Estimating bulldozer production off-the-job . .1-49 Mounted equipment — Bulldozers, sidebooms, Sheet metal guarding near track and on dozer.
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1TRACK-TYPE TRACTORS1 AGRICULTURAL TRACTORS2 MOTOR GRADERS3 EXCAVATORS4 BACKHOE LOADERS5 SKIDDERS6 PIPELAYERS7 WHEEL TRACTOR-SCRAPERS8 CONSTRUCTION & MINING TRUCKS/TRACTORS9 ARTICULATED TRUCKS10 WHEEL TRACTORS cSOIL/LANDFILL COMPACTORS11 WHEEL LOADERS12 TRACK LOADERS13 INTEGRATED TOOLCARRIERS14 TELESCOPIC HANDLERS15 PAVING PRODUCTS16 ELPHINSTONE UNDERGROUND MINING MACHINES17 HYDROMECHANICAL WORK TOOLS18 CONTENTSPage Preface . . . . . . . . . . . . . . . . . . . . . 4Operator andMachine Protection . . . . . . . . . 5Replacement Parts Warning . . . . 7Nomenclature . . . . . . . . . . . . . . . 8
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Machine performance must ultimately be meas-ured 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 trans- mission, speeds and operating costs. The Perfor- mance Handbook considers these factors in detail. There are other less direct machine performance fac- tors for which no tables, charts or graphs are pos- sible. 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 orcurves showing cycle times or hourly production fig- ures for Caterpillar machines under certain con- ditions. Statements of conditions always accompany or precede the curves or tables. Before using any per- formance information in this Handbook, a complete understanding of the qualifying conditions is essential. The data is based on field testing, computer analy- sis, laboratory research and experience; and every effort has been made to assure their correctness.However, all such data is based upon 100% effi- ciency in operation Ñ 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, oper- ator efficiency, material characteristics, haul road conditions, altitude and other factors which may reduce performance or production on a particular job.Methods for estimating machine owning and oper- ating costs vary widely, depending on locality, indus- try 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 ÒexcellentÓ conditions, another may consider ÒsevereÓ or ÒaverageÓ, depending on his own experience and basis of comparison. Therefore, these guidelines should be considered only approximations.Caterpillar Inc. has made every effort to assurethat 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 estimat- ing the production or performance of earthmoving machinery, their consumption of fuel and lubricants, tire life and repair costs, and the possibility of inad- vertent 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 per- formance will be achieved on a given job.Specifications shown in this Handbook were cur-rent at time of printing. However, due to CaterpillarÕs many machine improvement programs, specifica- tions and materials may change without notice. For current specifications relating to a machineÕs per- formance, please refer to the most recent Caterpillar product specification sheet.Caterpillar Inc.4PREFACE
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OPERATOR AND MACHINE PROTECTION Awell 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 placefor their employees. The purchaser of a Caterpillar machine has a duty to review his/her particular appli- cation and job site for the machine to identify poten- tial hazards inherent to that application or job site. Based on the results of this hazard analysis, the appropriate operator and machine protection con- figuration can be determined.Caterpillar designs, builds, and tests its productsto ensure the safety of operators, maintenance per- sons, service persons, and bystanders. Caterpillar pro- vides as standard equipment the appropriate operator and machine protection for most applications. How- ever, 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 fab- ricate, or request Caterpillar to provide, custom or special guarding. Your Caterpillar Dealer can help you with this hazard analysis and guarding config- uration process.I.Operator Training and Protection Practices Remember that any kind of machine or mechanicaldevice can be hazardous if not kept in good condi- tion, or if operated by careless or