00-001 Excavator Safety Manual
Contents
1. state provincial and or federal laws rules and regulations IMPORTANT Before you operate a Gradall Hydraulic Excavator make sure you have all the proper manuals The Gradall Hydraulic Excavator Safety Manual the appropriate Owner Operator Manual for the machine and the EMI Excavator Safety Manual should all be contained in the manual holder tray in the operator s cab If any manual is missing or illegible get a replacement from your employer your equipment distributor or directly from Gradall Keep all Safety and Instruction manuals with the excavator at all times Read understand and comply with the instructions and warnings in these manuals AT ALL TIMES Highway speed machines are also furnished with a CIMA Dumper Safety Manual Form No 20013 lt Hydraulic Excavator Safety Manual 1 0 The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS AT RISK The Safety Alert Symbol spotlights important safety messages on A DAN G E R hydraulic excavators safety signs in manuals or elsewhere The symbol will typically appear in one of three dominant colors Red Orange or Yellow These colors follow a descending hierarchy of hazard or risk In other words red indicates the highest level of risk Yellow the lowest Typically the Safety Alert Symbol and the appropriate SIGNAL WORD will appear as a header bar on a machine decal This symbol indicates an extreme hazard which would result in hig2. There may also be local or state provincial laws that apply to the excavator and or its use as well as specific work site or employer rules It is important that you understand and comply with all applicable laws and tules KEY RULES OF OPERATION Before starting operating or performing maintenance procedures on a Gradall Hydraulic Excavator there are a number of key Rules of Operation with which you must comply e Conduct a thorough walk round inspection before starting e Conduct a complete operational check of the hom before Starting the excavator and make sure you can hear the travel alarm inside the operator s cab with the engine running e Conduct a complete operational check of all controls brakes and steering e Know the capacity and operating characteristics of the excavator e Know the requirement for line of sight while operating e Never modify or remove any part of the excavator e Always wear the safety belt while operating the mahine if equipped Hydraulic Excavator Safety Manual Form No 20013 e Keep all other personnel away from the excavator before Starting the engine e Never use attachments that are not approved by Gradall e Always make sure the excavator is equipped with a correct and legible Capaity Chart for the specific excavator attachment combination e Follow all traffic rules when traveling e f your visibility is impaired use a spotter or signal person CLEAN UP Clean windshields mirro
3. care and professional attention Here are some important factors to remember 8 6 EREORM SAFE MAINTENANCE Always maintain the proper tire pressure NEVER over inflat 0 tire as it could explode NEVER reinflate a tire that has been run flat or seriously under inflaial without removing the tire from the wheel Have the tire and wheel closely inspected for damage before remounting Clean the area around all wheel lug nuts or bolts and periodically check the torque per Gradall specifications After torque has stabilized at the proper rated value check at regularly scheduled intervals NEVER weld on a Gradall wheel Always maintain the correct tire pressure Do not inflate the tires above the recommended pressure Inspect fires and wheels daily Do not operate with low pressure cuts bubbles damaged rims or missing lug nuts or bolts N ever cut or weld the rim or rim parts This could cause explosive decompression Form No 20013 lt Hydraulic Excavator Safety Manual PERFORM SAFE MAINTENANCE o 8 7 e An increase in tire pressure during operation is normal It TRACK MAINTENANCE should NOT be reduced High speeds during transport Maintain proper track tension When operating in mud snow etc may produce excessive tire pressure due to heat REDUCE material will stick to the track parts and cause the tracks to become YOUR SPEED or stop and let the tires cool down too tight Refer to the Service Manual and or Owner Operator Manua
4. machine before you operate it Form No 20013 lt Hydraulic Excavator Safety Manual Ether is flammable Do not smoke when using ether Always follow the instructions on the ether can and in the Owner Operator Manual for your machine Do not use ether if the engine is equipped with a glow plug or other type of preheater Always use a nonflammable solvent when you clean parts Do not use gasoline diesel fuel or other flammable fluid Store all flammable fluids and materials away from your work area in suitable containers per local regulations Check the readiness of all fire extinguishers fire suppression systems and fire detectors ue Hydraulic Excavator Safety Manual Form No 20013 8 5 TIRE MAINTENANCE Check your tires and wheels every day The stability of the excavator is dramatically reduced by improperly inflated tires Check tires for e Correct inflation pressure e Cuts or bulges e Nails or other punctures e Uneven or excessive wear e Condition of valve stems and caps Check wheels for e Damage to the rims e Missing or loose lug nuts or bolts e Obvious misalignment TIRE AND WHEEL HAZARDS Changing tires is DANGEROUS All tire service should be performed by a qualified tire service center or by an authorized person that has been properly trained in the procedures and use of safety equipment designed for tire servicing The wheels and tires installed on Gradall Excavators require special
