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Caterpillar Performance Handbook Ed.37

Caterpillar Performance Handbook Ed.37 - Caterpillar...

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Unformatted text preview: Caterpillar Performance Handbook Edition 37 Caterpillar Performance Handbook Edition 37 SEBD0347 ® ® CONTENTS Page Preface . . . . . . . . . . . . . . . . . . . . .4 Operator and Machine Protection . . . . . . . . .5 Operator Training . . . . . . . .5 Machine Modifications . . . . .6 Equipment Options . . . . . . .6 Machine Protection . . . . . . .6 Fire Prevention . . . . . . . . . . .6 Safety Regulations . . . . . . . .7 Sound Suppression . . . . . . . .7 Replacement Parts Warning . . . . . . . . . .7 Nomenclature . . . . . . . . . . . . . . .8 TRACK-TYPE TRACTORS 1 MOTOR GRADERS 2 SKID STEER LOADERS 3 EXCAVATORS 4 BACKHOE LOADERS 5 FOREST PRODUCTS 6 PIPELAYERS 7 WHEEL TRACTOR-SCRAPERS 8 CONSTRUCTION & MINING TRUCKS/TRACTORS 9 ARTICULATED TRUCKS 10 WHEEL DOZERS ● SOIL COMPACTORS 11 WHEEL LOADERS ● INTEGRATED TOOLCARRIERS 12 TRACK LOADERS 13 TELESCOPIC HANDLERS 14 PAVING PRODUCTS 15 UNDERGROUND MINING EQUIPMENT 16 HYDROMECHANICAL WORK TOOLS 17 ENGINES 18 1 CATERPILLAR® PERFORMANCE HANDBOOK a Cat® publication by Caterpillar Inc., Peoria, Illinois, U.S.A. FEBRUARY 2007 Performance information in this booklet is intended for estimating purposes only. Because of the many variables peculiar to individual jobs (including material characteristics, operator efficiency, underfoot conditions, altitude, etc.), neither Caterpillar Inc. nor its dealers warrant that the machines described will perform as estimated. NOTE: Always refer to the appropriate Operation and Maintenance Manual for specific product information. Materials and specifications are subject to change without notice. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. Printed in U.S.A. 2 © 1979-2007 Caterpillar Inc. SEBD0347 FORMER MODELS 19 OWNING & OPERATING COSTS 20 TIRES 21 MINING AND EARTHMOVING 22 STOCKPILE COAL HANDLING 23 LAND CLEARING 24 WASTE HANDLING 25 INFORMATION PRODUCTS AND SOLUTIONS 26 TABLES 27 3 PREFACE Machine performance must ultimately be measured in unit cost of material moved, a measure that includes both production and costs. Factors bearing directly on productivity include such things as weight to horsepower ratio, capacity, type of transmission, speeds and operating costs. The Performance Handbook considers these factors in detail. There are other less direct machine performance factors for which no tables, charts or graphs are possible. Serviceability, parts availability and operator convenience are examples. In comparing machine performance, all factors should be considered. This Handbook is intended as an aid which, when coupled with experience and a good knowledge of local conditions, can assist in estimating true machine performance. Many sections of the Handbook include tables or curves showing cycle times or hourly production figures for Caterpillar machines under certain conditions. Statements of conditions always accompany or precede the curves or tables. Before using any performance information in this Handbook, a complete understanding of the qualifying conditions is essential. The data is based on field testing, computer analysis, laboratory research and experience; and every effort has been made to assure their correctness. However, all such data is based upon 100% efficiency in operation — a status which cannot be achieved continuously even under ideal conditions. Thus, in using such performance and production data, it is necessary to correct the results indicated in the handbook tables by appropriate factors. This allows for the anticipated actual job efficiency, operator efficiency, material characteristics, haul road conditions, altitude and other factors which may reduce performance or production on a particular job. 4 Methods for estimating machine owning and operating costs vary widely, depending on locality, industry practices, owner preferences and other factors. One method is suggested in the Handbook section on Owning and Operating Costs. When used with good judgment, it has provided reasonably accurate estimates in the past. Included in the Owning and Operating Section are guidelines, based on working conditions, to assist in estimating consumption of fuel and lubricants, tire life and repair costs for Caterpillar machines. However, what one Handbook user regards as “excellent” conditions, another may consider “severe” or “average”, depending on his own experience and basis of comparison. Therefore, these guidelines should be considered only approximations. Caterpillar Inc. has made every effort to assure that the information contained in this Handbook is accurate and is a fair statement of the results to be achieved in the circumstances indicated. However, because of the many variables involved in estimating the production or