IPER

SEBU8406-01August 2010

Operation andMaintenanceManual793F Off-Highway TruckSSP1-Up (Machine)

SAFETY.CAT.COM

i03991620

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 asDANGER, 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 pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by NOTICE labelson 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 mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe 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 thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-placement parts or parts with equivalent speci-fications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

SEBU8406-01 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 6

Additional Messages ............................................. 13

General Hazard Information ................................. 14

Crushing Prevention and Cutting Prevention ........ 17

Burn Prevention .................................................... 17

Fire Prevention and Explosion Prevention ............ 18

Fire Safety ............................................................ 21

Fire Extinguisher Location .................................... 22

Tire Information ..................................................... 22

Electrical Storm Injury Prevention ......................... 23

Before Starting Engine .......................................... 23

Engine Starting ..................................................... 23

Before Operation .................................................. 23

Visibility Information .............................................. 24

Restricted Visibility ................................................ 24

Operation .............................................................. 25

Parking .................................................................. 25

Sound Information and Vibration Information ....... 26

Operator Station ................................................... 28

Guards (Operator Protection) ............................... 28

Product Information Section

General Information .............................................. 30

Identification Information ....................................... 32

Operation Section

Before Operation .................................................. 34

Machine Operation ............................................... 37

Engine Starting ..................................................... 93

Parking .................................................................. 98

Transportation Information .................................. 105

Jacking Location Information .............................. 108

Towing Information ............................................... 110

Engine Starting (Alternate Methods) .................... 116

Maintenance Section

Tire Inflation Information ...................................... 119

Lubricant Viscosities and Refill Capacities ......... 120

Maintenance Support .......................................... 126

Maintenance Interval Schedule .......................... 130

Warranty Section

Warranty Information .......................................... 222

Reference Information Section

Reference Materials ............................................ 223

Index Section

Index ................................................................... 226

4 SEBU8406-01Foreword

ForewordLiterature InformationThis manual should be stored in the operator'scompartment in the literature holder or seat backliterature storage area.

This manual contains safety information, operationinstructions, transportation information, lubricationinformation and maintenance information.

Some photographs or illustrations in this publicationshow details or attachments that can be differentfrom your machine. Guards and covers might havebeen removed for illustrative purposes.

Continuing improvement and advancement ofproduct design might have caused changes to yourmachine which are not included in this publication.Read, study and keep this manual with the machine.

Whenever a question arises regarding your machine,or this publication, please consult your Caterpillardealer for the latest available information.

SafetyThe safety section lists basic safety precautions. Inaddition, this section identifies the text and locationsof warning signs and labels used on the machine.

Read and understand the basic precautions listedin the safety section before operating or performinglubrication, maintenance and repair on this machine.

OperationThe operation section is a reference for the newoperator and a refresher for the experiencedoperator. This section includes a discussion ofgauges, switches, machine controls, attachmentcontrols, transportation and towing information.

Photographs and illustrations guide the operatorthrough correct procedures of checking, starting,operating and stopping the machine.

Operating techniques outlined in this publication arebasic. Skill and techniques develop as the operatorgains knowledge of the machine and its capabilities.

MaintenanceThe maintenance section is a guide to equipmentcare. The Maintenance Interval Schedule (MIS) liststhe items to be maintained at a specific serviceinterval. Items without specific intervals are listedunder the "When Required" service interval. TheMaintenance Interval Schedule lists the pagenumber for the step-by-step instructions required toaccomplish the scheduled maintenance. Use theMaintenance Interval Schedule as an index or "onesafe source" for all maintenance procedures.

Maintenance Intervals

Use the service hour meter to determine servicingintervals. Calendar intervals shown (daily, weekly,monthly, etc.) can be used instead of service hourmeter intervals if they provide more convenientservicing schedules and approximate the indicatedservice hour meter reading. Recommended serviceshould always be performed at the interval thatoccurs first.

Under extremely severe, dusty or wet operatingconditions, more frequent lubrication than isspecified in the maintenance intervals chart mightbe necessary.

Perform service on items at multiples of the originalrequirement. For example, at every 500 servicehours or 3 months, also service those items listedunder every 250 service hours or monthly and every10 service hours or daily.

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

Certified Engine MaintenanceProper maintenance and repair is essential to keepthe engine and machine systems operating correctly.As the heavy duty off-road diesel engine owner, youare responsible for the performance of the requiredmaintenance listed in the Owner Manual, Operationand Maintenance Manual, and Service Manual.

SEBU8406-01 5Foreword

It is prohibited for any person engaged in thebusiness of repairing, servicing, selling, leasing, ortrading engines or machines to remove, alter, orrender inoperative any emission related device orelement of design installed on or in an engine ormachine that is in compliance with the regulations(40 CFR Part 89). Certain elements of the machineand engine such as the exhaust system, fuel system,electrical system, intake air system and coolingsystem may be emission related and should not bealtered unless approved by Caterpillar.

Machine CapacityAdditional attachments or modifications may exceedmachine design capacity which can adversely affectperformance characteristics. Included would bestability and system certifications such as brakes,steering, and rollover protective structures (ROPS).Contact your Caterpillar dealer for further information.

Caterpillar Product IdentificationNumberEffective First Quarter 2001 the Caterpillar ProductIdentification Number (PIN) has changed from 8 to 17characters. In an effort to provide uniform equipmentidentification, Caterpillar and other constructionequipment manufacturers are moving to complywith the latest version of the product identificationnumbering standard. Non-road machine PINs aredefined by ISO 10261. The new PIN format will applyto all Caterpillar machines and generator sets. ThePIN plates and frame marking will display the 17character PIN. The new format will look like thefollowing:

g00751314Illustration 1

Where:

1. Caterpillar's World Manufacturing Code (characters1-3)

2. Machine Descriptor (characters 4-8)

3. Check Character (character 9)

4. Machine Indicator Section (MIS) or ProductSequence Number (characters 10-17). These werepreviously referred to as the Serial Number.

Machines and generator sets produced before FirstQuarter 2001 will maintain their 8 character PINformat.

Components such as engines, transmissions, axles,etc. and work tools will continue to use an 8 characterSerial Number (S/N).

6 SEBU8406-01Safety SectionSafety Messages

Safety Sectioni03398340

Safety MessagesSMCS Code: 7000; 7405

There are several specific safety messages on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all safetymessages.

Make sure that all of the safety messages arelegible. Clean the safety messages or replace thesafety messages if the words or the images becomeunreadable. When you clean the safety messages,use a cloth, water and soap. Do not use solvent,gasoline, or other harsh chemicals to clean the safetymessages. Solvents, gasoline, or harsh chemicalscould loosen the adhesive that secures the safetymessage. Loose adhesive will allow the safetymessage to separate from the machine.

Replace any safety message that is damaged, ormissing. If a safety message is attached to a partthat is replaced, install a safety message on thereplacement part. Any Caterpillar dealer can providenew safety messages.

SEBU8406-01 7Safety Section

Safety Messages



Safety Messages



Do Not Operate (1)This safety message is located inside the cab.

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Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.

Seat Belt (2)This safety message is located inside the cab.

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A seat belt should be worn at all times during ma-chine operation to prevent serious injury or deathin the event of an accident or machine overturn.Failure to wear a seat belt during machine opera-tion may result in serious injury or death.

High Pressure Cylinder (3)This safety message is located on the steeringaccumulators. The steering accumulators are locatednear the front on the left outside frame rail.

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Hydraulic accumulator contains gas and oil underhigh pressure. Improper removal or repair proce-dures could cause severe injury. To remove or re-pair, instructions in the service manual must befollowed. Special equipment is required for test-ing and charging.


