247B2 and 257B2 Multi Terrain Loaders - Safety
Contents
1. 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 103656846 Guards Operator Protection SMCS Code 7150 MCH 7325 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 SEBU8386 03 33 Safety Section Guards 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 recommended for your machine 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 Any alteration or any modification to the ROPS FOPS Structure could weaken the structure This places the operator into an unpro2. Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter in order to check the battery charge Daily inspect battery cables that are in areas that are visible Inspect cables clips straps and other restraints for damage Replace any damaged parts Check for signs of the following which can occur over time due to use and environmental factors e Fraying e Abrasion e Cracking SEBU8386 03 25 Safety Section Fire Prevention and Explosion Prevention e Discoloration e Cuts on the insulation of the cable e Fouling e Corroded terminals damaged terminals and loose terminals Replace damaged battery cable s and replace any related parts Eliminate any fouling which may have caused insulation failure or related component damage or wear Ensure that all components are reinstalled correctly An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface A battery cable short produces heat from the battery current which may be a fire hazard An exposed wire on the ground cable between the battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes into contact with a grounded surface This may result in an unsafe condition for servicing the machine Repair components or replace components before servicing the machine Fire o
3. in serious injury or death 16 Safety Section Safety Messages SEBU8386 03 Multipurpose Bucket 16 These warning messages are located on the front of the multipurpose bucket g01389199 No clearance for person in this area during oper ation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation Utility Fork 17 These warning messages are located on top of the fork carriage g01381064 No clearance for person in this area during op eration Severe injury or death from impalement could occur Stay away from the work tool while it is in operation SEBU8386 03 17 Safety Section Safety Messages Industrial Grapple Fork 18 These warning messages are located on top of the fork carriage g01381064 No clearance for person in this area during op eration Severe injury or death from impalement could occur Stay away from the work tool while it is in operation Angle Blade 19 These warning messages are located on the back side of the blade 901377717 No clearance for person in this area during oper ation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation 18 Safety Section Safety Messages SEBU8386 03 Utility Grapple Fork 20 These warning messages are located on top of the fork carriage g01381064 No clearance for
4. 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 When you perform maintenance above ground level use appropriate devices such as ladders or man lift machines If equipped use the machine anchorage points and use approved fall arrest harnesses and lanyards Pressurized Air and Water Pressurized air and or water can cause debris and or hot water to be blown out The debris and or hot water could result in personal injury When pressurized air and or pressurized water is used for cleaning wear protective clothing protective 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
5. please consult your Caterpillar dealer for the latest available information Safety The safety section lists basic safety precautions In addition this section identifies the text and locations of warning signs and labels used on the machine Read and understand the basic precautions listed in the safety section before operating or performing lubrication maintenance and repair on this machine Operation The operation section is a reference for the new operator and a refresher for the experienced operator This section includes a discussion of gauges switches machine controls attachment controls transportation and towing information Photographs and illustrations guide the operator through correct procedures of checking starting operating and stopping the machine Operating techniques outlined in this publication are basic Skill and techniques develop as the operator gains knowledge of the machine and its capabilities Maintenance The maintenance section is a guide to equipment care The Maintenance Interval Schedule MIS lists the items to be maintained at a specific service interval Items without specific intervals are listed under the When Required service interval The Maintenance Interval Schedule lists the page number for the step by step instructions required to accomplish the scheduled maintenance Use the Maintenance Interval Schedule as an index or one safe source for all maintenance procedures Main
6. the machine and from the area Clear all obstacles from the path of the machine Beware of hazards such as wires ditches etc Make sure that all windows are clean Secure all doors in the closed position Secure the windows in the open position or in the shut position Make sure that the machine horn the backup alarm and all other warning devices are working properly Fasten the seat belt securely Lower the armrest i03766071 Operation SMCS Code 7000 Only operate the machine while you are in the seat The seat belt must be fastened while you operate the machine Only operate the controls while the engine is running Before you move the machine you must be certain that no one will be endangered While you operate the machine and the work tool slowly in an open area check for proper operation of all controls and all protective devices Do not allow riders on the machine Never use the work tool for a work platform Note any needed repairs during machine operation Report any needed repairs Use only Caterpillar Approved Work Tools on this machine Obey all the lift restrictions Refer to Operation and Maintenance Manual Caterpillar Approved Work Tools for the approved work tools and the lift restriction information Carry work tools low Lower the lift arms fully Tilt back the work tool in order to keep the work tool off of the ground Do not go close to the edge of a cliff an excavation or an overhan