5. operated by inexperienced personnel NO SMOKING N ever smoke while operating and or refueling the excavator Never fill the fuel tank with the engine running or near an open flame Make sure you have adequate visibility and good NII ventilation Form No 20013 lt Hydraulic Excavator Safety Manual MOUNT SAFELY Whenever you mount or dismount e Make sure the steps and handrails are clean e Maintain three point hand foot contact with the access system e Face the machine e Never jump on or off the machine e Never attempt to mount or dismount a moving machine Do not use the steering wheel or any control lever as a hand hold when mounting or dismounting The cab must be aligned with the undercarriage centerline and the boom must be properly stowed before you enter or exit the cab CAUTION WARN PERSONNEL BEFORE STARTING Before starting walk completely around the machine Make sure no one is under the machine on if or close by and that all guards and covers are in place or closed Sound the hom to let other workers and bystanders know you are starting up Don t start up until EVERYONE is clear of the machine Hydraulic Excavator Safety Manual Form No 20013 STARTING THE ENGINE Start the engine while seated in the operator s seat only Never attempt to start the engine by shorting across starter terminals or reaching the key from the ground or outside the cab The excavator may start in gea
6. speed and traffic control signs Crawler mountd machines may damage road surfaces For over Hydraulic Excavator Safety Manual Form No 20013 the road travel transport the machine by truck Some wheel mounted Gradall excavators are highway speed capable In other words they can be driven on the road at normal if lower highway speeds If you are transporting a Gradall excavator over the road make sure clearance flags lights and warming signs are all in place and visible Place the boom and bucket in the transport position Fold in mirrors to reduce width and secure all accessory equipment While traveling on public roads or streets obey all local traffic regulations appropriate to local classifications If required make sure the Slow Moving Vehicle emblem is visible to any vehicle approaching from the rear Always use hazard waming lights if traveling at a low rate of speed Find out if you must use an escort vehicle or are required to have a roading permit eee een Pr E ea R TRR XX GRADALL 3 4 EMERGENCY Always know where to get assistance in an emergency Know where to find and how to use 0 first aid kit Know where fo find and how to use E 0 fire extinguisher fire suppression system Never leave the operator s seat without first safely shutting down the excavator setting the Park Brake if equipped and removing the key A running unattended excavator could unexpectedly move or be
7. sure you knowwhat clearance limitations you will encounter overhead and behind you through doorways and down aisles Also know the weight limitations of floors and ramps Make sure the working area is well ventilated USE CAUTION WHEN FUELING AN WARNING Never fill the fuel tank with the engine running while smoking or when near an open flame Never overfill the tank or spill fuel If fuel is spilled clean it up immediately Ground the fuel funnel or nozzle against the filler neck to prevent sparks and be sure to replace the fuel tank cap For additional information on fire hazards see Avoid Fire and Explosion Hazards page 8 4 Form No 20013 lt Hydraulic Excavator Safety Manual PREPARE FOR SAFE OPERATION 33 RULES OF THE ROAD If driving a highway speed capable excavator over the road DON T SPEED Know your axle weights and machine height and width Know your stopping distance at any given speed and regulat your travel speed accordingly Avoid panic stops and sharp tums If traffic backs up pull over and allow other vehicles to pass Stop at all railroad crossings and look both ways before proceeding Never park in traffic areas If you have to stop at night pull off the road and set up flares or reflectors When driving at night use appropriate lights If traveling slowly use hazard lights Always use hand signals or turn signals when turning Approach intersections with caution Observe
8. Be WARNING excavator may roll sure the drain is closed before starting the engine USE JACKS AND HOISTS CAREFULLY If you must work beneath raised equipment always use wood NOT CONCRETE blocks jack stands or other rigid and stable supports When using jacks and hoists be sure they are adequately supported A Never use concrete blocks for supports They can collapse under even light loads WARNING Make sure the hoists and jack stands you use are in good repair Never use jack stands with cracked bent or twisted parts Never use frayed twisted or pinched cables Never use bent or distorted hooks LX ee Form No 20013 lt Hydraulic Excavator Safety Manual 8 3 HYDRAULIC SYSTEM HAZARDS COOLING SYSTEM HAZARDS The hydraulic system may be under pressure whenever the Liquid cooling systems build up pressure as the engine gets engine is running and may hold pressure even after shutdown hot Before removing the radiator cap stop the engine and let Block the cylinders and equipment securely before working on the system cool Remove the radiator cap only after the coolant the hydraulic system is cold using a heavy rag for protection l l a EA Cycle all hydraulic functions steering and other controls after if shutdown to relieve system pressure For pilot actuated systems follow the instructions in the Owner Operator and Service Manuals to relieve the pressure When venting or filling the hydraulic system loosen the
9. GRADALL a E gt RAN L 7 ne RER o W z E slag E 7 epos T kog O oo tae TART ts A E F D AEL H ORS INT a T ane Savie M P N 2460 4161 Form No 20013 Issued 7 00 HYDRAULIC EXCAVATOR A 5000 CCP TABLE OF CONTENTS _ Nomenclature Note on Illustrations Introduction l Safety Alert Symbol 2 A Word to the Operator HYDRAULIC EXCAVATOR SAFETY MANUAL gt Pe fo Sofe rota 4 Start Safely 5 Operate Safely 6 Park Safely 7 Load and Unload the Machine Safely 8 Perform Safe Maintenence 9 Test Your Knowledge Hydraulic Excavator Safety Manual Form No 20013 NOMENCLATURE There are four basic types of Gradall Hydraulic Excavators 1 Wheel Mounted Integral Carrier NOTE The terms hydraulic excavator and excavator are used interchangeably throughout this Safety Manual 3 Wheel Mounted Separate Operation and Transport Cabs a i af b e i ad er 4 Track Mounted IMM s Truck Mounted Radio Remote Controlled Scalers Railroad Guide Wheels and Gantries Gradall also manufactures a range of Industrial Maintenance Machines IMMs designed less for construction applications and more for specialized industrial applications primarily steel mills underground mining railroad maintenance and gantries All these machines are covered inthis Manual Form No 20013 lt Hydraulic Excavator Safety Manual lllustrations in red circles over
