120H and 135H Motor Graders - Safety
Contents
1. Do not use the wheel lean locking bolt and the wheel lean lock bracket in order to center the wheel lean of the machine While you operate the machine slowly in an open area check for proper operation of all controls and all protective devices Before you move the machine you must make sure that no one will be endangered Do not allow riders on the machine unless the machine has the following equipment e additional seat e additional seat belt e Rollover Protective Structure ROPS Reduce engine speed when you maneuver in tight quarters or when you are going over a hill When you operate the machine downhill use two transmission gears less than the transmission gear that is used when you operate the machine up the same hill SEBU7474 03 21 Safety Section Engine Stopping Do not allow the engine to overspeed when you operate the machine downhill If overspeed exists use the service brake control to decrease the speed to a level that will allow you to downshift Repeat this process until a stable speed is obtained Note any needed repairs during machine operation Report any needed repairs Carry attachments approximately 40 cm 15 inches above ground level Do not go close to the edge of a cliff an excavation or an overhang If the machine begins to sideslip downward on a grade immediately remove the load and turn the machine downhill Avoid any conditions that can lead to tipping the machine The mach2. ROPS FOPS Structures can weaken the structures Consult your Caterpillar dealer for mounting guidelines The Tip Over Protection Structure TOPS is another type of guard that is used on mini hydraulic excavators This structure protects the operator in the event of a tipover The same guidelines for the inspection the maintenance and the modification of the ROPS FOPS Structure are required for the Tip Over Protection Structure Other Guards If Equipped Protection from flying objects and or falling objects is required for special applications Logging applications and demolition applications are two examples that require special protection A front guard needs to be installed when a work tool that creates flying objects is used Mesh front guards that are approved by Caterpillar or polycarbonate front guards that are approved by Caterpillar are available for machines with a cab or an open canopy On machines that are equipped with cabs the windshield should also be closed Safety glasses are recommended when flying hazards exist for machines with cabs and machines with open canopies If the work material extends above the cab top guards and front guards should be used Typical examples of this type of application are listed below e Demolition applications e Rock quarries e Forestry products Additional guards may be required for specific applications or work tools The Operation and Maintenance Manual for your machine or y
3. Severe injury or death from crushing could occur Connect steering frame lock between front and rear frames before lifting transporting or servicing machine in articulation area Discon nect lock and secure before resuming operation Accumulator 7 This message is positioned on the steering accumulator AA WARNING HIGH PRESSURE CYLINDER DO NOT REMOVE ANY PARTS UNTIL PRESSURE HAS BEEN RELIEVED TO NITROGEN GAS 977308 g00107646 High Pressure Cylinder Do not remove any parts until pressure has been relieved to avoid possible personal injury Charge with dry nitrogen gas SEBU7474 03 9 Safety Section Safety Messages Engine Coolant 8 This message is positioned inside the cover for the radiator cap AA WARNING a aal ELC liini g00782457 Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Improper Connections For Jump Start Cables 9 This message is positioned inside the door of the service center g00907918 Improper jumper cable connections may cause an explosion resulting in personal injury Batteries may be located in separate compartments When using jumper cables always connect positive cable to positive terminal of battery c
4. of the rubber deterioration of rubber and corrosion of rim components To avoid overinflation proper nitrogen inflation equipment and training in the usage of the equipment are necessary A tire blowout or a rim failure can result from improper equipment or from misused equipment When you inflate a tire stand behind the tread and use a self attaching chuck Servicing tires and rims can be dangerous Only trained personnel that use proper tools and proper procedures should perform this maintenance If correct procedures are not used for servicing tires and rims the assemblies could burst with explosive force This explosive force can cause serious personal injury or death Carefully obey the specific instructions from your tire dealer 101122596 Electrical Storm Injury Prevention SMCS Code 7000 When lightning is striking in the vicinity of the machine the operator should never attempt the following procedures e Mount the machine e Dismount the machine If you are in the operator s station during an electrical storm stay in the operator s station If you are on the ground during an electrical storm stay away from the vicinity of the machine 101861206 Before Starting Engine SMCS Code 1000 7000 g00949005 Illustration 22 SEBU7474 03 19 Safety Section Before Starting Engine Place frame lock link 1 in the storage bracket The frame lock link must be removed from the
