Dossier d'intervention Numéro du rapport

RAPPORT
D'ENQUÊTE DPI4013431 RAP0176098

Annexe E - Le manuel d'entretien de la chargeuse sur roues

CATERPILLAR - MODÈLE 966
(EXTRAIT)

Thibault Démolition Itée, 31 août 2002 Page1 55

 SEBU5438-01
December 1982

25U1-UP
30K1253-UP
42J2487-UP
76J4144-UP
78G1-UP
 FOREWORD
This book is a guide to equipment care. The illustrated, step-by-step instructions are grouped
by servicing intervals; items without specific intervals are listed under WHEN REQUIRED.
Circled numbers in the LUBRICATION AND MAINTENANCE CHART are to key the charted
items to the instructions in the book.

Use the service meter to determine servicing intervals. Calendar intervals (daily, weekly, 2
weeks, etc.) shown may be used instead of service meter intervals if it provides more convenient
servicing schedules; and approximates the indicated service meter reading.
NOTE
Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the
LUBRICATION AND MAINTENANCE CHART may be necessary.

Electric Service Meter

Perform previous interval items at multiples of the original requirement. For example, at
EVERY 100 SERVICE HOURS OR 2 WEEKS, also perform those items listed under EVERY 50
SERVICE HOURS OR WEEKLY and EVERY 10 SERVICE HOURS OR DAILY.

Some photographs in this publication may show details or attachments that may be different
from your unit. Also, for some photographs, the ROPS (Rollover Protective Structure) may have
been removed for illustrative purposes.

Continuing improvement and advancement of product design may cause changes to your
machine which may not be included in this publication. Each publication is reviewed and
revised, as required, to update and include these changes in later editions.

Whenever a question arises regarding your Caterpillar product, or this publication, please
consult your Caterpillar dealer for the latest available information.
Safety 3

