SAFETY - Caterpillar
Contents
1. Damage to the structure can be caused by an overturn or by falling objects Do not mount items fire extinguishers first aid kits work lights etc by welding any brackets to the ROPS or by drilling holes in the ROPS See your Caterpillar dealer for mounting guidelines i00721004 Burn Prevention SMCS Code 7000 Coolant When the engine is at operating temperature the engine coolant is hot and the engine coolant is under pressure The radiator and all lines to the heaters or to the engine contain hot coolant or steam Any contact with hot coolant or with steam can cause severe burns Only check the coolant level after the engine has been stopped Make sure that the radiator cap is cool before you remove the radiator cap with your bare hand Remove the radiator 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 Allow cooling system components to cool before you drain the cooling system Oils Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin When the hydraulic system is at operating temperature the hydraulic oil is hot and the hydraulic oil is under pressure Make sure that the hydraulic tank filler cap is cool before you remove the hydraulic tank filler cap with your bare hand Remove the hydraulic tank filler cap slowly2. cm 15 inches above ground level while you drive the machine Do not drive the machine near an overhang near the edge of a cliff or near the edge of an excavation If the machine begins to sideslip on a grade immediately dispose of the load and turn the machine downhill Be careful to avoid any ground condition which could cause the machine to tip Machine rollover can occur when you work on hills on banks or on slopes Machine rollover can also occur when you cross ditches ridges or other unexpected obstacles When possible operate the machine up slopes and down slopes Avoid operating the machine across the slope when possible Keep the machine under control Do not overload the machine beyond capacity Make sure that the towing devices are adequate for the application Make sure that the draft arm hitch points are adequate for the application Connect trailing equipment only to a drawbar or to a hitch Never straddle a wire rope cable Never allow other personnel to straddle a wire rope cable When you maneuver in order to connect the equipment make sure that no personnel are between the machine and trailing equipment Block up the hitch of the trailing equipment in order to align the equipment with the drawbar Know the maximum dimensions of your machine When you operate on icy roads reduce travel speed 16 Safety Section Machine Parking After operating in muddy conditions allow sufficient time fo
3. 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 Do not weld a bracket on the 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 One mounting bracket is provided The mounting bracket is on the left frame rail toward the front For the information on the mounting of this bracket consult any Caterpillar dealer The bracket is designed to hold a 127 mm 5 inch extinguisher that weighs 4 5 kg 10 Ib 14 Safety Section Electrical Storm Injury Prevention i00721379 Electrical Storm Injury Prevention SMCS Code 7000 When lightning is striking in the near 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 during an electrical storm 100721426 Mounting and Dismounting SMCS Code 7000 Mount the machine and dismount the machine only at locations that have steps and or handholds Before you mount the machine clean the steps and the handholds Inspect the stairs and handholds Make any necessary repairs Face the rear of the machine when
4. generated If dust which 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 or grinding materials that contain asbestos Use a wet method to clean up asbestos debris A vacuum that is equipped with the high efficiency particulate air filter HEPA filter 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 Comply with applicable rules and regulations for the work place In the USA use Occupational Safety and Health Administration requirements These OSHA requirements can be found in 29 CFR 1910 1001 Obey environmental regulations for disposal of asbestos Stay away from areas that might have asbestos particles in the air 11 Safety Section Crushing Prevention and Cutting Prevention 100720875 Crushing Prevention and Cutting Prevention SMCS Code 7000 Support the equipment properly when you perform work beneath the equipment Do not depend on the hydraulic cylinders to hold up the equipment An implement can fall if a control lever is moved or if a hydraulic line breaks Never jump across the starter solenoid terminals in order to start the machine Unexpected machine movement could result Never attempt adjustments while the machine is moving or while the engine is running Whenever there a
5. in order to relieve pressure Relieve all pressure in the air system in the oil system in the fuel system or in the cooling system before you disconnect any lines fittings or related items Batteries Batteries give off flammable fumes which can explode Do not smoke while you are observing the battery electrolyte levels Electrolyte is an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses when you work on batteries 101183498 Fire Prevention and Explosion Prevention SMCS Code 7000 All fuels most lubricants and some coolant mixtures are flammable Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Do not smoke while you refuel the machine or while you are in a refueling area Do not smoke in battery charging areas or in areas that contain flammable material Batteries may be installed in separate compartments When you use jump start cables always connect the positive jump start cable to the positive terminal of the battery that is connected to the starter solenoid Connect the negative jump start cable from the external power source to the negative terminal of the starter See the Operation and Maintenance Manual Starting with Jump Start Cables for specific starting instructions Clean all electrical connections and tighten a
6. G label is shown below A WARNING The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The message 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 For a list of the most current publication form numbers available se
