CAT + Caterpillar IT24F Integrated Toolcarrier Operation & Maintenance Manual by Heavy Equipment Manual

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

OperationandMaintenanceManual WorkTool(Custom)341-1859PalletFork

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009

Foreword

SMCS-7606

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsthatcanbedifferentfromyour worktool.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour worktoolwhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machinethatyourworktoolisinstalledon.

Wheneveraquestionarisesregardingyourworktool,orthispublication,pleaseconsultyour Caterpillardealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofsafetysignsandlabelsusedontheworktool.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthisworktool.

Operation

s00272057

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,worktoolcontrols, transportationandtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingtheworktool.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeoftheworktoolanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.Theillustrated,step-by-stepinstructionsare groupedbyserviceintervals.Itemswithoutspecificintervalsarelistedunderthewhenrequired interval.Itemsinthemaintenanceintervalsschedulearereferencedtodetailedinstructionsthat follow.

MaintenanceIntervals

Calendarintervalsshown(daily,weekly,monthly,etc)canbeusedinsteadofservicehourmeter intervalsiftheyprovidemoreconvenientservicingschedulesandapproximatetheindicatedservice hourmeterreading.Recommendedserviceshouldalwaysbeperformedattheintervalthatoccurs first.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalsschedulemightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

TueSep2700:09:33UTC+05302022

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

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009

i01828834

WeldingonMachinesandEngineswithElectronicControls

SMCS-1000;7000

Properweldingproceduresarenecessaryinordertoavoiddamagetotheelectroniccontrolsandtothe bearings.Thefollowingstepsshouldbefollowedinordertoweldonamachineoranenginewith electroniccontrols.

Note:Ifyouareweldingonaworktool,removetheworktoolfromthehostmachinebeforewelding.

1.Turnofftheengine.

2.TurnthebatterydisconnectswitchtotheOFFposition.Ifthereisnobatterydisconnectswitch, removethenegativebatterycableatthebattery.

3.Clampthegroundcablefromtheweldertothecomponentthatwillbewelded.Placetheclamp ascloseaspossibletotheweld.Makesurethattheelectricalpathfromthegroundcabletothe componentdoesnotgothroughanybearing.Usethisprocedureinordertoreducethe possibilityofdamagetothefollowingcomponents:

Bearingsofthedrivetrain

Hydrauliccomponents

Electricalcomponents

Othercomponentsofthemachine

DoNOTuseelectricalcomponents(ECMorECMsensors)or electroniccomponentgroundingpointsforgroundingthewelder.

4.Protectanywiringharnessesfromthedebriswhichiscreatedfromwelding.Protectanywiring harnessesfromthesplatterwhichiscreatedfromwelding.

5.Usestandardweldingproceduresinordertoweldthematerialstogether.

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine OperationandMaintenanceManual

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009 i03474182

MaintenanceIntervalSchedule

SMCS-6700

Ensurethatallsafetyinformation,warnings,andinstructionsarereadandunderstoodbeforeany operationoranymaintenanceproceduresareperformed.

Theuserisresponsiblefortheperformanceofmaintenance,includingalladjustments,theuseof properlubricants,fluids,filters,andthereplacementofcomponentsduetonormalwearandaging. Failuretoadheretopropermaintenanceintervalsandproceduresmayresultindiminished performanceoftheproductand/oracceleratedwearofcomponents.

Usemileage,fuelconsumption,servicehours,orcalendartime,WHICHEVEROCCURSFIRST,in ordertodeterminethemaintenanceintervals.Productsthatoperateinsevereoperatingconditions mayrequiremorefrequentmaintenance.

Note:Beforeeachconsecutiveintervalisperformed,allmaintenancefromthepreviousintervalmust beperformed.

Every10ServiceHoursorDaily

HydraulicFittings-Inspect

PalletFork-Inspect PalletFork-Lubricate

TueSep2700:21:23UTC+05302022

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009 i01203214

HydraulicFittings-Inspect

SMCS-5057-040-X6

Checkallhydraulicfittingsfordamagedfittingsorleaks.Replacealldamagedpartsormissingparts. Wipeallfittingsbeforeyouconnectthehydrauliclines.