Maintenance Recommendations 4

Walk-Around Inspection 6

Fuel and Lubricant Specifications 7

Lubrication and Maintenance Chart 8

Every 10 Service Hours or Daily 10

Every 50 Service Hours or Weekly 12

Every 100 Service Hours or 2 Weeks 13

Every 250 Service Hours or Monthly ., 15

Every 500 Service Hours or 3 Months 19

Every 1000 Service Hours or 6 Months 22

Every 2000 Service Hours or 1 Year 24

When Required 30

Wiring Diagrams 38

Tire Inflation Information 39

Refill Capacities 40
Serial Number Locations .. 40

GET Bolt Torque 40

Lower all equipment with slight Read warning and caution infor- Engage parking brake, block tires
down pressure before servicing mation provided on the loader. and attach warning tags to con-
loader. Follow servicing instructions trols while servicing loader.
carefully.
Always inspect cooling system with engine
stopped.
Remove filler cap slowly to relieve pressure.
Steam can cause personal injury.
Do not allow corrosion inhibitor, which contains
alkali, to contact skin or eyes.
Do not smoke while refueling. Fumes from fuel
are flammable.
Batteries give off flammable fumes that can
explode. Do not smoke when observing electrolyte
level.
Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes.
When using pressure air wear protective face
shield and protective clothing. Maximum air pres-
sure must be below 30 psi (205 kPa) for cleaning
purposes.
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to contact
skin.
To avoid possible weakening of the ROPS (Rol-
lover Protective Structure), consult a Caterpillar
dealer before altering the ROPS in any way. The
protection offered by the ROPS will be impaired if it
has been subjected to structural damage or has
been involved in an overturn incident.
Personal injury can result if machine is articu-
lated when someone is in the pivot area. Connect
3
frames with safety link, shut off engine and relieve
hydraulic pressure before working in pivot area.
Do not attempt adjustments while machine is
moving or the engine is running.
Do not allow unauthorized personnel on
machine while it is being serviced.
Wear hard hat, safety glasses and safety shoes
as the job requires.
Use the proper tools. Repair or replace broken
or damaged equipment.
Operate engine only in well ventilated area.
Store oily rags and other combustible material in
a safe place.
Do not smoke while refueling.
Use a self-attaching air chuck and stand behind
tread when inflating tires.
Hydraulic oil is flammable. Do not weld on pipes
or tubes that are filled with oil.
To prevent personal injury, always lower all
equipment with slight down pressure, stop engine,
set parking brake and block or restrain machine
before servicing it, unless otherwise specified.
If engine is not running, do not release
emergency or parking brake systems unless
machine is blocked or restrained. Machine could
move and cause injury to personnel.
Connect frame with anti-pivot Turn disconnect switch OFF be- Use caution when removing
link before servicing machine fore servicing electrical system. radiator cap, drain plugs, grease
center area, unless advised
otherwise.
COOLING
CAUTION
Never add coolant to an overheated engine,
allow engine to cool first.
Measure specific gravity of antifreeze solution
frequently in cold weather to assure adequate
protection.
When permanent antifreeze and water solu-
tions are used in the cooling system, the solu-
tion should be drained and replaced every 2000
hours or yearly.
When additions of inhibitor are made to the
cooling system every 500 service hours or 3
months, it is not necessary to drain and refill
yearly. Cooling system drain period can then
be extended to 4000 service hours or 2 years.
Maintain a 3% concentration of Caterpillar Cor-
rosion Inhibitor or equivalent in the cooling
system regardless of antifreeze concentration.
if machine is to be stored in, or shipped to an
area with below freezing temperatures, the
cooling system must be protected to the lowest
expected ambient temperature or drained
completely.
fittings or pressure taps.
NOTE
The engine cooling system is protected to -20°F (-29°C),
with permanent-type antifreeze, when shipped from the
factory.
Pure undiluted antifreeze will freeze at -10°F (-23°C).
Use clean water that is low in scale forming min-
erals, not softened water. Add Caterpillar Corro-
sion Inhibitor, or equivalent, to the water to provide
corrosion protection. Follow the recommenda-
tions on the container for the quantity required.
Whenever draining and refilling the cooling sys-
tem, always measure the coolant level when the
engine reaches normal operating temperature.
Filling at over 5 gpm (19 litres/min) rate can
cause air pockets in the cooling system.
When measuring the coolant level, inspect the
filler cap gasket. Replace gasket if it is damaged.
Premix antifreeze solution to provide protection
to the lowest expected ambient temperature.
Operate with a thermostat in the cooling system
all year-round. Cooling system problems can arise
without a thermostat.
FUEL
CAUTION
Fill fuel tank at the end of each day of operation
to drive out moisture laden air and to prevent
condensation. Do not fill the tank to the brim.
The fuel expands when it gets warm and may
overflow.
Water and sediment should be drained from the
tank at the start of each shift or after the fuel tank
has been filled and allowed to stand for 5 to 10
minutes.
If engine fuel system is equipped with a water
separator, drain water from water separator daily
before starting engine. Always drain water from
separator before it becomes one-half full. Fre-
quent draining may be necessary in areas of high
humidity or when fuel supply is contaminated with
water.
Drain water and sediment from the main fuel
storage tank weekly, and before the tank is refil-
led. This will help prevent water or sediment from
being pumped from the storage tank into the
machine fuel tank.
Measure fuel level with dipstick in filler opening.
After changing fuel filter, always bleed fuel sys-
tem to remove air bubbles from system.
AIR INTAKE
Inspect air intake precleaner daily for accumula-
tion of dust and debris.
Service air cleaner when RED band in indicator
locks in visible position.
ELECTRICAL
CAUTION
When using external electrical source to start
machines with direct electric starting, turn
disconnect switch off and remove key before
attaching cable to emergency starting recep-
tacle.
When using jumper cables, be sure to connect
in parallel: POSITIVE (+) to POSITIVE (+) and
NEGATIVE ( - ) to NEGATIVE ( - ) .
Do not allow free end of jumper cables to touch
either machine. This helps avoid electrical
shock.
5
When starting a machine with jumper cables,
remove ail caps from both batteries. Leave these
off during the starting process to allow venting of
hydrogen gas.
Connect one cable to the ungrounded terminal
of the battery of machine to be started.
Connect the other end of this cable to the termi-
nal of the same polarity [POSITIVE (+) to POSI-
TIVE (+) and NEGATIVE ( - ) to NEGATIVE ( - ) ]
on the auxiliary battery.
Connect second cable to the other terminal of
the stronger battery.
Finally, connect the remaining cable end to the
starter ground terminal.
An emergency starting kit facilitates starting
from an external power source, ft provides a per-
manent receptacle on the machine to plug in a
jumper cable. Two different cables are needed for
auxiliary starting from an operating machine or
from an auxiliary power pack.
HYDRAULIC SYSTEM
CAUTION
Make-up oil added to the hydraulic system
must mix with the oil already in the tank. Use
only petroleum products unless system is
equipped for use with special products.
If hydraulic oil becomes cloudy, water or air is
entering the hydraulic system. Drain fluid,
purge system*, and retighten hydraulic suction
line clamps. Water or air in the hydraulic sys-
tem can cause pump failure.
*Contact your Caterpillar dealer for correct purg-
ing procedure.
GENERAL
CAUTION
Accumulated grease and oil on a machine is a
fire hazard. Remove this debris with steam
cleaning or high pressure water every 1000
hours or each time any significant quantity of
oil is spilled on a machine.
Wipe all fittings, caps and plugs before servic-
ing.
For your own safety and maximum service life of the vehicle, a thorough walk-around inspection should be
made before mounting the machine to start the engine. Inspect around and under machine for such items
as loose bolts, trash build-up, oil or coolant leaks, condition and inflation of tires, condition of bucket and
linkage.