7. Operation and Maintenance Manual for your machine or your work tool will provide specific requirements for the guards Consult your Caterpillar dealer for additional information 17 Safety Section Guards
8. SAFETY Operation and Maintenance Manual Excerpt O 2010 Caterpillar All Rights Reserved CATERPILLAR A SEBU7072 07 CATERPILLAR January 200 Operation and Maintenance Manual Challenger 65E Challenger 75E Challenger 85E and Challenger 95E Agricultural Tractors 6GS1 Up Machine 6HS1 Up Machine 6JS1 Up Machine 6KS1 Up Machine i01097883 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 WARNIN
9. d make sure that the full pedal travel can be obtained when the seat is fully rearward Make sure that the machine is equipped with a lighting system that is adequate for the job conditions Make sure that all machine lights are working properly Before you start the engine and before you move the machine make sure that no one is underneath the machine around the machine or on the machine Make sure that the area is free of personnel i00733695 Engine Starting SMCS Code 1000 7000 If a warning tag is attached to the engine start switch or to the controls do not start the engine Also do not move any controls Move all hydraulic controls to the HOLD position before you start the engine Move the transmission control lever to the NEUTRAL position Engage the parking brake Diesel engine exhaust contains products of combustion which can be harmful to your health Always run the engine in a well ventilated area If you are in an enclosed area vent the exhaust to the outside Start the engine only from the operator compartment Never short across the starter terminals or across the batteries Shorting could damage the electrical system by bypassing the engine neutral start system When the engine is running and the steering wheel is turned the machine will turn with the transmission in NEUTRAL and the parking brake engaged Do not start the engine until the area is free of personnel This will aid in avoiding personal inju
10. e the Service Manual Contents Microfiche REG1139F A WARNING 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 strength and material Failure to heed this warning can lead to prema ture failures product damage personal injury or death 6 Safety Section Safety Signs and Labels Safety Section i01148528 Safety Signs and Labels SMCS Code 7000 7405 There are several specific warning signs on this machine The exact location of the hazards and the description of the hazards are reviewed in this section Please become familiarized with all warning signs Make sure that all of the warning signs are legible Clean the warning signs or replace the warning signs if you cannot read the words Replace the illustrations if the illustrations are not visible When you clean the warning signs use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the warning signs Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning sign Loose adhesive will allow the warning sign to fall Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the machine that is replaced install a warning sign on the replacement part Any Caterpillar dealer can provide new warning sign
11. elements according to local regulations Use all cleaning solutions with care Report all necessary repairs Do not allow unauthorized personnel on the machine 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 Unless you are instructed otherwise perform the maintenance under the following conditions e The machine is parked on level ground e The implements are lowered to the ground e The transmission control is in the NEUTRAL position e The parking brake is engaged e The engine is stopped e The engine start switch key is turned off and the engine start switch key is removed e Allow the machine to cool Pressure Air Pressure air can cause personal injury When pressure air is used for cleaning wear a protective face shield protective clothing and protective shoes The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi Fluid Penetration Always use a board 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
12. epair the machine These warning tags are available from your Caterpillar dealer 10 Safety Section General Hazard Information When the engine is running and the steering wheel is turned the machine will turn with the transmission in NEUTRAL and the parking brake engaged Do not start the engine until the area is free of personnel This will aid in avoiding personal injury due to unexpected machine movement If necessary apply the service brakes in order to counteract any steering when you start the engine Know the width of your equipment in order to maintain proper clearance when you operate the machine near fences or near boundary obstacles 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 machine Make sure that all protective guards and all covers are secured in place on the machine Keep the machine free from foreign material Remove debris oil tools and other items from the deck from walkways and from steps Secure lunch boxes tools and other loose items that are not a part of the machine 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 Never put maintenance fluids into glass containers Drain all liquids into a suitable container Discard any drained fluids and discard any filter
13. ever you mount the machine and whenever you dismount the machine Maintain a three point contact with the steps and with handholds Note Three point contact can be two feet and one hand Three point contact can also be one foot and two hands Never mount a moving machine Never dismount a moving machine Never jump off the machine Do not carry tools or supplies when you try to mount the machine or when you try to dismount the machine Use a hand line to pull equipment onto the platform Do not use any controls as handholds when you enter the operator compartment or when you exit the operator compartment Alternate Exit Machines that are equipped with cabs have alternate exits For additional information see Operation and Maintenance Manual Windows 100733633 Before Starting Engine SMCS Code 1000 7000 Start the engine only from the operator compartment Never short across the starter terminals or across the batteries Shorting could damage the electrical system by bypassing the engine neutral start system Inspect the condition of the seat belt and of the mounting hardware Replace any parts that are worn or damaged 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 so that full pedal travel can be achieved with the operator s back against the back of the seat Note If the seat s fore aft lever is use