7. work tool with your machine consult your Caterpillar dealer Make sure that all necessary guarding is in place on the host machine and on the work tool SEBU8386 03 29 Safety Section Parking Keep all windows and doors closed on the host machine Always wear protective glasses Always wear the protective equipment that is recommended in the work tool s operation manual Wear any other protective equipment that is required for the operating environment To prevent personnel from being struck by flying objects ensure that all personnel are out of the work area While you are performing any maintenance any testing or any adjustments to the work tool stay clear of the following areas cutting edges pinching surfaces and crushing surfaces 101946967 Parking SMCS Code 7000 Park on a level surface If you must park on a grade chock the machine 1 Move the speed direction control lever slowly to the HOLD position in order to stop the machine 2 Move the governor control lever to the LOW IDLE position 3 Lower the loader arms and tilt the linkage so that the work tool rests firmly on the ground 4 Move the hydraulic control levers to the HOLD position 5 Turn the engine start switch key to OFF position and remove the key 6 Raise the armrest and exit the machine 103745198 Slope Operation SMCS Code 7000 Machines that are operating safely in various applications depend on these criteria the
8. AEJXXXX MAYXX ISO XXXX 1994 FOPS SAEJ ISOXXXX APR98 LEVEL ISOXXXX 1992 LEVEL Il Kg LB XXXX XXXX XX XXX XX XXX XXXX XXXX XXXX XXXX XX XXX XX XXX g01211895 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 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 film 10 Safety Section Safety Messages SEBU8386 03 Cab Support 3 This warning message is located on the left side of the machine near the cab support lever This warning message is also located inside the cab on the lower left side g01427440 Do not go beneath cab unless cab is empty and support lever is engaged Failure to follow the instructions or heed the warn ings could result in injury or death Crush Hazard 4 This warning is located on the loader arms of the machines that are equipped with extended reach g01378775 No clearance for person in this area during oper ation Severe injury or death from crushing could occur Stay away from the work tool whil
9. AT0O789BG 6 8L12345 Doo o Illustration 1 g00751314 Where 1 Caterpillar s World Manufacturing Code characters 1 3 2 Machine Descriptor characters 4 8 3 Check Character character 9 4 Machine Indicator Section MIS or Product Sequence Number characters 10 17 These were previously referred to as the Serial Number Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format Components such as engines transmissions axles etc and work tools will continue to use an 8 character Serial Number S N 6 Safety Section Safety Messages SEBU8386 03 Safety Section 103939829 Safety Messages SMCS Code 7000 7405 There are several specific safety messages 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 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 th
10. 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 103162317 Visibility Information SMCS Code 7000 Before you start the machine perform a walk around inspection in order to ensure that there are no hazards around the machine While the machine is in operation constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine Your machine may be equipped with visual aids Some examples of visual aids are Closed Circuit Television CCTV and mirrors Before operating the machine ensure that the visual aids are in proper working condition and that the visual aids are clean Adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual If equipped the Work Area Vision System shall be adjusted according to Operation and Maintenance Manual SEBU8157 Work Area Vision System It may not be possible to provide direct visibility on large machines to all areas around the machine Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area Examples of job site organization include the following S
11. SAFETY Operation and Maintenance Manual Excerpt 2010 Caterpillar All Rights Reserved CATERPILLAR A O SEBUB8386 03 CATERPILLAR T 20 Operation and Maintenance Manual 247B2 and 257B2 Multi Terrain Loaders 103991620 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 In
12. afety instructions Controlled patterns of machine movement and vehicle movement Workers that direct traffic to move when it is safe Restricted areas Operator training Warning symbols or warning signs on machines or on vehicles A system of communication Communication between workers and operators prior to approaching the machine Modifications of the machine configuration by the user that result in a restriction of visibility shall be evaluated 101027818 Engine Starting SMCS Code 1000 7000 If a warning tag is attached to the 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 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 28 Safety Section Before Operation SEBU8386 03 102552731 Before Operation SMCS Code 7000 Video tapes and safety information are available in English for the machine A list of some of the material is available in the Operation and Maintenance Manual Reference Material Consult your Caterpillar dealer in order to obtain copies of the material The information should be reviewed by every person that operates the machine Clear all personnel from
