CAT + Caterpillar IT18 Integrated Toolcarrier Operation & Maintenance Manual by Heavy Equipment Manual

Product:INTEGRATEDTOOLCARRIER

Model:IT18INTEGRATEDTOOLCARRIER7ZB

Configuration:1T18INTEGRATEDTOOLCARRIER7ZB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual

IT18,IT18B,IT28ANDIT28BINTEGRATEDTOOLCARRIERS

MediaNumber-SEBU6072-02PublicationDate-01/05/1990DateUpdated-11/10/2001

AfterStartingtheEngine

SMCS-1000;1400;4203;4490;5070;5927;6700;7000;7008;7220;7327;7347;7400;7451; 7490;7541;7604;7605;7606

1.Keeptheenginespeedlowuntiltheoilpressurelightgoesout.Iftheoilpressurelightdoesnot gooutwithin10seconds,stoptheengineandinvestigate.

2.Pushthepaneltestswitchtothetestpositiontotesttheindicatorlights.

3.Ifthelightsdonotcomeon,makeanynecessaryrepairs.

4.Ifanyoftheindicatorlightsstayon,haveanynecessaryrepairsmadebeforeoperatingthe machine.

5.Lookattheoperator'spanelfrequentlyduringoperation.Ifanyoftheindicatorlightscomeon, stopthemachine,ifnecessary,andinvestigate.

ThuMar2800:00:21UTC+05302024

Product:INTEGRATEDTOOLCARRIER

Model:IT18INTEGRATEDTOOLCARRIER7ZB

Configuration:1T18INTEGRATEDTOOLCARRIER7ZB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual

IT18,IT18B,IT28ANDIT28BINTEGRATEDTOOLCARRIERS

MediaNumber-SEBU6072-02PublicationDate-01/05/1990DateUpdated-11/10/2001

BeforeStartingtheEngine

SMCS-1000;1400;4203;4490;5070;5927;6700;7000;7008;7220;7327;7347;7400;7451; 7490;7541;7604;7605;7606

Walk-AroundInspection

Hotoilandcomponentscancausepersonalinjury.Donotallowhotoil orcomponentstocontactskin.

Atoperatingtemperature,theenginecoolantishotandunderpressure.

Steamcancausepersonalinjury.

Checkthecoolantlevelonlyaftertheenginehasbeenstoppedandthe fillcapiscoolenoughtotouchwithyourbarehand.

Removethefillcapslowlytorelievepressure.

Coolingsystemconditionercontainsalkali.Avoidcontactwiththeskin andeyestopreventpersonalinjury.

Foryourownsafetyandmaximumservicelifeofthevehicle,makeathoroughwalk-around inspectionbeforemountingthemachinetostarttheengine.

Lookaroundandunderthemachineforsuchitemsaslooseormissingbolts,trashbuild-up,oil, coolantorfuelleaks.Inspecttheconditionandinflationofthetires,conditionofhydrauliclines andhoses,conditionoftheimplementandimplementlinkage.

Removeanytrashanddebris.Adjusttireinflationasneeded.Haveanynecessaryrepairsmade, looseconnectionsandpartstightenedtotheirspecifiedtorquesandanymissingpartsreplaced beforestartingtheengineoroperatingthemachine.

1.Inspectimplementfordamageorexcessivewear.

2.Inspectimplementcontrollinkagefordamageorexcessivewear.

3.Inspectlightsforbrokenbulbsandlenses.Checkforlooseorfrayedwires.

4.Inspectradiatorguardfortrashbuild-up.

5.Inspectcoolingsystemforleaksandtrashbuild-up.

6.Inspectengineprecleanerfordirtbuild-up.

7.Inspectenginecompartmentforengineoilleaksandtrashbuild-up.

8.Inspecttheconditionandcleanlinessofthestepsandhandholds.InspecttheRolloverProtective Structure(ROPS)forcracks,damage,etc.Seethe"RolloverProtectiveStructure(ROPS)"section inthispublication.

9.Inspectdifferentials(frontandrear)undermachineforleaks.

