat GraderBits System These replaceable tungsten carbide tipped bits extend downward from the blade like a row of teeth to provide the best possible combination of penetration ability and lon
161. ner protector on the Caterpillar 980G H bucket system Caterpillar s new corner protectors feature extra wear material to make them last even longer Bucket Protectors Bolt On Half Arrow Cutting Edges for 966 972 CGS Buckets Cat bolt on half arrow edge protection systems are ideal for abrasive and dense material applications where severe bucket wear can occur The system fits all Cat base edges drilled to accept standard and heavy duty cutting edges and consists of three centre edges and two end edges These cutting edges protect the full length of the bottom and leading edge of the base edge where wear can be severe The half arrow profile provides protection for the front and top bevel area of the base edge For still greater wear centre and end edges with ARM Abrasion Resistant Material are available as an option Both the end and centre edges have lifting eyes that will aid in handling and installation This is especially useful when changing edges in the field where fixtures and other mounting tools aside from a simple hoist are unavailable PIE gm f r E a 4 TW L Ti E LA der e L esu d ls ms DR reme m vu ee The end edges which typically wear faster than the centre edges are thicker to extend their wear life to more closely match that of the centre edges 3 200mm 980 SERIES LOADERS ANg Cage SEn OO
162. ning lights Do daily walk around inspections Application concerns might involve e Ambient temperature e Design of haul roads and repetitiveness of the work Repair Indicators There are two types of indicators planned and problem Planned indicators are part of a good differential maintenance management programme that will give you before failure repair options to lower your operating costs Planned indicators are those that are performed or checked routinely such as SeOeS oil analysis technical analysis service meter hours service history and Site Operations Maintenance Advisor SOMA software SOMA assesses customers operating and maintenance practices and provides component life estimates Problem indicators are usually found during inspection and include noises leaks overheating and poor performance Even with excellent maintenance eventually repairs will be needed However problems can be caught early by performing daily inspections and responding quickly to repair indicators Keep in mind determining the cause 15 usually easier said than done A visual exam may identify the type of damage but it may not aid in recognising what is causing the problem Remember if you merely replace the failed component without finding and fixing the root cause the replacement component will most likely endure the same wear and damage as the original For a list of planned and problem indicators for Cat differentials see the
163. nt com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission rr i amp 1 1 AL f a 1 i he e i I L UNA Reduced odour high dust capacity longer life Cat Dust and Odour Reduction Cabin Air Filters are designed for use in landfill applications or anywhere superior odour reduction is necessary They offer extended service life without compromising heating or cooling capabilities The activated carbon in the filter see magnification below provides a fast rate of absorption There is no operator exposure to loose carbon particles even in rough applications ient air filter i UMP E lt Barloworld Equipment e 9 ee 4 CABS AND ACCESSORIES Cat Air Conditioning Kits Improve operator comfort and boost productivity Cat air conditioning kits provide an effective retrofit solution to combat the heat All kits except combined AC Heater Kits are designed for use with machines that have an AC ready heater group installed The benefits e Right fit each kit is made for your Cat machine and contains parts to install a highly efficient R134A system in the cab e Durable all part
164. ntain position and alignment of gears and shafts and to minimise friction heat and wear They also carry the weight of the vehicle and payload subjecting them to very high loads and temperatures Cat bearings have precision surfaces that are separated by a film of lube It is critical that the surface of the contact areas retains an adequate oil film thickness to prevent metal to metal contact with the mating part Caterpillar bearing design is application driven which means we offer the correct bearing for the application Below are two examples of application specific bearings e Textured anti friction bearings for use in slow speed high load applications e Debris resistant anti friction bearings in high load tight tolerance applications provide twice the life of standard bearings Causes of premature failure In order to maximise bearing life it is important to eliminate the four primary causes of premature failure e Improper installation bearings are not properly installed with the correct pre load Improper tolerances width tolerances are incorrect for the application e Overload fatigue resulting from machine overloading or long hours of use Contaminated lube oil causes accelerated surface pitting and premature failure 4 DRIVE TRAIN How they work The basic function of gears in the final drive system is to provide speed reduction and increase torque Loads are transferred through
165. ntrol valve Dirt entry Wrong oil used Extended oil change period Worn gears bearings Disc disintegration External damage Technical Analysis Inspection Repair Determination Inspection 5 0 5 Services Customer Dealer Discussion 5 0 5 Services Customer Dealer Discussion Repair Determination Inspection Customer Dealer Discussion Technical Analysis Inspection Repair Determination Inspection Customer Dealer Discussion DRIVE TRAIN Transmission maintenance DO s and DON Ts Do s 1 Make sure the fluid meets ISO standards before pouring it in your machine 2 Use the correct transmission oil Caterpillar recommended fluids found in the Operation and Maintenance Manual 3 Use Cat filters 4 Cutopen old filters to inspect for indications of a problem 5 Keep accurate records 6 Follow the proper machine service hour guidelines DON Ts 1 Do not open your transmission system in a dirty environment 2 Always keep in mind proper Contamination Control guidelines 3 Do not abuse your machine application operation etc 4 Do not pre fill filters fuel or oil Training scheduling and record keeping 9000909090000909900000909090000090000090000000000000009000000900000009000900000900000090900000000900000900000000000000900000090000009090990009 Training Operating technique has a direct impact on drive train wear and maximising machine life Proper training is important to
166. nts fit ahead of the blade hold up to 11 shanks and loosen a path 46 1168 mm wide They are available to fit Cat 12 120 140 and 112 motor graders Straight Block scarifiers are mounted on the rear of the machine and are best used for higherspeed applications up to 3rd gear in shallow low impact applications Available to fit Cat 12 and 14 motor graders Cat Straight Block Scarifiers accept up to 17 shanks and loosen a path 72 1828 mm wide In some light duty applications straight block scarifier arrangements may be used as a mid mount scarifier Scarifier Shanks are through hardened and tempered to resist wear bending and breakage Shanks are available in two lengths e Short for most applications e long for applications requiring extra penetration ability Scarifier Tips Caterpillar offers three types of scarifier tips for use on washboarded and potholed road areas or where surface reconditioning is needed They feature a range of materials to suit various ground conditions with material combinations optimised for wear strength and low operating costs In normal to light duty applications the General Purpose Scarifier Tip will provide excellent reconditioning capabilities The General Purpose Tip is made from through hardened DH 2 steel and provides the lowest operating costs of the three options The Heat Resistant Scarifier Tip is made from DH 3 material and is intended for use in applications where s
167. o protect them from wear Chrome white iron and a mild steel backing plate combine with a uniquely engineered design to provide an effective solution for a wide range of environments GET WEAR PLATES Wear Protection Mechanically Attached Wear Plate System MAWPS cont d Parts Consist Mechanically Attached Wear Plate System 20 Series 844 966 980 988 138 0020 138 0022 138 0008 7 87 200 mm 275 5444 345B other similar 0 70 thick 18 8 85 7 87 1 38 3 minimum sizes 5 35 Ib 2 43 kg 225 mmx 200 mm x 35 mm 14 151b 6 42 Heavy Duty same same 138 0023 138 0006 same 22 275 4 B85inx7 87inx1 97in 225 mm x 200 mm x 50 mm 23 91b 10 85 kg ARM 30 Series 854 990 992 375 138 0030 138 0032 138 0000 1575in 400mm 275 5444 5080 other similar 0 86 hick 22 108inx7 8 inx177in minimum sizes 8 21b 3 72 kg 275 mm x 200 mm x 45 mm _ 21 3 Ib 9 67 kg Heavy Duty same same 138 0033 138 0006 same 275 5444 10 8 in x 7 87 in x 2 36 in _ 275 mm x 200 mm x 60 mm 32 61b 14 8 kg ARM 40 Series 5110 5130 other 138 0040 138 0042 138 0007 31 501 800 mm 275 5444 Similarsizes 1 14 thick 29 10 8 7 87 2 36 minimum 10 151b 461kg 275 mm x 200 mm x 60 mm 2 29 2516 13 28 Heavy Duty same sam
168. ocesses e New articulated piston bushings are installed using correct installation methods to ensure retention of bushing in bore e New liners and rings are installed for exact fit and smooth operation All components are extensively tested and inspected for conformance to factory specifications ENGINES Cat Pistons Rings Liners and Rods Continued Fast easy installation Cat Reman Cylinder Packs contain the cylinder liner piston rings pin retainers connecting rod and all necessary seals They come preassembled and ready for installation as a unit reducing your turnaround time Plus our special tooling and repair technique can save up to an hour per cylinder during installation so it s possible to complete an entire in frame overhaul in one day No other engine manufacturer offers this kind of service Fully warranted low cost repair options Cat Reman Cylinder Packs are priced at 45 50 of the cost of new parts and offer the same factory fresh performance prove it Caterpillar backs Reman Cylinder Packs with a same as new parts warranty Cat engine bearings resist scuffing and friction prevent corrosion and ensure proper clearance and oil flow for maximum performance and protection of engine parts Cat pistons rings and liners versus competitor parts Caterpillar randomly tests competitive parts to determine quality differences These comparisons consistently reveal the following sho