13. at 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 safety messages 7 Safety Section Safety Messages SEBU8386 03 g02155981 Illustration 2 SEBU8386 03 8 Safety Section Safety Messages o lt i g01433202 Illustration 3 SEBU8386 03 9 Safety Section Safety Messages Do Not Operate 1 This warning message is located inside the cab on the upper left side g01370904 Read and understand the instructions and warn ings in the operation and maintenance manuals Contact any Caterpillar dealer for replacement manuals Proper care is your responsibility Be alert Know work conditions Note and avoid all hazards and obstructions Keep by standers away when operating Fasten seat belt and lower armrest Make certain all controls are in neutral position and start engine Disengage parking brake Machine controls are active Failure to follow the instructions or heed the warn ings could result injury or death Rollover Protective Structure Falling Object Protective Structure 2 This warning film and certification film are located inside the cab on the upper left side ROPS S
14. axis Y axis Z axis X axis Y axis Z axis Multi Terrain Loader v shape motion 1 21 1 00 0 82 0 30 0 84 0 32 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 EM9 The seat has a transmissibility factor of SEAT lt 0 9 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 1 59 meter per second squared for this machine Guidelines for Reducing Vibration Levels on Earthmoving Equipment Properly adjust machines Properly maintain machines Operate machines smoothly Maintain the conditions of the terrain The f
15. can cause oil to spray Fluid penetration can cause serious injury and possible death SEBU8386 03 21 Safety Section General Hazard Information 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 Illustration 7 g00687600 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 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 Spe
16. cial 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 Inhalation Illustration 8 g02159053 Exhaust Use caution Exhaust fumes can be hazardous to your health If you operate the machine in an enclosed area adequate ventilation is necessary Asbestos Information Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free Caterpillar recommends the use of only genuine Cat 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 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 compr
17. de of the cab floor in front of the console for the speed direction control Consult your Caterpillar dealer for the proper procedure for mounting the fire extinguisher 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 SEBU8386 03 27 Safety Section Before Starting Engine 100771840 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 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
18. e it is in operation SEBU8386 03 11 Safety Section Safety Messages Batteries 5 This warning message is located on the inside of the engine access door Stay Inside Operator Station 6 This warning message is located below the operator seat g01370909 Improper jumper cable connections can cause ex plosion resulting in personal injury Batteries may be located in separate compartments always con nect positive cable to positive terminal of battery connected to starter solenoid and negative cable from external source to engine block or frame g01427449 Keep your body inside the operator station while you are operating the loader Never work with your arms feet or legs beyond the operator station Failure to follow the instructions or heed the warn ings will result in injury or death 12 Safety Section Safety Messages SEBU8386 03 Never Permit Riders 7 This warning message is located below the operator seat g01427444 Never permit riders Never use work tool for a work platform Failure to follow the instructions or heed the warn ings could result in injury or death Seat Belt 8 This warning message is located below the operator seat g01370908 A seat belt should be worn at all times during ma chine operation to prevent serious injury or death in the event of an accident or machine overturn Failure to wear a s
19. eat belt during machine opera tion may result in serious injury or death Refer to Operation and Maintenance Manual Seat Belt for more information SEBU8386 03 13 Safety Section Safety Messages Pressurized System 9 This warning message is located below the radiator cap g01378799 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure Crush Hazard 10 This warning is located on the loader arms of the machines that are equipped with extended reach g01378775 No clearance for person in this area during oper ation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation 14 Safety Section Safety Messages SEBU8386 03 Brace for the Loader Lift Arms 11 This warning message is located on the brace for the loader lift arms Work Tool Coupler 12 This warning message is located inside the cab on the upper left side g01427443 Loader lift arm brace must be in place when work ing under raised lift arms Failure to follow the instructions or heed the warn ings could result in injury or death Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation for operating information g01427447 Improper Attachment of the Work Tool could result in injury or death Do not ope