This is the sample of the manual if you need complete manual Click Here to download

10.Inspecthydraulicsystemforleaks.Checkforloosehoseconnections.Checkforfrayedhoses.

11.Inspectfinaldrives(frontandrear)forleaks.

12.Besurecoversandguardsarefirmlyinplace.Inspectfordamage.

13.Inspecttransmissionforleaks.

14.Inspecttires(frontandrear)fordamageandproperinflation.

15.Inspectthewheelbrakesforoilleaks.

16.Inspectbeltsforcracks,breaksorotherdamage.

NOTE:Beltsformultiplegroovepulleysmustbereplacedasmatchedsets.

17.Inspectinstrumentpanelforbrokengaugesandindicatorlights.Inspectoperator's compartmentforcleanliness.

Measurethecrankcaseoillevel.ThelevelshouldbeabovetheADDmarkontheENGINE STOPPEDsideofthedipstick.

Observethehydraulicsystemoillevel.MaintaintheoillevelabovetheADDmarkinthesight gauge.

Inspecttheprecleaner.Emptyandcleanthecup,ifnecessary.

Measurethetransmissionoillevel.Oillevelmustbeatthe"MINSAFESTART-COLDOIL" markonthedipstick.

Observethecoolantlevel.Maintainthecoolantwithin1cm(1/2inch)ofthebottomofthefill pipe.

Measurethetirepressure.Seethetopic"TireInflationInformation."

Measurethefuellevel.Fillthefueltankaftereachdayofoperationtohelppreventcondensation inthetank.

WedMar2723:59:46UTC+05302024

Product:INTEGRATEDTOOLCARRIER

Model:IT18INTEGRATEDTOOLCARRIER7ZB

Configuration:1T18INTEGRATEDTOOLCARRIER7ZB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual

IT18,IT18B,IT28ANDIT28BINTEGRATEDTOOLCARRIERS

MediaNumber-SEBU6072-02PublicationDate-01/05/1990DateUpdated-11/10/2001

Coolant,FuelandLubricantSpecifications

SMCS-1000;1400;4203;4490;5070;5927;6700;7000;7008;7220;7327;7347;7400;7451; 7490;7541;7604;7605;7606

CoolantSpecifications

NOTICE

Useamixtureofwater,ethyleneglycol(antifreeze)andcoolingsystem conditioner.Pure,undilutedantifreezewillfreezeat-23°C(-10°F).

Excessivecoolantconditioner(greaterthantherecommended6% initialfill)togetherwithconcentrationsofantifreezegreaterthan65% causedepositstoformandmayresultinradiatortubeblockageand overheating.

DonotuseCaterpillarcoolingsystemconditionerorcoolant conditionerelementswithDowtherm209Full-Fillcoolant.Followthe instructionsprovidedwiththeDowtherm209Full-Fillcoolant.

Referto"KnowYourCoolingSystem,"FormSEBD0518,formoredetailedspecifications.

Water

Acceptablewaterforuseintheethyleneglycolandwatermixtureisshowninthechartbelow:

ppm=partspermillion

Antifreeze

Usethecorrectamountofethyleneglycolmixedwithwater,toprovidefreezeprotectiontothe lowestexpectedoutsidetemperature.

Conditioner

NOTICE

Alwaysaddliquidcoolingsystemconditionertowater,orinstalla coolantconditionerelement(ifequipped).Neverusewateronly.

Neverusebothliquidcoolingsystemconditionerandacoolant conditionerelement(ifequipped)atthesametime.

UseCaterpillarliquidcoolingsystemconditioneroracoolantconditionerelement(ifequipped). Thiswillprovidea3%to6%concentrationofconditionerinthecoolingsystemtohelpprevent corrosion.

ConditionercanbepurchasedfromyourCaterpillardealer.

FuelSpecificationsandInformation

TypesofFuel

Caterpillardieselengineshavetheabilitytoburnawidevarietyoffuels.Thesefuelsaredivided intotwogeneralgroups,preferredandpermissible.

Thepreferredfuelsprovidemaximumengineservicelifeandperformance.Theyaredistillate fuels.Theyarecommonlycalleddieselfuel,furnaceoil,gasoilorkerosene.