10. anual Form No 20013 NEVER use a bucket or other attachment on a Hydraulic Excavator as a work platform or personnel carrier Do not use a Gradall Excavator or Industrial Maintenance Machine to lift personnel A DANGER Without exception Gradall explicitly prohibits the use of Hydraulic Excavators to lift personnel b a OPERATE SAFELY TRAVELING ON OR TO THE JOBSITE Take it slow and easy when traveling through congested areas Traffic courtesy pays off FT T AF E S S 4 b pe M HE GRADAN AN ly li me a a e The Give right of way to loaded machines Maintain a safe distance from other machines Pass cautiously Don t obstruct your vision when traveling Carry the bucket or other attachments in the transport position for maximum stability visibility andadequate clearance Operate at speeds slow enough so you have complete control at all times Travel slowly over rough or slippery ground and on hillsides Stay in gear when traveling downhill Do not shift into Neutral Maintain engine RPM to provide steering and braking functions so that engine compression can help you control the excavator Use the same gear for traveling down a grade as you would for traveling up the grade Before entering an underpass check for hazards or obstructions Also check the clearance height Avoid steep slopes or unstable surfaces When operating on a Slope keep the
11. aring all the protective clothing and personal safety devices issued to you or called out by job conditions 5 3 a OPERATE SAFELY FT DANGER Never undercut a high bank The edges could collapse and or a slide might occur causing severe injury or death Never operate the machine close to the edge of an overhang or stockpile AN WARNING Do not dig under the machine or stabilizers A cave in could result and the machine could fall into the excavation FT DANGER Scaling toward the machine could cause scale to land on the machine causing severe injury or death FLAGPERSON It is the operator s responsibility to know where the flagperson is and fo establish communication that both the flagperson and operator understand Don t allow the flagperson out of sight or to remove items from the excavator while it is running or to get in the excavator swing or boom path DON T UNDERMINE YOURSELF The overall rule of thumb here is that you need to maintain a solid footing underneath the excavator If you are not careful and attentive while you work you might inadvertently dig yourself into some serious trouble Work the jobsite in such a manner as to avoid creating overhangs or the need to be on top of banks or slopes Extreme caution should be used when working along the top of banks or slopes Keep away from the edge If possible level the area before starting work When working at the base of a bank overha
12. bucket and boom low and proceed with extreme caution Do not drive ACROSS a steep slope under any circumstances Drive straight up and down a steep slope Avoid turning on an incline If tuming is unavoidable use extreme caution and make the turn wide and SLOW with the bucket and boom in the retracted and lowered position When using Carrier engine to travel on or to the jobsite do not let upperstructure engine idle to warm hydraulic oil It could affect steering When traveling always fully raise the stabilizers if equipped to minimize machine width TRANSPORTING ATTACHMENTS Always position the attachment for maximum visibility and proper overhead clearance when traveling with the attachment connected to the boom end In some cases attachments are shipped with additional manuals Consult attachment manual for additional transport information Form No 20013 lt Hydraulic Excavator Safety Manual SAFETY PRECAUTIONS Completely familiarize yourself with the appropriate Owner Operator Manual and Safety Manual before you operate a Gradall Hydraulic Excavator Make sure the area is clear of all persons before operating Before operating the excavator engage park brake If equipped lower the stabilizers and or level the machine as much as Never operate the excavator from outside the cab Severe injury or death can result Always operate the excavator from the correct seated position Never lift move or swing a load o
13. could result from improper jump starting procedures Never jump start a frozen battery Ether Cold Start Fluid is highly flammable and explosive Before using it always read the instructions on the ether container and the instructions in the Owner Operator Manual DO NOT use ether if the engine is equipped with a glow plug type pre heater or other intake manifold type pre heater AFTER STARTING THE ENGINE Observe all gauges instruments and waming lights to make sure they are functioning and their readings are within the correct Operating range RUN AN OPERATING CHECK DO NOT use a machine that is not in proper operating condition J It is the OPERATOR S RESPONSIBILITY to check the condition of all Ss Systems and to run the check in a safe area TEST THE CONTROLS Make sure the engine is operating correctly With the transmission in Neutral test the engine speed control Operate each equipment control lever to make sure all functions are correct Operate the shift control s to ensure correct operation in Forward Neutral and Reverse Release the swing lock if the machine is so equipped Check the parking brake service brakes and swing brakes Test steering right and left while moving slowly Be certain you can control the speed direction braking swing and boom operations before operating WARNING the machine Look and listen for malfunctions Stop if a malfunction or erratic operation is de
14. d lining assemblies clutch plates and some gaskets The asbestos used in new components is bound in a resin or sealed Normal handling is usually not hazardous as long as airborne dust which contains asbestos is not generated If dust which may contain asbestos is present there are several common sense guidelines that should be followed 8 8 EREORM SAFE MAINTENANCE Never use compressed air for cleaning such as blowing out brakes prior to repair 2 Avoid brushing or grinding of asbestos containing materials 3 For clean up use wet methods or a vacuum equipped with a High Efficiency Particulate Air HEPA filter 4 Use exhaust ventilation on permanent machine installations 5 Wear an approved respirator 6 Comply with applicable rules and regulations for the work place for example in the U S A OSHA requirements as set forth in 29 CFR 1926 58 7 Follow environmental rules and regulations for disposal of asbestos 8 Avoid areas where asbestos particles may be in the air 9 Shower after any contact 10 Store food drink and personal belongings away from the work area 11 Never eat drink or smoke where asbestos is in the area Form No 20013 lt Hydraulic Excavator Safety Manual TEST_YOUR KNOWLEDGE 9 0 NOW THAT YOU HAVE READ THIS SAFETY MANUAL DO YOU UNDERSTAND Your safety program The Owner Operator Manual for the particular machine you are operating Proper clothing and personal sa