Safety Messages

High Pressure Cylinder (4)This safety message is located on the brakeaccumulators The brake accumulators are located onthe left inside frame rail near the transmission.

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Hydraulic accumulator contains gas and oil underhigh pressure. Improper removal or repair proce-dures could cause severe injury. To remove or re-pair, instructions in the service manual must befollowed. Special equipment is required for test-ing and charging.

Do Not Weld or Drill the ROPS (5)This safety message is located inside the cab.

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Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture's protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. Consult a Caterpillar dealer to deter-mine this structure's limitations without voidingits certification.

Hot Coolant Under Pressure (6)This label is located on the expansion tank besidethe radiator filler cap.

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The coolant is hot and the coolant is under pres-sure. Do not touch the hot surfaces. Refer to theOperation and Maintenance Manual for the proce-dure to follow when you check the radiator.

Explosion Hazard (7)This safety message is located on the battery accesscover.

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Explosion Hazard! Improper jumper cable connec-tions can cause an explosion resulting in seriousinjury or death. Batteries may be located in sep-arate compartments. Refer to the Operation andMaintenance Manual for the correct jump startingprocedure.


Fall Hazard (8)This safety message is located on the right and leftsides of the radiator overflow tank.

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Do not use this surface as a step or platform. Thissurface may not support additional weight or maybe slippery. Serious injury or death could occurfrom a fall.

Truck Body Retaining Cables (9)This safety message is located on the rear of themachine near the connection points for the truckbody retaining cables.

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When it is necessary to work under the machinewith the body (bed) raised, attach the body (bed)retaining cables to the body retaining pins. Installthe body retaining pins through the ends of the re-taining cables. Always use both retaining cables.

Failure to properly secure the body (bed) may re-sult in personal injury or death.

High Pressure Cylinder (10)This safety message is located on each of the foursuspension cylinders.

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High Pressure Cylinder.

Do not remove any valve, hydraulic fitting, orvalve core nor disassemble any cylinder partsuntil pressure is relieved. Personally injury ordeath may occur.

See service manual for correct procedure to re-lieve pressure and to charge cylinders.


Additional Messages

Crushing Hazard (11)This safety message is located on each of the foursuspension cylinders.

g01370911

HIGH PRESSURE CYLINDER

Do not remove any valve, hydraulic fitting, or valvecore, nor disassemble any parts until pressurehas been relieved.

To relieve pressure, truck frame must be proper-ly supported. Failure to comply with this warningwill cause unexpected machine movement result-ing in serious injury or death.

Refer to your Service Manual for correct proce-dures for relieving pressure and/or correct charg-ing procedures.

See your Caterpillar dealer who has tools anddetailed information for servicing and chargingcylinders.

i03401060

Additional MessagesSMCS Code: 1000; 7000; 7405

There are several specific messages on thesemachines. The exact location of the messages andthe description of the messages are reviewed inthis section. Please become familiarized with allmessages.

Make sure that all of the messages are legible.Clean the messages or replace the messages if thewords or images are unreadable. When you cleanthe messages, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures themessages. Loose adhesive will allow the messagesto separate from the machine.

Replace any message that is damaged, or missing.If a message is attached to a part that is replaced,install a message on the replacement part. AnyCaterpillar dealer can provide new messages.

Retarding Guidelines

This message is located inside the cab.


Typical example

Information for Air Conditioner System Service

This message is located inside the cab.

Do not work on the air conditioning system until youhave read the service manual and you understandthe service manual.


ELC (Extended Life Coolant) Cooling System

14 SEBU8406-01Safety SectionGeneral Hazard Information

This message is located near the filler cap for thecooling system.

This machine is shipped from the factory with ELC.


24 Volt Electrical System

This message is located near the batteries and thismessage is located near the power receptacle.

This machine is equipped with a 24 volt electricalsystem.


No Lifting Point

This message is located on the shipping eyes that arelocated on the frame rails. Do not use this locationas a lifting point.


Weight of the Wheel Chock (If Equipped)

This message is located on each wheel chock. Useproper lift and carry techniques when the wheelchocks are handled.


i04010649

General Hazard InformationSMCS Code: 7000



General Hazard Information

Attach a Do Not Operate warning tag or a similarwarning tag to the start switch or to the controls.Attach the warning tag before you service theequipment or before you repair the equipment. Thesewarning tags (Special Instruction, SEHS7332) areavailable from your Cat dealer.

Operating the machine while distracted can resultin the loss of machine control. Use extreme cau-tion when using any device while operating themachine. Operating the machine while distractedcan result in personal injury or death.

Know the width of your equipment in order to maintainproper clearance when you operate the equipmentnear fences or near boundary obstacles.

Be aware of high voltage power lines and powercables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the equipment.

Make sure that all protective guards and all coversare secured in place on the equipment.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools,and other items that are not a part of the equipment.

Know the appropriate work site hand signals andthe personnel that are authorized to give the handsignals. Accept hand signals from one person only.

Do not smoke when you service an air conditioner.Also, do not smoke if refrigerant gas may be present.Inhaling the fumes that are released from a flame thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditionerrefrigerant through a lighted cigarette can causebodily harm or death.

Never put maintenance fluids into glass containers.Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and Maintenance Manualfor the procedure for placing the equipment in theservicing position.

When you perform maintenance above ground level,use appropriate devices such as ladders or man liftmachines. If equipped, use the machine anchoragepoints and use approved fall arrest harnesses andlanyards.

Pressurized Air and WaterPressurized air and/or water can cause debris and/orhot water to be blown out. The debris and/or hotwater could result in personal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when thenozzle is deadheaded and the nozzle is used withan effective chip deflector and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Trapped PressurePressure can be trapped in a hydraulic system.Releasing trapped pressure can cause suddenmachine movement or attachment movement. Usecaution if you disconnect hydraulic lines or fittings.High-pressure oil that is released can cause a hoseto whip. High-pressure oil that is released can causeoil to spray. Fluid penetration can cause seriousinjury and possible death.

16 SEBU8406-01Safety SectionGeneral Hazard Information

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting, and repair of theequipment. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for the following items:

Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Inhalation


Exhaust

Use caution. Exhaust fumes can be hazardousto your health. If you operate the machine in anenclosed area, adequate ventilation is necessary.

Asbestos Information

Cat equipment and replacement parts that areshipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCat replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is boundin a resin or sealed in some way. Normal handlingis not hazardous unless airborne dust that containsasbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestosmaterials.

A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.


Crushing Prevention and Cutting Prevention

Use exhaust ventilation on permanent machiningjobs.

Wear an approved respirator if there is no otherway to control the dust.

Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposalof asbestos.

Stay away from areas that might have asbestosparticles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i01359664

Crushing Prevention andCutting PreventionSMCS Code: 7000

Support the equipment properly before you performany work or maintenance beneath that equipment.Do not depend on the hydraulic cylinders to holdup the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Do not work beneath the cab of the machine unlessthe cab is properly supported.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or whilethe engine is running.

Never jump across the starter solenoid terminalsin order to start the engine. Unexpected machinemovement could result.

Whenever there are equipment control linkages theclearance in the linkage area will change with themovement of the equipment or the machine. Stayclear of areas that may have a sudden change inclearance with machine movement or equipmentmovement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to performmaintenance, always install the guards after themaintenance is performed.

Keep objects away from moving fan blades. The fanblade will throw objects or cut objects.

Do not use a kinked wire cable or a frayed wire cable.Wear gloves when you handle wire cable.

When you strike a retainer pin with force, the retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes, wear protective glasses when you strikea retainer pin.