Thepermissiblefuelsarecrudeoilsorblendedfuels.Useofthesefuelscanresultinhigher maintenancecostsandreducedengineservicelife.

Referto"FuelsforCaterpillarDieselEngines,"FormSEHS7067,foradetailedsummaryof preferredandpermissiblefuelsandtheirspecifications.

RefertoS.A.E.J313DieselFuelsforinformationaboutbetterqualityfuels,suchasignition quality,gravity/density,viscosity,cloudpoint,sulfurcontent,etc.

FuelSulfurContent

Thepercentageofsulfurinthefuelwillaffecttheengineoilrecommendations.See"EngineOils" under"LubricantSpecifications."

Fuelsulfurischemicallychangedduringcombustiontoformsulfuricacid.Theacidchemically attacksmetalsurfacesandcausescorrosivewear.HigherengineoilTBN(TotalBaseNumber) valuesareessentialtominimizecorrosivewear.

Periodicallyrequestfuelsulfurcontentinformationfromyourfuelsupplier.Fuelsulfurcontent canchangewitheachbulkdelivery.

FuelCetaneRequirement

Theminimumfuelcetanenumberrecommendedforthedirectinjectionengineis40.

FuelCloudPoint

Fuelwaxingcanplugthefuelfiltersincoldweather.Thefuelcloudpointmustbebelowthe temperatureofthesurroundingairtopreventfilterwaxingandpowerloss.Fuelheating attachmentsareavailablefromyourCaterpillardealertominimizefuelfilterwaxing.

LubricantSpecifications

TheabbreviationslistedbelowfollowS.A.E.J754nomenclature.Theclassificationsfollow S.A.E.J183classifications.TheMILspecificationsareU.S.A.MilitarySpecifications.These definitionswillbeofassistanceinpurchasinglubricants.Therecommendedoilviscositiesare foundonthe"LubricantViscosityRecommendations"chart.

Theprefix"SPC"isageneralabbreviationusedbyCaterpillartoidentifyspecialoilssuchas syntheticsorsemi-syntheticoils.

EngineOils

UseoilsthatmeettheEngineServiceClassificationCD/SEorCD/SF(MIL-L-2104D).

Consultthe"EMALubricatingOilsDataBook,"FormSEBU5939,foralistingofCD/SEor CD/SFoilbrands.

Thepercentageofsulfurinthefuelwillaffecttheengineoilrecommendations.Ifthefuelhasover 0.5%sulfurcontent,theCD/SEorCD/SFengineoilmusthaveaTBNof20timesthepercentage offuelsulfur(TBNasmeasuredbytheASTMD-2896method).Ifthesulfurcontentisgreater than1.5%byweight,useanoilwithaTBNof30andreducetheoilchangeintervalbyonehalf. ConsultyourCaterpillardealerforcorrectengineoilrecommendations.

HigherTBNvaluesareessentialtoretardthecorrosivedamagetometalengineparts.

Youroilsuppliershouldbeabletofurnishthecorrectoils.

PowerTrainSystemOil-DifferentialsandFinalDrives,Transmission,TorqueConverter andClutchOil(CD/TO-2)

UseServiceClassificationCDoilsthathavesatisfactoryperformanceintheCaterpillarOilTest NumberTO-2.TheseoilsarereferredtoasServiceClassificationCD/TO-2oils.

HydraulicOils(HYDO)

UseEngineServiceClassificationCC(MIL-L-2104B),CC/SF(MIL-L-46152B),CD(MIL-L2104D)orindustrial-typehydraulicoilsthatarecertifiedbytheoilsuppliertohaveantiwear, antifoam,antirust,andantioxidationadditivepropertiesforheavydutyuse.

LubricatingGrease(MPGM)

UseMultipurpose-typegrease(MPGM)whichcontains3%to5%molybdenumdisulfide.NLGI No.2Gradeissuitableformosttemperatures.UseNLGINo.1orNo.0Gradeforextremelylow temperatures.

HydraulicBrakeFluid(BF)

UseheavydutyhydraulicbrakefluidcertifiedbytheoilsuppliertomeetSAE1703f specifications.