20. essed 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 22 Safety Section Crushing Prevention and Cutting Prevention SEBU8386 03 e 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 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 9 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 i
21. f 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 it is 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 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 Pre
22. g 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 machine can tip when you work on banks and on slopes Also the machine can tip when you cross ditches ridges or other unexpected obstacles Never exceed a slope that is greater than 3 to 1 18 4 degrees Maintain control of the machine Do not overload the machine beyond the machine capacity Never straddle a wire cable Never allow personnel to straddle a wire cable Know the maximum dimensions of your machine Always keep the Rollover Protective Structure ROPS installed during machine operation Machine Operating Temperature Range The machine must function satisfactorily in the anticipated ambient temperature limits that are encountered during operation The minimum limits of items that will effect the safe operation of the machine to be considered are 0 100 relative humidity for 32 C 25 F to 43 C 109 4 F temperatures unless specified in the functional specifications Observe any local government regulations when you use the machine to lift heavy objects 101115299 Work Tools SMCS Code 6700 Only use work tools that are approved by Caterpillar for use on Caterpillar machines Refer to the Operation and Maintenance Manual Caterpillar Approved Work Tools If you are in doubt about the compatibility of a particular
23. ine if the machine is equipped with a thermal starting aid for cold weather starting 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 2 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 personnel Fire Extinguisher As an additional safety measure keep a fire extinguisher on the machine Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Follow the recommendations on the instruction plate Consider installation of an aftermarket Fire Suppression System if the application and working conditions warrant the installation 101820946 Fire Extinguisher Location SMCS Code 7000 7419 Make sure that a fire extinguisher is on the machine Make sure that you are familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher Obey the recommendations on the instruction plate 3L 3L 3L it f oO HU 4300 ae J Illustration 14 g00929625 Mount the fire extinguisher on the left si
24. ions are also required Consult the Operation and Maintenance Manual sections for the proper fluid level requirements and intended machine use 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 103894899 Sound Information and Vibration Information SMCS Code 7000 Sound Level Information The operator Equivalent Sound Pressure Level Leq is 89 dB A when ANSI SAE J1166 Feb 2008 is used to measure the value for an enclosed cab This is a work cycle 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 pro
25. isture of the surface material may drastically affect the machine s traction and machine s stability Rocky surfaces may promote side slipping of the machine Slippage due to excessive loads This may cause downhill tracks or downhill tires to dig into the ground which will increase the angle of the machine Width of tracks or tires Narrower tracks or narrower tires further increase the digging into the ground which causes the machine to be less stable Implements attached to the drawbar This may decrease the weight on the uphill tracks This may also decrease the weight on the uphill tires The decreased weight will cause the machine to be less stable Height of the working load of the machine When the working loads are in higher positions the stability of the machine is reduced Operated equipment Be aware of performance features of the equipment in operation and the effects on machine stability 30 Safety Section Equipment Lowering with Engine Stopped SEBU8386 03 Operating techniques Keep all attachments or pulled loads low to the ground for optimum stability Machine systems have limitations on slopes Slopes can affect the proper function and operation of the various machine systems These machine systems are needed for machine control Note Safe operation on steep slopes may require special machine maintenance Excellent skill of the operator and proper equipment for specific applicat
26. itional Messages SMCS Code 7000 7405 Product Link g01418953 Illustration 4 The Product Link System is a satellite communication device that transmits information regarding the machine back to Caterpillar and Caterpillar dealers and customers All logged events and diagnostic codes that are available to the Caterpillar Electronic Technician ET on the CAT data link can be sent to the satellite Information can also be sent to the Product Link System The information is used to improve Caterpillar products and Caterpillar services Refer to Operation and Maintenance Manual Product Link for more information 104010649 General Hazard Information SMCS Code 7000 Illustration 5 g00104545 20 Safety Section General Hazard Information SEBU8386 03 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls Attach the warning tag before you service the equipment or before you repair the equipment These warning tags Special Instruction SEHS7332 are available from your Cat dealer A WARNING Operating the machine while distracted can result in the loss of machine control Use extreme cau tion when using any device while operating the machine Operating the machine while distracted can result in personal injury or death Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary ob