169. of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILT IN For more information contact our call centre on 0800 21 22 48 P 1 OWO ri d N or visit www barloworld equipment com E 2013 Caterpillar Inc Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission gt Barloworld Equipment CAT Top Mounted Wear Plates for Wheel Loaders General purpose and multi purpose buckets These wear plates are specifically designed for use with bolt on half arrow cutting edges and will fit standard Cat base edges for selected wheel loader models with 119 57 126 and 134 5 bucket widths These wear plates protect the bevel and top of the base edge along its entire length where wear can be severe in highly abrasive dense material applications Description Top mounted wear plates are made from through hardened DH 2 steel section for optimum strength and wear life The wear plate system consists of two centre edges and a left and right hand end edge Each edge is approximately 16mm thick and is intended to match the wear life of the half arr
170. omer demand for improved machine availability and reduces concerns by providing newer technology and assuring ROPS integrity operator satisfaction comfort and safety CABS AND ACCESSORIES Cat Comfort Seat With three point operator restraint made for comfort made for mining The Cat Comfort Seat 15 available as a retrofit option on a wide range of Cat off highway mining trucks and has proven advantages in terms of ergonomics and safety on the toughest sites High back design provides additional head and neck support for maximum operator comfort Dual Retractor Belt System with highly visible two inch orange shoulder belt which is easily seen when properly worn Infinitel nfinitely and latched adjustable lumbar support Extra thick contoured cushions with special side bolsters keep the operator positioned in the centre of the seat Fully adjustable arm rests can be flipped up and out of the way when not in use dual arm rests are available only on certain applications Lower cushion tilt adjustment helps reduce operator fatigue and fits a wider range of operator sizes Cast gears for long ite and durability Dampener adjustment allows the operator to gt tune the suspension to five firmness settings Proven Toggle Link Air Suspension System compensates for the operator s weight and provides maximum suspension travel Adjustment levers are at t
171. on What happens to the transmission when fluid becomes too hot The transmission oil additives deteriorate and lose their ability to control wear Oil samples results will show high oxidation and an increase in viscosity KEEP IT REAL KEEP IT CAT Barloworld gt Equipment Contents 1 3 Bearing Maintenance An Introduction 1 6 Trouble Shooting Charts 1 7 10 Factors Causing Premature Failure BEARING MAINTENANCE Bearing Maintenance An Introduction Caterpillar is known for having products that provide exceptional performance extraordinary du rability and long life Caterpillar bearings offer just that and more Bearings are used in every drive train component and virtually every mechanical component of Caterpillar machines But because of the varying speed power and torque and thrust force going through the drive train one type of bearing does not meet all the rigorous demands Several types of bearings are needed with each bearing being highly crafted and precisely matched to the kind of load it carries Bearings serve to allow parts to move together smoothly with minimum friction heat and wear often under extreme loads Caterpillar offers two fundamental types of bearings plain bushing and anti friction This section will focus on antifriction bearings which use balls and rollers as the primary elements between contacting surfaces Anti friction bearings con
172. on placement all while eliminating the need for a hose service centres across southern Africa provide pusher The swaged nut and improved plating process on each io di TRUE Te LT SR couplings Reusable Couplings For Cat XT Hose Cat reusable couplings for XT hose feature a unique two piece design that allows you to reuse the couplings When you need to replace worn hose we just take off the coupling install the new hose and reattach the coupling We ll have your repaired hose assembly ready fast so you can get back to work quickly On new Cat machine models Caterpillar has discontinued the Reuseable Coupling series and replaced it with the No Skive Coupling Series See above HYDRAULICS On Site Hose Support A Novel Container Service When and where you need it For mines and contractors operating on remote sites the introduction of Barloworld Equipment s hydraulic hose assembly container service cuts out part delivery lead times and ensures fast and efficient maintenance On the spot hose changes mean there s minimal machine downtime and all tooling meets the requirements for Cat no skive and reusable couplings Catering for low medium or high pressure applications hose Hose tooling comprises a Cat 56 2 radial press with the and coupling inventories are customized to match the client s series 111 Crimputer permanent coupling software set up machine population for both Cat and other OEM products
173. or remote day tank or fuel truck applications HOW IS FUEL CLEANLINESS MEASURED 18 16 13 PER ISO 4406 ISO Code Particles 4 microns Particles 6 microns Actual Particle Count Range per ml Critical points when it comes to fuel e Use fuels that satisfy all the performance requirements of Cat Fuel Specification ASTM 0975 or equivalent e Fil machine or engine fuel tanks with fuel that meets or exceeds 18 16 13 cleanliness level per ISO 4406 e Change fuel filters per service requirements typically every 500 hours e Drain water separators daily in accordance with the operating and maintenance manual O amp MM and e Drain fuel tanks of sediment every 500 hours or three months per the O amp MM s a 1 Genuine Cat pa rts Fi n 0 EN E line Keep it Real Keep it Cat For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com k o 2013 Caterpillar Inc Rights Reserved CAT CATERPILLAR their respective logos B Id Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product ar owor identity used herein are trademarks of Caterpillar and may not be used without permission AD q ip e nt d Fuel Management Cat Fuel Water Separators and Primetime Priming Pumps Advanced High Efficiency Fu
174. orking on a side hill shifts the weight and load balance to the downhill side of the machine This increases the wear rate on the components and parts on the sides that are on the upper side of the hill Working on a crown shifts the load to the inboard components increasing wear on inner links inner roller idler treads and grouser ends Working in a depression shifts the load to the outboard components increasing wear on outer links outer roller idler treads and grouser ends Factors Affecting Wear Always use the narrowest shoe possible Use narrow shoes which still provide adequate flotation for your application Proper flotation helps to reduce wear by keeping track from being submerged in material but using wider shoes than required by your application can lead to Increased bushing and sprocket wear Turning resistance loads and weight increase with wider shoes especially in rough underfoot conditions This added stress causes faster wear rates for bushings and sprockets e Increased link track roller idler tread and flange wear Using shoes that are too wide increases the interference between these surfaces causing them to wear faster e Loosening of pins bushings and shoe hardware Leverage forces increase with wider shoes In high impact or especially rough terrain greater leverage forces may lead to premature loosening of bolted and pressed fit components e Reduction of track joint life Bending
175. orque increase occurs Caterpillar designs and manufactures its final drive components with these demands in mind using testing processes that simulate real world applications In order to get the productivity and efficiency you demand it is important to maximise the life of these components by properly managing and maintaining them To withstand the forces of high torque and impact loads Cat final drive components are e Designed to work and wear as a system for smooth reliable operation e Manufactured and tested for precise fit and consistent quality e Heat treated for durability and long life in their specific application Controlled manufacturing processes and use of high quality materials enable Cat final drives to be remanufactured for a second life Cat Reman final drives offer same as new performance long life and quick turnaround all at a fraction of new prices Currently Reman final drives are available for off highway trucks large wheel loaders large wheel dozers large compactors and specific track type tractors A good drive train management programme is a team effort your regular maintenance programme supplemented by Barloworld Equipment s maintenance support products and services logether we can maximise drive train and component performance identify and react to any potential problems before they become failures and lower your owning and operating costs The key components in final drive
176. ots
177. ow cutting edges so that maintenance is minimised Features The wear plates are angled downward at the forward edge to tuck in behind the half arrow edge that sticks up above the base edge to provide unobstructed material flow The rear edge of the wear plates is tapered to a very low profile to reduce material carry back after a load has been dumped The half arrow edges and the top mounted wear plates work together to protect the top and bottom surfaces of the base edge along its entire length The top mounted wear plates bolt in place quickly and easily using longer cutting edge bolts and nuts Lower your bucket maintenance and repair costs in abrasive loading applications 962G11 963C 9666 GII 966D E F G GII 980F G H 970 970F 970 970F 9726G 972GII 9726G 972GII 973C The Benefits Longer base edge life by eliminating wear on the upper surface of the base edge and in the area of the base edge bevel Tight bolt on fit eliminates part to part wear from excessive movement No danger of base edge cracking from hard facing application More uptime due to quick and easy wear plate removal and installation as compared to hardfacing application Tapered rear edge prevents carry back of material GET WEAR PLATES Total Wear Protection The Total Wear Protection line from Caterpillar consists of the Mechanically Attached Wear Plate System MAWPS heel shrouds chocky bars wear