ThuMar2800:03:54UTC+05302024

Product:INTEGRATEDTOOLCARRIER

Model:IT18INTEGRATEDTOOLCARRIER7ZB

Configuration:1T18INTEGRATEDTOOLCARRIER7ZB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual

IT18,IT18B,IT28ANDIT28BINTEGRATEDTOOLCARRIERS

MediaNumber-SEBU6072-02PublicationDate-01/05/1990DateUpdated-11/10/2001

Every10ServiceHoursorDaily

SMCS-1000;1400;4203;4490;5070;5927;6700;7000;7008;7220;7327;7347;7400;7451; 7490;7541;7604;7605;7606

Walk-AroundInspection

InspectMachine

Lines,TubesandHoses

Inspectallhydraulic,pressureoil,fuel,hightemperaturewater,etc.,lines,tubesandhosesfor damage,excessivewearandrecommendedtorques.Donotuseyourbarehandstocheckforleaks.

Replacedamaged,worn,etc.,lines,tubesandhosesorcontactyourCaterpillardealerforrepairor replacement.

Forotheritemstobeinspectedsee"Walk-AroundInspection"inthe"BeforeStartingtheEngine" sectionofthispublication.

Fueltankdrainvalveislocatedundertherightrearofthemachine.Openthefueltankdrainvalve. Drainwaterandsediment.Closethedrainvalve.

EngineCrankcase

MeasureOilLevel

Hotoilandcomponentscancausepersonalinjury.Donotallowhotoil orcomponentstocontactskin.

Thedipstickislocatedontherightsideofthemachine.Thelevelismeasuredwiththeengine stoppedonly.

1.Opentheaccessdoor.

Withtheenginestopped,theoillevelshouldbebetweentheADDandFULLmarksonthe dipstick.

3.Ifitisnecessarytoaddoil,removetheengineoilfillercap.

4.Addoiltothecorrectlevel.

5.Inspectthecapseal.Replacetheseal,ifitisdamaged.

6.Installtheoilfillercap.

HydraulicTank

Atoperatingtemperature,thehydraulictankishotandunderpressure.

Hotoilcancauseburns.

Removethefillcaponlywhentheengineisstopped,andthecapiscool enoughtotouchwithyourbarehand.Removethefillcapslowlyto relievepressure.

Thehydraulicfilltankislocatedontheleftsideofthemachine.

Checkthehydraulicoillevelinthesightgauge.Whentheoiliscold,theoillevelshouldbejust abovetheADDmark.Whentheoilishot,itshouldfillthesightgaugecompletely.

1.Ifitisnecessarytoaddoil,removethehydraulictankcapslowlytorelieveanypressure.Add oiltobringtheoilleveljustabovetheADDmarkinthesightgauge.

2.Inspectthehydraulictankcapgasket.Replacethegasket,ifitisdamaged.

3.Installthehydraulictankcap.

Drainvalveislocatedundertherightrearofthemachine.Drainvalveaccessisthroughthehole intheguard.

Openthedrainvalvetodrainanymoistureandsediment.Closethevalve.

NOTE:Yourmachinemaybeequippedwithanadditionalairtankfortheparkingbrake.Ifso, followthesameproceduretodrainmoistureandsedimentfromthesecondairtank.

NOTE:Yourmachinemaybeequippedwithanairdryer.Ifso,checktheairtanktoseeifitis collectingwateroroil.Somewaterisnormal.Ifexcessivewaterisobserved,contactyour Caterpillardealerformorespecificmaintenanceprocedures.

Radiator

InspectConditionofFoldedCoreRadiator

Pressureaircancausepersonalinjury.

Whenusingpressureairforcleaning,wearaprotectivefaceshield, protectiveclothingandprotectiveshoes.

Themaximumairpressuremustbebelow205kPa(30psi)forcleaning purposes.

Compressedair,highpressurewaterorsteamcanbeusedtoremovedust,leavesandgeneral debrisfromafoldedcoreradiator.Cleanasrequiredbyconditionofradiator.