5. second squared Information Concerning Whole Body Vibration Level This section provides vibration data and a method for estimating the vibration level for motor graders Note Vibration levels are influenced by many different parameters Many items are listed below Operator training behavior mode and stress Job site organization preparation environment weather and material Machine type quality of the seat quality of the suspension system attachments and condition of the equipment It is not possible to get precise vibration levels for this machine The expected vibration levels can be estimated with the information in Table 1 in order to calculate the daily vibration exposure A simple evaluation of the machine application can be used Estimate the vibration levels for the three vibration directions For typical operating conditions use the average vibration levels as the estimated level With an experienced operator and smooth terrain subtract the Scenario Factors from the average vibration level in order to obtain the estimated vibration level For aggressive operations and severe terrain add the Scenario Factors to the average vibration level in order to obtain the estimated vibration level Note All vibration levels are in meter per second squared SEBU7474 03 23 Safety Section Sound Information and Vibration Information Table 1 ISO Reference Table A Equivalent vibration levels of whole bo
6. the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in injury or death Con tact your Caterpillar dealer for replacement manu als Proper care is your responsibility Do Not Weld the ROPS 3 This message is positioned on the ROPS A WARNIN e STRUCTURAL DAMAGE AN OVERTURN MODIFICATION ALTERATION OR IMPROPER REPAIR CAN IMPAIR THIS STRUCTURE S PROTECTION CAPABILITY THEREBY VOIDING THIS GER TIFICATION DO NOT WELD ON OR DRILL HOLES IN THE STRUCTURE CONSULT A CATERPILLAR DEALER TO DETERMINE THIS STRUCTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION ROLLOVER ROPS AND FALLING OBJECT FOPS PROTECTIVE STRUCTURE CERTIFICATION yoge po O T ON TEST MASS THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE WHICH JEON aa 00 IS NOT ALTERED TO EXCEED THE CERTIFICATION TEST MASS MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J395 SAE J1040 APRAB ISO 3471 1986 ISO 3471 1994 SAE J231 JANB1 1S0 3449 1984 ISO 3449 1992 LEVEL II 14H 300 CATERPILLAR INC PEORIA ILLNCIS USA ten cary ad g00910837 Structural damage an overturn modification al teration or improper repair can impair this struc ture s protection capability thereby voiding this certification Do not weld on or drill holes in the structure Consult a Caterpillar dealer to deter mine this structure s limitations without voiding its certification This
7. 0949322 To avoid engine damage use only Caterpillar radial seal air filters as replacement filters Refer to the following topics for correct replacement instructions e Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace e Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 102443908 General Hazard Information SMCS Code 7000 Illustration 13 g00104545 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment These warning tags Special Instruction SEHS7332 are available from your Caterpillar dealer Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles SEBU7474 03 13 Safety Section General Hazard Information Be aware of high voltage power lines and power cables that are buried If the machine comes in contact with these hazards serious injury or death may occur from electrocution X HO 98 3D BES Illustration 14 g00702020 Wear a hard hat protective glasses and other protective equipment as required Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment Make sure that all protective guards and all covers are secured in place on the equipment Keep the equip
8. SAFETY Operation and Maintenance Manual Excerpt 2010 Caterpillar All Rights Reserved CATERPILLAR H SEBU7474 03 CATERPILLAR Fenaa Operation and Maintenance Manual 120H and 135H Motor Graders 101658146 Important Safety Information Most accidents that involve product operation maintenance and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential hazards This person should also have the necessary training skills and tools to perform these functions properly Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Safety precautions and warnings are provided in this manual and on the product If these hazard warnings are not heeded bodily injury or death could occur to you or to other persons The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER WARNING or CAUTION The Safety Alert WARNING label is shown below The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The messa
9. ain the conditions of the terrain The following guidelines can help reduce the whole body vibration level 1 Use the right type and size of machine equipment and attachments 2 Maintain machines according to the manufacturer s recommendations a Tire pressures b Brake and steering systems c Controls hydraulic system and linkages 3 Keep the terrain in good condition a Remove any large rocks or obstacles Vibration Levels Y axis 0 48 0 64 0 36 Scenario Factors Z axis X axis Y axis Z axis 0 38 0 22 0 26 0 14 0 78 0 21 0 21 0 30 0 58 0 25 0 25 0 34 b Fill any ditches and holes c Provide machines and schedule time in order to maintain the conditions of the terrain Use a seat that meets ISO 7096 Keep the seat maintained and adjusted a Adjust the seat and suspension for the weight and the size of the operator b Inspect and maintain the seat suspension and adjustment mechanisms Perform the following operations smoothly a Steer b Brake c Accelerate d Shift the gears Move the attachments smoothly Adjust the machine speed and the route in order to minimize the vibration level a Drive around obstacles and rough terrain b Slow down when it is necessary to go over rough terrain Minimize vibrations for a long work cycle or a long travel distance a Use machines that are equipped with suspension systems b Use the ride control system on moto