178. ozers loaders and mining shovels e Their round profile is designed to provide maximum wear protection while minimising drag as the edge proceeds through the media Roll bars offer impact deflection improved media penetration and overall weight reduction 3 0 Roll 280 4098 BlockAs Wear Bar Wear Blocks Cat wear blocks are used in areas where a single piece needs to cover a large or specific surface area e he wear block has a thicker profile which provides extended wear life in extreme applications e he zig zag inset design allows for material on material wear and prevents the detrimental channel wear common to wear plates that have grooves parallel to the direction of media flow 280 4099 Block As 6 amp x8 Tile 203 Wear Cat Wear Buttons Cat wear buttons have been designed for use in applications that lend themselves to optimising their round profile or where the round design is needed to cover a specific surface area e The buttons utilise a tri bar design which traps fine media between the three raised bars e trapped media will provide material on material wear prolonging the life of the product Block As Wear 2 5 Button 280 4092 Block As Wear 280 4095 _ 6 0 Button Bolt Protectors Designed to provide maximum protection to hardware and retention components Cat bolt protectors are welded around the components t
179. p Reman generators are remanufactured in a factory environment with Cat controlled processes and are tested with the same rigor as a new Cat generator Reman generators are shipped without a doghouse providing more flexibility for your application Short and Long Blocks Cat Reman long and short blocks are disassembled thoroughly flushed to meet rigid cleanliness standards and 10096 inspected for cracks erosion or other damage Block and cylinder head faces are resurfaced to factory specifications Crankshafts are reground polished and checked for lift and endplay All bearings seals gaskets and piston rings are replaced with new Cat parts Blocks are tested electronically to ensure consistent quality and long life Cylinder Heads Reman cylinder heads are 100 magnafluxed to detect cracks erosion or other damage and are updated to include engineering changes he bottom deck is resurfaced to ensure a tight seal and to help prevent combustion gas and coolant leaks All critical wear and sealing components are replaced with new Cat parts Cat Reman cylinder heads are pressure tested for leaks before they leave the factory Air Compressors Crankshaft and journal surfaces are reground and polished and cylinder bores re honed to exact dimensions Each unit has new piston rings rubber parts springs seals gaskets and washers to help deliver like new performance Alternators Starters To ensure same as new
180. performance all alternator gaskets and seals and starter O rings seals and boots are replaced Crankshafts Crankshafts are 10096 magnafluxed to detect cracks Crankshaft journals are machined to the same surface finish roundness and location tolerance of new crankshafts to extend service life Remanufactured Engines and Engine Components Continued Cylinder Packs Cat Reman cylinder packs ensure your engine is overhauled using performance matched Cat parts Only Caterpillar preassembles the connecting rod liner and piston as a unit cutting overhaul time by as much as 2596 ECUs Cat Reman has developed its own line of remanufactured ECUs This ensures electronic control units are thoroughly diagnosed and remanufactured and critical engineering updates are completed When the remanufacturing process is complete the units pass through rigorous durability test requirements Flywheels Cat Reman flywheels are balanced to factory specifications with factory surface finish which means a smoother engine operation and better clutch break in Cat Reman also inspects all ring gears and replaces when necessary Fuel Injection Pumps and Governor Groups gasket seals and worn parts are replaced with new Each unit is computertested for 20 critical quality points to ensure maximum performance and fuel economy Oil Coolers Unlike other rebuilders who clean and reuse bundles Cat Reman oil coolers use only new
181. portant to remove old filters carefully to ensure the contaminants they hold do not re enter the drive train system It is also critical to keep new filters in their packaging until you are ready to install them This protects the filter and reduces the chances of contaminants entering the system especially on the clean side of the filter media Select the right fluid filters The use of fluid filters in final drive systems varies by machine type Filters can be found on the 797 and 793 off highway trucks and machines using a common reservoir system such as backhoe loaders For further information on selecting the correct fluid filters consult your machine s Operation and Maintenance Manual or contact your Barloworld Equipment customer service representative DRIVE TRAIN Repair management Repair indicators Repair management helps you select before failure and after failure repair options that allow you to control repair costs and minimise downtime Performing daily inspections is an important way to identify small problems before they become major failures Inspection Daily walk around inspections should include a complete visual and operational check of your machine You should be aware of any strange noises leaks slippage overheating or brake chatter When used alongside Preventive Maintenance and S O S Services a good inspection programme maximises equipment value by minimising repair costs and unscheduled downtime A
182. preventive inspection plan can e Detect potential problems and impending failures before any additional damage occurs e Help schedule maintenance and any needed repairs to plan for downtime and control costs Site Operations and Maintenance Advisor SOMA Site Operations and Maintenance Advisor SOMA can significantly reduce your owning and operating costs SOMA Is a software tool that can help you identify repair before failure opportunity windows It is able to provide component life estimates by assessing the machine s operating and maintenance practices Contact your Barloworld Equipment customer service representative to arrange a comprehensive SOMA study Repair indicators There are two types of indicators planned and problem Planned indicators are those that are performed or checked routinely such as S O S Oil Analysis Technical Analysis service meter hours service history and SOMA software Problem indicators are usually found during inspections and include noises leaks overheating and poor performance Even with excellent maintenance eventually final drive repairs will be needed However problems can be caught early by performing daily inspections and responding quickly to repair indicators Brake Slippage Worn plates and discs Wrong oil used Unusual Noises Overheating Debris on Magnetic Plug Vibration Bearing failure Worn hard or cracked Seals Selecting the right repair option i
183. protect your engine investment Bearings play vital roles inside your engine preventing damage to crankshaft journal surfaces and maintaining correct oil flow and pressure between parts so installing the correct bearing is critical By installing Cat engine bearings you can prevent damage to expensive engine components minimise repairs and maximise uptime Three bearing choices optimise system performance Caterpillar is constantly looking for new and improved engine bearing material and designs to match engine performance demands The three bearing designs described below offer optimised performance based on variables unique to each engine system e Bi metal bearings feature an advanced aluminium alloy and no overlay providing more consistent bearing clearance and little wear e Aluminium alloy bearings feature aluminium bearing and copper bonding materials to prevent scuffing and corrosion reducing the chance of failure e Copper lead bearings feature greater fatigue strength increasing durability and reliability Quality construction extended life greater protection Consistent construction means Cat engine bearings deliver maximum performance and life and provide greater protection for other more expensive engine components Consistent wall thickness When the main or rod cap is bolted in place the bearing and crankshaft journal are in close proximity A film of oil exists between the two components during en
184. proven in abrasive low to high impact shot rock truck loading applications in mines and quarries New wider half arrow segments and top wear plates provide enhanced value for Cat High Abrasion Rock Buckets by reducing the gap be tween the segment top wear plate and adapter cover his should eliminate wear in that area of the base edge which can occur in some mate rial conditions The segments match the adapter cover bottom thickness to provide flat under bucket surfaces while the half arrow shape protects base edge blunt height from wear Top wear plates reduce wear on the bevel and the top front surface of the bucket base edge and are designed to match half arrow wear life reducing bucket downtime for parts replacement Half arrows are 60 mm thick to match the bottom thickness of the adapter covers providing a flat bottom surface They have been made 60 mm wider across the front to reduce clearance between the segment and adapter cover Top wear plates in turn are 25 mm thick and bent to follow the 35 base edge bevel You have to push every day To meet tomorrow s deadline To secure the next contract To stay ahead of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILTIN Keep it Real Keep it Cat For more information contact call centre on 0800 21
185. provides optimum load distribution across the bearing even when misalignment is present This serves to minimise stress in the bearing and maximise bearing life 6 Improper Fit Having proper bearing fit is essential to capitalising on bearing performance and life A variety of improper fits can cause significant damage including forcing a bearing onto a shaft that is too large for the inside diameter of the bearing race fitting an outer race insecurely too loose in its housing and having a loose fit between the shaft and the inside bore of the bearing These inadequate fits can cause split races fretting corrosion and creep wear Caterpillar s Solution Caterpillar bearings are made with specialised tolerances for precise fit of the bearing to the shaft or housing and ensures exact positioning of related parts 7 Vibration Damage Anti friction bearings must roll while under a load Subsequently subjecting a bearing to vibration while it remains immobile can cause depressions on the race from fretting Caterpillar s Solution n Caterpillar bearings eliminating vibration is a prime factor in determining the type of bearing cage required Brass cages and non metallic bearing cages are two types which minimise vibration and provide maximum life in harsh applications 8 Defects in Material Defects in antifriction bearings are particularly rare especially when it comes to the material forming machining heat treat grinding and assemb