Theuseofcompressedairispreferred.

Referto"KnowYourCoolingSystem,"FormSEBD0518,forthecompleteprocedureand instructions.

CheckCoolantLevel

Atoperatingtemperature,enginecoolantishotandunderpressure. Steamcancausepersonalinjury.

CheckcoolantlevelONLYwhenengineisstoppedandradiatorfiller capiscoolenoughtotouchwithyourbarehand.

Removefillercapslowlytorelievepressure.

Coolingsystemconditionercontainsalkali.Avoidcontactwithskinand eyestopreventpersonalinjury.

Useallcleaningsolutionswithcare.

1.Observethecoolantlevelwiththeenginestoppedandcool.Removetheradiatorcapslowlyto relievethepressure.

2.Maintainthecoolantlevel1cm(1/2inch)belowthefillerneck.

3.Addcoolant,ifnecessary,tobringthecoolantleveltowithin1cm(1/2inch)belowthefiller neck.

4.Inspecttheradiatorcapgasketandreplaceitifitisdamaged.Installtheradiatorcap.

MeasureOilLevel

Hotoilandcomponentscancauseinjury.Donotallowhotoilor componentstocontacttheskin.

Thetransmissionoillevelcanbecheckedwiththeoilcoldorhot.

Themachinemustbeparkedonlevelgroundandtheenginestopped.Lockthetransmission controlinNEUTRAL.

Lowerthebucketwithslightdownpressure.Applytheparking/secondarybrake.

1.Measuretheoillevel.

WithCOLDOIL:Maintainoillevelatthe"MINSAFESTART-COLDOIL"markonthe dipstick.

WithHOTOIL:MaintainoillevelbetweentheADDandFULLmarksonthe"ENGINEAT LOWIDLE"sideofthedipstick.

2.Inspectthetransmissionfillercapgasket.Replacethegasket,ifitisdamaged.

3.Installthetransmissionfillercap.

IndicatorsandGauges

TestandInspect

Withtheenginerunning,movethepaneltestswitchtotheTESTposition.Allindicatorlights shouldcomeonandthefaultalarmshouldsound.

Themainfaultlightshouldflashwhenthepaneltestswitchisactivated.Investigateandreport anymalfunction.

Inspectallgaugesforbrokenlensesorindicators.Haveanyneededrepairsmade.

ThuMar2800:05:43UTC+05302024

Product:INTEGRATEDTOOLCARRIER

Model:IT18INTEGRATEDTOOLCARRIER7ZB

Configuration:1T18INTEGRATEDTOOLCARRIER7ZB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual

IT18,IT18B,IT28ANDIT28BINTEGRATEDTOOLCARRIERS

MediaNumber-SEBU6072-02PublicationDate-01/05/1990DateUpdated-11/10/2001

Every100ServiceHoursor2Weeks

SMCS-1000;1400;4203;4490;5070;5927;6700;7000;7008;7220;7327;7347;7400;7451; 7490;7541;7604;7605;7606

RearAxleTrunnionBearings

Lubricate

1.Lubricateonefittinginthefronttrunnionoftherearaxle.

2.Lubricateonefittinginthereartrunnionoftherearaxle. Totaloftwofittings.

SteeringCylinderBearings

Lubricate

1.Lubricateonefittingintheheadendlubeblockofthesteeringcylinderoneachsideofthe machine.(Attachmentguardgroupshown).

2.Lubricateonefittingintherodendofthesteeringcylinderoneachsideofthemachine.

Totaloffourfittings.

ImplementCylinderandLinkageBearings

Lubricate

Lubricateelevenfittingsontheleftsideofthemachine.

Lubricateelevenfittingsontherightsideofthemachine.

Totalof22fittings.

ThuMar2800:06:05UTC+05302024

Product:INTEGRATEDTOOLCARRIER

Model:IT18INTEGRATEDTOOLCARRIER7ZB

Configuration:1T18INTEGRATEDTOOLCARRIER7ZB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual

IT18,IT18B,IT28ANDIT28BINTEGRATEDTOOLCARRIERS

MediaNumber-SEBU6072-02PublicationDate-01/05/1990DateUpdated-11/10/2001

Every1000ServiceHoursor6Months

SMCS-1000;1400;4203;4490;5070;5927;6700;7000;7008;7220;7327;7347;7400;7451; 7490;7541;7604;7605;7606

2.Lubricateonefittinginthefrontuniversaljointofthecentershaft.