15. e all hydraulic pressure see Machine Shutdown page 6 0 Block all hydraulically operated attachments if they must be in a raised position Place all controls in Neutral and block the wheels tracks NEVER work on machinery with the engine running unless you are specifically instructed to do so by the Service ot Owner Operator Manual AN nen NEVER operate any type of engine without proper ventilation Exhaust fumes can kill e If if is necessary to run an engine in an enclosed area ventilate the exhaust fumes with an exhaust pipe extension If you do not have an exhaust pipe extension make sure you open the doors and get outside air into the area Unless the swing function is required you must engage the swing lock if equipped before performing any maintenance e fadjustments must be made with the engine running always work as a 2 person team with one person sifting in the operator s seat while the other works on the machine Know what each person is supposed to be doing at all times Activate controls slowly and only when directed Hydraulic Excavator Safety Manual Form No 20013 e Remove only guards or covers that provide access Wipe away excess grease and oil e Never leave guards off or access doors open with the machine unattended Keep bystanders away if access doors are open e Make certain all guards screens or panels and safety signs are re installed on the machine When servicing an ai
16. equired by law from underground gas power telephone and water utilities WARNING Ad DANGER A cut fiber optic cable can cause severe eye injury if you look into the damaged end of the cable SELECT A PARKING SITE Whenever possible park on level ground If you must park on an incline position the machine across the slope engage the parking brake if equipped and lower the attachment to the ground and block the mahine Haul roads are not suitable for parking If you must park on one or if your machine is disabled on one mark the machine with flags in daytime and flares or flashing lights at night according to federal state and local regulations MACHINE SHUTDOWN Refer to the appropriate Owner Operator Manual for detailed shutdown procedures In general the procedure should include the following Stop the machine using the service brake Swing the machine to align upperstructure with the undercarriage Engage the swing lock if equipped Lower any attachments or the boom fo the ground or place it in a secure position Engage the parking brake if equipped Shift controls to Neutral Park and if possible lock them Idle the engine for a short cool down period Stop the engine 6 0 PARK SAFELY Cyde all hydraulic controls to relieve system pressure Remove the ignition key Shut off the master electrical switch if the machine has one Lock the cab When dismounting always maintain three p
17. er and get WARNING medical attention Wear rubber gloves and protective clothing to keep acid off skin wash off immediately with clean water then seek medical attention Lead acid batteries produce flammable and explosive gasses Keep arcs sparks flames and lighted tobacco away Use a flashlight to check battery electrolyte level Always check with the engine stopped For a sealed battery a bulged end indicates that A the battery is frozen Do not charge a battery or jump start the engine if the battery is frozen Warm WARNING to 60 F 15 C or the battery may explode 84 EREORM SAFE MAINTENANCE AVOID FIRE AND EXPLOSION HAZARDS Stop the engine and shut off the electrical equipment while filling the fuel tank Use extra caution when fueling a hot engine Always ground the fuel nozzle against the filler neck to avoid any sparks Never smoke while handling fuel or working on the A fuel system The fumes in an empty fuel container are explosive Never cut or weld on fuel lines tanks WARNING containers Handle all solvents and dry chemicals according to procedures identified on manufacturers containers Work in a well ventilated area Make sure you know where fire extinguishers are kept and how to use them Remove all trash or debris from the machine Ma ke sure that oily rags or other flammable material are removed from the machine Check for fuel oil or hydraulic fluid leaks Repair the leaks and clean the
18. fety equipment The excavator controls warning signs devices and safety equipment H ow fo properly inspect mount and start the excavator H ow to check the excavator for proper operation The work area and special hazards that may exist Proper operating procedures Operating safety precautions Proper loading and unloading procedures for transporting Under what conditions you should not operate the excavator e Proper parking shutdown and dismounting procedures e Proper maintenance procedures A FINAL WORD TO THE USER You have just finished reading the Gradall Hydraulic Excavator Safety Manual It is impossible for this Manual to cover every hazardous situation you may encounter But your knowledge of these safety precautions and your compliance with the basic rules of safety will help build good judgement Our objective is to help you develop good safety habits and make you a safer Hydraulic Excavator Operator I M Pee B Hydraulic Excavator Safety Manual Form No 20013 ee 1 T d vd nrar GRADALL tycroulic covers hla 406 Mill Ave SW New Philadelphia Ohio 44663 USA Phone 330 339 2211 Fax 330 339 8468 Gradall is a registered trademark for hydraulic excavators hydraulic material handlers attachments and other components built by The Gradall Company 2000 Gradall www gradall com p Y pany