Chips or other debris can fly off an object when youstrike the object. Make sure that no one can beinjured by flying debris before striking any object.

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Burn PreventionSMCS Code: 7000

Do not touch any part of an operating engine.Allow the engine to cool before any maintenance isperformed on the engine. Relieve all pressure in theair system, in the oil system, in the lubrication system,in the fuel system, or in the cooling system beforeany lines, fittings or related items are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

18 SEBU8406-01Safety SectionFire Prevention and Explosion Prevention

Check the coolant level only after the engine hasbeen stopped.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot components can cause personalinjury. Do not allow hot oil to contact the skin. Also,do not allow hot components to contact the skin.

Remove the hydraulic tank filler cap only after theengine has been stopped. The filler cap must becool enough to touch with a bare hand. Follow thestandard procedure in this manual in order to removethe hydraulic tank filler cap.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i04018872

Fire Prevention and ExplosionPreventionSMCS Code: 7000


GeneralAll fuels, most lubricants, and some coolant mixturesare flammable.

To minimize the risk of fire or explosion, Catrecommends the following actions.

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operate amachine when a fire hazard exists. Contact your Catdealer for service.

Understand the use of the primary exit and alternativeexit on the machine. Refer to Operation andMaintenance Manual, Alternative Exit.

Do not operate a machine with a fluid leak. Repairleaks and clean up fluids before resuming machineoperation. Fluids that are leaking or spilled onto hotsurfaces or onto electrical components can cause afire. A fire may cause personal injury or death.

Remove flammable material such as leaves, twigs,papers, trash, etc. These items may accumulate inthe engine compartment or around other hot areasand hot parts on the machine.

Keep the access doors to major machinecompartments closed and access doors in workingcondition in order to permit the use of fire suppressionequipment, in case a fire should occur.

Clean all accumulations of flammable materials suchas fuel, oil and debris from the machine.

Do not operate the machine near any flame.

Keep shields in place. Exhaust shields (if equipped)protect hot exhaust components from oil spray or fuelspray in case of a break in a line, in a hose, or in aseal. Exhaust shields must be installed correctly.

Do not weld or flame cut on tanks or lines that containflammable fluids or flammable material. Empty andpurge the lines and tanks. Then clean the lines andtanks with a nonflammable solvent prior to weldingor flame cutting. Ensure that the components areproperly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallichoods or fenders may be flammable and/or explosive.Repair such components in a well ventilated areaaway from open flames or sparks. Use suitablePersonal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration.Replace damaged lines and hoses. The lines andthe hoses should have adequate support and secureclamps. Tighten all connections to the recommendedtorque. Damage to the protective cover or insulationmay provide fuel for fires.


Fire Prevention and Explosion Prevention

Store fuels and lubricants in properly markedcontainers away from unauthorized personnel. Storeoily rags and flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.


Use caution when you are fueling a machine. Do notsmoke while you are fueling a machine. Do not fuela machine near open flames or sparks. Always stopthe engine before fueling. Fill the fuel tank outdoors.Properly clean areas of spillage.

Follow practices for safe fueling that are describedin the Operation section of the Operation andMaintenance Manual section and follow localregulations. Never store flammable fluids in theoperator compartment of the machine.

Battery and Battery Cables


Cat recommends the following in order to minimizethe risk of fire or an explosion related to the battery.

Do not operate a machine if battery cables or relatedparts show signs of wear or damage. Contact yourCat dealer for service.

Follow safe procedures for engine starting with jumpstart cables. Improper jumper cable connections cancause an explosion that may result in injury. Refer toOperation and Maintenance Manual, Engine Startingwith Jump Start Cables for specific instructions.

Do not charge a frozen battery. This may cause anexplosion.

Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter inorder to check the battery charge.

Daily inspect battery cables that are in areas thatare visible. Inspect cables, clips, straps, and otherrestraints for damage. Replace any damaged parts.Check for signs of the following, which can occurover time due to use and environmental factors:

Fraying

Abrasion

Cracking

Discoloration

20 SEBU8406-01Safety SectionFire Prevention and Explosion Prevention

Cuts on the insulation of the cable

Fouling

Corroded terminals, damaged terminals, and looseterminals

Replace damaged battery cable(s) and replaceany related parts. Eliminate any fouling, which mayhave caused insulation failure or related componentdamage or wear. Ensure that all components arereinstalled correctly.

An exposed wire on the battery cable may causea short to ground if the exposed area comes intocontact with a grounded surface. A battery cableshort produces heat from the battery current, whichmay be a fire hazard.

An exposed wire on the ground cable between thebattery and the disconnect switch may cause thedisconnect switch to be bypassed if the exposed areacomes into contact with a grounded surface. Thismay result in an unsafe condition for servicing themachine. Repair components or replace componentsbefore servicing the machine.

Fire on a machine can result in personal injuryor death. Exposed battery cables that come intocontact with a grounded connection can result infires. Replace cables and related parts that showsigns of wear or damage. Contact your Caterpillardealer.

WiringCheck electrical wires daily. If any of the followingconditions exist, replace parts before you operatethe machine.

Fraying

Signs of abrasion or wear

Cracking

Discoloration

Cuts on insulation

Other damage

Make sure that all clamps, guards, clips, and strapsare reinstalled correctly. This will help to preventvibration, rubbing against other parts, and excessiveheat during machine operation.

Attaching electrical wiring to hoses and tubes thatcontain flammable fluids or combustible fluids shouldbe avoided.

Consult your Cat dealer for repair or for replacementparts.

Keep wiring and electrical connections free of debris.

Lines, Tubes, and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bent ordamaged. Use the appropriate backup wrenches inorder to tighten all connections to the recommendedtorque.


Check lines, tubes, and hoses carefully. WearPersonal Protection Equipment (PPE) in order tocheck for leaks. Always use a board or cardboardwhen you check for a leak. Leaking fluid that is underpressure can penetrate body tissue. Fluid penetrationcan cause serious injury and possible death. A pinhole leak can cause severe injury. If fluid is injectedinto your skin, you must get treatment immediately.Seek treatment from a doctor that is familiar with thistype of injury.

Replace the affected parts if any of the followingconditions are present:

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are swelling or ballooning.

Flexible parts of the hoses are kinked.

Outer covers have exposed embedded armoring.

End fittings are displaced.


Fire Safety

Make sure that all clamps, guards, and heat shieldsare installed correctly. During machine operation, thiswill help to prevent vibration, rubbing against otherparts, excessive heat, and failure of lines, tubes, andhoses.

Do not operate a machine when a fire hazardexists. Repair any lines that are corroded, loose,or damaged. Leaks may provide fuel for fires.Consult your Cat dealer for repair or for replacementparts. Use genuine Cat parts or the equivalent, forcapabilities of both the pressure limit and temperaturelimit.

EtherEther (if equipped) is commonly used in cold weatherapplications. Ether is flammable and poisonous.

Follow the correct cold engine starting procedures.Refer to the section in the Operation and MaintenanceManual with the label Engine Starting.

Do not spray ether manually into an engine if themachine is equipped with a thermal starting aid forcold weather starting.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49 C (120.2 F). Keep ether cylinders awayfrom open flames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Fire ExtinguisherAs an additional safety measure, keep a fireextinguisher on the machine.

Be familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Follow the recommendationson the instruction plate.

Consider installation of an aftermarket FireSuppression System, if the application and workingconditions warrant the installation.

i04025591

Fire SafetySMCS Code: 7000

Note: Locate secondary exits and how to use thesecondary exits before you operate the machine.

Note: Locate fire extinguishers and how to use a fireextinguisher before you operate the machine.

