Sebu7247-01 S

Download as pdf or txt
Download as pdf or txt
You are on page 1of 19

SAFETY

Operation and Maintenance


Manual Excerpt

2010 Caterpillar
All Rights Reserved

SEBU7247-01
May 2001

Operation and
Maintenance
Manual
D8R Series II Track-Type Tractor
AKA1-Up (Machine)
6YZ1-Up (Machine)

i01097883

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for this


product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

6
Safety Section
Safety Signs and Labels

Safety Section
i01506904

Safety Signs and Labels


SMCS Code: 7000; 7405
There are several specific warning signs on this
machine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all warning
signs.
Make sure that all of the warning signs are legible.
Clean the warning signs or replace the warning
signs if you cannot read the words. Replace the
illustrations if the illustrations are not visible. When
you clean the warning signs, use a cloth, water, and
soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the warning signs. Solvents,
gasoline, or harsh chemicals could loosen the
adhesive that secures the warning sign. Loose
adhesive will allow the warning sign to fall.
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of
the machine that is replaced, install a warning sign
on the replacement part. Any Caterpillar dealer can
provide new warning signs.

Do Not Operate

Illustration 3

DO NOT OPERATE OR WORK ON THIS MACHINE


UNLESS YOU HAVE READ AND UNDERSTAND
THE INSTRUCTIONS AND WARNINGS IN THE
OPERATION AND MAINTENANCE MANUALS.
FAILURE TO FOLLOW THE INSTRUCTIONS OR
HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH. CONTACT ANY CATERPILLAR
DEALER FOR REPLACEMENT MANUALS. PROPER CARE IS YOUR RESPONSIBILITY.

Improper Connections for Jump


Start Cables

Illustration 4
Illustration 2

g00681858

g00680090

g00680037

This warning sign is in the battery compartment.


This warning sign is positioned in the cab beneath
the left window.

7
Safety Section
Safety Signs and Labels

Illustration 5

g00681941

Improper jumper cable connections can cause an


explosion resulting in personal injury. Batteries
can be located in separate compartments. When
using jumper cable always connect positive (+) cable to positive (+) terminal of battery connected to
starter solenoid and negative () cable from external source to starter negative () terminal. (If not
equipped with starter negative terminal, connect
to engine block.)

Do Not Weld On ROPS

Illustration 6

This warning sign is on the ROPS.

g00680059

8
Safety Section
Safety Signs and Labels

g00681859

Illustration 7

Structural damage, an overturn, modification, alteration, or improper repair can impair this structures protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to determine this structures limitations without voiding
its certification.

Do Not Weld on FOPS

Illustration 8

This warning sign is located on the FOPS.

g00680079

9
Safety Section
Safety Signs and Labels

g00681859

Illustration 9

Structural damage, an overturn, modification, alteration, or improper repair can impair this structures protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to determine this structures limitations without voiding
its certification.

High Pressure Cylinder


Illustration 11

g00681875

Personal injury or death can result from grease


under pressure.
Grease coming out of the relief valve under pressure can penetrate the body causing injury or
death.

Illustration 10

g00689430

This warning sign is on the dipstick that is attached


to the cover for each recoil spring compartment.

Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened.
Loosen the relief valve one turn only.
If track does not loosen, close the relief valve and
contact your Caterpillar dealer.

10
Safety Section
Safety Signs and Labels

Compressed Recoil Spring

Illustration 15
Illustration 12

g00681903

g00681889

This warning sign is located inside both track roller


frames.

Personal injury or death can result from a compressed recoil spring being released suddenly using incorrect disassembly procedures.
A recoil spring that is still held in compression
can result in the recoil spring being released unexpectedly with extreme force which could cause
serious injury or death.
Make sure that the correct disassembly procedure
is used, if a front track roller frame that has a crack
in the parent metal or weld connection (or a tubular section that has separated from the front of the
frame assembly) when the recoil spring is still held
in compression.

Illustration 13

g00681894

Refer to Special Instruction, SMHS8273 which


contains the disassembly procedure that must be
used to decrease the possibility of injury while
performing service on the track roller frame.

Unit Injectors

Illustration 14

g00681891

This warning sign is located inside both track roller


frames.

Illustration 16

g00467451

The warning sign for the electronic unit injector is


typically located on the valve cover base.