improperly trained operators, or if operated in an irresponsible manner. Listed below are some recommended basic stepsthat can be broadly applied to most work environments: cTrain 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: ÐCompletes proper training to operate the assigned machine and understands that seat belts must be worn whenever seated in operatorÕs compartment. ÐReads and understands the Operation & Main- tenance manual for that machine, and knows that a copy of that manual is stored in the oper- atorÕs compartment. ÐReads and understands the EMI (Equipment ManufacturerÕs Institute), CIMA(Construction Industry Manufacturers Association), or any other furnished manual related to rules for safe machine operation and identification of hazards.ÐHas appropriate personal safety equipment and knows how to use it. This includes such things as hard hat, gloves, safety glasses, hearing pro- tection and safety shoes.ÐKnows what the job requirements are, what other machines are working in the area, and is aware of any hazardous conditions that may arise.cBe sure operators are alert and in proper physi-cal and mental condition to perform their work assignments safely. No machine should be oper- ated by a person who is drowsy, under the affect of medicines or drugs, suffers blackouts, or is suf- fering from any physical or mental distraction that could contribute to unsafe operation.5
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cMaintain proper job conditions and working pro-cedures. Check the job for possible hazards, both above and below ground level. Look for all possi- ble 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, con- gestion, etc. Hazardous work conditions should be corrected wherever possible and adequate warn- ings should be posted when applicable.cProvide the correct machine to handle the job andequip it properly for the job to provide the neces- sary operator protection. Check for compliance with all applicable governmental and local regu- lations. It is the machine ownerÕs or employerÕs legal responsibility to see that his equipment com- plies with, and is operated in accordance with, all such requirements.cMake sure the machine is properly maintained.Awalk-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 cor- rected. Some examples include: ÐLoose, bent or missing grab irons, railings or steps;ÐWorn, cut or missing seat belts (any seat belt over three (3) years old must be replaced regard- less of condition);ÐDamaged windows in the operatorÕs compartment; ÐWorn, rubbing or abraded electrical insulation and hoses;ÐAny fluid leaks; and ÐMissing or damaged guards. It is the machine ownerÕs or employerÕs responsi- bility 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 machinethat:ÐInterfere with operator visibility; ÐInterfere with ingress, egress from the machine; ÐExceed the rated payload or gross combination weight of the machine resulting in overloading the braking and/or steering system or the roll- over protective structure (ROPS) capacity rat- ing (shown on a plate affixed to the ROPS); orÐPlace objects in the cab that intrude into the oper- atorÕs space or that are not firmly fixed into place. III.Operator-related Equipment Options Each job presents unique conditions that must betaken into account. Consider direct dangers to the operator as well as all possible sources of distrac- tion that could reduce operator efficiency and increase the chances of costly and dangerous mistakes. Climate- controlled, sound-suppressed cabs, and special exte- rior lighting are options available from Caterpillar that can address requirements of special working environments.ÒFlexibleÓ machines include hydraulic excavators(track-type, wheel-type, and compact), skid-steer loaders, backhoe loaders and integrated tool-carri- ers. Work tools or any tool used in hazardous appli- cations like demolition and logging, can create a need for special operator guarding. When flying debris from impact, cutting, shearing or sweeping attach- ments is present, additional protective devices such as a front screen, Falling Object Guarding System (FOGS, includes top & front guarding), thick poly- carbonate 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 conditionsthat 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 instru- ment 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 areflammable!To minimize the risk of fire, Caterpillar recom- mends following these basic steps:ÐRemove trash (leaves, twigs, papers, etc.) that may accumulate in the engine compartment.