14. lements 900408360 Illustration 9 The warning sign is located on the quick hitch if equipped A WARNING Personal injury could result from improperly cou pled implements Be certain latches are fully en gaged on both sides before transporting or pulling the implement Power Take Off Illustration 10 g00408362 The warning sign is located above the shield for the power take off To avoid personal injury due to entanglement with rotating shaft keep PTO master cover and all pow er drive system covers in place Install PTO shaft guard when the system is not in use Brake Accumulator Illustration 11 g00408363 The warning sign is located on the left side of the frame Relieve accumulator pressure before removing or attaching any service tooling 9 Safety Section General Hazard Information High Pressure Cylinder Illustration 12 g00408364 The warning sign is located above the belt tension cylinders High pressure cylinder Do not remove any parts until all hydraulic pressure has been relieved to avoid possible personal injury To relieve pres sure slowly open bleeder valve up to one turn maximum to discharge hydraulic oil 00717932 General Hazard Information SMCS Code 7000 Illustration 13 g00037887 Attach a Special Instruction SEHS7332 Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the machine or before you r
15. ll electrical connections Check the electrical wires daily for wires that are loose or frayed Tighten all loose electrical wires before you operate the machine Repair all frayed electrical wires before you operate the machine Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do not weld pipes or tubes if these components contain flammable fluids Do not flame cut pipes or tubes if these components contain flammable fluids Before you weld pipes or tubes or before you flame cut pipes or tubes clean the pipes or tubes thoroughly with nonflammable solvent Remove all flammable materials before the flammable materials accumulate on the machine Do not expose the machine to flames Protective shields must be installed correctly If a line a tube or a seal ruptures these shields protect hot exhaust components from oil spray or from fuel spray Ether Ether is poisonous and flammable Inhaling ether vapors or repeated contact with skin can cause personal injury Use ether only in well ventilated areas Do not smoke while you install ether cylinders To avoid fires use ether carefully Do not store ether cylinders in living areas or in the operator compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard ether cylinders in an approved place Do not
16. must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Asbestos Information 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 generated 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 encased in a resin The asbestos may also be sealed Handling the asbestos is not hazardous unless airborne dust that contains asbestos is
17. n the 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 some smaller machines 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 Flying Object or Falling Object Guard If Equipped Logging demolition and other specific applications require special flying or falling operator protection It is recommended that safety glasses be worn in addition to the flying or falling object guard A flying object guard needs to be installed when a work tool that creates flying objects is used Mesh 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 When you perform demolition applications that are above the top of the cab or you perform logging applications Caterpillar recommends the installation of a falling object guard structure The falling object guard structure protects the front of the structure and the top of the structure Additional guards may be required for specific applications or work tools An example of the additional guards is a polycarbonate window that may have a front screen cover or a guard The
18. ne with a damaged structure The operator becomes exposed 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 described in the Operation and Maintenance Manual Operating Techniques information Rollover Protective Structure ROPS Falling Object Protective Structure FOPS or Tip Over Protection Structure TOPS The ROPS FOPS Structure on your machine is specifically designed tested and certified for that machine 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 Siructure or by drilling holes in the ROPS FOPS Structure Welding brackets or drilling holes i
19. on g00408357 Illustration 5 The warning sign is located on each belt tension cylinder Spring force can cause personal injury or death Do not repair until you have read the Operation and Maintenance Manual 8 Safety Section Safety Signs and Labels Ground Speed Sensor Illustration 6 g00408358 The warning sign is located below the ground speed sensor if equipped Microwave radiation may cause eye damage To avoid injury to eyes do not look directly into the face of the ground speed sensor Rollover Protective Structure ROPS 900408359 Illustration 7 The warning sign is located under the cab roof above the door 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 Three Point Hitch OF a he Te EN Fe Illustration 8 g00408361 The warning sign is located in the operator s compartment on the door Unexpected hitch movement during implement coupling or uncoupling can occur To prevent personal injury the hitch control must be set in the manual mode while coupling or uncoupling implements Consult the Operation and Main tenance Manual for complete three point hitch operating instructions Improperly Coupled Imp