If you find that you are involved in a machine fire, yoursafety and that of others on site is the top priority.The following actions should only be performed if theactions do not present a danger or risk to you andany nearby people. At all times you should assessthe risk of personal injury and move away to a safedistance as soon as you feel unsafe.

Move the machine away from nearby combustiblematerial such as fuel/oil stations, structures, trash,mulch, and timber.

Lower any implements and turn off the engine assoon as possible. If you leave the engine running,the engine will continue to feed a fire. The fire willbe fed from any damaged hoses that are attachedto the engine or pumps.

If possible, turn the battery disconnect switch to theOFF position. Disconnecting the battery will removethe ignition source in the event of an electrical short.Disconnecting the battery will eliminate a secondignition source if electrical wiring is damaged by thefire, resulting in a short circuit.

Notify emergency personnel of the fire and yourlocation.

If your machine is equipped with a fire suppressionsystem, follow the manufacturers procedure foractivating the system.

Note: Fire suppression systems need to be regularlyinspected by qualified personnel. You must be trainedto operate the fire suppression system.

Use the on-board fire extinguisher and use thefollowing procedure:

1. Pull the pin.

2. Aim the extinguisher or nozzle at the base of thefire.

3. Squeeze the handle and release the extinguishingagent.

4. Sweep the extinguisher from side to side acrossthe base of the fire until the fire is out.

22 SEBU8406-01Safety SectionFire Extinguisher Location

Remember, if you are unable to do anything else,shut off the machine before exiting. By shutting offthe machine, fuels will not continue to be pumpedinto the fire.

If the fire grows out of control, be aware of thefollowing risks:

Tires on wheeled machines pose a risk of explosionas tires burn. Hot shrapnel and debris can bethrown great distances in an explosion.

Tanks, accumulators, hoses, and fittings canrupture in a fire, spraying fuels and shrapnel over alarge area.

Remember that nearly all of the fluids on themachine are flammable, including coolant and oils.Additionally, plastics, rubbers, fabrics, and resinsin fiberglass panels are also flammable.

i02935282

Fire Extinguisher LocationSMCS Code: 7000; 7419

Make sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

The fire extinguisher needs to be at least a 4.5 kg(10 lb) fire extinguisher unless the machine hasa permanent, built in extinguishing system. Themounting location must not damage any safetyfeatures. The mounting location must not obstructthe operator compartment, or the operator fromaccessing or exiting the cab.

A mounting surface that is suitable for a fireextinguisher is located inside the cab on the floorplatein front of the center console.

Do not weld a bracket on the Rollover ProtectiveStructure (ROPS) in order to install the fireextinguisher. Also, do not drill holes in the ROPS inorder to mount the fire extinguisher on the ROPS.

i01557411

Tire InformationSMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.

A tire explosion is much more violent than ablowout. The explosion can propel the tire, the rimcomponents, and the axle components as far as500 m (1500 ft) or more from the machine. Both theforce of the explosion and the flying debris can causeproperty damage, personal injury, or death.


(A) At least 15 m (50 ft)(B) At least 500 m (1500 ft)

Do not approach a warm tire. Maintain a minimumdistance, as shown. Stay outside the shaded area inIllustration 20.

Do not use water or calcium as a ballast for the tires.Dry nitrogen gas is recommended for inflation of tires.If the tires were originally inflated with air, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

Nitrogen inflated tires reduce the potential ofa tire explosion because nitrogen does not aidcombustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration of rubber, and corrosion ofrim components.

To avoid overinflation, proper nitrogen inflationequipment and training in the usage of the equipmentare necessary. A tire blowout or a rim failure canresult from improper equipment or from misusedequipment.

When you inflate a tire, stand behind the tread anduse a self-attaching chuck.

Servicing tires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tiresand rims, the assemblies could burst with explosiveforce. This explosive force can cause seriouspersonal injury or death. Carefully obey the specificinstructions from your tire dealer.


Electrical Storm Injury Prevention

i01122596

Electrical Storm InjuryPreventionSMCS Code: 7000

When lightning is striking in the vicinity of themachine, the operator should never attempt thefollowing procedures:

Mount the machine.

Dismount the machine.

If you are in the operator's station during an electricalstorm, stay in the operator's station. If you are on theground during an electrical storm, stay away fromthe vicinity of the machine.

i03622260

Before Starting EngineSMCS Code: 1000; 7000

Note: Start the engine only from the operator'scompartment. Never short across the starterterminals or across the batteries. Shorting couldbypass the engine neutral start system. Shortingcould also damage the electrical system.

Before you mount the machine, perform awalk around inspection. Look for any damagedcomponents or leaks. Report discrepancies andmake any necessary repairs before operatingthe machine. Perform all daily inspections. Referto Operation and Maintenance Manual, DailyInspection for more information.

Once you mount the machine, inspect the platformfor any loose items or debris. Look for any othersigns of damage or wear.

When you enter the cab, inspect the condition of theseat belt and the condition of mounting hardware.Replace any damaged parts and any worn parts.Regardless of appearance, replace the seat belt afterthree years of use. Do not use a seat belt extensionon a retractable seat belt.

Adjust the seat in order to achieve full pedal travelwhen the operator's back is against the back of theseat.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Make sure that all lights are working properly.

Before you start the engine or before you move themachine, make sure that there is no personnel onthe machine, underneath the machine, or around themachine.

i03622280

Engine StartingSMCS Code: 1000; 7000

If a warning tag is attached to the engine start switchor to the machine controls, do not start the engine.Also, do not move any machine controls.

Make sure that the transmission control is in theParking Brake Applied (P) position.

Make sure that the dump body is down. Put the hoistcontrol in the FLOAT position.

Note: The engine may be started with the body in theRAISED position if the truck body retaining cablesare properly installed.

Diesel engine exhaust contains products ofcombustion which can be harmful to your health.Always start the engine in a well ventilated area.Always operate the engine in a well ventilated area.If you are in an enclosed area, vent the exhaust tothe outside.

i03622860

Before OperationSMCS Code: 7000

Clear all personnel from the machine and from thearea.

Clear all obstacles from the path of the machine.Remove any wheel chocks. Beware of hazards suchas electrical wires, ditches, etc.

Make sure that all windows are clean. Secure thedoors in the closed position.

For the best visibility of the area that is close to themachine, adjust the rear view mirrors.

Make sure that the machine horn, the backup alarm,the action alarm, the dash indicator lights and allother warning devices are working properly.

Fasten the seat belt securely.

24 SEBU8406-01Safety SectionVisibility Information

i03162317

Visibility InformationSMCS Code: 7000

Before you start the machine, perform a walk-aroundinspection in order to ensure that there are nohazards around the machine.

While the machine is in operation, constantly surveythe area around the machine in order to identifypotential hazards as hazards become visible aroundthe machine.

Your machine may be equipped with visual aids.Some examples of visual aids are Closed CircuitTelevision (CCTV) and mirrors. Before operating themachine, ensure that the visual aids are in properworking condition and that the visual aids are clean.Adjust the visual aids using the procedures that arelocated in this Operation and Maintenance Manual.If equipped, the Work Area Vision System shall beadjusted according to Operation and MaintenanceManual, SEBU8157, Work Area Vision System.