186. r you an upgrade on standard nitrile seals for exceptional high tem perature applications This specially formulated material is available for O Ring face seals ORFS Straight thread O rings STORS and D rings Key features Longer seal life less maintenance e Superior heat resistance prevents hardening and ensures sealing quality at extreme temperatures In lab tests conducted at 135 C FKM seals lasted 10 times e Seal life can be as much as 10 times longer in longer than NBR seals Longerlasting seals mean less exceptionally high temperature working conditions downtime to replace them reducing costs resulting in less maintenance and fewer replacement seals e Resistance to high pressures improves sealing Improved resistance to high performance and prevents fluid contamination and leaks e Seals with PTFE polytetrafluoroethylene coating ease installation and prevent tears and damage FKM seals can also be used in Caterpillar high pressure applications that require improved performance Increased material strength allows the O ring to withstand higher pressures without extrusion or nibbling on the outside Superior performance in high temperatures diameter The FKM seal material has better resistance to compression set or loss of sealing force Cat FKM seals are designed to perform optimally in temperatures from 40 to 175 C They are an upgrade to nitrile butadine rubber NBR seals which can fail due
187. rage the two measurements Refer to Chart 2 to determine the correct sag for your model For SystemOne machines with or without carrier rollers refer to chart 3 If your track requires adjustment locate the hydraulic fill and relief valve in the rear roller frame and remove the inspection cover Using a manual grease gun add grease at the adjustment mechanism to tighten the track To loosen the track open the relief valve and allow grease to escape Then close the relief valve Operate the machine in forward and reverse then re measure track tension To avoid damage to internal roller frame components do not allow the length of the exposed tube B to exceed the dimensions listed in Chart 4 LEN i E nt le ine UNDERCARRIAGE Chart 1 Proper Track Sag Machines without carrier roller D5H D4H 517 561H 561M Chart 2 Proper Track Sag Machines with carrier rollers D11T DTIR DTIN D10 D8T DSR D N DBL 578 983 T R D5N D5M D4H 561H 561M Chart 3 Proper Track Sag SystemOne Machines with carrier rollers 081 DSR f excessive track jumping occurs run the track adjustment to the minimum side of the track sag range Chart 4 Track Roller Frame Extension Specifications Machines with and without carrier rollers D11T D11R 7PZ 8TR00202 UP 9XR001 54 UP 78 D9T RUS DOR ACL ABK 8BL1422 UP 7TL1212 UP D6T D6R STD 2YN545 and UP 3ZN764 a
188. regularly and properly to achieve top performance Use the right drive train oil Caterpillar Transmission Drive Train Oil is specially formulated to increase the life and performance of your Cat drive train components This oil reduces transmission slippage controls brake chatter provides greater machine rimpull and increases friction material life up to 45 percent Cat TDTO surpasses the TO 4 specification requirements and is specified as factory fill for all Caterpillar machine compartments where TO 4 oils are the primary recommendation Change oil properly Changing oil properly and at correct intervals is critical to realising maximum component life Actual oil life is determined by many factors such as operating conditions and applications or contamination control You can reduce contamination by e Washing the transmission tank and drain before removing the cap e Draining oil as quickly as possible and doing so when it is agitated and warm Using a filtered transfer cart to add new oll Installing and removing filters carefully Keeping filters in their packaging until ready for use Cutting open and inspecting used filters before installing new ones Filters Caterpillar filters are specifically designed around key factors such as sediment capacity collapsibility burst strength and pressure fatigue By properly and regularly changing filters and by selecting the right filters you maintain drive train s
189. rtcomings about competitive pistons rings and liners Competitive pistons e mprecise fit can cause liner scuffing and piston seizure e Partially disbonded ring bands and out of spec ring grooves can cause blowby and cylinder damage Competitive rings e Thin chrome plating can reduce wear life e Soft gray iron construction can reduce durability and lead to failure Competitive liners e Lack of heat treating and roll burnishing can lead to flange cracks and breaks e Random cross hatch pattern can result in poor oil control and increased oil consumption Cat liners are plateau bored for proper mating of piston rings and liner better oil control and long life Pistons Rings and Liners Competitive liners are non plateau bored and require breaking in producing wear and delays proper oll control Firing on all Cylinders Precious Metals Engine Rebuild Kits Introducing the Precious Metals Engine Rebuild Kit series for 3176 3306 3406 3406C and 3406E engines Caterpillar s recently launched Precious Metals Engine Rebuild series comes in pre packaged kits that contain all the necessary components to effect maintenance interventions at set stages In an engine s working life To get machines back to work fast there are four kit options in turn includes the Bronze kit plus six Cat Reman cylinder Bronze Silver Gold and Platinum with all parts enclosed pack assemblies whilst Platinum incorporates all Gold kit mee
190. s Help your final drives reach a new level of performance with Cat FDAO Compatible with Cat Transmission Drive Train Oil Excellent protection against rust and copper corrosion Controls foaming for increased lubrication Low oxidation rate for improved oil life Maintains desired viscosity and film strength Provides reduced wear from debris particles suspended in the oll Cat FDAO is a factory fill for e Off highway truck front wheels differentials and final drives Repairing before failure gets your machine back to work sooner and costs two to three times less than after failure repairs e D6R D11 dozers pipelayers 572 583 589 and track skidder final drives steel tracked machines with elevated final drives except the D5M and 561M Change oil properly It is critical to change oil properly and at the correct intervals Actual oil life is determined by many factors such as operating conditions applications and contamination control reduce contamination it is important to e Drain oil as quickly as possible and when it is agitated and warm e Usea filtered transfer cart when filling with or adding new oll e Remove and install filters carefully e Keep filters in their package until ready for use e Cut open and inspect used filters before installing new ones It is essential that components be run in the correct Always consult your Operations and Maintenance Manual for the spec
191. s e Maximise parts reusability designed into many differential parts e Allow you to schedule downtime and plan costs e Maximise equipment life and productivity Differential repair options Reseal required when oil leaks are discovered during Inspections e Re bearing and reseal signalled by excessive leaks elevated S O S results or target hours e Before failure overhaul involves rebuilding the entire differential After failure repairs Repairing before failure is the best way to reduce your downtime and costs However if your differential system does fail we are in the best position to help you control costs and save time Part replacement costs are kept to a minimum using Cat Parts Reusability Guidelines and replacing only damaged components Possible options include using Exchange or Cat Reman components Cat Reman components are available from inventory offer same as new performance and carry the same warranty as new components at a lower cost Afterfailure overhaul is recommended when large pieces of metal are discovered during magnetic plug inspections when failure occurs or when broken parts are discovered during before failure procedures It includes removal and replacement of the entire differential and axle group Scheduling and record keeping Good scheduling means maintenance inspections and planned repairs are done on time to prevent differential failures caused by overlooked maintenance You
192. s a way to lower owning and operating costs Before Failure Repairs Repairing before failure gets your machine back to work sooner and costs two to three times less than afterfailure repairs Our before failure repair options e Help prevent major failures and failure of related parts e Maximise parts reusability designed into many final drive parts e Allow you to schedule downtime and plan costs e Maximise equipment life and productivity Final drive repair options Reseal required when oil leaks are discovered during Inspections e Re bearing and reseal signalled by excessive leaks elevated S O S results or target hours e Upper pinion re bearing and reseal low sprocket TTT recommended when an S O S report shows elevated results of iron and lead e Steering clutch and brake reconditioning addresses worn friction materials to ensure proper steering and brake performance Before failure overhaul involves rebuilding the entire final drive After failure repairs Repairing before failure is the best way to reduce your downtime and costs However if your final drive system does fail we are in the best position to help you control costs and save time Part replacement costs are kept to a minimum using Cat Parts Reusability Guidelines and replacing only damaged components Possible options include using Exchange or Cat Reman components Cat Reman components are available from inventory offer same as n
193. s are heavy duty and made to withstand harsh operating environments and severe vibration CAT AIR CONDITIONING KITS e al Easy Installation quickly install components with easy Machine Model to follow installation instructions ZB Good value each part is covered under the Caterpillar LEE XI New Parts Warranty od TM 2EN T 7XM These kits provide a field installed 12 volt or 24 volt R134A in cab alr conditioning system for the machines listed in the AE table right Wheel Reader aww eaw 715 9GW AAW 63X 675 768 02X 769C 01X 232 7900 772 64W 773B 63W Integrated IT38G 192 1513 1CW 7BS 2 Tool Carrier 1T62G 192 1512 6Ps 12G 192 7424 1M7711 up 120G 192 7424 87V5734 up 74V2059 up 3YK 22K 2HS 120H 4MK 6NM 6YN 1927424 2 A roof mounted air conditioning system 135H 192 5372 1406 192 1511 2zK SAS BKM OTN OZN 160H 192 1511 2Hs 3GM 6WM 9EJ TH62 TH63 TH82 232 7910 TH83 TH103 Telehandler TH330B TH350B 217 5973 TH3608 TH460B TH560B 266 9213 z 6 266 9194 36 266 9216 252 FDG 262 CED 266 9213 c 266 9189 Skid Steer Loader 24 CMB 24 557 2 4YZ Multi Terrain Loader 257 MM 277 CNC 287 CNY i a 1 Table Notes Incomplete kit Additional parts required Combined AC Heater Kit QT