27. ly marked containers away from unauthorized personnel Store oily rags and flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Illustration 11 g00704059 Use caution when you are fueling a machine Do not smoke while you are fueling a machine Do not fuel a machine near open flames or sparks Always stop the engine before fueling Fill the fuel tank outdoors Properly clean areas of spillage Follow practices for safe fueling that are described in the Operation section of the Operation and Maintenance Manual section and follow local regulations Never store flammable fluids in the operator compartment of the machine Battery and Battery Cables Illustration 12 g02298225 Caterpillar recommends the following in order to minimize the risk of fire or an explosion related to the battery Do not operate a machine if battery cables or related parts show signs of wear or damage Contact your Cat dealer for service Follow safe procedures for engine starting with jump start cables Improper jumper cable connections can cause an explosion that may result in injury Refer to Operation and Maintenance Manual Engine Starting with Jump Start Cables for specific instructions Do not charge a frozen battery This may cause an explosion Gases from a battery can explode Keep any open flames or sparks away from the top of a battery
28. machine model configuration machine maintenance operating speed of the machine conditions of the terrain fluid levels and tire inflation pressures The most important criteria are the skill and judgment of the operator A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability Operator training provides a person with the following abilities observation of working and environmental conditions feel for the machine identification of potential hazards and operating the machine safely by making appropriate decisions When you work on side hills and when you work on slopes consider the following important points Speed of travel At higher speeds forces of inertia tend to make the machine less stable Roughness of terrain or surface The machine may be less stable with uneven terrain Direction of travel Avoid operating the machine across the slope When possible operate the machine up the slopes and operate the machine down the slopes Place the heaviest end of the machine uphill when you are working on an incline Mounted equipment Balance of the machine may be impeded by the following components equipment that is mounted on the machine machine configuration weights and counterweights Nature of surface Ground that has been newly filled with earth may collapse from the weight of the machine Surface material Rocks and mo
29. n a machine can result in personal injury or death Exposed battery cables that come into contact with a grounded connection can result in fires Replace cables and related parts that show signs of wear or damage Contact your Cat dealer Wiring Check electrical wires daily If any of the following conditions exist replace parts before you operate the machine e Fraying e Signs of abrasion or wear e Cracking e Discoloration e Cuts on insulation e Other damage Make sure that all clamps guards clips and straps are reinstalled correctly This will help to prevent vibration rubbing against other parts and excessive heat during machine operation Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should be avoided Consult your Cat dealer for repair or for replacement parts Keep wiring and electrical connections free of debris 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 Use the appropriate backup wrenches in order to tighten all connections to the recommended torque Illustration 13 g00687600 Check lines tubes and hoses carefully Wear Personal Protection Equipment PPE in order to check for leaks 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 inj
30. nd 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 104090611 Fire Prevention and Explosion Prevention SMCS Code 7000 I Illustration 10 g00704000 General All fuels most lubricants and some coolant mixtures are flammable To minimize the risk of fire or explosion Caterpillar recommends the following actions Always perform a Walk Around Inspection which may help you identify a fire hazard Do not operate a machine when a fire hazard exists Contact your Cat dealer for service Understand the use of the primary exit and alternative exit on the machine Refer to Operation and Maintenance Manual Alternative Exit Do not operate a machine with a fluid leak Repair leaks and clean up fluids before resuming machine operation Fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire A fire may cause personal injury or death Remove flammable material such as leaves twigs papers trash and so on These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine Keep the access doors
31. ollowing 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 b Fill any ditches and holes 32 Safety Section Guards SEBU8386 03 c Provide machines and schedule time in order to maintain the conditions of the terrain 4 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 5 Perform the following operations smoothly a Steer b Brake c Accelerate d Shift the gears 6 Move the attachments smoothly 7 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 8 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 multi terrain loaders c If no ride control system is available reduce speed in order to prevent bounce d Haul the machines between workplaces 9 Les