BUCKET
Inspect for damage
or excessive wear.

BUCKET CONTROL
LINKAGE
Inspect for damage
or excessive wear.
TIRES
Inspect for damage
and proper
inflation. FINAL DRIVES
(front and rear)
Inspect for leaks.

LIGHTS
Inspect for broken
INSTRUMENT PANEL
bulbs.
Inspect for broken
gauges.

COVERS AND GUARDS

Be sure they are OPERATOR'S COMPARTMENT
firmly in place. • Inspect for cleanliness—
Inspect for damage broken gauges.

HYDRAULIC SYSTEM
Inspect for leaks.
DIFFERENTIALS
(front and rear)
inspect under machine
for leaks. . TRANSMISSION
Inspect for leaks.

ENGINE COMPARTMENT
Inspect for leaks— COOLING SYSTEM
trash buildup. Inspect for leaks—
trash buildup.

6
FUEL AND LUBRICANT SPECIFICATIONS

NOTE
The abbreviations listed below, except for LO, follow S.A.E. J754 nomenclature. The classifications follow S.A.E. J183
classifications. The MIL specifications are U.S.A. Military Specifications. These definitions will be of assistance in
purchasing. The specific classifications for this machine are found on the "RECOMMENDED LUBRICANTS" chart.

Diesel Fuel Lubricating Oils (LO)

Distillate fuels that conform to ASTM No. 1 or
No. 2 Fuel Oil or No. 1D or No. 2D Diesel Fuel Oil
Specifications with a minimum cetane of 35 are the
preferred fuels and provide proven maximum en-
gine service life.
Some crude oils and blended fuels are regarded
as permissible and can be used with extra fuel fil-
ters and adjusted oil change periods. However, this
will result in less than maximum engine service life.
Contact your Caterpillar dealer regarding the
Caterpillar SPECIAL INSTRUCTION titled "FUELS
FOR CATERPILLAR DIESEL ENGINES", FORM
SEHS7067, which specifies requirements for other
preferred and permissible fuels.
Transmission And Clutch Oil (CD/TO-2)
Use Service Classification CD oils that have Multipurpose-type Gear Lubricant (MPL)
satisfactory friction retention performance in the
Caterpillar Oil Test No. TO-2: Referred to as Ser- Use Gear Lubricant Classification GL-5 (MIL-L-
vice Class CD/TO-2 Oil. 2105B).
Use oils that meet Engine Service Classification
CC (MIL-L-2104B or MIL-L-46152) CD or CD/TO-2.
Lubricating Grease (MPG)
Use Multipurpose-type Grease (MPG).
Multipurpose-type grease which contains 3% to
5% molybdenum disulfide is also acceptable, and
preferred. NLGI No. 2 Grade is suitable for most
temperatures. Use NLGI No. 1 or No. 0 Grade for
extremely low temperatures.
Hydraulic Oil (HYDO)
Use (LO) or industrial-type hydraulic oils which
are certified by the supplier as having anti-wear,
anti-foam, anti-rust and anti-oxidation additive
properties for heavy duty use.

Engine Oils (CD) Hydraulic Brake Fluid (BF)

Use oils that meet Engine Service Classification Use heavy duty hydraulic brake fluid meeting the
CD (MIL-L-2104C) or CD/TO-2. requirements of SAE J1703e.