194. s costs rack Lin Stepped Bushing To help you get the most from your Cat undercarriage Barloworld Equipment offers the Cat Custom Track Service Oil Reservoir CTS a comprehensive programme for managing your track system We analyse your application to determine if Positive Pin Retention Track will improve undercarriage wear life and gt lt gt lower your cost per hour CO TS NEN By monitoring and inspecting your track regularly i T q d providing reports that list service options we help you make A informed decisions so you can plan maintenance and avoid Ss 5 E costly unscheduled downtime are J fp T Pin When your track does need repair we have the trained professionals proper equipment and excellent parts Oil P availability to get your machine up and running quickly and Rubber Stopper and Plug Positive Pin Rigid Seal Retention Ring Thrust Ring UNDERCARRIAGE Heavy Duty Track A sealed and lubricated track for medium size and H Series track type tractors Increased durability and wear life T R N and H Series machines because of their versatility are used in all types of underfoot conditions This tests the limits of undercarriage structural reliability wear life and sealability Heavy Duty Track is designed to meet the needs of T R N and H Series machines It is strong enough for aggressive impact applications yet has
195. shings replaced and machined to new specifications e Vane pump rotors and cams are remanufactured to Cat specifications or replaced with new components e Vanes are all replaced with new components e All cartridges pumps and motors are adjusted and tested to ensure like new performance e All tubes rods and other components are fully remanufactured to Cat specifications or replaced with new Cat parts e All rods are induction hardened improving resistance to nicks and dents and extending seal life e Most rods feature inertia welded eyes for superior strength e All required new bearings are installed Core exchanges help reduce your costs Reman hydraulic pumps motors and The price of your Cat Reman hydraulic component is based components on the condition of your used component so the better the condition of your core the more you save Because Cat hydraulic components are designed to be remanufactured we can often award credit even when you think a component has no value left That means the price you pay for Cat Reman cylinders rods pumps and motors is always less than that of new parts e All returned units are disassembled and thoroughly cleaned and inspected e Port plates are reconditioned and updated to the latest designs or replaced with new parts Equipment coverage Contact your Barloworld Equipment customer service representative for the latest information as we are
196. showing top clockwise a wear block chocky bar wear button and roll bar centre ALL ROUND PROTECTION Heel Shrouds Heel shrouds are used to protect the lower outside corner of all types of Cat buckets as well as other brand buckets The heel shrouds wrap around the bottom and side to give wear protection and structural support to the bucket For moderate wear applications and sites especially concerned about mechanically fastened parts these weld on heel shrouds are an excellent option e Extra wear material is concentrated in the corner where it Is most needed e The inside corner is reinforced to prevent interference with the bucket structure and weld joints e Straight and curved heel shrouds are available in two different sizes to best match bucket contour and size as well as abrasiveness of the application Chocky Bars Cat chocky bars designed in four distinct shapes conform to virtually any surface or application e he V groove design allows these items to be bent around a radius i e side bucket profiles or separated to change the length requirement needed e The inset of the Cat logo allows for the trapping of fine material in each section extending the life of the wear material itself Block As 1 5 Chocky 280 4088 Block As Wear 280 4091 4 0 Chocky Roll Bars Cat roll bars are a unique product designed to protect the leading edge of earthmoving machinery such as d
197. sist of spherical or cylindrical elements held in races that rotate with the adjoining surfaces preventing metal to metal contact and ultimately reducing friction heat and wear Caterpillar offers a variety of different antifriction bearings ball bearings roller bearings and needle bearings All three types of bearings have similar components hardened steel rings called races and optional separators or cages which provide spacing for the rolling elements between the races In some applications the rolling elements are in direct contact with the shaft or other mounting It is evident that bearings play a critical role in safe and reliable equipment operation bearing failure can cause metal particles to enter the machine s lubrication system wearing gear teeth and ultimately damaging the components Thus maintaining high quality operating conditions for the bearings will minimise repair costs and downtime The importance of lubrication Lubrication is an important factor in bearing maintenance Lubrication supplies an oil film for balls and rollers reducing friction between bearing components while providing a protective coating to prevent rust and transports heat away Using the appropriate quality type and viscosity of lubricant is vital to good bearing performance and life Overlubricating can lead to churning causing friction and heat which eventually initiates premature failure Lack of lubricant can be harmful given tha
198. specially harmful to the electronics Solenoids in your electronics control when and how quickly your clutches engage When the solenoids become contaminated they become sluggish and your clutches may engage too quickly or they may slide get the most use out of this filter cover the breather before washing your equipment and check your breather for clogging when inspecting other machine components Contamination Control Customers demand more power faster cycle times and easier operation To meet these needs Caterpillar is responding with higher system pressure and more sophisticated productive machines Controlling contamination is more critical than ever because these high tech machines require tighter clearances and fluid systems that are more sensitive to contamination Contamination leads to reduced efficiency increased cycle times shortened component and fluid life and catastrophic failure causing costly downtime and repairs Causes of Contamination Contamination can be introduced at the refinery during machine operation or during maintenance Contaminants include Dirt Sealing material Metals Grease Products from oil oxidation Weld spatter Heat Air Water Effects of contamination in transmissions Paint flakes Rag fibres Contaminants in transmissions cause e Shifting problems from plugged control valves Preventing contamination Prevent contamination by practicing good hous
199. st soot talc etc immediately cake on the surface quickly making the filter very efficient Less dust gets to the engine improving fuel economy while reducing wear and maintenance costs e Surface particle cake is more porous than dust coated media causing less restriction during filter life to improve capacity engine performance and fuel economy In tests air flow restriction through UHE air filter media increased at a lower rate than five other major brands e Because particles get trapped in the build up on the surface of UHE air filters the media stays permeable longer unlike filters with standard media which become dust filled deep inside This extends filter life and filtration efficiency up to six times that of standard media Extending filter change intervals also means the Au 1 e engine will be j M Avoiding excessive dust on the job site 4 may not be possible Avoiding damage the dust can cause is possible with Cat UHE air filters If only had used Genuine Cat parts KEEP IT REAL KEEP IT CAT You have to push every day To meet tomorrow s deadline To secure the next contract To stay ahead of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILT IN For more information contact our call centre on 0800 21 2
200. t indicator should reset within three pushes Yellow Core Movement After the engine accelerates to high idle the yellow The Benefits core should latch at or near the highest vacuum attained during the acceleration test Primary Filter When changing the primary element at 250 operating hours and the secondary element at 750 operating hours Shows you how much filter life remains and ensures optimum engine performance Minimises filter changes and reduces filter costs Indicates airflow resistance even when the machine is not running Can be reset with the spring release button If the indicator will not easily reset or not latch at level filter is no longer allowing attained the indicator sufficient air into the should be replaced engine and must be changed Cat Advanced High Efficiency Engine Oil Filters Improved filtration for a cleaner engine Cat Advanced High Efficiency engine oil filters increase contamination control performance pro viding for a much cleaner running engine lubrication system Cat Advanced oil filters provide enhanced filtration without the shorter change intervals often required by other brands higher efficiency filters The Cat 1R 1807 and 1R 1808 filters contain an improved higher efficiency filter media This media is designed to increase contaminant capturing efficiency while maintaining excellent dirt holding capacity characteristics The Ca
201. t 1R 1807 and 1R 1808 filters offer better filtration efficiency than standard oil filters improved engine cleanliness and a longer component life An option for improved engine oil filtration Cat Advanced oil filters are now installed on new engines in production They are also the approved upgrade option for Cat engine models that use the 1R 0739 and 1R 0716 Standard Efficiency Engine Oil Filters Improved filtration for less wear To increase contamination control capability the Cat Advanced Oil Filter combines improved filtration efficiency excellent contaminant holding capacity and low pressure drop characteristics The graphs to the right demonstrate in blue the improved filtration efficiency the 1R 1807 and 1R 1808 filters offer over the corresponding standard efficiency filters The result is less wear on oil lubricated engine parts 1R 1807 EFFICIENCY PERFORMANCE MERE A us 1 Multipass Efficiency 96 0 Particle Size Microns 1R 1808 EFFICIENCY PERFORMANCE 1R 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 Particle Size Microns I Multipass Efficiency 96 M uf Chil FH ra 2 22 Eea oops pt Consistent quality from filter to filter Caterpillar engineers 115 liquid filters to avoid metal contaminants leaks pleat bunching and movement