It may not be possible to provide direct visibility onlarge machines to all areas around the machine.Appropriate job site organization is required in orderto minimize hazards that are caused by restrictedvisibility. Job site organization is a collection of rulesand procedures that coordinates machines andpeople that work together in the same area. Examplesof job site organization include the following:

Safety instructions

Controlled patterns of machine movement andvehicle movement

Workers that direct traffic to move when it is safe

Restricted areas

Operator training

Warning symbols or warning signs on machinesor on vehicles

A system of communication

Communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration by theuser that result in a restriction of visibility shall beevaluated.

i03660439

Restricted VisibilitySMCS Code: 7000

The size and the configuration of this machine mayresult in areas that can not be seen when the operatoris seated. Illustration 21 provides an approximatevisual indication of the areas of significant restrictedvisibility. Illustration 21 indicates the restrictedvisibility areas at ground level inside a radius of24.00 m (78.74 ft) from the operator on a machinewithout the use of optional visual aids. This illustrationdoes not provide areas of restricted visibility fordistances outside a radius of 24.00 m (78.74 ft).

This machine may be equipped with optional visualaids that may provide visibility to some of therestricted visibility areas. For the areas that arenot covered by the optional visual aids, job siteorganization must be utilized to minimize hazardsof this restricted visibility. For more informationregarding job site organization refer to Operation andMaintenance Manual, Visibility Information.


Top view of the machine

Note: The shaded areas of illustration 21 indicatethe approximate locations with significant restrictedvisibility.


Operation

i03634227

OperationSMCS Code: 7000

Machine Operating TemperatureRangeThe standard machine configuration is intended foruse within an ambient temperature of 40 C (40 F)to 50 C (122 F). Special configurations for differentambient temperatures may be available. Consultyour Caterpillar dealer for additional information onspecial configurations of your machine.

Machine Operation

Do not allow a companion to ride on the ma-chine unless the companion is seated within theRollover Protective Structure (ROPS) or FallingObject Protection Structure (FOPS) with the seatbelt fastened. The companion must have the seatbelt fastened while the machine is in operation.The operator of the machine is responsible for thesafety of the companion. Personal injury or deathmay occur if the companion is not restrained andprotected.

Only operate the machine while you are in theoperator seat. The seat belt must be fastened whileyou operate the machine. Only operate the controlswhile the engine is running.

Before you move the machine, you must make surethat no one will be endangered.

During warm-up, operate the machine slowly in anopen area while you check for the proper operationof all controls and all protective devices.

Do not allow riders on the machine unless themachine has the following equipment:

Additional seat

Additional seat belt

Rollover Protective Structure (ROPS)

Note any needed repairs during machine operation.Report any needed repairs.

When the truck is on a upward slope, avoid dumpingthe truck. The truck could tip backward.

Avoid any conditions that can lead to tipping themachine. The machine can tip when you work onhills, on banks and on slopes. Also, the machinecan tip when you cross ditches, ridges or otherunexpected obstacles.

Avoid operating the machine across the slope. Whenpossible, operate the machine up the slopes anddown the slopes.

Maintain control of the machine. Do not load themachine beyond the machine capacity.

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure(ROPS) installed during machine operation.

Always anticipate the grade and select the propergear range for the grade.

Lower the truck bed completely before travel. Keepthe hoist control in the FLOAT position during travel.

When the machine is being operated or loaded, stayin the cab of the machine.

Obey all road signs.

A signalman should be present when you move themachine in reverse, and when you move the machinein a building or out of a building.

NOTICECaterpillar recommends stopping the truck immedi-ately if a flat tire is discovered. Driving on a flat tiremay cause damage to the tire and rim.

i03626623

ParkingSMCS Code: 7000

Park the machine on a level surface and install wheelchocks. When you park the machine on a grade, turnthe wheels into a suitable bank, when possible.

Apply the service brakes in order to stop the machine.Move the transmission control to the P position.When the transmission control is in the P position,the parking brakes are automatically engaged andthe transmission is in neutral.

Turn the engine start switch to the OFF position inorder to stop the engine. Remove the engine startswitch key.

26 SEBU8406-01Safety SectionSound Information and Vibration Information

Place the battery disconnect switch in the OFFposition and place a padlock on the switch in orderto secure (lockout) the switch in the OFF position ifthe machine will not be in operation for an extendedperiod of time. This will prevent current discharge ofthe battery. Any of the following conditions can causea current discharge of the battery: a battery shortcircuit and any current draw from certain components.

i03455020

Sound Information andVibration InformationSMCS Code: 7000

Sound Level InformationThe operator Equivalent Sound Pressure Level (Leq)is 78 dB(A) when SAE J1166:Feb2008 is used tomeasure the value for an enclosed cab. This is a workcycle sound exposure level. The cab was properlyinstalled and maintained. The test was conductedwith the cab doors and the cab windows closed.

Hearing protection may be needed when themachine is operated with an open operator station forextended periods or in a noisy environment. Hearingprotection may be needed when the machine isoperated with a cab that is not properly maintained, orwhen the doors and windows are open for extendedperiods or in a noisy environment.

The average exterior sound pressure level is 90dB(A) when the SAE J88:2006 - Constant SpeedMoving Test procedure is used to measure the valuefor the standard machine. The measurement wasconducted under the following conditions: distance of15 m (49.2 ft) and the machine moving forward in anintermediate gear ratio.

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the EU DirectivesThe dynamic operator sound pressure level is 76dB(A) when ISO 6396:2008 is used to measure thevalue for an enclosed cab. The measurement wasconducted at 70% of the maximum engine cooling fanspeed. The sound level may vary at different enginecooling fan speeds. The cab was properly installedand maintained. The measurement was conductedwith the cab doors and the cab windows closed.

The European Union PhysicalAgents (Vibration) Directive2002/44/EC

Vibration Data for Off-Highway Trucks

Information Concerning Hand/Arm VibrationLevel

When the machine is operated according to theintended use, the hand/arm vibration of this machineis below 2.5 meter per second squared.

Information Concerning Whole Body VibrationLevel

This section provides vibration data and a method forestimating the vibration level for off-highway trucks.

Note: Vibration levels are influenced by manydifferent parameters. Many items are listed below.

Operator training, behavior, mode, and stress

Job site organization, preparation, environment,weather, and material

Machine type, quality of the seat, quality of thesuspension system, attachments, and condition ofthe equipment

It is not possible to get precise vibration levels forthis machine. The expected vibration levels can beestimated with the information in Table 1 in orderto calculate the daily vibration exposure. A simpleevaluation of the machine application can be used.

Estimate the vibration levels for the three vibrationdirections. For typical operating conditions, use theaverage vibration levels as the estimated level. Withan experienced operator and smooth terrain, subtractthe Scenario Factors from the average vibration levelin order to obtain the estimated vibration level. Foraggressive operations and severe terrain, add theScenario Factors to the average vibration level inorder to obtain the estimated vibration level.

Note: All vibration levels are in meter per secondsquared.


Sound Information and Vibration Information

Table 1

ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.

Vibration Levels Scenario FactorsMachineType

Typical OperatingActivity X axis Y axis Z axis X axis Y axis Z axis

loading process 0,20 0,22 0,21 0,19 0,17 0,19

travel loaded 0,61 0,63 0,82 0,21 0,24 0,34

travel unloaded 0,73 0,73 0,87 0,20 0,25 0,33Off-HighwayTrucks

unloading 0,37 0,37 0,33 0,14 0,13 0,08

Note: Refer to ISO/TR 25398 Mechanical Vibration -Guideline for the assessment of exposure to wholebody vibration of ride on operated earthmovingmachines for more information about vibration.This publication uses data that is measuredby international institutes, organizations andmanufacturers. This document provides informationabout the whole body exposure of operators ofearthmoving equipment. Refer to Operation andMaintenance Manual Supplement , SEBU8257 formore information about machine vibration levels.