performance of earthmoving machinery, their consumption of fuel and lubricants, tire life and repair costs, and the possibility of inadvertent errors or omissions in assembling this data, Caterpillar cannot and does not imply that all data in this book are complete nor that this level of performance will be achieved on a given job. Specifications shown in this Handbook were current at time of printing. However, due to Caterpillar’s many machine improvement programs, specifications and materials may change without notice. For current specifications relating to a machine’s performance, please refer to the most recent Caterpillar product specification sheet. Caterpillar Inc. OPERATOR AND MACHINE PROTECTION A well trained operator, working under suitable conditions, utilizing a modern, properly-equipped machine provides a machine-operator team capable of giving maximum production. These factors, along with appropriate job site rules and communication procedures, are essential to coordinate people and machines working together. Appropriately protected and maintained machines are less likely to suffer premature component failure or damage, and give operators the confidence and assurance they need to carry out their work. Furthermore, training is not complete until the operator reads, understands and agrees to follow the instructions provided in the Operation and Maintenance Manual included with every Caterpillar machine. Employers have a duty to provide a safe work place for their employees. The purchaser of a Caterpillar machine has a duty to review his/her particular application and job site for the machine to identify potential hazards inherent to that application or job site. Based on the results of this hazard analysis, the appropriate operator and machine protection configuration can be determined. Caterpillar designs, builds, and tests its products to ensure the safety of operators, maintenance persons, service persons, and bystanders. Caterpillar provides as standard equipment the appropriate operator and machine protection for most applications. However, particular applications may require additional operator and/or machine protection. Caterpillar offers related options for most such applications. However, there may be very special applications where the Caterpillar Dealer or the Purchaser may want to fabricate, or request Caterpillar to provide, custom or special guarding. Your Caterpillar Dealer can help you with this hazard analysis and guarding configuration process. I. Operator Training and Protection Practices Remember that any kind of machine or mechanical device can be hazardous if not kept in good condition, or if operated by careless or improperly trained operators, or if operated in an irresponsible manner. Listed below are some recommended basic steps that can be broadly applied to most work environments: ● Train operators for the job they are assigned to do. The length and type of training must comply with governmental and local regulations wherever they apply. As an example, machine operators in mining activities must be trained in accordance with Mine Safety and Health Administration (MSHA) regulations. Where specific regulations do not apply, no operator should be assigned to a job until he or she meets the following minimum requirements: – Completes proper training to operate the assigned machine and understands that seat belts must be worn whenever seated in operator’s compartment. – Reads and understands the Operation & Maintenance manual for that machine, and knows that a copy of that manual is stored in the operator’s compartment. – Reads and understands the EMI (Equipment Manufacturer’s Institute), CIMA (Construction Industry Manufacturers Association), or any other furnished manual related to rules for safe machine operation and identification of hazards. – Has appropriate personal safety equipment and knows how to use it. This includes such things as hard hat, gloves, safety glasses, hearing protection and safety shoes. – Knows what the job requirements are, what other machines are working in the area, and is aware of any hazardous conditions that may arise. ● Be sure operators are alert and in proper physical and mental condition to perform their work assignments safely. No machine should be operated by a person who is drowsy, under the affect of medicines or drugs, suffers blackouts, or is suffering from any physical or mental distraction that could contribute to unsafe operation. 