TueSep2700:21:44UTC+05302022

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

OperationandMaintenanceManual WorkTool(Custom)341-1859PalletFork

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009

PalletFork-Inspect

SMCS-6136-040

DescriptionsoftheForkTine

Parts

i03468363

Illustration1g01598401

TypicalExample

(1)Blade-Thehorizontalpartoftheforktinethatsupportstheload (2)Heel-Theradiusontheforktinethatconnectsthebladetotheshank (3)Shank-Theverticalpartoftheforktinethathasthehooksthatsupporttheforktinesattached.

(4)HookorHanger-Carriersthatmounttheforktinestothecarriage

(5)Tip-Thefreeendoftheblade

Surfaces Illustration2g01598403

TypicalExample

(6)UpperFaceoftheBlade-Theuppersurfaceofthebladethatcarriestheload

(7)BottomofHeel-Thelowersurfaceofthebladethatincludesthetapers

(8)FrontFaceofShank-Thedistancefortheloadcenterismeasuredfromthefrontfaceofthe shankandthefaceoftheshankcontactstheload.

(9)Flanks-Thesidefacesofthebladeandtheshank.

(10)BladeBevel-Theupperandlowersurfacesofthetiponthebladethataretaperedforeasy insertionoftheforktines

(11)TipFlanks-Thesidesurfacesofthetiponthebladethataretaperedforeasyinsertionofthe forktines

(12)TopofShank-Theuppersurfaceontheshank

(13)Shaft-Thetubesthataremountedontheforktinesformountingtheforktinestothecarriage

Dimensions

TypicalExample

(T)Thickness-Thethicknessofthebladeattheclosestpointtotheheel

(W)Width-Thewidthofthebladeattheclosestpointtotheheel

(BH)BackHeight-Thedistancefromthebottomofthebladetothetopoftheshank (BL)Length-Thelengthofthebladeismeasuredfromthefrontfaceontheshanktothetiponthe blade.

(A)Angle-Theanglefromtheuppersurfaceofthebladetothefrontfaceoftheshank.

InspectionoftheForkTines

Checktheforktinesdailyforanytwistingorbendingoftheforktines.Ifanytwistingorbendingis observed,theforktinesshouldbechangedpriortoanyliftingoperation.Iftheforktinesaredamaged, consultyourCaterpillardealer.

Checktheforktinesforwearorfordamage.Inspectthewelds,thelocks,theshafts,andtheforktines fordamage.Ifthecomponentsaredamaged,consultyourCaterpillardealer.Referto,"Daily Inspection"foradditionalinformation.

BladeThickness

Illustration4g01600073

TypicalExample

1.Measurethethicknessoftheshank.Ensurethatthemeasuringdeviceisheldsquareacrossthe shankinordertoacquireanaccuratemeasurement.

Illustration5g01600074

TypicalExample

2.Measurethebladeoftheforktineneartheheel.Ensurethatthemeasuringdeviceisheldsquare acrossthebladeinordertoacquireanaccuratemeasurement.

3.Comparethemeasurementofthebladeandthemeasurementoftheshank.

4.Ifthedifferenceinmeasurementsislessthan10%,theforktinecanremaininservice.

5.Ifthedifferenceinmeasurementsisgreaterthan10%,theforktinemustbetakenoutof service.Forktinewearthatisgreaterthan10%,representsa20%reductioninthecapacityof theforktine.

ConsultyourCaterpillardealerforadditionalinformation.

AngleoftheHeel

Illustration6g01600075

TypicalExample

1.Placeameasuringdeviceinthetopinsideareaoftheheelontopoftheblade.Ensurethatthe measuringdeviceisheldflatagainstthebladeinordertoacquireanaccuratemeasurement.