The Caterpillar suspension seat meets the criteria ofISO 7096. This represents vertical vibration levelunder severe operating conditions. This seat is testedwith the input spectral class EM1. The seat has atransmissibility factor of SEAT

28 SEBU8406-01Safety SectionOperator Station

9. Less operator comfort may be caused by other riskfactors. The following guidelines can be effectivein order to provide better operator comfort:

a. Adjust the seat and adjust the controls in orderto achieve good posture.

b. Adjust the mirrors in order to minimize twistedposture.

c. Provide breaks in order to reduce long periodsof sitting.

d. Avoid jumping from the cab.

e. Minimize repeated handling of loads and liftingof loads.

f. Minimize any shocks and impacts during sportsand leisure activities.

SourcesThe vibration information and calculation procedureis based on ISO/TR 25398 Mechanical Vibration- Guideline for the assessment of exposureto whole body vibration of ride on operatedearthmoving machines. Harmonized data ismeasured by international institutes, organizationsand manufacturers.

This literature provides information about assessingthe whole body vibration exposure of operators ofearthmoving equipment. The method is based onmeasured vibration emission under real workingconditions for all machines.

You should check the original directive. Thisdocument summarizes part of the content of theapplicable law. This document is not meant tosubstitute the original sources. Other parts of thesedocuments are based on information from the UnitedKingdom Health and Safety Executive.

Refer to Operation and Maintenance Manual,SEBU8257, The European Union PhysicalAgents (Vibration) Directive 2002/44/EC for moreinformation about vibration.

Consult your local Caterpillar dealer for moreinformation about machine features that minimizevibration levels. Consult your local Caterpillar dealerabout safe machine operation.

Use the following web site in order to find your localdealer:

Caterpillar, Inc.www.cat.com

i03634321

Operator StationSMCS Code: 7000; 7301; 7325

Any modifications to the inside of the operator stationshould not project into the operator space or intothe space for the companion seat (if equipped).The addition of a radio, fire extinguisher, and otherequipment must be installed so that the definedoperator space and the space for the companion seat(if equipped) is maintained. Any item that is broughtinto the cab should not project into the definedoperator space or the space for the companion seat(if equipped). A lunch box or other loose items mustbe secured. Objects must not pose an impact hazardin rough terrain or in the event of a rollover.

i03656846

Guards(Operator Protection)SMCS Code: 7000; 7150; 7325

There are different types of guards that are used toprotect the operator. The machine and the machineapplication determines the type of guard that shouldbe used.

A daily inspection of the guards is required in order tocheck for structures that are bent, cracked or loose.Never operate a machine with a damaged structure.

The operator becomes exposed to a hazardoussituation if the machine is used improperly or if pooroperating techniques are used. This situation canoccur even though a machine is equipped with anappropriate protective guard. Follow the establishedoperating procedures that are recommended for yourmachine.


Guards

Rollover Protective Structure(ROPS), Falling Object ProtectiveStructure (FOPS) or Tip OverProtection Structure (TOPS)The ROPS/FOPS Structure (if equipped) on yourmachine is specifically designed, tested andcertified for that machine. Any alteration or anymodification to the ROPS/FOPS Structure couldweaken the structure. This places the operatorinto an unprotected environment. Modifications orattachments that cause the machine to exceed theweight that is stamped on the certification plate alsoplace the operator into an unprotected environment.Excessive weight may inhibit the brake performance,the steering performance and the ROPS. Theprotection that is offered by the ROPS/FOPSStructure will be impaired if the ROPS/FOPSStructure has structural damage. Damage to thestructure can be caused by an overturn, a fallingobject, a collision, etc.

Do not mount items (fire extinguishers, first aidkits, work lights, etc) by welding brackets to theROPS/FOPS Structure or by drilling holes in theROPS/FOPS Structure. Welding brackets or drillingholes in the ROPS/FOPS Structures can weakenthe structures. Consult your Caterpillar dealer formounting guidelines.

The Tip Over Protection Structure (TOPS) isanother type of guard that is used on mini hydraulicexcavators. This structure protects the operator inthe event of a tipover. The same guidelines for theinspection, the maintenance and the modification ofthe ROPS/FOPS Structure are required for the TipOver Protection Structure.

Other Guards (If Equipped)Protection from flying objects and/or falling objects isrequired for special applications. Logging applicationsand demolition applications are two examples thatrequire special protection.

A front guard needs to be installed when a work toolthat creates flying objects is used. Mesh front guardsthat are approved by Caterpillar or polycarbonatefront guards that are approved by Caterpillar areavailable for machines with a cab or an open canopy.On machines that are equipped with cabs, thewindows should also be closed. Safety glasses arerecommended when flying hazards exist for machineswith cabs and machines with open canopies.

If the work material extends above the cab, topguards and front guards should be used. Typicalexamples of this type of application are listed below:

Demolition applications

Rock quarries

Forestry products

Additional guards may be required for specificapplications or work tools. The Operation andMaintenance Manual for your machine or yourwork tool will provide specific requirements for theguards. Consult your Caterpillar dealer for additionalinformation.

30 SEBU8406-01Product Information SectionGeneral Information

Product InformationSection

General Informationi04030282

SpecificationsSMCS Code: 7000

Note: Materials and specifications are subject tochange without notice.

EngineTable 2

793F Caterpillar Diesel Engine

Model C175

Type Turbo ChargedDirect Injection (CommonRail)Air to Air Aftercooled

Cylinders 16

Displacement 85 L (5187 cubic inch)

Gross Power (SAE1995) 1976 kW (2650 hp) at 1750RPM

Net Power (SAE J1349) 1848 kW (2478 hp) at 1750RPM

TransmissionTable 3

793F Caterpillar Power Shift TransmissionTravel Speeds at 1900 RPM

Transmission Gear Speed

1 12.9 km/h (8 mph)

2 17.4 km/h (10.8 mph)

3 23.8 km/h (14.8 mph)

4 32.1 km/h (19.9 mph)

5 43.6 km/h (27.1 mph)

6 60 km/h (37.3 mph)

R 11.8 km/h (7.3 mph)

Dimensions

g01787513Illustration 22Dimensions reflect an MSD II body. All dimensions areapproximate. Dimensions will vary depending on the configurationand the options.

(A) Overall Width 830 cm (27 ft 3 inch)(B) Overall Tire Width 761 cm (24 ft 11 inch)(C) Overall Height (body down and empty) 651 cm (21 ft 4 inch)(D) Overall Length 1370 cm (44 ft 11 inch)(E) Loading Height (body empty) 653 cm (21 ft 5 inch)(F) Overall Height (body raised) 1388 cm (45 ft 6 inch)(G) Wheel Base 591 cm (19 ft 5 inch)

WeightsThe empty weight of a fully assembled 793FOff-Highway Truck with body will range fromapproximately 149325 kg (329200 lb) toapproximately 175000 kg (385800 lb). The emptyweight of the 793F will depend on the configurationand the options.

The target gross machine operating weight is listedunder Application/Configuration Restrictions (seebelow).

SEBU8406-01 31Product Information Section

General Information

The empty machine weight of the 793F will dependon the configuration of the machine. Weigh theempty machine in order to get an accurate weight. Ifa suitable scale is not available, contact your localCaterpillar dealer for an approximate weight of themachine, as equipped when shipped from the factory.This weight will not include additional equipment oroptions that have been installed on the machine afterleaving the factory.

The target payload depends on the machineconfiguration. In order to calculate the target payload,subtract empty machine weight from the target grossmachine operating weight.

The Caterpillar payload overload policy, referred toas the 10/10/20 Overload Policy, states that no morethan 10% of payloads may exceed 110% of the targetpayload, and no single payload shall ever exceed120% of the maximum target payload.