11
Safety Section
Safety Signs and Labels

Illustration 17

g00467452

Illustration 19

g00774176

This warning sign is located on top of the console


that is to the right of the operators seat.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
This engine uses high voltage to the unit injectors.
Disconnect the unit injector enable circuit connector
in order to prevent personal injury. Do not come into
contact with the unit injector terminals while the
engine is operating.

Hydraulic System Accumulator

Illustration 20

g00773721

Accumulator and lines under high pressure. Disconnecting or disassembly while pressurized can
result in personal injury or death. Refer to the service manual for instructions.

Illustration 18

g00774172

This warning sign is located on the front of the


console that is to the right of the operators seat.

Illustration 21

g00774178

12
Safety Section
General Hazard Information

This warning sign is located on the accumulator.


The accumulator is in the console that is located to
the right of the operators seat. The accumulator is
mounted to the right, rear ROPS post.

Illustration 22

g00773672

Illustration 24

High pressure cylinder. Rapid discharging from


disconnecting or disassembly can result in personal injury or death. See your Caterpillar dealer
for tools and instructions for relieving pressure or
charging. Precharge only with nitrogen gas.

i01426767

General Hazard Information


SMCS Code: 7000

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.

Illustration 23

g00104545

Attach a Do Not Operate warning tag or a similar


warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment. These warning tags (Special
Instruction, SEHS7332) are available from your
Caterpillar dealer.

Do not smoke when you service an air conditioner.


Also, do not smoke if refrigerant gas may be
present. Inhaling the fumes that are released from a
flame that contacts air conditioner refrigerant can
cause bodily harm or death. Inhaling gas from air
conditioner refrigerant through a lighted cigarette
can cause bodily harm or death.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care. Report all
necessary repairs.

Know the width of your equipment in order to


maintain proper clearance when you operate the
equipment near fences or near boundary obstacles.

Do not allow unauthorized personnel on the


equipment.

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.

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.

13
Safety Section
General Hazard Information

Pressure Air and Water


Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result
in personal injury.
When pressure air and/or pressure 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 below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be
below 275 kPa (40 psi).

Trapped Pressure

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 containing fluids.

Pressure can be trapped in a hydraulic system.


Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.
High pressure oil that is released can cause a hose
to whip. High pressure oil that is released can
cause oil to spray. Fluid penetration can cause
serious injury and possible death.

Refer to Special Publication, NENG2500, Tools and


Shop Products Guide for the following items:

Fluid Penetration

Obey all local regulations for the disposal of liquids.

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.

Asbestos Information

Tools that are suitable for collecting fluids and


equipment that is suitable for collecting fluids

Tools that are suitable for containing fluids and


equipment that is suitable for containing fluids

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 26

g00702022

Caterpillar equipment and replacement parts that


are shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine
Caterpillar replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.

Illustration 25

g00687600

14
Safety Section
Crushing Prevention and Cutting Prevention

Use caution. Avoid inhaling dust that might be


generated when you handle components that
contain asbestos fibers. Inhaling this dust can
be hazardous to your health. The components
that may contain asbestos fibers are brake pads,
brake bands, lining material, clutch plates, and
some gaskets. The asbestos that is used in these
components is usually bound in a resin or sealed in
some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.

Dispose of Waste Properly

If dust that may contain asbestos is present, there


are several guidelines that should be followed:

Never use compressed air for cleaning.


g00706404

Avoid brushing materials that contain asbestos.

Illustration 27

Avoid grinding materials that contain asbestos.

Improperly disposing of waste can threaten the


environment. Potentially harmful fluids should be
disposed of according to local regulations.

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.

Always use leakproof containers when you drain


fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01359664

Use exhaust ventilation on permanent machining


jobs.

Wear an approved respirator if there is no other

Crushing Prevention and


Cutting Prevention

way to control the dust.


SMCS Code: 7000

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.

Support the equipment properly before you perform


any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold
up the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
Do not work beneath the cab of the machine unless
the cab is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while
the engine is running.
Never jump across the starter solenoid terminals
in order to start the engine. Unexpected machine
movement could result.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.

15
Safety Section
Burn Prevention

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.

Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow
the standard procedure in this manual in order to
remove the hydraulic tank filler cap.