10. ap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure Cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Oils Hot oil and hot components can cause personal injury Do not allow hot oil to contact the skin Also do not allow hot components to contact the skin Remove the hydraulic tank filler cap only after the engine has been stopped The filler cap must be cool enough to touch with a bare hand Follow the standard procedure in this manual in order to remove the hydraulic tank filler cap Batteries Electrolyte is an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended 101359795 Fire Prevention and Explosion Prevention SMCS Code 7000 I Illustration 18 g00704000 All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire Fire may cause personal injury and property damage Remove all flammable materials such as fuel oil and debris from the machine Do not allow any flammable materials to accumulate on the machine Store fuels and lubrican
11. are refueling a machine Do not refuel a machine near open flames or sparks Always stop the engine before refueling Fill the fuel tank outdoors OOQ Illustration 20 g00704135 Gases from a battery can explode Keep any open flames or sparks away from the top of a battery Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Improper jumper cable connections can cause an explosion that can result in injury Refer to the Operation Section of this manual for specific instructions Do not charge a frozen battery This may cause an explosion Fire Extinguisher Make sure that a fire extinguisher is available Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Obey the recommendations on the instruction plate Ether Ether is flammable and poisonous Use ether in well ventilated areas Do not smoke while you are replacing an ether cylinder or while you are using an ether spray Do not store ether cylinders in living areas or in the operator compartment of a machine Do not store ether cylinders in direct sunlight or in temperatures above 49 C 120 F Keep ether cylinders away from open flames or sparks Dispose of used ether cylinders properly Do not puncture an ether cylinder Keep ether cylinders away from unauthorized pers
12. documents are based on information from the United Kingdom Health and Safety Executive Refer to Operation and Maintenance Manual SEBU8257 The European Union Physical Agents Vibration Directive 2002 44 EC for more information about vibration Consult your local Caterpillar dealer for more information about machine features that minimize vibration levels Consult your local Caterpillar dealer about safe machine operation Use the following web site in order to find your local dealer Caterpillar Inc www cat com i01649970 Operator Station SMCS Code 7000 Any modifications to the inside of the operator station should not project into the operator space The addition of a radio fire extinguisher and other equipment must be installed so that the defined operator space is maintained Any item that is brought into the cab should not project into the defined operator space A lunch box or other loose items must be secured Objects must not pose an impact hazard in rough terrain or in the event of a rollover 101992325 Guards Operator Protection SMCS Code 7000 There are different types of guards that are used to protect the operator The machine and the machine application determines the type of guard that should be used A daily inspection of the guards is required in order to check for structures that are bent cracked or loose Never operate a machine with a damaged structure The operator becomes expos
13. dy vibration emission for earthmoving equipment Machine Typical Operating Type Activity X axis finish grading 0 41 Motor F Graders hard grading 0 61 transfer 0 39 Note Refer to ISO TR 25398 Mechanical Vibration Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines for more information about vibration This publication uses data that is measured by international institutes organizations and manufacturers This document provides information about the whole body exposure of operators of earthmoving equipment Refer to Operation and Maintenance Manual SEBU8257 The European Union Physical Agents Vibration Directive 2002 44 EC for more information about machine vibration levels The Caterpillar suspension seat meets the criteria of ISO 7096 This represents vertical vibration level under severe operating conditions This seat is tested with the input spectral class EM4 The seat has a transmissibility factor of SEAT lt 1 1 The whole body vibration level of the machine varies There is a range of values The low value is 0 5 meter per second squared The machine meets the short term level for the design of the seat in ISO 7096 The value is 0 63 meter per second squared for this machine Guidelines for Reducing Vibration Levels on Earthmoving Equipment Properly adjust machines Properly maintain machines Operate machines smoothly Maint
14. e operation of the machine from the operator s seat Adjust the steering wheel tilt lock in order to enhance the operation of the machine from the operator s seat Make sure that the machine is equipped with a lighting system that is adequate for the job conditions Make sure that all lights are working properly Before you start the engine or before you move the machine make sure that no one is on the machine underneath the machine or around the machine Make sure that there are no personnel in the area 20 Safety Section Engine Starting SEBU7474 03 102441047 Engine Starting SMCS Code 1000 7000 If a warning tag is attached to the engine start switch or to the machine controls do not start the engine Also do not move any machine controls Move all hydraulic controls to the HOLD position or to the OFF position before you start the engine Move the transmission control lever to the NEUTRAL position Engage the parking brake control Diesel engine exhaust contains products of combustion which can be harmful to your health Always start the engine in a well ventilated area Always operate the engine in a well ventilated area If you are in an enclosed area vent the exhaust to the outside i01901299 Before Operation SMCS Code 7000 7600 Clear all personnel from the machine and from the area Clear all obstacles from the path of the machine Beware of hazards such as wires ditches etc Make