If this machine has a CE plate that is required forthe European Union, the weight on the CE plate isbased on the following:

Empty machine weight with a flat floor body andhigh impact liner

Full tank of fuel

75 kg (165 lb) operator

Intended UseThe 793F Off-Highway Truck is an earthmovingmachine. The 793F is classified as a dumper asdescribed in ISO 6165:2006. This is a self-propelledwheeled machine with a rigid frame and wheelsteering. This dumper has an open body that isintended for the following applications: transportingloose material and dumping loose material

Application/Configuration Restrictions

The 793F Off-Highway Truck cab structure isROPS certified to ISO 3471:1994 up to 156400 kg(344800 lb) as a rigid frame dumper ROPS onlyoption. This number excludes dumper body weight.This number also excludes carryback debris weight.

Target Gross Machine Operating Weight forStandard Wheel Stations

The Target Gross Machine Operating Weight(including payload) for the 793F Off-HighwayTruck equipped with standard wheel stations is386000 kg (851000 lb). The braking systems andthe steering systems in the 793F Off-Highway Truckare in compliance with ISO standards when testedto Caterpillar Global Mining Division's 10/10/20Overload policy.

Target Gross Machine Operating Weight forExtended Life Wheel Stations

The Target Gross Machine Operating Weight(including payload) for the 793F Off-HighwayTruck equipped with extended life wheel stations is390000 kg (860000 lb). The braking systems andthe steering systems in the 793F Off-Highway Truckare in compliance with ISO standards when testedto Caterpillar Global Mining Division's 10/10/20Overload policy.

General Operating RestrictionsUse only in a non-explosive gas environment.

Table 4

793F Operating Restrictions Grade

Parking Brake Holding Capability(1) 15%

Maximum Side Grade Operation(Except Dumping/Spreading)(2)

15%

Maximum Side Grade forDumping/Spreading(3)

0%

Maximum Negative Grade (uphill) forDumping/Spreading(4)

0%

(1) The listed restriction assumes that the brake components arewithin working specifications, the machine mass is at maximumallowable, a graded ground surface, and a dry, firm underfoot.The machine operator is responsible for evaluating thecondition of the machine, the environment, and use appropriatejudgment to maintain control of the machine.

(2) Operating on a side grade is not recommended. The listedrestriction assumes a machine operating perpendicular toa side grade, graded ground surface, nominal payload,homogeneous payload distribution in the bowl, and operatingon dry, firm underfoot. Refer to Operation and MaintenanceManual, Slope Operation for more information.

(3) Dumping on a side grade is not recommended. The center ofgravity of the machine changes very rapidly during dumpingon a side grade.

(4) Trucks are designed to dump on level ground with somevariation in underfoot surface conditions. Dumping whilemachine is on a negative grade is not recommended becauseunder some conditions, variations in payload densities andpayload discharge characteristics could result in the frontwheels lifting off the ground.

32 SEBU8406-01Product Information SectionIdentification Information

Identification Informationi03405640

Plate Locations and FilmLocationsSMCS Code: 1000; 7000

The Product Identification Number (PIN) will be usedto identify a powered machine that is designed foran operator to ride.

Serial Numbers will be used to identify engines,transmissions and major attachments.

For quick reference, record the identification numbersin the spaces that are provided below the illustration.

Product Identification Number (PIN)


(1) Machine PIN____________________________________________

European Union


This plate is positioned on the bottom left side ofplate (1) for the PIN.

Note: The CE plate is on machines that are certifiedto the European Union requirements that wereeffective at that time.

For machines compliant to 2006/42/EC, the followinginformation is stamped onto the CE plate. For quickreference, record this information in the spaces thatare provided below.

Engine Power Primary Engine (kW)_________________

Engine Power for Additional Engine (If Equipped)_______________________________________________________________

Typical Machine Operating Weight for EuropeanMarket (kg)________________________________________________

Year of Construction____________________________________

Machine Type ____________________________________________

Serial Number Plate (SN)


(2) Dump Body Serial Number __________________________


(3) Transmission Serial Number_________________________

SEBU8406-01 33Product Information SectionIdentification Information


(4) Engine Serial Number_________________________________

The following information is stamped on thecomponent.


(5) Torque Converter Serial Number___________________

Differential Sequence Number___________________________

Wheel Station Sequence Number______________________

Certification

ROPS/FOPS Plate

This certification plate is located outside the cab onthe right side of the ROPS.

Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture's protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. Consult a Caterpillar dealer to deter-mine this structure's limitations without voidingits certification.


This machine has been certified to the standards thatare listed on the certification plate. The maximummass of the machine, which includes the operatorand the attachments without a body or a payload,should not exceed the mass on the certification plate.

i04019095

Emissions Certification FilmSMCS Code: 1000; 7000; 7405

Note: This information is pertinent in the UnitedStates, in Canada and in Europe.

Consult your Cat dealer for an Emission ControlWarranty Statement.

This label is located on the engine.

34 SEBU8406-01Operation SectionBefore Operation

Operation Section

Before Operationi04021647

Mounting and DismountingSMCS Code: 7000


Typical example

Mount the machine and dismount the machine onlyat locations that have steps and/or handholds. Beforeyou mount the machine, clean the steps and thehandholds. Inspect the steps and handholds. Makeall necessary repairs.

Face the machine whenever you get on the machineand whenever you get off the machine.

Maintain a three-point contact with the steps and withthe handholds.

Note: Three-point contact can be two feet and onehand. Three-point contact can also be one foot andtwo hands.

Do not mount a moving machine. Do not dismount amoving machine. Never jump off the machine. Donot carry tools or supplies when you try to mount themachine or when you try to dismount the machine.Use a hand line to pull equipment onto the platform.Do not use any controls as handholds when youenter the operator compartment or when you exit theoperator compartment.

Machine Access SystemSpecificationsThe machine access system has been designed tomeet the intent of the technical requirements in ISO2867 Earth-moving Machinery Access Systems.The access system provides for operator access tothe operator station and to conduct the maintenanceprocedures described in Maintenance section.

Alternate ExitMachines that are equipped with cabs have alternateexits. For additional information, see Operation andMaintenance Manual, Alternate Exit.

i03722260

Daily InspectionSMCS Code: 1000; 7000

For a maximum service life of the machine, completea thorough walk-around inspection before you mountthe machine and before you start the engine.

Inspect the area around the machine and under themachine. Visually inspect the condition of all majorcomponents. Look for loose bolts, trash buildup,oil leakage, coolant leakage, broken parts, or wornparts.

Note: If you suspect a leak or you observe a leak,qualified personnel should complete an inspectionbefore you operate the machine.

Remove any trash and any debris.

Report any abnormalities to the shop. Qualifiedpersonnel should complete any necessary repairsbefore you operate the machine.

Check the grease fittings on the machine for leaksand for damage.

SEBU8406-01 35Operation SectionBefore Operation


Inspect cover (1) on the control box. Inspect warninglight (2). Make sure that the cover for engineshutdown switch (3) is down.

Inspect the ladders for damage.

Inspect the radiator for leaks.

Remove any debris that could block the air flow tothe radiator, the aftercooler, or the air conditioningcondenser.

Inspect the engine for oil leaks and for coolant leaks.

Inspect both front tires. Check the tire inflation. Checkthe inside of the tire for damage and for wear. Inspectthe tire treads for damage. Remove large rocks fromthe treads. Check for fasteners that are loose ormissing.