TypicalExample

2.Movetheupperarmofthemeasuringdevicetowardthefaceoftheshank.Ensurethatthe measuringdeviceisheldflatagainst`thefaceoftheshankinordertoacquireanaccurate measurement.

3.Checktheanglethatwasmeasuredwiththedevicefortheangleoftheheel.

4.Iftheangleisbetween87degreesand93degrees,theforktinecanremaininservice.

5.Iftheangleislessthan87degreesorgreaterthan93degrees,theforktinemustbetakenoutof service.Theforktinesmustbeinspectedforthefollowingconditions: permanentdeformation stresscracks

otherdefects

ConsultyourCaterpillardealerforadditionalinformation.

TueSep2700:22:11UTC+05302022

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

OperationandMaintenanceManual WorkTool(Custom)341-1859PalletFork

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009

PalletFork-Lubricate

SMCS-6136-086

Note:Wipeallthefittingsbeforeyoulubricatethefittings.

1.Lubricatefittings(1).Therearefourfittings.

ReferenceRefertoOperationandMaintenanceManual,SEBU6250,"CaterpillarMachineLubricant Recommendations"forinformationonlubricants.

i03468384

TueSep2700:22:35UTC+05302022

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

OperationandMaintenanceManual

WorkTool(Custom)341-1859PalletFork

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009

WorkToolInstallationandRemoval

SMCS-6700-010

CouplingtheWorkTool

Placetheforkinasafepositionbeforeengagingordisengagingthe quickcoupler.Ensurethattheforkisnotcarryingaload.

Seriousinjuryordeathmayresultfromengagingordisengagingthe forkwhenitisinanunstablepositionorcarryingaload.

Inspectthequickcouplerengagementbeforeoperatingthemachine.

Seriousinjuryordeathmayresultfromimproperlyengagedcoupler.

1.Positiontheforkonalevelsurface.

2.MovethequickcouplerswitchtotheUnlockorDisengageposition.

Ifthecoupleriscontrolledbythe3rdAuxiliaryHydraulicControlLever,movethecontrolbackto theUnlockorDisengageposition.RefertotheOperationandMaintenanceManualofthehost machineforadditionalinformationoncontrols.

i03465321

Illustration1g01807693

TypicalExample

3.Tiltthecouplerforward.Ensurethatthecouplerisbelowthehooksonthefork.Refertoillustration 1.

4.SlowlydrivethemachineFORWARD.Centerthecouplerbetweenthehooksonthefork.

Illustration2g01807694

5.Raisethecoupleruntilthecouplercomesincontactwiththehooksonthefork.Continuetoslowly raisethecoupleruntiltheforkbeginstolift.Ensurethattheforkhasremainedlevel.

Illustration3g01808958

6.Tiltthecouplerbackwarduntiltheforkfullycontactsthecoupler.Refertoillustration3.

7.MovethequickcouplerswitchtotheLockorEngageposition.

Ifthecoupleriscontrolledbythe3rdAuxiliaryHydraulicControlLever,movethecontrolforward totheLockorEngageposition.RefertotheOperationandMaintenanceManualofthehostmachine foradditionalinformationoncontrols.

Inspectthequickcouplerengagementbeforeoperatingthemachine.

Seriousinjuryordeathmayresultfromimproperlyengagedcoupler.

8.Visuallyinspectthequickcouplerinordertoensurethatthecouplerwedges(1)arefullyextended throughthecorrespondingholes(2)inthefork.

9.Alsousethefollowingproceduretoverifyengagementofthecouplerwedges.

a.Enterthemachine.

b.Fastentheseatbeltandlowerthearmrests.

c.Starttheengine.

d.Disengagetheparkingbrake.

e.Raisetheforkandfullydumpthefork.

f.Shaketheforkupanddownwiththetiltcylindersinordertoverifyengagementofthecoupler wedges.

10.Ensurethatthecouplingsforthequickdisconnectofthetopclampareclean.Connectthecouplings tothehostmachine.