5 ● Maintain proper job conditions and working procedures. Check the job for possible hazards, both above and below ground level. Look for all possible sources of danger to the operator and others in the area. Pay particular attention to conditions which may be hazardous or near the operating limits of the machine: e.g., side slopes, steep grades, potential overloads, etc. Examine the work site for restricted traffic patterns, obstructed views, congestion, etc. Hazardous work conditions should be corrected wherever possible and adequate warnings should be posted when applicable. ● Provide the correct machine to handle the job and equip it properly for the job to provide the necessary operator protection. Check for compliance with all applicable governmental and local regulations. It is the machine owner’s or employer’s legal responsibility to see that his equipment complies with, and is operated in accordance with, all such requirements. ● Make sure the machine is properly maintained. A walk-around inspection should be performed at the beginning of each shift before the machine is placed in operation. If this inspection reveals any problems that could affect safety, the machine must not be operated until these problems are corrected. Some examples include: – Loose, bent or missing grab irons, railings or steps; – Worn, cut or missing seat belts (any seat belt over three (3) years old must be replaced regardless of condition); – Damaged windows in the operator’s compartment; – Worn, rubbing or abraded electrical insulation and hoses; – Any fluid leaks; and – Missing or damaged guards. It is the machine owner’s or employer’s responsibility to ensure the machine is properly maintained. Your Caterpillar Dealer will be glad to assist you in selecting and equipping the machine best suited for your job and in providing maintenance for your machines. II. Machine Modifications Modifications must not be made to the machine that: – Interfere with operator visibility; – Interfere with ingress, egress from the machine; – Exceed the rated payload or gross combination weight of the machine resulting in overloading the braking and/or steering system or the rollover protective structure (ROPS) capacity rating (shown on a plate affixed to the ROPS); or – Place objects in the cab that intrude into the operator’s space or that are not firmly fixed into place. 6 III. Operator-related Equipment Options Each job presents unique conditions that must be taken into account. Consider direct dangers to the operator as well as all possible sources of distraction that could reduce operator efficiency and increase the chances of costly and dangerous mistakes. Climatecontrolled, sound-suppressed cabs, and special exterior lighting are options available from Caterpillar that can address requirements of special working environments. “Flexible” machines include hydraulic excavators (track-type, wheel-type, and compact), skid-steer loaders, backhoe loaders and integrated tool-carriers. Work tools or any tool used in hazardous applications like demolition and logging, can create a need for special operator guarding. When flying debris from impact, cutting, shearing or sweeping attachments is present, additional protective devices such as a front screen, Falling Object Guarding System (FOGS, includes top & front guarding), thick polycarbonate windshields or a combination of these is recommended by Caterpillar. Contact your Caterpillar Dealer for operator guarding options on your machine. IV. Machine Protection Check the job for unusually demanding conditions that could cause premature failure or excessive wear of machine components. Additional protective devices such as heavy-duty radiator guards, crankcase guards, engine enclosures, track roller guards and/or brake shields may be needed. Also, consider the use of anti-vandalism devices, such as cap locks and instrument panel guards. Contact your Caterpillar dealer for machine-protection and vandalism-prevention options for your machine. V. Fire Prevention Remember that most fluids on your machine are flammable! To minimize the risk of fire, Caterpillar recommends following these basic steps: – Remove trash (leaves, twigs, papers, etc.) that may accumulate in the engine compartment. – Do not operate a machine if leakage of flammable fluids is noticed. Repair leaks before resuming machine operation. Most fluids used in Caterpillar machines should be considered flammable. – Keep access doors to major machine compartments in working order to permit the use of fire fighting equipment, should a fire occur. – Avoid attaching electrical wiring to hoses and tubes that contain flammable or combustible fluids. – Replace any rubbing, damaged, frayed, kinked or leaking hydraulic hoses or fittings. – Follow safe fueling practices as described in Caterpillar Operation & Maintenance Manuals, EMI or CIMA Safety Manuals, and local regulations. As an additional safety measure, keep a 10-pound (4.5 kg) minimum fire extinguisher on the machine in a location as specified in the Operator and Maintenance Manual. VI. Safety Regulations Regulations vary from country to country and often within country. Your Caterpillar dealer can assist you in properly equipping your machine to meet applicable requirements. Note: The general summaries given below are not substitutes for reading and being familiar with the appropriate local