15. e the messages if you cannot read the words Replace the illustrations if the illustrations are not legible When you clean the messages use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the messages Solvents gasoline or harsh chemicals could loosen the adhesive that secures the messages Loose adhesive will allow the messages to fall SEBU7474 03 11 Safety Section Additional Messages Replace any message that is damaged or missing If a message is attached to a part that is replaced install a message on the replacement part Any Caterpillar dealer can provide new messages Fuel Filler 1 This message is located on the filler tube for the fuel tanks NOTICE USE ONLY A CATERPILLAR APPROVED FAST FILL SYSTEM TO FUEL MACHINES OVER PRESSURIZATION MAY CAUSE TANK DEFORMATION AND FUEL SPILLAGE CONTACT YOUR CAT DEALER FOR FAST FILL SYSTEM AVAILABILITY 224 6637 Illustration 6 g00907956 NOTICE Use only a Caterpillar approved fast fill system to fuel machines Over pressurization may cause tank defor mation and fuel spillage Contact your Cat dealer for fast fill system availability No Step 2 If equipped this message is located on the guard for each fuel tank This message is also located on each fuel tank Illustration 7 g00906093 Do not use the fuel tank as a step The surface is not covered with a nonslip tread Do Not Weld the Fra
16. ed to a hazardous situation if the machine is used improperly or if poor operating techniques are used This situation can occur even though a machine is equipped with an appropriate protective guard Follow the established operating procedures that are recommended for your machine SEBU7474 03 25 Safety Section Guards Rollover Protective Structure ROPS Falling Object Protective Structure FOPS or Tip Over Protection Structure TOPS The ROPS FOPS Structure if equipped on your machine is specifically designed tested and certified for that machine Excavators are not equipped with ROPS structures Any alteration or any modification to the ROPS FOPS Structure could weaken the structure This places the operator into an unprotected environment Modifications or attachments that cause the machine to exceed the weight that is stamped on the certification plate also place the operator into an unprotected environment Excessive weight may inhibit the brake performance the steering performance and the ROPS The protection that is offered by the ROPS FOPS Structure will be impaired if the ROPS FOPS Structure has structural damage Damage to the structure can be caused by an overturn a falling object a collision etc Do not mount items fire extinguishers first aid kits work lights etc by welding brackets to the ROPS FOPS Structure or by drilling holes in the ROPS FOPS Structure Welding brackets or drilling holes in the
17. g00706404 Improperly disposing of waste can threaten the environment Potentially harmful fluids should be disposed of according to local regulations Always use leakproof containers when you drain fluids Do not pour waste onto the ground down a drain or into any source of water 101359664 Crushing Prevention and Cutting Prevention SMCS Code 7000 Support the equipment properly before you perform any work or maintenance beneath that equipment Do not depend on the hydraulic cylinders to hold up the equipment Equipment can fall if a control is moved or if a hydraulic line breaks Do not work beneath the cab of the machine unless the cab is properly supported Unless you are instructed otherwise never attempt adjustments while the machine is moving or while the engine is running Never jump across the starter solenoid terminals in order to start the engine Unexpected machine movement could result Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement Stay clear of all rotating and moving parts If itis necessary to remove guards in order to perform maintenance always install the guards after the maintenance is performed Keep objects away from moving fan blades The fan blade will throw objects or cut objects Do
18. ge that appears under the warning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive If a tool procedure work method or operating technique that is not specifically recommended by Caterpillar is used you must satisfy yourself that it is safe for you and for others You should also ensure that the product will not be damaged or be made unsafe by the operation lubrication maintenance or repair procedures that you choose The information specifications and illustrations in this publication are on the basis of information that was available at the time that the publication was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes can affect the service that is given to the product Obtain the complete and most current information before you start any job Caterpillar dealers have the most current information available When replacement parts are required for this product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent specifications including but not limited to phys ical dimensions type strengt