Donotapplydownwardpressureontheforktines.Donotprywiththe forktines.Donotsideloadtheforktines.Prematurefailureofthefork tinesmayoccurandcauseacrushhazard.Personalinjuryordeath mayoccur.

UncouplingtheWorkTool

Placetheforkinasafepositionbeforeengagingordisengagingthe quickcoupler.Ensurethattheforkisnotcarryingaload.

Seriousinjuryordeathmayresultfromengagingordisengagingthe forkwhenitisinanunstablepositionorcarryingaload.

Palletforkmayswingawayfromthecouplerasthewedgesarereleased andthecoupleristiltedorlowered.Couldcauseseriousinjuryor death.Keepallpersonnelawayfromthepalletforkwhenuncoupling thepalletfork.

1.Positiontheforkonalevelsurface.

2.MovethequickcouplerswitchtotheUnlockorDisengageposition.

Ifthecoupleriscontrolledbythe3rdAuxiliaryHydraulicControlLever,movethecontrolbackto theUnlockorDisengageposition.

Note:Ifthecouplerwedges(1)arestuck,performthefollowingprocedureinorderto releasethecouplerwedges.

a.Raisetheforkslightlyabovetheground.Shaketheforkupanddownwiththetiltcylinders. Repeatsteps2and3. Illustration4g01807694

3.AfterthecouplerwedgesareUnlockedorDisengaged,tiltthecouplerforwarduntilthebottomorthe coupleris305mm(12inch)fromthefork.Refertoillustration4.

4.Lowerthecoupleruntilthecouplerisnolongerincontactwiththehooksonthefork.Ensurethatthe couplerisbelowthehooksonthefork.Refertoillustration5.

Palletforkmayswingawayfromthecouplerasthewedgesarereleased andthecoupleristiltedorlowered.Couldcauseseriousinjuryor death.Keepallpersonnelawayfromthepalletforkwhenuncoupling thepalletfork.

5.Slowlydrivethemachinebackwardawayfromthefork.

6.MovethequickcouplerswitchtotheLockorEngageposition.

Ifthecoupleriscontrolledbythe3rdAuxiliaryHydraulicControlLever,movethecontrolforward totheLockorEngageposition.

InstallationProcedureofForkTines

Note:Alldirectionsarefromtheoperatorseatandfacingthefrontofthehostmachine.

1.Byusingasuitableliftingdevice,placeforktines(5)onasurfacethatislevelandsolid.Theweight ofeachforktine(5)isapproximately182kg(401lb).

2.Byusingasuitableliftingdevice,installshaft(1)throughtheleftsideboreoftheforkcarriage, throughtheboresofforktines(5),andintotherightsideboreofthecarriage.Theweightofshaft(1) isapproximately68kg(150lb).

3.Installplates(2)onbothsidesofthecarriageinordertosecureshaft(1).

4.Installplates(4)ontines(5)inordertosecurethebottomofforktines(5)totheforkcarriage.

5.Useasuitableprybarinordertopositionforktines(5)tothehydrauliccylinders.Installboltsand nuts(3)inordertosecureforktines(5)tothehydrauliccylinders.

RemovalProcedureofForkTines

1.Byusingasuitableliftingdevice,placeforktines(5)onasurfacethatislevelandsolid.Theweight ofeachforktine(5)isapproximately182kg(401lb).

2.Removeboltsandnuts(3)fromforktines(5)andthehydrauliccylinders.

3.Removeplates(4)onforktines(5).

4.Removeplates(2)onbothsidesoftheforkcarriage.

5.Byusingasuitableliftingdevice,removeshaft(1)fromtheboresoftheforkcarriageandforktines (5).Theweightofshaft(1)isapproximately68kg(150lb).

TueSep2700:17:01UTC+05302022

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

OperationandMaintenanceManual WorkTool(Custom)341-1859PalletFork

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009 i03078661

DailyInspection

SMCS-6700

Personalinjuryordeathcanresultfromimproperlycheckingfora leak.