Batteries
Electrolyte is an acid. Electrolyte can cause
personal injury. Do not allow electrolyte to contact
the skin or the eyes. Always wear protective glasses
for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is
recommended.

i01329099

Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in
the air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings or related items are
disconnected.

i01359795

Fire Prevention and Explosion


Prevention
SMCS Code: 7000

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam
can cause severe burns. Allow cooling system
components to cool before the cooling system is
drained.
Check the coolant level only after the engine has
been stopped.
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.

Illustration 28

g00704000

All fuels, most lubricants, and some coolant mixtures


are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
Remove all flammable materials such as fuel, oil,
and debris from the machine. Do not allow any
flammable materials to accumulate on the machine.

16
Safety Section
Fire Prevention and Explosion Prevention

Store fuels and lubricants in properly marked


containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.

Use caution when you are refueling a machine. Do


not smoke while you are refueling a machine. Do
not refuel a machine near open flames or sparks.
Always stop the engine before refueling. Fill the fuel
tank outdoors.

Do not operate the machine near any flame.


Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.
Do not weld on lines or on tanks that contain
flammable fluids. Do not flame cut lines or tanks
that contain flammable fluid. Clean any such lines
or tanks thoroughly with a nonflammable solvent
prior to welding or flame cutting.
Check all electrical wires daily. Repair any wires that
are loose or frayed before you operate the machine.
Clean all electrical connections and tighten all
electrical connections.
Dust that is generated from repairing nonmetallic
hoods or nonmetallic fenders can be flammable
and/or explosive. Repair such components in a well
ventilated area away from open flames or sparks.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and the hoses must have adequate
support and secure clamps. Tighten all connections
to the recommended torque. Leaks can cause fires.

Illustration 30

g00704135

Gases from a battery can explode. Keep any open


flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause
an explosion.

Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Ether
Illustration 29

g00704059

Ether is flammable and poisonous.


Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while
you are using an ether spray.

17
Safety Section
Track Information

Do not store ether cylinders in living areas or in the


operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49 C (120 F). Keep ether cylinders away
from open flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the machine
is equipped with a thermal starting aid for cold
weather starting.

Grease or oil under high pressure coming out of


the relief valve can penetrate the body causing
injury or death. Do not watch the relief valve to
see if grease or oil is escaping. Watch the track
or track adjustment cylinder to see if the track is
being loosened.
The pins and bushings in a dry track pin joint
can become very hot. It is possible to burn the
fingers if there is more than brief contact with these
components.
i01122596

Lines, Tubes and Hoses


Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not
use your bare hand to check for leaks. Use a
board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Replace the parts if any of the following conditions
are present:

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:

Mount the machine.


Dismount the machine.
If you are in the operators station during an
electrical storm, stay in the operators station. If you
are on the ground during an electrical storm, stay
away from the vicinity of the machine.

End fittings are damaged or leaking.


i01411864

Outer coverings are chafed or cut.

Mounting and Dismounting

Wires are exposed.

SMCS Code: 7000

Outer coverings are ballooning.


Flexible part of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During machine operation,
this will help to prevent vibration, rubbing against
other parts, and excessive heat.
i01329108

Track Information
SMCS Code: 4170; 7000
Track adjusting systems use either grease or oil
under high pressure to keep the track under tension.

Illustration 31

g00037860

Mount the machine and dismount the machine


only at locations that have steps and/or handholds.
Before you mount the machine, clean the steps and
the handholds. Inspect the steps and handholds.
Make any necessary repairs.

18
Safety Section
Before Starting Engine

Face the machine whenever you mount the machine


and whenever you dismount the machine.

i01492207

Engine Starting

Maintain a three-point contact with the steps and


with the handholds.

SMCS Code: 1000; 7000

Note: Three-point contact can be two feet and one


hand. Three-point contact can also be one foot and
two hands.

If a warning tag is attached to the start switch or


attached to the controls, do not start the engine.
Also, do not move any controls.

Never mount a moving machine. Never dismount a


moving machine. Never jump off the machine.

Move all hydraulic controls to the HOLD position


before starting the engine. Move the transmission
control to NEUTRAL position.

Do not carry tools or supplies when you mount the


machine or when you dismount the machine. Use a
hand line to raise and lower tools or supplies.