19. h and material Failure to heed this warning can lead to prema ture failures product damage personal injury or death 6 SEBU7474 03 Safety Section Safety Messages Safety Section i01892609 Safety Messages SMCS Code 7000 A WARNING Illustration 2 g00985131 A WARNING AA WARNING Illustration 3 g00985132 There are several specific safety messages on this machine The exact location of the messages and the description of the messages are reviewed in this section Please become familiarized with all safety messages SEBU7474 03 7 Safety Section Safety Messages Make sure that all of the safety messages are legible Clean the safety messages or replace the safety messages if you cannot read the words Replace the illustrations if the illustrations are not legible When you clean the safety messages use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the safety messages Solvents gasoline or harsh chemicals could loosen the adhesive that secures the safety message Loose adhesive will allow the safety message to fall Replace any safety message that is damaged or missing If a safety message is attached to a part that is replaced install a safety message on the replacement part Any Caterpillar dealer can provide new safet
20. in order to mount the fire extinguisher If the fire extinguisher weighs more than 4 5 kg 10 Ib mount the fire extinguisher low on one leg of the ROPS Do not mount the fire extinguisher on the upper one third portion of the leg 101557411 Tire Information SMCS Code 7000 Explosions of air inflated tires have resulted from heat induced gas combustion inside the tires Explosions can be caused by heat that is generated by welding by heating rim components by external fire or by excessive use of brakes A tire explosion is much more violent than a blowout The explosion can propel the tire the rim components and the axle components as far as 500 m 1500 ft or more from the machine Both the force of the explosion and the flying debris can cause property damage personal injury or death A B Illustration 21 g00337832 A At least 15 m 50 ft B At least 500 m 1500 ft Do not approach a warm tire Maintain a minimum distance as shown Stay outside the shaded area in Illustration 21 Do not use water or calcium as a ballast for the tires Dry nitrogen gas is recommended for inflation of tires If the tires were originally inflated with air nitrogen is still preferred for adjusting the pressure Nitrogen mixes properly with air Nitrogen inflated tires reduce the potential of a tire explosion because nitrogen does not aid combustion Nitrogen helps to prevent oxidation
21. ine can tip when you work on hills on banks and on slopes Also the machine can tip when you cross ditches ridges or other unexpected obstructions Avoid operating the machine across the slope When possible operate the machine up the slopes and down the slopes Maintain control of the machine Do not overload the machine beyond the machine capacity Never straddle a wire cable Never allow other personnel to straddle a wire cable Before you maneuver the machine make sure that no personnel are between the machine and attachments Know the maximum dimensions of your machine Always keep the Rollover Protective Structure ROPS installed during machine operation 102624835 Engine Stopping SMCS Code 1000 7000 Do not stop the engine immediately after the machine has been operated under load This can cause overheating and accelerated wear of engine components After the machine is parked and the parking brake is engaged allow the engine to run for two minutes before shutdown This allows hot areas of the engine to cool gradually i01681008 Parking SMCS Code 7000 Park the machine on a level surface If you must park on a grade chock the machine s wheels Apply the service brake in order to stop the machine Move the transmission control lever to the NEUTRAL position Move the throttle control to the LOW IDLE position Engage the parking brake Lower all equipment to the ground Activate any contro
22. l locks Stop the engine Turn the engine start switch to the OFF position and remove the engine start switch key Turn the battery disconnect switch to the OFF position Remove the disconnect switch key if you do not operate the machine for an extended period of time This will prevent drainage of the battery A battery short circuit any current draw from certain components and vandalism can cause drainage of the battery 101329161 Equipment Lowering with Engine Stopped SMCS Code 7000 Before lowering any equipment with the engine stopped clear the area around the equipment of all personnel The procedure to use will vary with the type of equipment to be lowered Keep in mind most systems use a high pressure fluid or air to raise or lower equipment The procedure will cause high pressure air hydraulic or some other media to be released in order to lower the equipment Wear appropriate personal protective equipment and follow the established procedure in the Operation and Maintenance Manual Equipment Lowering with Engine Stopped in the Operation Section of the manual 22 Safety Section Sound Information and Vibration Information SEBU7474 03 102703472 Sound Information and Vibration Information SMCS Code 7000 Sound Level Information The operator Equivalent Sound Pressure Level Leq is 77 dB A when ANSI SAE J1166 OCT 98 is used to measure the value for an enclosed cab This is a work c
23. locked position in order to articulate the machine Illustration 23 g00949012 Remove wheel lean bolt 2 from the locked position The wheel lean bolt must be removed in order to lean the wheels Start the engine only from the operator s compartment Never short across the starter terminals or across the batteries Shorting could bypass the engine neutral start system Shorting could also damage the electrical system wrt Illustration 24 g00811951 Make sure that the machine horn works properly Illustration 25 g00810739 The mirrors on your machine may be different Adjust the mirrors for the best operator vision Adjust the inside mirror or the inside mirrors before you operate the machine If the machine is equipped with outside mirrors adjust the outside mirrors before you operate the machine Inspect the condition of the seat belt and the condition of mounting hardware Replace any damaged parts and any worn parts Regardless of appearance replace the seat belt after three years of use Do not use a Seat belt extension on a retractable seat belt Adjust the seat in order to achieve full pedal travel when the operator s back is against the back of the seat Adjust the steering column tilt lever in order to enhance th