202. t heal KEEP It al You have to push every day meet tomorrow s deadline To secure the next contract To stay ahead of the competition No matter what challenges lie ahead Caterpillar and Barloworld Equipment are committed to bringing you machines solutions and support to help your business keep pushing forward SAFETY BUILT IN For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com Follow us on Facebook Barloworld Equipment Southern Africa Follow us on Twitter Barloworldequip Be sure your track is always properly adjusted Every application affects undercarriage wear differently and requires proper track adjustment Adjust your track in the underfoot conditions in which your machine is working For example if track that is correctly adjusted for a non packing application is put into a packing situation packing materials will increase track tension making the track adjustment too tight Added track tension increases both the load and the wear on all mating components of your undercarriage Improperly adjusted track can result in problems and wear on other components such as Bushing and sprocket accelerated wear Tight track increases loads which advances wear Wear occurs as the bushing rotates and or slides in the sprocket e Link track roller and idler accelerated wear To a lesser extent tight track increases loads between the links rollers and idlers This
203. t hydraulic systems Every O ring Caterpillar makes meets specific material and dimensional requirements Ethylene Propylene Diene Modified Rubber EPDM These are the primary materials used in Cat O rings Other materials in a variety of hardness types are used in specialty applications Seal kits for speciality applications cater for air conditioning fittings plus low pressure high temperature environments Maintain your cooling system High fluid temperatures are the number one cause of shortened seal life FKM Advantage FKM rubber seals are available for O Ring face seals ORFS straight thread O rings STORS and D rings ORFS FKM seals are designed for brake control lines fuel lines and hydraulic control systems STORS FKM seals are designed for fluid fittings and plugs in engines D Ring FKM seals are designed for high pressure hydraulic systems Don t risk expensive components with in expensive after market O rings Maintain your cooling system High fluid temperatures 10 O Ring Tips Keep O rings packaged until installation Remove old O rings with brass or plastic picks to prevent groove damage Don t select O rings based on material colour There is no universal colour standard are the numberone cause of shortened seal life HYDRAULICS Cat Optional High Temperature FKM Seals Longer lasting more heat resistant Cat FKM rubber seals offe
204. t not enough oil will be available to do the job ensure optimum bearing performance Caterpillar offers a full line of Cat lubricants to meet your everyday needs In splash lubrication systems such as in final drives it is imperative to retain the right type and quantity of lubricant in the housing and to change the lubricant and filters at recommended intervals Using lubricant rated for the proper temperature must also be noted When operating at extreme temperatures it can lead to oxidising the oil and breaking down of additives Regardless of the type of lubrication system you are using be sure to understand and follow the manufacturer s recommendations to establish the right type and frequency of lubrication that is needed for your specific bearing design and application Additionally set up an S O S oil analysis programme for your machines if one has not already been put in place This programme can easily help identify abnormal wear prior to it becoming a major problem Thorough inspection Detecting defects and deterioration before failure involves periodically removing cleaning and inspecting the bearings Remove bearings carefully as they can easily be damaged during this removal procedure See Frequently Asked Questions It is important note that you should always use recommended tools and adhere to the outlined procedures in the machine s service manual Avoid harmful removal procedures such as flame
205. t ten times longer than halogen lights e Halogen lights are shock resistant to provide longer life e Light Emitting Diode LED lights are designed for long life and lower maintenance Radios e Heavy duty radios have been tested and exceed shock and vibration standard SAE J1455 e They withstand both hot and cold temperature extremes e Both XM and SIRIUS satellite models are available Seats e Cat Comfort Seats have an ergonomic high back design e Extra thick contoured cushions e And adjustable lumbar support Contact your Barloworld Equipment customer service representative for advice on ways to help enhance both your operators environment and your bottom line Access System Upgrade Cat 777D Series Trucks Improved bumper walkway and cab access Caterpillar is pleased to announce the introduction of a field installed diagonal stairway retrofit kit for Cat 777D Series large off highway trucks The stairway improves access to and from the bumper walkway and cab thereby reducing risks of slips trips and falls The 777D Series retrofit stairway is 600 mm 24 wide andis Product Support integrated diagonally across the front of the machine This kit Product Specifics includes a stairway bumper extension handrails and walkway Detailed step by step Cat 777D Special Instructions Ordering Information SI with graphics are m available electronically don i o New 777D Series machines are
206. termining the cause is usually easier said than done A visual examination may identify the type of damage but it may not aid it recognising what is causing the problem Take this situation for example if a bearing has scored and heat discoloration on the roller ends you know it is burned up and needs to be replaced h Hi E 1 htm em ENTITY HE Yet the cause could be linked to various factors such as insufficient or improper lubrication improper adjustment or any combination of these factors For this instance you should carefully investigate the mounting installation and parts affecting the bearing operation to decipher the cause of the damage Remember if you merely replace the failed bearing without finding and fixing the root cause the replacement bearing will most likely endure the same wear and damage as the original Maximise the life of your bearings For any machine to be safe reliable and productive proper bearing maintenance is an absolute must That s because bearings are used in and affect the performance of virtually all mechanical components You could cross your fingers and hope nothing ever goes wrong Or you could take a proactive approach by eliminating bearing problems before they begin with prevention and scheduled maintenance programmes that will ultimately minimise repair costs and downtime And that s what you really want from any machine gt BEARING MAINTENANC
207. ting Caterpillar s exacting quality standards components plus a Cat Reman cylinder head Reman fuel injectors and Reman water and oil pumps Bronze covers basic repairs typically caused by factors such as dust ingress whilst Silver and Gold kits are designed for At this stage Precious Metals Engine Rebuild Kits are being mid life top and bottom rebuilds Platinum kits meet complete Introduced locally for 3176 3306 and 3406 3406C or 3406E rebuild requirements optimising the second and third life engines The 3406 series caters for the following machine capabilities of Cat engines models e Cat 980G and 980F wheel loaders As the basic building block for all higher levels Bronze e Cat D8N and D8R track type tractors includes components that one might not think of replacing e Cat 735 and Cat 740 articulated trucks but which could lead to unplanned downtime and costly e Cat 824G wheel dozers failures a prime example being exhaust manifold sleeves e Cat 826G compactors and Cat 621G 623G 627F and 627G scrapers Bronze components include gaskets and seals oil and fuel filters camshaft bearings turbo nuts and bolts and a coolant The 3306 rebuild kit caters for models that include temperature regulator e Cat 140H and 160H motor graders e Cat 966G wheel loaders Silver builds on Bronze with the addition of pistons e Cat D7 dozer cylinder liners wrist pins piston rings and retainers Gold Rebuild It Right The Right Parts
208. tion Cat FDAO Final Drive Axle Oil was developed specifically to protect gears and bearings in bevel gears differentials final drives and axles that do not contain friction materials Cat FDAO is the preferred lubricant for Cat off highway truck front wheels differentials and final drives It is compatible with Cat final drives and axles that previously specified 4 lubricants and do not contain friction material Cat FDAO has the following qualities Compatible with Cat Transmission Drive Train Oil Excellent protection against rust and copper corrosion Minimises foaming for increased lubrication Low oxidation rate for improved oil life Maintains desired viscosity and film strength Provides reduced wear from debris particles suspended in the oll Cat Gear Oil offers maximum protection against the following damage scoring of the gear teeth pitting of the gear teeth and pitting of the parts in roller bearings Cat Gear Oil provides e Excellent stability under high temperature conditions e Superior low temperature performance e Protection against rust and corrosion Some applications require additives for the extreme pressures that can occur at the edges of the components For these applications Cat Gear Oil provides the extra protection Cat Gear Oil should not be used in compartments that specify TO 4 or TO AM oll SeOeS Services Importance of 5 0 5 Oil Analysis Scheduled Oil Sampling is
209. to last even under incredible stress Drive train components operate under incredible stress and their ability to stand up to tough conditions can mean significant cost savings The friction material used in Cat components is designed to last until regularly scheduled assembly overhauls Its life is better matched to that of other drive train components so you can make all repairs and replacements at once minimising repair costs and downtime Genuinely Better Cat friction material is designed just for Cat drive train components working in Cat machines Here are a few examples of problems that can be avoided by using Cat friction material Material selection Unapproved adhesives can result in poor bond strength or premature bond failure Improper density weight hardness thickness or composition can affect braking and shifting and cause premature wear noise drag creep and damage to the mating part in the system Heat treatment Improper heat treat can cause premature spline wear and damage to the mating part Manufacturing processes Improper forming of materials can cause misalignment premature wear and power overloading Improper groove type width and depth can affect oil flow and cooling resulting in higher running temperatures loss of coefficient of friction wear glazing and discolouration Improper positioning of the friction material on the core can interfere with the mating part Failure to conform to