32. perly maintained or when the doors and windows are open for extended periods or in a noisy environment The average exterior sound pressure level is 75 dB A when the SAE J88Feb2006 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 89 dB A when ISO 6396 2008 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 exterior sound pressure level of the machine is noted on the film that is located under the cab door on the frame Construction machines may not be modified in any manner that would cause an increase in noise level The European Union Physical Agents Vibration Directive 2002 44 EC Vibration Data for Multi Terrain Loaders 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 second squared Information Concerning Whole Body Vibration Level This section provides vibration data and a method for estimating the vib
33. person in this area during op eration Severe injury or death from impalement could occur Stay away from the work tool while it is in operation Dozer Blade 21 These warning messages are located on the back side of the blade g01371644 A WARNING No clearance for person in this area during oper ation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation Dozer Blade 22 This warning is located on right hand side on the back of the blade g01370904 A WARNING 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 IN JURY OR DEATH CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS PROP ER CARE IS YOUR RESPONSIBILITY SEBU8386 03 19 Safety Section Additional Messages Dozer Blade 23 This warning message is located on top of the dozer blade g00946617 Falling Hazard Area may be oily and slippery Do not step on cylinders Serious injury or death could occur from a fall Dozer Blade 24 This warning message is located on top of the dozer blade g01378775 No clearance for person in this area during oper ation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation 102879615 Add
34. rate the machine without confirmation that the coupler pins are fully engaged Follow the operating procedures in the Operation and Main tenance Manual Tilt the work tool downward Put down pressure on the work tool Move the machine backward Ensure that the work tool has not separated from the coupler assembly SEBU8386 03 15 Safety Section Safety Messages Accumulator 13 This warning message is located near the accumulator underneath the cab Product Link 15 This safety message is located inside the cab on the right hand window g01370912 Accumulator may contain high pressure oil Do not service the accumulator or any hydraulic lines until all of the pressure has been relieved See the Service Manual for proper procedures Failure to heed this warning could result in injury or death Aerosol Starting Aid 14 This warning message is located on top of the fuel pump housing g01372254 Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury g01370917 This machine is equipped with a Caterpillar Product Link communication device When elec tric electronic detonators are used this com munication device should be deactivated within 12 m 40 ft of a blast site or within the distance mandated under applicable legal requirements Failure to do so could cause interference with blasting operations and result
35. ration level for multi terrain loaders Note Vibration levels are influenced by many different parameters Many items are listed below e Operator training behavior mode and stress SEBU8386 03 31 Safety Section Sound Information and Vibration Information e Job site organization preparation environment weather and material e 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 Table 1 ISO Reference Table A Equivalent vibration levels of whole body vibration emission for earthmoving equipment Vibration Levels Scenario Factors Machine Type EEA pe ctivity X
36. ront 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 windows 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 your work tool will provide specific requirements for the guards Consult your Caterpillar dealer for additional information
37. s operator comfort may be caused by other risk factors The following guidelines can be effective in order to provide better operator comfort 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 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
38. son engaged in the business of repairing servicing selling leasing or trading engines or machines to remove alter or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations 40 CFR Part 89 Certain elements of the machine and engine such as the exhaust system fuel system electrical system intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar Machine Capacity Additional attachments or modifications may exceed machine design capacity which can adversely affect performance characteristics Included would be stability and system certifications such as brakes steering and rollover protective structures ROPS Contact your Caterpillar dealer for further information Caterpillar Product Identification Number Effective First Quarter 2001 the Caterpillar Product Identification Number PIN has changed from 8 to 17 characters In an effort to provide uniform equipment identification Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard Non road machine PINs are defined by ISO 10261 The new PIN format will apply to all Caterpillar machines and generator sets The PIN plates and frame marking will display the 17 character PIN The new format will look like the following C
39. stacles 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 3 BES Illustration 6 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 equipment 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