laws. (a) United States (US) With a few exceptions, all machine operations in the United States are covered by federal and/or state regulations. If the machine is used in mining activities, the regulations are administered by the Mine Safety and Health Administration (MSHA). Other activities, including construction, are under regulations administered by the Occupational Safety and Health Administration (OSHA). These agencies require employers to provide a safe working environment for employees. Caterpillar has the same objective. OSHA and MSHA have adopted criteria for ROPS, Falling Object Protective Structures (FOPS), seat belts, warning horns, back-up alarms, operator sound levels, steering systems, and braking systems. Additional operator’s compartment protection may be required for machines engaged in logging, demolition and other special applications. (b) European Union (EU) The EU Machinery Safety Directive applies to Caterpillar machines and most work tools. It requires that the “CE mark” be applied to the product and that a manufacturer’s declaration be provided. The “CE mark” indicates that safety issues have been addressed by applying the appropriate safety standards in the design and manufacture of the machine. The objective of the Safety Directive is to protect operators, spectators and maintenance personnel. Caterpillar fully supports this objective. VII. Sound Suppression Different marketing areas have different noise emission requirements. Noise regulations usually specify limits for operators and spectators. (a) United States OSHA and MSHA noise-control regulations set permissible noise-exposure limits for machine operators and employees. Operator protection from machine noise can be achieved by use of factorybuilt cabs as offered in the Caterpillar Price List. These cabs, when properly maintained and operated with the doors and windows closed, reduce the operator sound level for an eight-hour operating period to meet the OSHA and MSHA noise-exposure limits in effect at the date of manufacture. Variables that may be encountered on the job site, such as other nearby noise sources or noise-reflecting surfaces, may reduce the allowable work hours. If this occurs, ear protective devices may be required. (b) European Union Operator sound-exposure requirements for machines in Europe are very similar to the OSHA and MSHA regulations mentioned above. In addition to operator sound-exposure requirements, certain types of Caterpillar machines are subject to European Commission regulations for exterior sound levels. Caterpillar ensures its products sold in the EU comply with the applicable noise regulations. VIII. Replacement Parts for your Caterpillar Machine ! WARNING When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. 7 Nomenclature THE CATERPILLAR PRODUCT LINE TRACK-TYPE TRACTORS *Waste Handling Arrangements (WHA) Flywheel power 52 to 634 kW (70 to 850 hp) **available for sanitary landfill applications D3G XL D3G LGP D4G XL D4G LGP D5G XL D5G LGP D6K XL D6K LGP D6N XL D6N LGP D6G Series II D7R Series II* D7R XR Series II* D7R LGP Series II* D8R D8T* D8R LGP D8T LGP D5N XL D5N LGP D6R Series III* D6R XL Series III* D6R XW Series III* D6R LGP Series III* D6T D9R D9T* D7G Series II D10T* MOTOR GRADERS D11R D11R CD *All Wheel Drive. Flywheel power 104 to 373 kW (140 to 500 hp) 120H Standard 120H Global 143H* Global 135H Standard 135H Global 160H Standard 160H Global 163H* Global 12H Standard 12H Global 14H Global SKID STEER LOADERS Operating Weight 2600 to 4350 kg (5710 to 9570 lb) 216B/226B 232B 8 236B/242B 246B/248B 252B/262B 268B Multi-Terrain 247B/257B 267B/277B 287B 140H Standard 140H Global 16H Global 24H Global HYDRAULIC EXCAVATORS Operating Weight 1650 to 316 600 kg (3640 to 698,000 lb) Track Models 301.5 301.6C 301.8C 302.5C 313C CR 313C SR 301.5 CR 303C CR 303.5C CR 304C CR 305C CR 307C 307C SB 315C 315C L 314C CR 314C LCR 324D 324D L 324D LN 321C LCR 308C CR 311C U 318C 318C L 318C LN 318C N 312C 312C L 320C 320C L 320C U 320C LU 330D 330D L 330D LN 325D 325D L 325D LN 320C LN 320C S 345C 345C L – FIX 345C L – VG 345C L – WVG Wheel Models 365C L 385C 385C L Front Shovels Operating Weight 74 300 to 318 500 kg (163,803 to 702,000 lb) 365C FS 385C FS M313D 5090B M316D M315D M318D M322D BACKHOE LOADERS Digging depth 4420 to 6528 mm (14'6" to 21'5") 416E 420E/420E IT 422E 428E 430E/430E IT 432E 442E 434E 444E 446D 9 FOREST PRODUCTS Wheel Skidders Track Skidders 525C 535C 545C 517 Cable 527 Cable Track Harvesters Wheel Harvester Track Forest Machines 517 Grapple 527 Grapple 320C FM 324D FM 325D FM Track Feller Bunchers 330D FM 345C FM Wheel Feller Bunchers Wheel Forest Machines 950H LL 966H LL 980H LL Felling Heads Work Tools Grapples Logging Forks Woodchip Dozers Scoops Rakes 988H LL IT62H LL Wheel Forwarders Knuckleboom Loaders HF 181 HF 201 HF 221 501 501 HD 511 521 522 550 532 541 551 55...
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