ÐDo not operate a machine if leakage of flam- mable fluids is noticed. Repair leaks before resuming machine operation. Most fluids used in Caterpillar machines should be considered flammable.ÐKeep access doors to major machine compart- ments in working order to permit the use of fire fighting equipment, should a fire occur. ÐAvoid attaching electrical wiring to hoses and tubes that contain flammable or combustible fluids.6
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8NomenclatureTHE CATERPILLAR PRODUCT LINE TRACK-TYPE TRACTORS Flywheel power 52 to 634 kW (70 to 850 hp) §Brazilian Domestic Only D3C Series III**D3C XL Series III** D3C LGP Series III**D5C Series III** D5C XL Series III** D5C LGP Series III**D5M XLD5M LGPD5E§D6R*D6R XL D6R XR D6R LGPD6M XLD6M LGPD6GD7G D7R*D7R XR D7R LGPD8R*D8R LGPD4E SR*D6G SR*Challenger 35Challenger 45 D9R*D10R*D11R *Waste Handling Arrangements (WHA) **available for sanitary landfill applications **Also available with hydrostatic power train. AGRICULTURAL EQUIPMENT *Variable Horsepower arrangements available (SR) Super Rural Challenger 75EChallenger 85E* Challenger 65E Challenger 55 Challenger 95E LEXION 460/465LEXION 480/485MOTOR GRADERS Flywheel power 104 to 373 kW (140 to 500 hp) 120H120H NA120H ES135H135H NA12H12H NA12H ES140H140H NA140H ES163H NA*14H16H 160H160H NA160H ES143H NA*D4C Series III**D4C XL Series III** D4C LGP Series III***All Wheel Drive 24H
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9HYDRAULIC EXCAVATORS Operating Weight 6700 to 316 600 kg (14,770 to 698,000 lb) Track Models 307B307B SB311B312B 312B L315B315B L320B320B L 320B N 320B LN 320B S330B330B L 330B LN345B345B L Ð FIX 345B L Ð VG 350350 L5130B322B322B L 322B LN325B325B L 325B LN301.55230Wheel ModelsFront Shovels Operating Weight 83 800 to 318 500 kg (184,600 to 702,000 lb) M315M31850805130B 5230BACKHOE LOADERS Digging depth 4420 to 6528 mm (14’6″ to 21’5″)WHEEL SKIDDERSFlywheel power 104 to 145 kW (140 to 195 hp) TRACK SKIDDERS Flywheel power 89 to 112 kW (120 to 150 hp) PIPELAYERS Lifting capacity 18 145 to 104 330 kg (40,000 to 230,000 lb)416C561M572R583R589 515525528B 426C428C436C438C446B M312M320517 Grapple527 Cable 527 Grapple517 Cable 375375 L318B L318B LN
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10WHEEL TRACTOR-SCRAPERS CONSTRUCTION & MINING TRUCKS/TRACTORS ARTICULATED TRUCKS Capacity 22.7 to 36.3 metric tons (25 to 40 U.S.tons) Standard Models Heaped capacity 15.3 to 33.6 m3(20 to 44 yd3)Elevating Scrapers Heaped capacity 8.4 to 26 m3(11 to 34 yd3)Tandem Powered Scrapers Heaped capacity 15.3 to 33.6 m3(20 to 44 yd3)Push-Pull Scrapers Heaped capacity 15.3 to 33.6 m3(20 to 44 yd3)Construction & Mining Trucks Capacity 36.8 to 218 metric ton Ñ 40.6 to 240 U.S.tons Construction & Mining Tractors Flywheel power 699 to 962 kW (938 to 1290 hp) 621F*631E Series II*651E* 613C Series II615C Series II623F633E Series II 627F*769D771D Quarry Truck 773D775D Quarry Truck 777D785C789C793C D25DD30D 776D784C 627F637E Series II*637E Series II657E*657ED250E Series IID300E Series IID350ED400E *Available in auger scraper version
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11WHEEL TRACTORS Flywheel power 164 to 597 kW (220 to 800 hp) LANDFILL COMPACTORS Flywheel power 164 to 353 kW (220 to 473 hp) SOIL COMPACTORS Flywheel power 164 to 235 kW (220 to 315 hp) WHEEL LOADERS Bucket Capacity (Heaped) 1.2 to 30 m 3(1.6 to 40 yd3)*High lift arrangement available. TRACK LOADERS Bucket Capacity (Heaped)** 1.0 to 3.6 m 3(1.3 to 4.2 yd3)**Wide track arrangements available. **General Purpose Bucket. INTEGRATED TOOLCARRIERS Bucket Capacity (Heaped)* 1.3 to 3.1 m 3(1.7 to 4.0 yd3)*General Purpose Bucket. 814F824G834B 815F825G 816F826G836 844854G914G924F928G 938G*950G962G966F Series II*970F 980G*988F Series II*990 Series II992G994* 933C*939C953C*963B*973* IT14GIT24FIT28GIT38GIT62G 906902
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