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Operator’s Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

D25C, D30C, D35C, & D350C Articulated Trucks

S/n 9YC458 & 459, 2GD088 & Up, 8XC200 & Up, 9YC467 & Up,

7ZC140 & Up

CT-O-D25CTK+

TABLE OF CONTENTS

Foreword .................................................................................................................. 2

Safety

Safety ........................................................ 3 Mounting and Dismounting .................. 1 2 Warning Plates and Labels ..................... .4 Preparing to Start the Engine ................ 12 General ..................................................... 8 Starting the Engine ................................ 13 Crushing or Cutting Prevention ............... 9 Preparing to Operate the Machine ........ 13 Burn Prevention ........................................ 9 Operating the Machine .......................... 14 Fire or Explosion Prevention .................. 1 0 Parking the Machine .............................. 14

Operation

Towing .................................................... 15 After Starting the Engine ...................... .42 Model Views ........................................... 1 8 Moving and Stopping the machine ...... .43 Operator's Compartment ....................... 20 Parking the Machine .............................. 44 Machine Controls .................................. 35 Operating Techniques .......................... .45 Implement Controls ............................... 37 Tire Inflation Information ...................... .49 Before Starting the Engine .................... 38 Identification Number Locations ........... 51 Starting the Engine ................................ 40

~·lIIaintenance Recommendations

Cooling System ...................................... 52 Fuel Specifications and Information ..... 60 Fuel System ............................................ 53 Lubricant Specifications ........................ 61 Hydraulic System ................................... 54 Approximate Refill Capacities ................ 62 Anti Vandal Filler Caps (if equipped) ..... 54 Lowering the Suspension ...................... 63 Air Inlet System ...................................... 55 Tilt Cab ................................................... 65 Electrical System .................................... 56 Lifting the Machine ................................ 66 Scheduled Oil Sampling ........................ 57 Lubrication and Maintenan'ce Chart ..... 67 General ................................................... 57 Recommended Lubricant Viscosities .... 69 Tightening Torques ................................ 58 Servicing Procedures ............................. 70 Coolant Specifications ........................... 59

1

Remove the hydraulic tank filler cap only after the engine has been stopped and the filler cap is cool enough to remove with your bare hand.

Remove the hydraulic tank f iller cap slowly to relieve pressure.

Relieve all pressure in air, oil. fuel or cooling systems before any lines, fittings or related items are di scon nected or removed.

Battery electrolyte conta ins ac id and can cause inj ury. Avo id contact w ith the ski n and eyes.

10

Fi re or Explosion Prevention

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

Do not smoke while refuel ing or in a refueling area .

Do not smoke in areas where batteries are charged, or where flammable materials are stored .

When starting from an external source, always connect the positive (+) boost cable to the positive (+) terminal of the battery of the engine to be started.

Attach the negative (-) boost ground cable last. away from the battery. See the Operation Guide for specific instruct ions.

Cl ean and tighten all electrical connections . Check daily for loose or fr ayed electrical wires. Have all loose or frayed electrical w ires tightened, repaired or replaced before operati ng the machine.

Keep all fuels and lubricants stored in properly marked contain ers an d away from all unauthorized persons.

Store all o ily rags or other f lam mable mater ial in a protective container, in a safe pl ace.

Do not we ld or f lam e cut on pipes or tubes that have conta ined fla mmable fluids. Clean them thoroughly w ith nonflammable so lvent before we lding or f lame cutting on them.

Rem ove all flammable mater ials such as fuel , o il and other debri s before they accu mulate on the machi ne.

Do not expose the machi ne to f lames, burning brush, etc., if at al l poss ible.

Do not bend or stri ke high pressu re lines. Do not install bent or damaged lines, tubes or hoses.

Repair any loose or damaged fuel and oil li nes, tubes and hoses. Leaks can cause f ires.

Inspect all lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. Tighten all connectionsto the recommended torque.

Make sure that all clamps, guards and heat shields, are installed correctly to prevent vibration, rubbing against other parts and excessive heat during operation.

Shields, which protect hot exhaust components from oil or fuel spray in the event of a line, tube or seal failure, must be installed correctly .

Ether is flammable. Do not smoke while changing ether cylinders .

Do not store replacement ether cylinders in living areas or in the operator's compartment.

Use ether only in well ventilated areas.

Keep ether cylinders out of the reach of unauthorized persons.

Do not store ether cylinders in direct sunlight. Discard cylinders in a safe place. Do not puncture or burn cylinders.

Fire Extinguisher

Always have a fire extinguisher on the machine and know how to use it. Inspect and have it serviced as recommended on its instruction plate.

Tire Information

Explosions of air-inflated earthmoving tires can result from heat-induced gas combustion inside the tires. The heat generated by welding or heating rim components, external fire or excessive use of brakes can cause gaseous combustion.

A tire explosion is much more violent than a blowout. The explosion can propel the tire, rim, and final drive components as far as 500 meters (1 500 feet) or more from the machine. Both the force of the explosion and the flying debris can cause personal injury or death, and property damage.

11

at least 15m at least 500m

Do not approach a tire suspected of being overheated closer than the outside of the area represented by the shaded area in the drawing .

Proper nitrogen Inflation equipment and training in its use are necessary to avoid overinflation. A tire blowout or rim failure can result from improper or misused equipment.

Stand behind the tread and use a self­attaching chuck when inflating a tire.

Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious personal injury or death. Follow carefully the specific information provided by your tire or rim servicing man or dealer .

Mounting and Dismounting

Mount and dismount the machine only where steps and/or handholds are provided .

Use both hands and face the machine; when mounting and dismounting .

Never get on or off a moving machine. Never jump off the machine.

Do not try to climb on or off the machine when carrying tools or supplies. Use a hand line to pull equipment up onto the platform.

12

Preparing to Start the Engine

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Inspect the condition of the seat belt and mounting hardware. Replace any damaged or worn parts. Replace the seat belt regardless of appearance. after three years.

Adjust the seat so that full brake pedal travel can be obtained with the operator's back against the seat back.

Make sure the machine is equipped with a lighting system as required by conditions.

Make sure all lights are working properly.

Make sure no one is working on. underneath or close to the machine before starting the engine or beginning to move the machine. Make sure the area is free of personnel.