19. filler cap slowly and remove it gradually If the system is equipped with an accumulator see the Service Manual for discharge and recharge instructions Keep all open flames away from the hydraulic system Clean up spilled fluid immediately Before loosening any hydraulic fitting be sure there is no trapped hydraulic pressure l G For cooling systems with an overflow tank the Diesel fuel or hydraulic fluid under pressure A coolant can usually be checked at the tank without can penetrate the skin or eyes and cause serious WARNING removal of the radiator cap WARNING injury blindness or death Fluid leaks under pressure may not be easily visible Use a piece of cardboard or wood to find leaks but do not use your bare hand Wear a face shield or safety goggles for eye protection If any fluid is injected into the skin seek medical attention immediately Hydraulic Excavator Safety Manual Form No 20013 ELECTRICAL SYSTEM HAZARDS Disconnect the battery before working on the electrical system Remove the ground cable first When re connecting the battery connect the ground cable last Never work on the electrical system unless you are thoroughly familiar with system details and the special handling required AVOID BATTERY HAZARDS Lead aad batteries contain sulfuric acid which will damage eyes or skin on contact Always wear a face shield to avoid acid in eyes If acid contacts eyes flush immediately with clean wat
20. h probability of death or serious injury if proper precautions are not taken When you see the Safety Alert Symbol pay particular attention to the DANGER WARNING or CAUTION note for the sake of your safety and the safety of others SIGNAL WORDS This symbol indicates a hazard which DANGER WARNING CAUTION could result in death or serious injury if proper Signal words are distinctive words that are typically found precautions are not taken on safety decals on a Gradall Hydraulic Excavator as well as on other equipment on the work site These words highlight 0 range of potential hazards and tisks A When you see this symbol pay particular attention to the DANGER WARNING or CAUTION note for the sake This symbol indicates a hazard which could result in injury or damage to equipment or property if proper precautions are not taken of your safety and the safety of others Hydraulic Excavator Safety Manual Form No 20013 bat PL Pe Me a 1 0 WORD TO THE OPERATOR AN CAUTION BE A RESPONSIBLE OPERATOR For safe operation of a Gradall Excavator you must be a responsible operator Make sure you e Clearly understand written instructions supplied by Gradall e Are fully trained including actual operation of the excavator S Understand and comply with all safety rules and regulations for the work site SAFETY AND YOU It is YOUR responsibility to read and understand this Safety Manual tt will he
21. l The pins and bushing in a dry joint can become very hot Wear gloves to prevent burns long hose with self attaching chuck Always stand behind the tread when adjusting tire pressure Be sure the area fo the side of the tire is clear of other people WARNING e When adjusting tire pressure do so from a distance Use a Check tracks for loose bent or broken track shoes and bolts worn Do not inflate tires with fl fr o not inflate fires with flammable gasses or from a or damaged pins and bushings Check the carer and idler rollers system utilizing an alcohol injector N ever strike or pound on track tension springs they may be under tremendous compression and could WARNING Shatter explosively Explosive separation of a tire and or rim parts can cause serious injury or death Always follow the manufacturer s recommendations or see your tire supplier eye a p i P i Hydraulic Excavator Safety Manual Form No 20013 A A SPECIAL NOTE ASBESTOS Some machines especially older ones may have components containing asbestos in friction and gasket materials These precautions pertain to these machines Avoid exposure to asbestos dust Extreme caution must be used to avoid breathing A dust that may be generated when handling components containing asbestos fibers If this dust CAUTION is inhaled it can be hazardous to your health Components that may contain asbestos fibers are brake pads brake band an
22. layed with a diagonal cross bar indicate prohibitions and could include e Unsafe working practices e Safety violations e Potential hazards As far as these are concerned there is one simple rule Just Don t Do It eee Hydraulic Excavator Safety Manual Form No 20013 INTRODUCTION AN WARNING This Safety Manual is not comprehensive It does not cover all possible eventualities Additional precautions may be necessary depending on the specific conditions of a particular work sife This Hydraulic Excavator Safety Manual underlines basic safety issues regarding the normal operation and maintenance of a Gradall Hydraulic Excavator The Manual recommends certain procedures precautions and other appropriate actions for safe operation and maintenance of the mahine This Safety Manual is not comprehensive It does not cover all possible eventualities Additional precautions may be necessary depending on the specific conditions of a particular work site REMEMBER It is YOUR responsibility to use sensible and appropriate safe practices when operating the excavator The information in this Manual supplements specific details about the excavator contained in the appropriate Gradall Owner Operator Manual and the EMI Excavator Safety Manual Other information which may affect the safe operation of the excavator is featured on safety decals affixed to the machine in your employer s safety programs in safety codes in local
23. lp you avoid accidents and keep the excavator in sound operating condition ALWAYS THINK SAFETY FIRST follow a carefully constructed plan for inspection maintenance and safe operation REMEMBER The Manual is not intended to cover all eventualities Any procedure must be thoroughly evaluated from the standpoint of safety before it is put into practice If you are not sure contact your Authorized Gradall Distributor for specific recommendations To help ensure safe operation do not modify any Gradall Excavator without written permission and procedures from Grodall A WORD ABOUT OPERATORS All operators must be responsible reliable and safety conscious Ine perienced personnel must not be allowed to operate the excavator All operators must know all job site safety rules PRACTICE MAKES PERFECT Before operating the excavator make sure you practice operating all controls Practice until you are completely familiar and comfortable with the excavator s response Practice maneuvering the excavator in a safe open area well away from people equipment and buildings OPERATE SAFELY A Gradall Hydraulic Excavator must ONLY be operated by trained and qualified personnel Check that all required maintenance is completed before operating the excavator NEVER operate the excavator without a correct and legible Capacity Chart in the operator s cab for the specific excavator attachment combination you are using Note There are no Capacity Char
