Caterpillar Operation and Maintenance Manual (EN)

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented. A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive.

You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

m WARNING When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

Стр. 2

3 Table of Contents Table of Contents Safety Section (D6T LGP (OEM)) Safety Messages ................................................... 6 Parking................................................................. 101 Transportation Information................................... 104 Additional Messages ........................................... 14 Towing Information .............................................. 106 General Hazard Information ................................ 17 Engine Starting (Alternate Methods).................... 111 Crushing Prevention and Cutting Prevention ....... 19 Maintenance Section (D6T LGP (OEM)) Lubricant Viscosities and Refill Capacities..........

113 Burn Prevention ................................................... 20 Fire Prevention and Explosion Prevention ........... 21 Maintenance Support .......................................... 121 Fire Safety ............................................................ 24 Maintenance Interval Schedule ......................... 123 Fire Extinguisher Location ................................... 24 Warranty Section (D6T LGP (OEM)) Warranty Information ........................................... 177 Track Information ................................................. 24 Electrical Storm Injury Prevention ........................

25 Reference Information Section (D6T LGP (OEM)) Reference Materials............................................. 178 Before Starting Engine ......................................... 25 Engine Starting .................................................... 25 Safety Section (Pipelayer Attachment Kit) Safety Messages - 72H Pipelayer ...................... 180 Before Operation ................................................. 25 Visibility Information ............................................. 25 Before Operation ............................................... 187 Restricted Visibility ...............................................

26 Visibility Information ........................................... 187 Operation ............................................................. 26 Operation ........................................................... 189 Parking ................................................................. 28 Parking ............................................................... 190 Slope Operation ................................................. 190 Slope Operation ................................................... 28 Equipment Lowering with Engine Stopped ....... 191 Engine Stopping .................................................. 29 Sound Information and Vibration Information ....

191 Equipment Lowering with Engine Stopped ......... 29 Guards ............................................................... 192 Sound Information and Vibration Information ...... 29 Product Information Section (Pipelayer Attachment Kit) General Information ............................................. 193 Operator Station ................................................... 32 Guards ................................................................. 32 Product Information Section (D6T LGP (OEM)) General Information ............................................... 34 Operation Section (Pipelayer Attachment Kit) Before Operation .................................................

197 Identification Information ....................................... 36 Maintenance and Lubrication Section (Pipelayer Attachment Kit) Lubricant Viscosities............................................ 210 Operation Section (D6T LGP (OEM)) Before Operation ................................................... 42 Machine Operation ................................................ 44 Maintenance Interval Schedule (MIS) ............... 212 Engine Starting ...................................................... 97 Index .................................................................. 227 Adjustments ......................................................... 100

Стр. 3

Maintenance

4 Foreword Foreword Note: Refer to the Caterpillar operation manual for detailed information on the specific operation of the tractor unit Literature Information Safety This manual should be stored in the operator's compartment in the literature holder or seat back literature storage area. The section entitled “Pipelayer Attachment Kit” of this manual contains a safety section, and the section entitled “D6T LGP (OEM)” contains a safety section. The safety sections list basic safety precautions. In addition, these sections identifie the text and locations of warning signs and labels used on the machine.

This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information. The information contained in the section entitled “Pipelayer Attachment Kit” of this manual is limited to the pipelayer attachment and specific modifications made to the tractor unit. Refer to the section entitled “D6T LGP (OEM)” for complete information regarding the tractor unit. Read and understand the basic precautions listed in the safety sections before operating or performing lubrication, maintenance and repair on this machine.

Operation Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes. The section entitled “Pipelayer Attachment Kit” of this manual contains an operation section, and the section entitled “D6T LGP (OEM)” contains an operation section. The operation sections are references for the new operator and a refresher for the experienced operator. These sections include a discussion of gauges, switches, machine controls, attachment controls, transportation and towing information.

Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. The latest version of this publication is available for downloaded from the internet at www.plmcat.com. Read, study and keep this manual with the machine. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine. Whenever a question arises regarding your machine, or this publication, please consult PipeLine Machinery International for the latest available information. Operating techniques outlined in this publication are basic.

Skill and techniques develop as the operator gains knowledge of the machine and its capabilities. Machine Description Maintenance The sideboom equipment is attached to a Caterpillar D6T LGP tractor. The primary use of this machine is for petroleum-product pipeline-construction in the 20" to 30" (510 to 765 mm) pipeline range. The section entitled “Pipelayer Attachment Kit” of this manual contains a maintenance section, and the section entitled “D6T LGP (OEM)” contains a maintenance section. The maintenance sections are guides to equipment care. The Maintenance Interval Schedules (MIS) list the items to be maintained at a specific service interval.

Items without specific intervals are listed under the "When Required" service interval. The Maintenance Interval Schedules liststhe page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedules as an index or "one safe source" for all maintenance procedures. The operator should read, understand, and follow both the tractor and the pipelayer operating and maintenance instructions. The operator must comply with all pipelayer procedures, regulations, and safety precautions. This equipment is to be operated by qualified personnel only. The daily service/inspection procedure should be performed before start-up.

Operate all pipelayer controls with no load, until familiar with machine operation.

Стр. 4

Caterpillar Product Identification Number

5 Foreword Maintenance Intervals Machine Capacity Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Additional attachments or modifications may exceed machine design capacity which can adversely affect performance characteristics. Included would be stability and system certifications such as brakes, steering, and rollover protective structures (ROPS).

Contact your Caterpillar dealer for further information. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Caterpillar Product Identification Number Effective First Quarter 2001 the Caterpillar Product Identification Number (PIN) has changed from 8 to 17 characters. In an effort to provide uniform equipment identification, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard. Non-road machine PINs are defined by ISO 10261.

The new PIN format will apply to all Caterpillar machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following: Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily. California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 1 Battery posts, terminals and related accessories contain lead and lead compounds.

Wash hands after handling. Certified Engine Maintenance Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. Illustration 1 It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 89).

Certain elements of the machine and engine such as the exhaust system, fuel system, electrical system, intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar. Where: 1. Caterpillar's World Manufacturing Code (characters 1-3) 2. Machine Descriptor (characters 4-8) 3. Check Character (character 9) 4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number. Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format. Components such as engines, transmissions, axles, etc.

and work tools will continue to use an 8 character Serial Number (S/N).

Стр. 5