Alwaysuseaboardorcardboardwhencheckingforaleak.Escaping airorfluidunderpressure,evenapin-holesizeleak,canpenetrate bodytissuecausingseriousinjury,andpossibledeath.

Iffluidisinjectedintoyourskin,itmustbetreatedimmediatelybya doctorfamiliarwiththistypeofinjury.

NOTICE

Accumulatedgreaseandoilonaworktoolisafirehazard.

Removedebriswithsteamcleaningorhighpressurewateratanytime asignificantquantityofoilisspilledontheworktool.

Note:Theworktoolshouldberemovedfromthequickcouplerduringthedailyinspectionof theworktool.Uncouplingtheworktooldailyhelpstopreventthecouplerwedgesfrom sticking.

Forthemaximumservicelifeoftheworktool,makeathoroughwalk-aroundinspectionbeforeyou mountthemachineandbeforeyoustarttheengine.

Positiontheworktoolonalevelsurface.Uncoupletheworktoolfromthequickcoupler.Referto OperationandMaintenanceManual,"Operation-UncouplingtheWorkTool".

Lowerthequickcouplertothegroundinfrontofthemachine.Stoptheengineonthehostmachine. Removetheenginestartswitchkeybeforeexitingthemachine.RefertotheOperationand MaintenanceManualofthehostmachineforadditionalinformation.

Cleananydebrisfromtheforks.

Cleananydebrisfromthecarriageassembly.

Inspecttheworktoolforthefollowingconditions:loosebolts,brokenparts,missingpartsandworn parts.

Checkthecarriageassemblyandtheforktinesforwearorfordamage.Inspectthewelds,thelocks, theshafts,andtheforktinesfordamage.Ifthecomponentsaredamaged,consultyourCaterpillar dealer.

Ifthepalletforksarenotoperatedforlongperiods,thepalletforksmustbelubricated.Referto OperationandMaintenanceManual,"PalletFork-Lubricate"forinformationonlubricatingthepallet forks.

Performallrepairsbeforetheworktoolisputintoservice.

Checkthesafetymessages.Replacethesafetymessageswhenthesafetymessagesaredamaged. Replacethesafetymessageswhenyoucannotreadthesafetymessages.Replacethesafetymessages whenthesafetymessagesaremissing.

Coupletheworktooltothequickcoupler.RefertoOperationandMaintenanceManual,"OperationCouplingtheWorkTool".Aftertheworktooliscoupled,ensurethatthecouplerwedgesarefully engagedintotheworktool.

TueSep2700:17:27UTC+05302022

Product:INTEGRATEDTOOLCARRIER

Model:IT24FINTEGRATEDTOOLCARRIER4NN

Configuration:IT24FIntegratedToolcarrier4NN00001-UP(MACHINE)POWEREDBY3114Engine

OperationandMaintenanceManual WorkTool(Custom)341-1859PalletFork

MediaNumber-GEBU0002-00PublicationDate-01/02/2009DateUpdated-18/02/2009

i03698420

Operation

SMCS-6700

NOTICE

Forspecificinformationonyourhostmachine,refertotheOperation andMaintenanceManualofyourhostmachine.

Note:Whenyouoperatethepalletforks,theforktinesmustbeproperlyseatedonthecarriage. Theforktinelocksmustbeinplaceatalltimes.Theforktinelocksmustbeinthelockposition atalltimes.

Note:Youmustensurethattheworktooliscompatiblewiththehostmachine.Consultany CaterpillardealerforinformationonmatchingtheWorkTooltothehostmachine.

LoadingtheFork

1.Positiontheforkinthecenteroftheload.

2.Movethehostmachineforwardintopositionandengagetheload.Thehostmachineshouldbe squarewiththeload.Spacetheforktinesevenlyundertheload.

3.Movethehostmachineforwarduntiltheloadtouchesthecarriage.

4.Tilttheforktinesupwardinordertoholdtheloadagainstthefork.

5.Carefullylifttheload.

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