24. ng stockpile or construction avoid dangers such as rock and or earth slides overhanging trees or a cave in When using a mine scaler or scaling attachment insure there is adequate lighting to perform the task Always scale while booming toward the rock face Be careful that the machine does not roll into the excavation when the stabilizers are raised When operating the excavator on a slope swing fo the uphill side to dump the load If downhill dumping is unavoidable swing only as far as required to dump the bucket Use extreme caution Always drop the spoil a sufficient distance from the trench fo avoid a cave in Situate the undercarriage parallel to the direction of a slope i e facing up or down the slope not across the slope Form No 20013 lt Hydraulic Excavator Safety Manual OPERATE SAFELY A LIFTING A LOAD WITH THE EXCAVATOR Before lifting a load make sure you know the machine s lifting capacity Do not attempt to lift a load without the proper Capacity Chart Perform a trial lift first Overloading is hazardous Make certain you are within the safe load and work radius limitations of this machine Also make sure you are on solid level ground before lifting any load A WARNING Attach chains and slings to the designated lifting points on the excavator boom Consult the Owner Operator Manual for the proper procedure When using the excavator to lift and place objects such as a pipe p
25. ns LIFTING AN EXCAVATOR For lifting instructions and machine weight consult your Machine s Serial Number Plate Owner Operator s Manual and or Gradall Distributor Hydraulic Excavator Safety Manual Form No 20013 ee eee 8 0 EREORM SAFE MAINTENANCE AN WARNING Keep clear of all rotating components Wrapping or entanglement may result in serious injury or death GENERAL MAINTENANCE SAFETY CONSIDERATIONS Do not perform any work on a machine unless you are authorized and qualified to do so If you have been authorized to do maintenance Read all applicable Service and Owner Operator Manuals Study the instructions check the lubrication charts examine all the warnings and instruction messages on the machine Maintenance can be dangerous unless performed properly Be sure you have the necessary skill information correct tools and equipment to do the job correctly Attach a Do Not Operate tag or similar warning tag to the steering controls before performing maintenance on the machine If the engine should not be started remove the ignition key PREPARE THE WORK AREA Choose a clean level work area Make sure you have sufficient room Check clearances Ma ke certain there is adequate light and ventilation Clean the walking and working surfaces Remove oil grease and water to eliminate slippery areas Put sand or other absorbent material on slippery areas PREPARE YOURSELF Wear all the
26. oint contact with the access system and face the machine Never jump off the machine And never try to dismount a moving machine Be careful of slippery conditions on platform steps ladders and hand holds when dismounting Block the wheels or tracks if the excavator is on aslope Form No 20013 lt Hydraulic Excavator Safety Manual LOAD AND UNLOAD THE MACHINE AEE 7 LOADING AND UNLOADING Not all excavators are loaded onto a trailer the same way Follow all instructions outlined in the appropriate Owner Operator Manual for your machine Several precautions are however applicable to all excavators e Know the weight of the machine you are operating e Know the correct loading and unloading procedures for your machine e Keep everyone clear of the area e Load and unload on a level and stable surface e Block the transport vehicle to prevent it from moving e Use ramps of adequate size and strength low angle and proper height e Keep the tires tracks trailer bed and ramps clear of mud oil ice snow and all materials which can become slippery e Engage the swing lock if equipped e Back the machine onto the trailer e Cover or remove the Slow Moving Vehicle emblem e Chain and block the machine securely e Secure any boom or attachment in the transport mode e Chain machine down using chain of adequate size Know the overall height and combined width of the transporter and machine to avoid overhead and narrow obstructio
27. osition your machine so that lowering is over the rear of the machine rather than either side Always lower the stabilizers if equipped to the ground before lifting If the ground is soft place pads or timbers under each stabilizer When lifting make sure the load is properly balanced Move slowly so the load does not sway or swing around If necessary use a tag line for additional control Do not lift and carry over sides stability is reduced Hydraulic Excavator Safety Manual Form No 20013 STAY CLEAR Check overhead clearances Know the size of doorways and canopies Know exactly how much clearance you have under power and telephone lines Make sure you know the location of gas lines water pipes and power cables before excavating Contact the diggers hot line in your area and or utility company and have them mark all underground utilities Check overhead clearances Know your margin of safety see note above Have power fo the lines disconnected or de energized If de energizing the lines is not possible request a signal person for guidance to maintain at least OSHA s minimum clearance DO NOT approach power lines overhead or underground cables or other power sources with any part of the excavator or load unless all local state provincial and federal regulations have been met and the appropriate utility company s hotline has been contacted to de energize the lines You must maintain the minimum distance r