3.Lubricateonefittingintherearuniversaljointofthecentershaft.

4.Lubricateonefittingineachofthetworearshaftuniversaljoints. Totaloffivefittings.

1.Lubricateonefittingattheupperpivotpin.

2.Lubricateonefittingatthelowerpivotpin.

Totaloftwofittings. Transmission

Hotoilandcomponentscancauseinjury.Donotallowhotoilor componentstocontacttheskin.

Whenusingpressureair,wearaprotectivefaceshieldandprotective clothing.Themaximumairpressuremustbebelow205kPa(30psi)for cleaningpurposes.

Useallcleaningsolutionswithcare.

1.Removethetransmissiondrainpluglocatedunderthemachineanddraintheoil.

2.Changethefilterelement.Seethetopic"Transmission"under"Every500ServiceHoursor3 Months."

3.Removethecover.

4.Removemagnetsandscreenfromthehousing.

5.Washthescreeninaclean,nonflammablesolvent.

6.Cleanthemagnetswithacloth,astiffbristlebrushorpressureair.

NOTICE

Donotdroporrapthemagnetsagainstanyhardobjects.Replaceany damagedmagnets.

7.Cleanthecoverandinspecttheseal.Replacetheseal,ifitisdamaged.

8.Insertmagnetsinthescreen.

9.Insertthescreenandmagnetsinthehousing.

10.Installthecover.Tightenthecoverbolts.

11.Cleanandinstallthetransmissiondrainplug.Fillthetransmissionwithoil.Seethe"Refill Capacities"chart.

12.Installanewbreatherlocatedontopofthetransmissioncase.

13.Starttheengine.Applytheservicebrake.Depresstherightbrakepedalonly.

14.Slowlyoperatethetransmissioncontrolstocirculatetheoil.Lockthetransmissioncontrolin NEUTRAL.

15.Inspectforleaks.Measuretheoillevel.

16.Addoilifnecessary,tobringtheoillevelbetweenthe"ADD"and"FULL"marksonthe "ENGINEATLOWIDLE"sideofthedipstick.

17.Stoptheengine.

RolloverProtectiveStructure(ROPS)

Inspect

ToavoidpossibleweakeningoftheRolloverProtectiveStructure (ROPS),consultaCaterpillardealerbeforealteringtheROPSinany way.TheprotectionofferedbytheROPSwillbeimpairedifithasbeen subjectedtostructuraldamageorhasbeeninvolvedinanoverturn incident.

Lookforanylooseordamagedbolts.Replacedamagedboltsormissingboltswithoriginal equipmentpartsonly.Retightenboltstotorque.

ReplaceROPSmountingpads,iftheROPSrattlesormakesanoisewhenthemachineisoperated onaroughsurface.

DonotstraightenorrepairbyweldingreinforcementplatestotheROPS.

ContactyourCaterpillardealerforrepairofcracksinwelds,castingsoranymetalsectiononthe ROPS.

Topreventpossibleinjury,donotusethestartermotortoturnthe flywheel.

Hotenginecomponentscancauseburns.Allowadditionaltimeforthe enginetocoolbeforemeasuringvalveclearance.

NOTICE

Measurethevalvelashwiththeenginestopped.Toobtainanaccurate measurement,allowatleast20minutesforthevalvestocooltoengine cylinderheadandblocktemperature.

Ifthevalveclearanceiswithin±0.08mm(.003in)ofthenominalclearancegiven,adjustmentis notrequired.Iftheclearanceisnotwithintheselimits,settheclearanceasgiveninthechart.

RefertotheServiceManualoryourCaterpillardealerforthecompletevalveadjustment procedure.

ThuMar2800:06:52UTC+05302024

This is the sample of the manual if you need complete manual Click Here to download