24. machine has been certified to the standards that are listed on the certification plate The maximum mass of the machine which includes the operator and the attachments without a payload should not exceed the mass on the certification plate 8 Safety Section Safety Messages SEBU7474 03 No Ether 4 This message is located on the prescreener assembly above the hood on some versions of this machine 44 WARNING 4P 6422 3 g00924889 If equipped with an air inlet heater AIH for cold weather starting do not use aerosal types of start ing aids such as ether Such use could result in an explosion and personal injury Falling Hazard 5 This message is positioned on the top surface of each fuel tank 231 0221 g00974904 Do not use the fuel tank as a step or a platform The fuel tank surface is not covered with a nonslip tread Serious injury or death could occur from a fall No Clearance 6 This message is positioned at the center pivot on both sides of the machine A WARNING AA NO CLEARANCE FOR PERSON IN THIS AREA WHEN MACHINE TURNS SEVERE INJURY OR DEATH FROM CRUSHING COULD OCCUR CONNECT STEERING FRAME LOCK BETWEEN FRONT AND REAR FRAMES BEFORE LIFTING TRANSPORTING OR SEAVICING MACHINE IN ARTICULATION AREA DISCONNECT LOCK AND SECURE BEFORE RESUMING OPERATION 301 7908 g00802218 No clearance for person in this area when ma chine turns
25. me 3 This message is located on the left side of the front frame behind the lift cylinder bracket DO NOT DRILL OR WELD TOP OR BOTTOM PLATES OF MAIN FRAME 5P3999 1 Illustration 8 g00906095 Do not drill or weld top or bottom plates of main frame Air Conditioner 4 This message is located on the front of the air conditioner under the operator s seat R134a _ L kg PAG 4C 2959 gt amp 110 6393 3 Illustration 9 g00939074 Read the service manual before you perform any maintenance on the air conditioner Alternate Exit 5 If your machine is equipped with a snow wing this message is located on the left ROPS support at the rear of the operator s compartment 12 Safety Section General Hazard Information SEBU7474 03 100 5612 1 Illustration 10 g00907967 If the primary exits are blocked use the hammer to break the window Exit the machine through the window Do Not Weld the ROPS 6 This message is located on each ROPS support assembly at the rear of the operator s compartment Illustration 11 g00906117 Do not weld the ROPS Do not drill the ROPS Read the service manual before you perform any work on the ROPS Air Cleaner 7 This message is located on the cover of the air cleaner The air cleaner is located inside the engine compartment on the right side of the machine Illustration 12 g0
26. ment free from foreign material Remove debris oil tools and other items from the deck from walkways and from steps Secure all loose items such as lunch boxes tools and other items that are not a part of the equipment Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals Accept hand signals from one person only Do not smoke when you service an air conditioner Also do not smoke if refrigerant gas may be present Inhaling the fumes that are released from a flame that contacts air conditioner refrigerant can cause bodily harm or death Inhaling gas from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death Never put maintenance fluids into glass containers Drain all liquids into a suitable container Obey all local regulations for the disposal of liquids Use all cleaning solutions with care Report all necessary repairs Do not allow unauthorized personnel on the equipment Unless you are instructed otherwise perform maintenance with the equipment in the servicing position Refer to Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position Pressurized Air and Water Pressurized air and or water can cause debris and or hot water to be blown out This could result in personal injury When pressurized air and or pressurized water is used for cleaning wear protective clothing protec
27. nerated when you handle components that contain asbestos fibers Inhaling this dust can be hazardous to your health The components that may contain asbestos fibers are brake pads brake bands lining material clutch plates and some gaskets The asbestos that is used in these components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present there are several guidelines that should be followed Never use compressed air for cleaning Avoid brushing materials that contain asbestos Avoid grinding materials that contain asbestos Use a wet method in order to clean up asbestos materials A vacuum cleaner that is equipped with a high efficiency particulate air filter HEPA can also be used Use exhaust ventilation on permanent machining jobs Wear an approved respirator if there is no other way to control the dust SEBU7474 03 15 Safety Section Crushing Prevention and Cutting Prevention Comply with applicable rules and regulations for the work place In the United States use Occupational Safety and Health Administration OSHA requirements These OSHA requirements can be found in 29 CFR 1910 1001 Obey environmental regulations for the disposal of asbestos Stay away from areas that might have asbestos particles in the air Dispose of Waste Properly Illustration 17