28. ou don t understand ask your supervisor to explain it fo you IMPORTANT This Manual covers safe operating practices for Gradall Hydraulic Excavators If your machine is equipped with other devices or special accessories read the manufacturer s literature pertaining to that equipment before using it 3 PREPARE FOR SAFE OPERATION CHECK THE SAFETY EQUIPMENT To protect you and others around you the excavator may be equipped with the following safety equipment See that each item is securely in place and in good operating condition Brakes Falling Object Guard Front Guard Lights Safety Signs Horn Guards Shields Travel Alarm Mirrors Fire Extinguisher Fire Suppression System if equipped First Aid Kit Windshield Wipers amp Washers Reflective Strips Use Them Never remove or disconnect any safety device A WARNING NEVER remove a falling object guard or front guard except for service After service or repair replace the guard s immediately Form No 20013 lt Hydraulic Excavator Safety Manual PREPARE FOR SAFE OPERATION e KNOW THE RULES OF OPERATION The Occupational Safety and Health Administration OSHA enforces federal laws that apply to the safety of operation application and maintenance of equipment on a work site Because it is an employer s responsibility to comply with these laws an OSHA representative may periodically inspect awork site to see that these laws are being obeyed
29. protective clothing the job requires Wear a rubber apron and rubber gloves when working with corrosive materials Wear gloves and safety shoes when handling wooden blocks wire rope or sharp edged metal Always wear safety glasses goggles or a face shield when working with fluids under pressure while grinding while servicing batteries and where there is any possibility of injury from flying debris Wear a face shield when you disassemble spring loaded components Wear a helmet or goggles with special lenses when you weld or cut with a torch Do not sand grind flame cut braze or weld without a NIOSH MSHA approved respirator or appropriate ventilation If you are welding on the machine refer to the Service Manual and Owner Operator Manual for instructions Keep hands and clothing away from all moving parts Don t tempt fate with dangling ties loose A sleeves rings or long hair Keep pockets free of all objects which could fall out and into the machinery WARNING l Handle tools and heaw parts carefully with regard to yourself and other persons Lower items don t drop them Always use a safety platform steps ladders etc to service those areas which are slippery or too high reach and where surfaces of the machine cannot support your weight Form No 20013 lt Hydraulic Excavator Safety Manual PERFORM SAFE N OINR IENANGK 8 PREPARE THE MACHINE Locate the machine on a level surface Stop the engine releas
30. r conditioning system refer to the freon container for proper use Use a recovery and recycling system to avoid venting the freon to the atmosphere Contact with the freon stream can cause severe frost burns COMPLETE ALL SERVICES AND REPAIRS BEFORE OPERATING THE MACHINE Inspect all parts during repair and replace if wom cracked or damaged Excessively worn or damaged parts can fail and cause injury or death WARNING Replace any damaged or illegible decals AN Tighten all bolts fittings and connections to torque specified in the Owner Operator Manual 8 REOR M SAFE MAINTENANCE Install all guards covers and shields after servicing Replace or BRAKE SAFETY TIPS repair if damaged Refill and recharge pressurized systems only Carefully follow instructions in the Service and Owner Operator with Gradall approved fluids Manuals when adjusting brakes Improperly adjusted brakes could Start the engine and check for leaks Operate all controls to cause 0 serious accident make sure the machine is functioning properly Road test the machine if necessary After testing shut down check the work you performed Re check all fluid levels before releasing the machine for operation DRAIN AIR TANKS DAILY On crawler mounted machines block the tracks before Drain tanks daily In coldweather it is especially important that releasing the park brake if possible Otherwise the the air tank s be thoroughly drained at least once per shift
31. r if neutral start circuitry is bypassed This could cause the machine to move suddenly and cause serious injury or death fo anyone in its path Know the exact starting procedure for your excavator You will find this information in the Owner Operator Manual that shipped with the excavator Sit in the operator s seat and adjust the seat so you can operate all the controls properly 2 Familiarize yourself with warning devices gauges and operating controls 3 Engage the parking brake if the excavator is so equipped and put all controls in the Neutral Park position 4 Clear the area of all personnel 5 Start the engine following the instructions in the Owner Operator Manual If it is necessary to run the engine or operate the excavator within an enclosed area be absolutely certain there is adequate ventilation AN WARNING Exhaust fumes can kill Always make sure there is adequate ventilation START SAFELY NEVER allow passengers fo ride with you A Gradall Hydraulic Excavator is designed for ONE PERSON operation only NEVER allow anyone to occupy the machine other than the operator STARTING AIDS If jumper cables are used follow the instructions in the Owner Operator Manual The operator must be seated in the operator s seat when jump starting the engine so the machine will be under control when the engine starts Jump starting is a two person operation A battery explosion or run away machine