210. tor technology Large rotor arm cross sectional area ensures that the rotor will not snap under load when impacted with mixed debris fields like wood chips chaff or small rocks The rotor accelerates the airflow to improve the separation process and curved swept arms sling debris to the outer orbits of the toroidal dome Exclusive sealed bearing cavity Bearings are packed in a 20 grease concentration instead of the typical 10 15 used by competitors to allow operation in extreme cold The bearings are protected with a labyrinth seal an o ring seal and a top cap to keep debris and moisture out Debris laden applications may require an optional heavy debris basket screen as shown on this Cat 953D unit Breakaway technology dome is designed to break away from the base if heavily impacted by an obstacle on the Jobsite This feature prevents costly damage to the engine air intake system Heavy debris screen kits Kits are available for debris laden applications such as landfill forestry etc Recommended Uses Air flow range Eight models in sizes that range from 3 to 8 to handle 50 1 400 cubic feet per minute CFM and much higher CFMs with multiple unit installations Please contact your Barloworld Equipment customer service representative for more information Mounting and equipment types Mounts on all vertical and horizontal air cleaner housings on all machines Recommended uses Construction mining
211. trademarks of Caterpillar and may not be used without permission FILTERS Cat Transmission Filters Filters designed specifically for transmission and powertrain oil applications A line of Cat filters has been introduced to better meet the specific needs of transmission ap plications These new Cat transmission filters feature a synthetic media designed to deliver a high level of filtration performance and to reduce pressure drop across the media The end result significantly higher dirt holding capacity and better cold weather performance Caterpillar recommends Cat Advanced High Efficiency Improved Transmission Performance Transmission Filters for transmission applications because they are designed to meet the specific needs of the The test results below demonstrate that Cat Advanced High powertrain Efficiency Transmission Filters with synthetic media reduce pressure drop issues in comparison to hydraulic filters with Switching to these new filters greatly increases filter life synthetic media This means reduced bypass and less wear of and provides better transmission component protection transmission components Cat Transmission Filters perform better in cold weather and during cold starts instances of filter bypass are greatly reduced especially when using higher viscosity oils Pressure Drop 30W Oil at 62 F 100 System and Performance Benefits 80 1 Hydraulic Filter o Greater dirt holding capacity for
212. tre along with another support for the right and left hand sides Note to readers Prolonged operation with loose hardware can cause the bolts to elongate the mounting holes in the support This makes it increasingly difficult to keep hardware tight Repeatedly burning off hardware also weakens the support around the bolt holes If cutting edges and end bits are not replaced soon enough severe wear and damage can occur to the cutting edge support If a blade is suffering from any of these problems a genuine Cat cutting edge support will ease the pain with its guaranteed dimensional accuracy Lifting Eyes Another advantage of the Cat EEWL cast end bit is that lifting eyes have been designed near the top face of the end bit and topside for Lifting eyes enable safe ay handling and installer installation and removal Front and rear perspectives the mounting surface of the end bit which attaches to the blade support has been machined for optimum flatness Blade Maintenance and Production Tips Use new bolts and nuts when installing new GET components When installing cutting edge bolts start at the centre and work out toward the ends or begin at one end and work to the other When downtime and production schedules are key factors it is usually more economical to turn or replace all edges and bits simultaneously even though all parts are not completely worn The torque values specified for GET plow
213. ts come in four levels Bronze Silver Gold and Platinum Whatever level you choose you ll find unmatched value as compared with competitive kits Camshaft Bearings Exhaust Manifold High Temperature Studs Complete Set of Reman Fuel Injectors Reman Oil Pump Re use of injector seals may cause fuel dilution and additional damage to the engine Debris from unexpected failure may damage turbo and internal cylinder components Replacement ensures compliance with Emissions and Noise Regulations To ensure proper cooling to prevent engine overheating Replaced to prevent any leaks from when seal was removed Locknuts are not reusable 2 Recommended by Caterpillar s engineers to maximise performance and reliability Recommended by Caterpillar s engineers to maximise performance and reliability Recommended Caterpillar s engineers to maximise performance and reliability Cat Reman parts provide same as new performance improved turnaround time and reliability at a fraction of the cost of buying new parts Actual consists may vary according to Engine Model and product options and attachments associated with your engine arrangement As compared with the Silver Level the Gold Level not only includes Reman Connecting Rods the cylinder packs are pre assembled saving additional labour hours Aftermarket kits typically require piston crowns to be ordered separately from the
214. tube bundles and end sheets which increases reliability and performance levels Turbochargers Centre housings are tested for seal integrity All thrust and antifriction bearings are replaced to ensure long life and performance Unit Injectors and Fuel Nozzles Every component is completely disassembled cleaned and extensively inspected to ensure same as new quality and reliability Advanced salvage techniques are applied to ensure components meet specifications All seals and O rings are replaced Fully assembled remanufactured injectors are tested and calibrated to new product specifications Water Pumps and Oil Pumps Cat Reman water and oil pumps are updated to meet the latest design standards and feature 10096 replacement of bearings and seals Simple core acceptance reduces costs Cat Reman engine components are typically priced at 40 7096 of new with the return of your used core through our easy core acceptance programme Our simple core acceptance criteria allow a quick determination of core credit We visually inspect the core on the spot providing an immediate decision on core condition and credit so you don t have to wait for or guess about repair costs Our two level pricing system ensures that engines with broken cracked or welded blocks can earn a partial refund Plus knowing the exchange price in advance means you ll avoid mid job surprises Basic Core Criteria e Component not visibly cracked
215. ty fuel low cetane rating or water in fuel Hard starting engine missing Coolant fuel leak into crankcase Improper oil fill Coolant fuel leakage into crankcase Extended oil change period Debris in oil filter Damaged bearings Incorrect oil use Dirt entryway Cat Final Drive Repair Indicators Worn plates and discs Brake Slippage Wrong oil used _ Linkage out of adjustment Worn plates and discs Unusual Noises Dirt in entryway _ Low fluid level Wrong oil used Overheating _ Low fluid level Worn or damaged seals Dirt in entryway Wrong oil used Extended oil change period Disc disintegration Worn gears or bearings Gear failure Vibration Sprocket failure Bearing failure Worn hard cracked seals Leaks Sprocket failure Bearing failure Plug Quick Reference Guides Cat Transmission Repair Indicators Hesitation Slippage Debris in Filter on Magnetic Screen Worn plates and discs _ Linkage out of adjustment Low fluid level Linkage not free Incorrect pressure settings Wrong oil used Worn gears bearings Dirt in entryway Aeration cavitation Low fluid levels Bent drive shaft Gear failure Bearing failure Wrong oil used Plugged radiator Worn pump pressure relief valve Worn or damaged seals Low fluid level Worn or dirty control valve Dirt in entryway Wrong oil used Extended
216. ucket bottoms and sides dozer push arms hydraulic Mild Steel Backing Plate Provides impact absorption for excavator ski runners and sides and crusher hoppers It greater durability offers equivalent wear protection at less weight than weld on or bolt on wear plates The compression retainer provides a hammerless method of installation and removal reducing downtime during replacement It allows for quick replacement and makes it easy to swap out wear plates retainer snaps into place to firmly hold the wear plate to the base plate MAWPS allows you to achieve a greater payload over other manufacturer s wear protection systems without exceeding gross vehicle weight limits Exceeding those limits can result in greater tyre wear more fuel consumption and a higher possibility of structural drive train and engine damage which can all greatly increase operating costs The skeletal Mechanically Attached Wear Plate System provides the same hammerless means of installation and removal as the solid MAWPS but is for use in the rear portion of truck bodies The skeletal plates are designed to trap material allowing for material on material wear rather than wear on the steel body liner Mechanical Hammerless Installation The Mechanically Attached Wear Plate System consists of a wear plate which slides onto a weld on base plate and is held in place with a patented compression retainer Worn wear A range of Cat wear protection items
217. ults in detecting defects and deterioration before they fail completely and damage other vital components Scheduling Good scheduling means maintenance inspections and planned repairs are done on time to prevent drive train failures caused by overlooked maintenance You can also view S O S Oil Analysis results online A HIGHER YIELD Medium Size Excavators Our current range offers excellent controllability and reliability impressive lift capacity better fuel efficiency simplified service and a more comfortable operator station to increase your productivity and lower your operating costs For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com _ 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission Record keeping By developing an accurate machine record keeping system you can identify high cost or problem areas track work flow control costs and increase machine resale value An accurate record keeping system documents drive train history by detailing component life and cost information We can help you set up manual record keeping and work order systems or we can help you install computer software programs to perform scheduling checklists and other recor