28. not use a kinked wire cable or a frayed wire cable Wear gloves when you handle wire cable When you strike a retainer pin with force the retainer pin can fly out The loose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pin Chips or other debris can fly off an object when you strike the object Make sure that no one can be injured by flying debris before striking any object 101329099 Burn Prevention SMCS Code 7000 Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine Relieve all pressure in the air system in the oil system in the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiator and all lines to the heaters or to the engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check the coolant level only after the engine has been stopped 16 Safety Section Fire Prevention and Explosion Prevention SEBU7474 03 Ensure that the filler cap is cool before removing the filler cap The filler c
29. onnect ed to starter solenoid and negative cable from external source to starter negative terminal If not equipped with starter negative terminal con nect to engine block Follow procedure in the Op eration and Maintenance Manual Unplanned Blade Movement 10 This message is positioned on the cover for the shift console in the cab A WARNING co Personal injury could result from sudden move ment of the blade when the centershift lockpin is released To prevent unexpected blade movement and possible injury lower the blade to the ground before you unlock the centershift linkage See the Operation and Maintenance manual for complete instructions before releasing the centershift lock pin 10 Safety Section Additional Messages SEBU7474 03 101900238 Additional Messages SMCS Code 7000 D Illustration 4 oF i Riada_ kg OPAG 40 2958 D h nm i AL OSA g00949330 P AI E SIG J Illustration 5 There are several specific messages on this machine The exact location of the messages and the description of the messages are reviewed in this section Please become familiarized with all messages g00949327 Make sure that all of the messages are legible Clean the messages or replac
30. onnel Do not spray ether into an engine if the machine is equipped with a thermal starting aid for cold weather starting Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Repair any lines that are loose or damaged Leaks can cause fires Consult your Caterpillar dealer for repair or for replacement parts Check lines tubes and hoses carefully Do not use your bare hand to check for leaks Use a board or cardboard to check for leaks Tighten all connections to the recommended torque Replace the parts if any of the following conditions are present e End fittings are damaged or leaking e Outer coverings are chafed or cut e Wires are exposed e Outer coverings are ballooning Flexible part of the hoses are kinked e Outer covers have embedded armoring e End fittings are displaced Make sure that all clamps guards and heat shields are installed correctly During machine operation this will help to prevent vibration rubbing against other parts and excessive heat 101258143 Fire Extinguisher Location SMCS Code 7000 Do not weld a bracket on the Rollover Protective Structure ROPS in order to install the fire extinguisher Also do not drill holes in the ROPS in order to mount the fire extinguisher on the ROPS 18 Safety Section Tire Information SEBU7474 03 Strap the mounting plate to a leg of the ROPS
31. or cardboard when you check for a leak Leaking fluid that is under pressure can penetrate body tissue Fluid penetration can cause serious injury and possible death A pin hole leak can cause severe injury If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for the following items e Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids e Tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids Asbestos Information Illustration 16 g00702022 Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free Caterpillar recommends the use of only genuine Caterpillar replacement parts Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris Use caution Avoid inhaling dust that might be ge
32. our work tool will provide specific requirements for the guards Consult your Caterpillar dealer for additional information
33. r graders c If no ride control system is available reduce speed in order to prevent bounce d Haul the machines between workplaces Less operator comfort may be caused by other risk factors The following guidelines can be effective in order to provide better operator comfort 24 Safety Section Operator Station SEBU7474 03 a Adjust the seat and adjust the controls in order to achieve good posture b Adjust the mirrors in order to minimize twisted posture c Provide breaks in order to reduce long periods of sitting d Avoid jumping from the cab e Minimize repeated handling of loads and lifting of loads f Minimize any shocks and impacts during sports and leisure activities Sources The vibration information and calculation procedure is based on ISO TR 25398 Mechanical Vibration Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines Harmonized data is measured by international institutes organizations and manufacturers This literature provides information about assessing the whole body vibration exposure of operators of earthmoving equipment The method is based on measured vibration emission under real working conditions for all machines You should check the original directive This document summarizes part of the content of the applicable law This document is not meant to substitute the original sources Other parts of these