RECOMMENDED LUBRICANTS
AT STARTING TEMPERATURES FROM - 1 0 0 F TO + 1 2 0 T (-23 0 C TO +48 0 C) (1)
STARTING TEMPERATURES
ABOVE 32°F BELOW 32°F
COMPARTMENT OR SYSTEM (00C) (0°C)
CD/TO-2
Transmission system SAE 30 SAE 10W
CD
Engine crankcase SAE 30 (2) SAE 10W(3)
HYDO
Hydraulic control system SAE 1OW SAE 10W
MPL
Differential and final drives SAE 90 SAE 80
BF
Brakes SAE J1703e
(1)
BeIow - 1 0 T (-230C) consult your Caterpillar dealer for Cold (3)
SAE 10W oil may be used in the diesel engine even if daytime
Weather Recommendations. ambient temperature rises to 700F (21°C). Below -10°F(-23 0 C) it
may be necessary to warm the engine oil so the engine can be
(2)
SAE 40 oil is preferred for temperatures above 900F (32°C). SAE cranked and the oil will circulate freely.
20W-40 is permissible for starting temperatures above 15°F
(-9°C).
7
LUBRICATION AND MAINTENANCE CHART

ITEM SERVICE
LUBRICATION AND MAINTENANCE CHART

(1)
Change oil anytime it becomes thick and dark. Key to Lubricants:
CD/TO-2 - Engine Service Classification CD 08s that meet
(2)
Check frequently if any signs of leakage develop or are suspected. Caterpillar Oil Test No. TO-2 requirements.
CO - Engine Service Classification CD or MIL-L-2104C
(3)
The percentage of sulfur in the fuel win affect the engine oil CC - Engine Service Classification CC, MIL-L-2104B or
recommendations. If the fue) has over 0.5% sulfur content, the CO MIL-L-46152
engine oil must have a TBN of 20 times the percentage of fuel LO - CD, CC or CD/TO-2
sulfur (TBN as measured by the ASTM D-2896 method). Your oil HYDO - LO, or certified Industrial-type Hydraulic Oils
supplier should be able to furnish the correct oils. MPL - GL-5 or MIL-L-2105B
MPG - Mutipurpose-type Grease
BF • Hydraulic Brake Fluid, SAE J1703e

9
 Dossier d'intervention Numéro du rapport
RAPPORT
D'ENQUÊTE DPI4013431 RAP0176098

Annexe F - Programme d'entretien préventif (PEP) de la machinerie lourde

CATERPILLAR recommandé par un garage spécialisé
(EXEMPLE)

Thibault Démolition Itée, 31 août 2002 Page11 66

 LUBRIFICATION

HUILES
ET FILTRES

INSPECTION
VISUELLE

SYSTÈME DE
REFROIDISSEMENT

AUTRES

INTERVENTION

Pour obtenir plus de précisions sur les vérifications et les opérations effectuées à chaque intervalle, veuillez vous reporter au guide d'entretien et de lubrification de votre machine.

Pointe-Claire Division Énergie Québec Trois-Rivières

(514)630-3111 (514)426-3000 (418)878-3000 (819)371-1005
Baie-Comeau Division Manutention Saint-Hubert Val-d'Or
(418)296-3003 (514)334-5260 (514)678-6888 (819)825-5494
Chicoutimi Hull Sept îles Wabush
(418)545-1560 1 800 567-1209 (418)962-7791 (709)282-3350
 Dossier d'intervention Numéro du rapport
RAPPORT
D'ENQUÊTE DPI4013431 RAP0176098

Annexe G - Liste des principaux témoins et autres personnes rencontrées

Thibault Démolition Itée, 31 août 2002 Page 68

 Dossier d'intervention Numéro du rapport
RAPPORT
D'ENQUÊTE DPI4013431 RAP0176098

Liste des principaux témoins et autres personnes rencontrées

Madame , présidente de « Thibault Démolition Ltée »

Monsieur , directeur général, Thibault Démolition Ltée
Madame , secrétaire comptable, Thibault Démolition Ltée
Monsieur , opérateur de machinerie lourde, Thibault Démolition Ltée
Monsieur , copropriétaire de Rebuts de Pâtes et Papiers de l'Outaouais
Monsieur , technicien certifié de Hewitt Équipement Ltée
Monsieur , président de l'entreprise Robinson & Frères Enr.
Madame , épouse de la victime
Monsieur , camionneur (par téléphone)
Monsieur , camionneur
Monsieur , camionneur
Monsieur , camionneur
Monsieur , travailleur autonome
Monsieur Stéphane Roy, enquêteur, MRC des Collines-de-l'Outaouais
Monsieur Dominic Robitaille, policier, MRC des Collines-de-l'Outaouais

Thibault Démolition ltée, 31 août 2002 Page11 69