Engage the parking brake switch.

Do not use any controls as handholds when you


enter the operator compartment or when you exit
the operator compartment.

Diesel engine exhaust contains products of


combustion. These products can be harmful to your
health. Always start the engine and always operate
the engine in a well ventilated area. If you are in an
enclosed area, vent the exhaust to the outside.

Alternate Exit
i01370348

Machines that are equipped with cabs may have


alternate exits. For additional information on
machines that are equipped with alternate exits,
see Operation and Maintenance Manual, Alternate
Exit.

Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
area.

i00037733

Before Starting Engine

Remove all obstacles from the path of the machine.


Beware of hazards such as wires, ditches, etc.

SMCS Code: 1000; 7000

Be sure that all windows are clean. Secure the


doors and the windows in either the open position
or the shut position.

Start the engine only from the operators


compartment. Do not short across the battery
terminals and do not short across the batteries.
Bypassing the engine neutral start system can
damage the electrical system.
Inspect the condition of the seat belt and mounting
hardware. Replace any damaged parts or worn
parts. Regardless of appearance, replace the
seat belt after three years of use. Do not use an
extension for a seat belt on a retractable seat belt.
Adjust the seat so that full pedal travel can be
achieved. Make sure that the operators back is
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 lights are working
properly. Before you start the engine or before
you move the machine, make sure that no one is
working on the machine, working underneath the
machine or working close to the machine. Make
sure that the area is free of personnel.

Adjust the rearview mirrors (if equipped) for best


vision close to the machine. Make sure that the
machine horn, the backup alarm (if equipped) and
all other warning devices are working properly.
Reference: Refer to Operation and Maintenance
Manual, Walk-Around Inspection in this manual.
Fasten the seat belt securely.
i01390839

Operation
SMCS Code: 7000
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate
the machine. Only operate the controls while the
engine is running. On machines that are disabled,
the controls may be used when the engine is not
running.

19
Safety Section
Parking

Check for proper operation of all controls and


protective devices while you operate the machine
slowly in an open area.
Before moving the machine, the operator must
ensure that no one will be endangered.

Always keep the Rollover Protective Structure


(ROPS) installed during machine operation.
i01492258

Parking

Do not allow riders on the machine unless the


machine has the following equipment:

SMCS Code: 7000

additional seat

Park on a level surface. If you must park on a grade,


use blocks to prevent the machine from rolling.

additional seat belt


Rollover Protective Structure (ROPS)
Report any repairs that are needed and noted
during operation.

Apply the service brake in order to stop the


machine. Move the transmission control to
NEUTRAL position and the speed control to LOW
IDLE position. Engage the parking brake switch.
Lower all attachments to the ground.

Carry attachments close to the ground,


approximately 40 cm (15 inches) above ground
level. Do not go close to the edge of a cliff, an
excavation, or an overhang.

Stop the engine.

If the machine begins to sideslip, perform the


following procedure:

Turn the key for the battery disconnect switch to the


OFF position. Remove the key when you exit the
machine for an extended period of time.

Discard the load.


Turn the machine downhill.

Turn the engine start switch key to OFF position


and remove the key.

Turning the battery disconnect switch to the OFF


position will provide the following benefits:

Be careful to avoid any condition which could lead


to tipping. Tipping can occur when you work on
hills, banks and slopes. Also, tipping can occur
when you cross ditches, ridges or other unexpected
obstructions.

Prevent battery discharge that is caused by a

Whenever it is possible, operate the machine up the


slopes and down the slopes. Avoid operating the
machine across the slope, when possible.

Prevent battery discharge that is caused by

Keep the machine under control. Do not overload


the machine beyond capacity.
Towing devices and eyes that are not part of
machine must be adequate.
Connect trailing equipment to a drawbar or to a
hitch only.
Never straddle a wire cable or allow other personnel
to straddle a wire cable.
When you maneuver to connect the equipment,
make sure that no personnel are between the
machine and trailing equipment. Block the hitch
of the trailing equipment in order to align the
equipment with the drawbar.
Know the maximum dimensions of your machine.

battery short circuit.

Prevent battery discharge that is caused by some


of the components.
vandalism.
i01329161

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.