34. sure that all windows are clean Secure the doors in the open position or in the shut position Secure the windows in the open position or in the shut position Remove the wheel lean locking bolt from the wheel lean lock bracket Make sure that the frame lock pin is stored in the unlocked position The frame lock pin must be removed in order to steer the machine For the best vision of the area that is close to the machine adjust the rear view mirrors if equipped Make sure that the machine horn the backup alarm if equipped and all other warning devices are working properly Fasten the seat belt securely 101863695 Operation SMCS Code 7000 7600 Machine Operating Temperature Range The standard machine configuration is intended for use within an ambient temperature range of 40 C 40 F to 50 C 122 F Special configurations for different ambient temperatures may be available Consult your Caterpillar dealer for additional information on special configurations of your machine Machine Operation Only operate the machine while you are in a seat The seat belt must be fastened while you operate the machine Only operate the controls while the engine is running Before you operate the machine remove the wheel lean locking bolt from the wheel lean lock bracket Make sure that the frame lock pin is stored in the unlocked position The steering frame lock link must be removed in order to steer the machine
35. tive shoes and eye protection Eye protection includes goggles or a protective face shield The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the nozzle is deadheaded and the nozzle is used with an effective chip deflector and personal protective equipment The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Trapped Pressure Pressure can be trapped in a hydraulic system Releasing trapped pressure can cause sudden machine movement or attachment movement Use caution if you disconnect hydraulic lines or fittings High pressure oil that is released can cause a hose to whip High pressure oil that is released can cause oil to spray Fluid penetration can cause serious injury and possible death Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure 14 Safety Section General Hazard Information SEBU7474 03 Illustration 15 g00687600 Always use a board
36. ts in properly marked containers away from unauthorized persons Store oily rags and any flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Do not operate the machine near any flame Exhaust shields if equipped protect hot exhaust components from oil spray or fuel spray in case of a break in a line in a hose or in a seal Exhaust shields must be installed correctly Do not weld on lines or on tanks that contain flammable fluids Do not flame cut lines or tanks that contain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting Check all electrical wires daily Repair any wires that are loose or frayed before you operate the machine Clean all electrical connections and tighten all electrical connections Dust that is generated from repairing nonmetallic hoods or nonmetallic fenders can be flammable and or explosive Repair such components in a well ventilated area away from open flames or sparks Inspect all lines and hoses for wear or for deterioration The hoses must be properly routed The lines and the hoses must have adequate support and secure clamps Tighten all connections to the recommended torque Leaks can cause fires Illustration 19 g00704059 SEBU7474 03 17 Safety Section Fire Extinguisher Location Use caution when you are refueling a machine Do not smoke while you
37. y messages Do Not Operate 1 This message is placed on the steering console in machines that are equipped with an open ROPS DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUC TIONS AND WARNINGS IN THE OPERA TION AND MAINTENANCE MANUALS FAILURE TO FOLLOW THE INSTRUC TIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH CON TACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS PROPER CARE IS YOUR RESPONSIBILITY SPB 5 g00920762 Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in injury or death Con tact your Caterpillar dealer for replacement manu als Proper care is your responsibility Do Not Operate 2 This message is placed on the door of the right hand glove box on machines that are equipped with a closed ROPS 4A WARNING DO NOT GPEAATE OA WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS FAILURE TO FOLLOW THE INSTRUCTIONS OA HEED THE WARNINGS COULD RESULT IN INJURY OA DEATH CONTACT ANY CATERPILLAR DEALEA FOR REPLACEMENT MANUALS PAOPER CARE IS YOUR RESPONSIBILITY iiai 2 g00788977 Do not operate or work on this machine unless you have read and understand the instructions and warnings in
38. ycle sound exposure level The cab was properly installed and maintained The test was conducted with the cab doors and the cab windows closed Hearing protection may be needed when the machine is operated with an open operator station for extended periods or in a noisy environment Hearing protection may be needed when the machine is operated with a cab that is not properly maintained or when the doors and windows are open for extended periods or in a noisy environment The average exterior sound pressure level is 71 dB A when the SAE J88Apr95 Constant Speed Moving Test procedure is used to measure the value for the standard machine The measurement was conducted under the following conditions distance of 15 m 49 2 ft and the machine moving forward in an intermediate gear ratio Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives The dynamic operator sound pressure level is 76 dB A when ISO 6396 1992 is used to measure the value for an enclosed cab The cab was properly installed and maintained The test was conducted with the cab doors and the cab windows closed The European Union Physical Agents Vibration Directive 2002 44 EC Vibration Data for Motor Graders Information Concerning Hand Arm Vibration Level When the machine is operated according to the intended use the hand arm vibration of this machine is below 2 5 meter per
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