218. urface temperature is in excess of 4000 F This material is specially formulated to resist the damaging effects of high temperatures and deliver longer wear life in applications where heat build up is a problem One such application would include relatively deep penetration of more than 2 and contact with the road bed for extended distances of a kilometre or more Ripper Scarifiers Rear mounted ripperscarifiers enhance versatility over conventional forward mounted scarifier configurations simply by changing shank position it s possible to either rip or scarify as work conditions require Curved ripper shanks are recommended for continuous ripping in tougher materials Ripper tips for motor graders are available in two designs centreline and penetration Centreline tips are appropriate for most applications whilst penetration tips are best for high impact or hard to penetrate materials 8 203 mm FLAT CUTTING EDGES Edge Length A78129 478119 a 04 413036 12 304 8 mm centres on bolt m 478119 uses pn quantity of 6 10 254 mm FLAT CUTTING EDGES Edge Length 416502 416508 476511 0775 19 mm 6 152 mm CURVED CUTTING EDGES Edge Length 9W1835 _ 509553 _ 509554 84043 063 16 mm Bolt Quantity 8 203 mm CURVED CUTTING EDGES Edge Length 109 3137a 122 0968 704509 509562 509561 509731 12 304 8 mm centres on bolt holes a 109 3137 uses bolt TN of 5 478131 uses bolt
219. used in the appropriate ap plication This guide will help you make informed GET decisions when choosing the right cutting edge which is critical for enhancing production and keeping total costs to a minimum The three factors to consider in choosing a cutting edge are e Shape e Width e Thickness Edge Shape There are two basic edge shapes flat and curved with serrated edges available in both configurations In addition the Cat GraderBits System dramatically expands the range of edge shape options Edge width translates into wear material so a wider edge usually delivers longer life For example a 203mm edge provides twice as much available wear material as a 152mm edge at only about 35 more cost Plus hardware usage and edge replacement downtime will be cut by 50 To extend cost savings even further a 254mm cutting edge will last three times longer than a 152mm edge when used under comparable conditions The influence of Crowning Crowning is a normal wear pattern in which the cutting edge eventually conforms to the profile of the material being graded When extreme crowning occurs or when finishing applications require tolerances of less than 6mm the best Correct moldboard position Correct moldboard position reduces wear and extends edge life If the grading angle is too shallow penetration will be poor and heat will build up on the edge his causes mushrooming or slivering which reduces ed
220. ware Caterpillar Grade 8 hardware is performance matched to Cat GET in both strength and durability Grade 8 nuts and forged dome head bolts have a minimum proof load of 120 000 psi 830 MPa and a tensile strength of 150 000 psi 1035 MPa If penetration is a problem choose a thinner edge a serrated edge or When replacing ground engaging tools always use Caterpillar standard hardware regardless of the application Motor Grader Edge Inspection and Installation Before installing new edges be sure to carefully inspect the face and underside of the moldboard check for bent or cracked areas as well as severe wear If necessary weld moldboard repair plates in place the Cat GraderBits System for the most compacted materials GET MOTOR GRADERS Scarifiers and Components While the main focus of motor grader operations is the moldboard there are also important choices to make when selecting scarifier components and ripperscarifier tools Caterpillar offers a range of built tough ripper and scarifier tools and components that make a difference by enhancing production and extending motor grader versatility Scarifiers are available in two configurations V Block and straight Block Both have tapered locking grooves to hold tips securely in place V Block scarifiers are the best choice for breaking up blacktop and loosening compacted surfaces rocky subgrades and frozen ground Cat V Block Scarifiers also known as mid mou
221. while providing excellent engine protection and Cat DEO Performance This table indicates the differences between ECF2 standards and the proprietary standards Tested of Caterpillar Beyond Industry Standards addition to the tests required for the ECF 2 classification Cat DEO undergoes four proprietary multi cylinder endurance tests a variety of quality assurance tests and thousands of hours of field service Only when it has passed all these tests can it be approved by Caterpillar Piston deposits and oil control Cat DEO Continued TYPICAL CHARACTERISTICS The values shown are typical values and should not be used as quality control parameters to either accept or reject product Specifications are subject to change without notice Not available in all regions PRODUCTIVITY THAT GIVES YOU THE CUTTING EDGE Caterpillar has a seamless range of continuous miners covering both soft and hard cutting applications in any seam thickness The range includes machines capable of operating in seams from 0 76 m to 4 70m Less downtime through Longer Overhaul Intervals e Superior performance via higher output engine e High maneuverability allows faster positioning and optimum cutting For more information contact our call centre on 0800 21 22 48 or visit www barloworld equipment com 2013 Caterpillar Inc All Rights Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER ED
222. y procedures honing cylinder tubes practicing contamination control and installing the industry s best hydraulic seals We even check for other problems such as dented or scored rods and we pressure test each resealed cylinder There s a lot more to resealing hydraulic cylinders than just installing new seals Find out how we can help you keep your costs low and your cylinders performing at peak efficiency Five reasons we re your best choice for hydraulic cylinder reseal service Proper disassembly and assembly Without the proper tooling completing the repair can take much longer You also risk damaging reusable parts or ruining the cylinder group We use tooling designed to disassemble and assemble cylinders quickly without damaging components Light honing We light hone cylinder tubes to remove minor scratches and other hard to see imperfections that quickly damage newly installed piston seals and piston wear bands This procedure in conjunction with proper contamination control practices substantially increases the life of new hydraulic cylinder seals Contamination control Worn seals allow contamination to enter the hydraulic cylinder These contaminants can damage newly installed seals or worse damage other system components such as pumps or valves We clean cylinder components and wash out any contaminants before re assembling the group Cat seals and seal kits Caterpillar is dedicated to designing t
223. your operators tend to work on one side of the machine more than the Do not spin the tracks since it reduces production while increasing wear on all undercarriage components especially on grouser bars Work it hard Make it last Fix it right Call your Barloworld Equipment parts and service representative for expert advice and service Adjust the track for correct tension Always adjust track in its working environment Correct track adjustment is critical Tighten the track hardware correctly using Caterpillar s torque turn method Make daily visual inspections of the equipment Check for loose bolts leaking seals and abnormal wear Keep the undercarriage clean of mud and debris so rollers can turn properly UNDERCARRIAGE Operating and Maintenance Tips Cat Undercarriage is designed to work and wear as a system to reduce your operating costs You make daily decisions that impact undercarriage wear and costs This guide can help you and your operators understand how undercarriage works and how to reduce wear and save money Al though wear can t be halted we are committed to helping you make each undercarriage system last with correct operation and maintenance Custom Track Service Your undercarriage is an expensive investment It accounts for as much as 20 percent of the price of a new track type machine Undercarriage can represent as much as 50 percent of machine maintenance costs Our go
224. yse results of performance test oil analysis and visual CHS Inspections Rep en e Provide a detailed report e Recommend repairs if needed as well as changes to the Recommended annually or every 2 000 hours CHS maintenance schedule inspections performed by Barloworld Equipment technicians include Performance tests e Engine performance e Hydraulic cylinder drift e Hydraulic system cycle times and pressure Custom Hydraulic Service inspections identify when machine s hydraulics e Engine and cooling system are not performing up to par and enable Cab corrective action to be taken e Electrical system e Undercarriage Ground Engaging Tools Cat O Rings Matched to your Cat system and designed for maximum seal life in demanding applications Cat O ring materials are specifically selected based on the different fluids and fluid temperatures in Cat engines and machines Seal material hardness is matched to the different fluid system pressures to maintain proper sealing force as well as minimise seal extrusion and seal abrasion In addition some Cat O rings have special coatings like PTFE to minimise friction and ensure proper seal installation in tight seal grooves Precise seal dimensions help ensure Cat O ring seals fit properly into Cat seal grooves without damage to the seal Cat Resealable O Ring Packaging and there are unique Cat O ring sizes designed for use in special applications where
225. ystem cleanliness reduce component wear and lower costs In addition to the standard Cat filters Caterpillar also provides High Efficiency Filters They use a synthetic media to remove a higher proportion of both large and small particles High Efficiency Filters should be used for 250 service hours after any maintenance rebuild or debris invasion or when suggested by particle count data from S O S Services It s then recommended to switch back to standard filters When replacing an old transmission filter it s extremely important to cut open the filter and inspect for signs of component wear or clogging Pieces of metal may be found in or around the magnetic screen and can indicate a certain component is failing Possible sources of metal pieces Aluminium torque converter Bronze coloured transmission clutches Gray iron transmission housing or pistons Brass rings in rotating clutches Shiny metals gear teeth Shiny flaky material bearings Breathers Breathers are extremely important in transmission preventive maintenance If breathers become plugged and temperatures dip down during the evening the cab becomes a vacuum because the cool air inside the cab shrinks As the air inside the cab shrinks it draws in air dirt and other contaminants through the gaskets and seals If this occurs regularly the gaskets and seals may sustain enough damage to allow water and other contaminants into the cab Dirt and water are e

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