Inspect all four rear tires. Check the tire inflation.Check the inside of the tire for damage and for wear.Inspect the tire treads for damage. Remove rocks thatare stuck between the tires. Remove large rocks fromthe treads. Make sure that the rock ejectors swingfreely. Check for fasteners that are loose or missing.

Note: Rust behind a bolt may indicate that the bolt isloose. Shiny metal areas around a bolt may indicatethat the bolt is loose.

Inspect the steering cylinders for leaks and fordamage. Inspect the steering tie rods for wear andfor damage. Inspect the front suspension cylindersfor leaks and for damage. Inspect the fasteners forthe front suspension cylinders.

Inspect the torque converter and the transmissionfor leaks.

Check the level in the fuel tank . Look for any leaks inthe fuel tank. Look for damage to the fuel tank.

Inspect the rear axle for leaks. Check the rearsuspension cylinders for leaks and for damage.

Check all lights, including headlights, operatinglights, backup lights, service lights, access lights,turn signals, running lamps, and stop lamps. Checkthe lights for proper operation. Inspect the lights fordamage.

Inspect the hydraulic tank for leaks and for damage.Make sure that the filler cap is installed.

Inspect the steering tank for leaks and for damage.Make sure that the filler cap is installed.


Check level gauge (4) on the automatic lubricantreservoir. Inspect tank (5) for leaks.

Remove any debris that may obstruct the air filters.

Remove any debris from the platform.

Make sure that the ladders and hand rails are secure.

Make sure that all of the windows are clean. Makesure that the operator's vision is not impaired by dust,mud, or other foreign materials. Adjust the mirrorsfor proper vision.

Inspect the cab air filter for a damaged element orreduced performance.

36 SEBU8406-01Operation SectionBefore Operation

When it is necessary to work under the machinewith the body (bed) raised, attach the body (bed)retaining cables to the body retaining pins. Installthe body retaining pins through the ends of the re-taining cables. Always use both retaining cables.

Failure to properly secure the body (bed) may re-sult in personal injury or death.

Raise the dump body to the fully raised position andinstall the truck body retaining cables. For the properprocedure, refer to Operations and MaintenanceManual, Cable (Truck Body Retaining).


Inspect body (6) and the frame (7) for cracks. Inspectthe body and the frame for damage.

Inspect the hoist cylinders for leaks or for damage.Inspect the hoist cylinders for cracking on the cylindersurface and for marks on the cylinder surface.

Check the steering system for proper response.

Check the braking system for proper operation.

Perform the following daily procedures for yourmachine:

Operation and Maintenance Manual, Air TankMoisture and Sediment - Drain

Operation and Maintenance Manual, BackupAlarm - Test

Operation and Maintenance Manual, Indicatorsand Gauges - Test

Operation and Maintenance Manual, CoolingSystem Coolant Level - Check

Operation and Maintenance Manual, Differentialand Final Drive - Check

Operation and Maintenance Manual, Engine OilLevel - Check

Operation and Maintenance Manual, Hoist andBrake Tank Oil Level - Check

Operation and Maintenance Manual, Seat Belt -Inspect

Operation and Maintenance Manual, SteeringSystem Oil Level - Check

Operation and Maintenance Manual, TorqueConverter Sump Oil Level - Check

Operation and Maintenance Manual, Front WheelOil Level - Check

SEBU8406-01 37Operation SectionMachine Operation

Machine Operationi03523061

Stairway Operation(Powered - If Equipped)SMCS Code: 7254

Crush Hazard! Stay back a safe distance from thepowered stairway when it is being raised or low-ered. Failure to stay back may result in injury ordeath.

NOTICEMake sure that the area is free of obstacles beforeraising or lowering the powered stairway.

Forward or reverse machine travel with the poweredstairway lowered could result in contact with theground or an obstacle resulting in damage to thepowered stairway.

The powered stairway is a set of electrohydrauliccontrolled retractable steps that can be lowered closeto the ground level for mounting and dismounting themachine.

Some machines are available with either a right-handaccess/egress or a left-hand access/egress.For the purposes of illustrations, the right-handaccess/egress arrangement is shown.


(1) Powered stairway

The powered stairway can be raised or lowered undernormal conditions with one of two different controlswitches. Control switch (2) for the powered stairwayis located on the handrail at the top of the stationarystairway. Control switch (3) for the powered stairwayis located on the front bumper near the base of thestationary stairway.

Battery disconnect switch (4) must be in the ONposition and the shift control must be in the P(parking brake applied) position in order to operatethe powered stairway control switches.

Note: Two circuit breakers are located on the backof the platform for the powered stairway. For moreinformation on the circuit breakers for the poweredstairway, refer to Operation and MaintenanceManual, Fuses, Circuit Breakers and Relays -Replace/Reset.

38 SEBU8406-01Operation SectionMachine Operation

LoweringPowered Stairway Lower In order tolower the powered stairway with one ofthe control switches, perform the following

steps:

1. Verify that the area around the powered stairwayis clear of people and obstacles before loweringthe powered stairway.

2. Hold control switch (2) or control switch (3) in theDOWN position in order to lower the poweredstairway. Release the switch in order to stop thepowered stairway from moving.

Note: When one of the control switches is used tomove the powered stairway, an audible alarm willsound while the powered stairway is in motion.

Note:When a control switch is used continuously tomove the powered stairway, the powered stairwaywill move from the fully raised position to the fullylowered position in approximately 7 seconds.

3. Always place the powered stairway in the fullylowered position before mounting and dismountingthe machine.

Manual Lowering


Powered Stairway Manual LoweringControl If necessary, the poweredstairway can be lowered with the use of

manual lowering control (5).

The manual lowering control is located on thehandrail above the platform for the powered stairway.

If the manual lowering control is used, the controlvalve linkage will need to be reset before the controlswitches can be used to move the powered stairway.

In order to lower the powered stairway with themanual lowering control, perform the following steps:

1. Verify that the area around the powered stairwayis clear of people and obstacles before loweringthe powered stairway.

2. Depress manual lowering control (5) in orderto manually lower the powered stairway. Themovement of the powered stairway cannot bestopped once the manual lowering control hasbeen depressed.

Note: When the manual lowering control is used tomove the powered stairway, the powered stairwaywill move from the fully raised position to the fullylowered position in approximately 3 seconds.

3. Perform the following steps in order to reset thecontrol valve linkage:


a. Remove tread plate (6) from the platform of thepowered stairway.

SEBU8406-01 39Operation SectionMachine Operation


b. Remove spring pin (7) and allow the controlvalve linkage to reset.

c. Reinstall the spring pin.

RaisingPowered Stairway Raise In order toraise the powered stairway with one ofthe control switches, perform the following

steps:

1. Verify that the area around the powered stairwayis clear of people and obstacles before raising thepowered stairway.

2. Hold control switch (2) or control switch (3) in theUP position in order to raise the powered stairway.Release the switch in order to stop the poweredstairway from moving.

Note: An audible alarm will sound while the poweredstairway is in motion.

3. Always place the powered stairway in the fullyraised position before operating the machine.

Note: If the engine is running and the parking brakeis released without the powered stairway in the fullyraised position, a warning category 2S will activate. Ifa warning occurs, take the following action:

Safely stop the machine.

Apply the parking brake.

Investigate the problem.

Refer to Operation and Maintenance Manual,Monitoring System for more information on theconditions that will occur during each warningcategory.

Locking the Powered StairwayThe powered stairway can be locked in the fullyraised position in order to prevent lowering.

1. Move the powered stairway to the fully raisedposition.


2. Retaining pin (9) is located on the front of theplatform for the powered stairway. Remove thelocking pin from the end of retaining pin andremove the retaining pin from the platform of thepowered stairway.

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