32. rating characteristics of the excavator e Never modify or remove any part of the machine except for service N ever allow riders on the machine Keep others away from the operation Before leaving the cab always place the excavator boom in the boom rest or the attachment on the ground Engage the parking brake if the machine is so equipped stop the engine cycle the hydraulic controls and remove the key see page 6 0 Machine Shutdown Make sure you understand the rules covering traffic at your jobsite Know what all signs flags and markings mean Understand hand flag horn whistle siren and bell signals Know when to use lights tum signals flashers and horns Hydraulic Excavator Safety Manual Form No 20013 KNOW THE EQUIPMENT Get to know the machine Know how to operate all equipment on your machine Know the purpose of all the controls gauges and indicators Know the load capacity speed range braking and steering characteristics turning radius and operating clearances Keep in mind that rain snow ice loose gravel soft ground and uneven terrain change the operating capabilities of the excavator Study the DANGER WARNING and CAUTION safety signs on the machine Study all the informational signs too Study the Owner Operators Manual before starting the engine If there is no Manual with the machine GET ONE Study it before you start work If there is something in the Manual y
33. rs and all lights Ma ke sure the Operator s area steps and hand holds are clean Oil grass snow ice or mud in these areas can cause you to slip and fall Clean the mud off your boots before climbing onto the machine Remove all loose personal items or other objects from the operator s area Secure all items or remove them from the machine Do not store water cans signs tools chains or any other unauthorized item on the deck of the excavator 3 PREPARE FOR SAFE OPERATION KNOW THE WORKING AREA Before operating the excavator leam as much as possible about your working area Check for Location of slopes Open trenches Drop offs or overhangs Soil conditions soft or hard Standing water and marshy areas Rocks and stumps Traces of buried foundations footings or walls Traces of buried trash or landfill Conditions of haul roads Direction of travel on haul roads Holes obstructions mud or ice Heavy traffic Thick dust smoke or fog The exact location of any buried and or overhead electrical gas telephone water sewer or other utility lines If necessary have the utility company mark shut off or relocate the line before you begin working Never approach power lines with any part of your machine unless all local state provincial and federal OSHA required safety precautions have been taken Use extreme caution Ay WARNING When operating the excavator inside a building make
34. tected Correct or report any trouble IMMEDIATELY before further operation ONE MACHINE ONE PERSON A Gradall Excavator is designed for one person operation only NEVER allow passengers to ride with you On wheeled excavators NEVER have both the upper and carrier cabs occupied at the same time RADIO REMOE MACHINES Some Gradall Industrial Maintenance Machines IMMs are operated by radio remote control and have no operators cab NEVER allow passengers fo ride on these machines Form No 20013 lt Hydraulic Excavator Safety Manual OPERATE SAFELY B U ALWAYS THINK SAFETY FIRST Never allow an untrained or unqualified person to operate a Gradall Excavator Handled improperly this machine could cause severe injury or death In addition there are several fundamental safety rules which apply in every situation where a Gradall Excavator is being operated Always look around before you back up hook up or swing an attachment Be sure that everyone is in the clear Know the pinch points and rotating parts on the machine Do not allow other personnel to place their arms or hands in boom holes at any time Do not allow other personnel to lean on the boom or any other part of the excavator Keep your head arms and other body parts inside the cab at all times Make sure access systems steps handrails etc are clean and in good condition at all times If damaged make sure repairs are made immediately Hydraulic Excavator Safety M
35. ts in the Industrial Maintenance Machines SPECIAL NOTE ON CONTROLLED SUBSTANCES A Drugs and alcohol affect your alertness your coordination and therefore your ability to safely pane operate a Hydraulic Excavator NEVER use drugs or alcohol while operating a hydraulic excavator If you are taking prescription or over the counta medication consult a medical professional regarding any side effects that would hinder yo ur ability to safely operate this equipment NEVER operate the excavator when your alertness or coordination is impaired Form No 20013 lt Hydraulic Excavator Safety Manual A WORD TO THE OPERATOR PROTECT YOURSELF Wear all the protective clothing and personal safety devices issued to you or called for by job conditions You May Need Hard Hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Wear whatever is needed Take no chances DO NOT wear loose fitting clothes flopping cuffs dangling neckties and scarves or rings WARNING 000 wrist watches that might get snagged in moving parts KNOW WHAT YOU RE DOING Most employers have rules governing operation and maintenance of equipment Before you start work at a new location check with your supervisor or the safety coordinator Ask about rules you may be expected to obey These are some of the rules you must work by e Know the capacity and ope
36. ver personnel or any other mahine Do not store shovels water cans chains signs footballs etc on machine If machine is equipped with 2 cabs only one cab is to be occupied at any time Hydraulic Excavator Safety Manual Form No 20013 Before starting to excavate set up safety barriers to the sides and back of machine to prevent anyone from walking into the working area without the DANGER operators knowledge Ad DANGER Never enter or allow anyone else to enter the excavator swing area Death or serious injury can result Be sure there are no obstructions and that there is sufficient clearance for tail swing USING ATTACHMENTS Listed below are some of the more common types of attachments used on a Gradall Hydraulic Excavator e Buckets s Hammers e Mowers e Rippers e Grapples s Boom Extensions e Augers e Telestick s Shears s Blades s Barrel Handler In some cases attachments are shipped with additional manuals Consult attachment manual for proper operating information OPERATE SAFELY 8 Ad Keep others clear of swing radius A WARNING Pinch Point locations will vary with different types of attachments Keep clear of all pinch points AN WARNING Flying debris is a hazard to the operator and all nearby personnel when using power attachments such as Hammers Augers or Mowers Ensure that the operator has all windows and guards in place and that all personnel are we
Download Pdf Manuals
Related Search