20
Safety Section
Sound Information and Vibration Information

i01273543

Sound Information and


Vibration Information
SMCS Code: 7000
The operator sound exposure Leq (equivalent
sound pressure level) measured according to the
work cycle procedures specified in ANSI/SAE
J1166May90 is 83 dB(A), for the cab offered by
Caterpillar, when properly installed and maintained
and tested with the doors and windows closed.
The operator sound pressure level measured
according to the procedures specified in SAE
J919Jun86 is 83 dB(A), for the cab offered by
Caterpillar, when properly installed and maintained
and tested with the doors and windows closed and
with the machine in middle gear range and moving.
The exterior sound pressure level for the standard
machine measured at a distance of 15 m (49.2 ft)
according to the test procedures specified in SAE
J88Jun86, with the machine in middle gear range
and moving, is 83 dB(A).

Sound Performance for Machines


Offered in European Union
Countries and in Countries that
Adopt the EU Directives
The operator sound pressure level is 81 dB(A)
measured according to dynamic test procedures
and conditions specified in ISO 6396 or
95/27/EC.
As manufactured by Caterpillar, this machines
exterior sound power level meets the criteria
specified in the European Directives noted on the
certificate of conformance and the accompanying
labels.

Vibration Level
The hands and arms are exposed to a weighted root
mean square acceleration that is less than 2.5 m/s2.
The whole body is exposed to a weighted root
mean square acceleration that is less than 0.5 m/s2.
Measurements are obtained on a representative
machine using the procedures in the following
standards:

ISO 2631/1
ISO 5349

SAE J1166
i01491726

Guards
(Operator Protection)
SMCS Code: 7150
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.
A daily inspection of the guards is required in order
to check for structures that are bent, cracked or
loose. Never operate a machine with a damaged
structure.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are described in the
Operation and Maintenance Manual, Operating
Techniques information.

Rollover Protective Structure


(ROPS), Falling Object Protective
Structure (FOPS) or Tip Over
Protection Structure (TOPS)
The ROPS/FOPS Structure on your machine is
specifically designed, tested and certified for that
machine. Any alteration or any modification to the
ROPS/FOPS Structure could weaken the structure.
This places the operator into an unprotected
environment. Modifications or attachments that
cause the machine to exceed the weight that is
stamped on the certification plate also place the
operator into an unprotected environment. Excessive
weight may inhibit the brake performance, the
steering performance and the ROPS. The protection
that is offered by the ROPS/FOPS Structure will be
impaired if the ROPS/FOPS Structure has structural
damage. Damage to the structure can be caused
by an overturn, a falling object, a collision, etc.
Do not mount items (fire extinguishers, first aid
kits, work lights, etc) by welding brackets to the
ROPS/FOPS 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.

21
Safety Section
Operator Station

The Tip Over Protection Structure (TOPS) is


another type of guard that is used on some smaller
machines. This structure protects the operator in
the event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.

Flying Object or Falling Object


Guard (If Equipped)
Logging, demolition and other specific applications
require special flying or falling operator protection.
It is recommended that safety glasses be worn in
addition to using the flying object or falling object
guard.
A flying object guard needs to be installed when
a work tool that creates flying objects is used.
Mesh front guards that are approved by Caterpillar
are available for machines with a cab or an open
canopy. On machines that are equipped with cabs,
the windshield should also be closed.
When you perform demolition applications that are
above the top of the cab or you perform logging
applications, Caterpillar recommends the installation
of a falling object guard structure. The falling object
guard structure protects the front of the structure
and the top of the structure.
Additional guards may be required for specific
applications or work tools. An example of the
additional guards is a polycarbonate window
that may have a front screen cover or a guard.
The 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.
i01334657

Operator Station
SMCS Code: 7000; 7301
This Caterpillar machine is equipped with a factory
installed cab that conforms to industry standards.
The standards specify the clearance that is required
in the cab for the operator. This machine complies
with one or more of the following standards:

SAE J154
ISO 3411
EN 474-1
EN 23411

Any modifications to the inside of the cab should


not project into this defined space. The addition of
a radio, fire extinguisher, and other equipment must
be installed so that the defined space is maintained.
Any item that is brought into the cab should not
project into this defined space. A lunch box or other
loose items must be secured. Objects must not
pose an impact hazard in rough terrain or in the
event of a machine rollover.

You might also like