40. tected 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 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 f
41. tenance Intervals Use the service hour meter to determine servicing intervals Calendar intervals shown daily weekly monthly etc can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading Recommended service should always be performed at the interval that occurs first Under extremely severe dusty or wet operating conditions more frequent lubrication than is specified in the maintenance intervals chart might be necessary Perform service on items at multiples of the original requirement For example at every 500 service hours or 3 months also service those items listed under every 250 service hours or monthly and every 10 service hours or daily California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling Certified Engine Maintenance Proper maintenance and repair is essential to keep the engine and machine systems operating correctly As the heavy duty off road diesel engine owner you are responsible for the performance of the required maintenance listed in the Owner Manual Operation and Maintenance Manual and Service Manual SEBU8386 03 5 Foreword It is prohibited for any per
42. to major machine compartments closed and access doors in working condition in order to permit the use of fire suppression equipment in case a fire should occur Clean all accumulations of flammable materials such as fuel oil and debris from the machine Do not operate the machine near any flame Keep shields in place 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 or flame cut on tanks or lines that contain flammable fluids or flammable material Empty and purge the lines and tanks Then clean the lines and tanks with a nonflammable solvent prior to welding or flame cutting Ensure that the components are properly grounded in order to avoid unwanted arcs Dust that is generated from repairing nonmetallic hoods or fenders may be flammable and or explosive Repair such components in a well ventilated area away from open flames or sparks Use suitable Personal Protection Equipment PPE Inspect all lines and hoses for wear or deterioration Replace damaged lines and hoses The lines and the hoses should have adequate support and secure clamps Tighten all connections to the recommended torque Damage to the protective cover or insulation may provide fuel for fires 24 Safety Section Fire Prevention and Explosion Prevention SEBU8386 03 Store fuels and lubricants in proper
43. uct Obtain the complete and most current information before you start any job Cat dealers have the most current information available When replacement parts are required for this product Caterpillar recommends using Cat re placement parts or parts with equivalent speci fications including but not limited to physical dimensions type strength and material Failure to heed this warning can lead to prema ture failures product damage personal injury or death In the United States the maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner s choosing 4 Foreword SEBU8386 03 Foreword Literature Information This manual should be stored in the operator s compartment in the literature holder or seat back literature storage area This manual contains safety information operation instructions transportation information lubrication information and maintenance information Some photographs or illustrations in this publication show details or attachments that can be different from your machine Guards and covers might have been removed for illustrative purposes Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication Read study and keep this manual with the machine Whenever a question arises regarding your machine or this publication
44. ury 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 Replace the affected 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 swelling or ballooning Flexible parts of the hoses are kinked e Outer covers have exposed embedded armoring End fittings are displaced 26 Safety Section Fire Extinguisher Location SEBU8386 03 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 excessive heat and failure of lines tubes and hoses Do not operate a machine when a fire hazard exists Repair any lines that are corroded loose or damaged Leaks may provide fuel for fires Consult your Cat dealer for repair or for replacement parts Use genuine Cat parts or the equivalent for capabilities of both the pressure limit and temperature limit Ether Ether if equipped is commonly used in cold weather applications Ether is flammable and poisonous Follow the correct cold engine starting procedures Refer to the section in the Operation and Maintenance Manual with the label Engine Starting Do not spray ether manually into an eng
45. vention 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 SEBU8386 03 23 Safety Section Fire Prevention and Explosion Prevention Check the coolant level only after the engine has been stopped Ensure that the filler cap is cool before removing the filler cap The filler cap 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 ha
46. volved The message that appears under the warning explains the hazard and can be either written or pictorially presented A non exhaustive list of 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 You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use including site specific rules and precautions applicable to the worksite 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 become unsafe by the operation lubrication maintenance or repair procedures that you intend to use 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 prod
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