20. puncture ether cylinders Do not burn ether cylinders Keep ether cylinders away from unauthorized personnel Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses if these hoses are damaged Repair lines tubes and hoses if any of these parts are loose or damaged Leaks can cause fires See your Caterpillar dealer for repairs 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 See Operation and Maintenance Manual General Hazard Information for details about fluid penetration Tighten all connections to the recommended torque Replace the parts if any of the following conditions exist e The end fittings are damaged or the end fittings are leaking e The outer covering is chafed or cut e The wire shield is exposed 13 Safety Section Fire Extinguisher Location e The outer covering is ballooning locally e The flexible part of a hose is kinked or crushed e The armoring is embedded in the outer cover Make sure that all clamps all guards and all heat shields are installed correctly in order to prevent vibration rubbing against other parts and excessive heat during operation 101472127 Fire Extinguisher Location SMCS Code 7000 7419 Ssh Illustration 14 g00364892 Make sure that a fire extinguisher is available Be
21. r the belts to reject debris and moisture before making high speed maneuvers Belts that are wet and belts that are muddy may impede the machine s steering If machine stability is noticeably affected reduce travel speed Select a gear that will control machine speed when you descend a hill Downshift if braking is required to control machine speed Never coast down a hill with the transmission in NEUTRAL Do not steer the machine when you cross ditches Ditches that are wide and or ditches that are deep may allow guide blocks to sag below the midwheels This can cause the belt to come off 100786413 Machine Parking SMCS Code 7000 Park on a level surface If you must park on a grade chock the machine s belts Move the transmission control lever to the NEUTRAL position Engage the parking brake Lower all implements to the ground Move the implement controls to the HOLD position Move the three point hitch mode switch if equipped to the manual mode Stop the engine Turn the engine start switch to the OFF position and remove the engine start switch key 01468856 Guards Operator Protection SMCS Code 7150 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 use A daily inspection of the guards is required in order to check for structures that are bent cracked or loose Never operate a machi
22. re attachment linkages the clearance in the linkage area will change with movement of the attachment Stay clear of all rotating parts and all moving parts Keep objects away from moving fan blades The fan blades will throw objects and the fan blades can cut objects Do not use a wire rope cable that is kinked or frayed Wear gloves when you handle wire rope cable When you strike a retainer pin the retainer pin might fly out The loose retainer pin can injure personnel Make sure that there are no people in the area 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 may fly off objects when you strike the objects Make sure that no one will be injured by flying debris before you strike any object Rollover Protective Structure ROPS or Falling Objects Protective Structure FOPS These structures are secured to the machine above the operator compartment To avoid the possible weakening of the ROPS or FOPS consult your Caterpillar dealer before you alter the structures Do not alter the structure by welding cutting adding weight or drilling holes into the structure 12 Safety Section Burn Prevention Any alteration that is not specifically authorized by Caterpillar invalidates the Caterpillar certification for the ROPS or for the FOPS The protection that is offered by the ROPS will be impaired if the ROPS has structural damage
23. ry due to unexpected machine movement If necessary apply the service brakes in order to counteract any steering that might occur when you start the engine 100733843 Before Operating Machine SMCS Code 7000 Clear all personnel from the machine and from the area Clear all obstacles from the machine s path Beware of hazards wires ditches etc Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rearview mirrors for the best visibility close to the machine Make sure that the horn the backup alarm if equipped and all other warning devices are working properly Fasten the seat belt securely i00785741 Machine Operation SMCS Code 7000 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 Check for proper operation of all controls and of all protective devices while you operate the machine slowly in an open area 15 Safety Section Before Operating Machine Make sure that no one will be endangered before you move the machine 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 Report any machine damage that was noted during machine operation Make any necessary repairs Hold attachments approximately 40
24. s Do Not Operate 900408354 Illustration 2 The warning sign is located in the operator s compartment on the door Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Man ual Failure to follow the instructions or heed the warnings could result in injury or death Contact your Caterpillar dealer for replacement manuals Proper care is your responsibility Jump Start Cables Illustration 3 g00408355 There are two warning signs One warning sign is located in the battery compartment The other warning sign is located on the left front frame rail A WARNING Improper jumper cable connections can cause ex plosion resulting in personal injury Batteries may be located in separate com partments When using jumper cables always connect positive cable to positive terminal of battery connected to starter solenoid and negative cable from external source to starter negative terminal if machine not equipped with starter negative terminal connect to engine block Follow procedure in the operation manual 7 Safety Section Safety Signs and Labels Electrical Shock Hazard AWARNING FLECTRICAL SHOCK HAZARD SR UNIT INJECTOR SYSTEM oF T gozo vous Ea Illustration 4 g00408356 The warning sign is located on the engine A WARNING Electrical shock hazard Unit injector system 90 120 volts Belt Tensi
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