SAFETY.CAT.

COM™

R1600
LOAD HAUL DUMP
Machine Safety

Excerpted from Operation & Maintenance Manual ((SEBU7327-01)

© 2007 Caterpillar ®
All Rights Reserved
 i01658146

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.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
6
Safety Section
Safety Signs and Labels

Safety Section
i01829284

Safety Signs and Labels

SMCS Code: 7000; 7405

There are several specific safety 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 safety
signs.
g00891950
Make sure that all of the safety signs are legible. Illustration 3
Clean the safety signs or replace the safety signs if
you cannot read the words. Replace the illustrations
if the illustrations are not legible. When you clean
the safety signs, use a cloth, water and soap. Do Do not operate or work on this machine unless you
not use solvent, gasoline, or other harsh chemicals have read and understand the instructions and
to clean the safety signs. Solvents, gasoline, or warnings in the Operation and Maintenance Man-
harsh chemicals could loosen the adhesive that uals. Failure to follow the instructions or heed the
secures the safety sign. Loose adhesive will allow warnings could result in injury or death. Contact
the safety sign to fall. your Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
Replace any safety sign that is damaged, or
missing. If a safety sign is attached to a part that is
replaced, install a safety sign on the replacement Do Not Weld the ROPS/FOPS
part. Any Caterpillar dealer can provide new safety
signs.

Do Not Operate

g00891999
Illustration 4

This safety label is located on the right side of the

operator’s station ROPS/FOPS.
g00891937
Illustration 2

This safety label is located in the operator’s station.

 7
Safety Section
Safety Signs and Labels

g00892002 g00892055
Illustration 5 Illustration 7

Structural damage, an overturn, modification, al- No clearance for person in this area when ma-
teration, or improper repair can impair this struc- chine turns. Severe injury or death from crushing
ture’s protection capability thereby voiding this could occur. Connect steering frame lock between
certification. Do not weld on or drill holes in the front and rear frames before lifting, transporting,
structure. Consult an Elphinstone dealer to deter- or servicing machine in articulation area. Discon-
mine this structure’s limitations without voiding nect lock and secure before resuming operation.
its certification.

STIC Steering Control

Rollover and Falling Object Protective
Structure Certification
This structure, when properly installed on a machine
which is not altered to exceed the certification test
weight meets, at the time of installation, criteria
established by: C.S.A B352-1990, SAEJ231-1981,
SAEJ1040-1994, ISO 3449-1992, AS2294-1997
FOPS LEVEL II, AS2294-1997 ROPS, ISO
3471/1-1994.

No Clearance

g00892141
Illustration 8

This safety label is located on the inside of the

operator’s station door (STIC steering machines).

g00950489
Illustration 6

This safety label is located on both sides of the

machine articulating hitch.
8
Safety Section
Safety Signs and Labels

g00892146 g00892173
Illustration 9 Illustration 11

Use grab handle not STIC control when entering Use grab handle not steering wheel when entering
or leaving operator’s station. or leaving operator’s station.

Severe injury or death may be caused by crushing Severe injury or death may be caused by crushing
when machine turns when machine turns.

Wheel Steering Control Operator’s Station Access

g00892172 g00892206
Illustration 10 Illustration 12

This safety label is located on the inside of the This safety label is located on the inside of the
operator’s station door (wheel steering machines). operator’s station door (STIC steering machines).
 9
Safety Section
Safety Signs and Labels

g00892207 g00892335
Illustration 13 Illustration 15

No clearance for person in operator’s station ac- No clearance for person in this area when bucket
cess area when machine turns. Severe injury or control group lowers. Severe injury or death from
death from crushing could occur. crushing could occur.

Engage transmission/primary steering lock before Install bucket control group safety pins before ser-
leaving the operator’s station. vicing machine in this area.

Remove safety pins and secure before resuming

Bucket Control Group operation.

High Pressure Cylinder (Brake

Accumulator)

g00950500
Illustration 14

This safety label is located on both sides of the

lift arm.
g00950492
Illustration 16

This safety label is located on the brake

accumulator.
10
Safety Section
Safety Signs and Labels

This safety label is located on the front frame near

the ride control accumulator (if equipped).

g00892403
Illustration 17

g00892476
Illustration 19

High Pressure Cylinder!

Do not remove any valve, hydraulic fitting, or valve High Pressure Cylinder!
core, nor disassemble any parts until pressure
has been relieved, or personal injury may occur. Do not remove any valve, hydraulic fitting, or valve
core, nor disassemble any parts until pressure
To relieve pressure: has been relieved, or personal injury may occur.
1. Refer to the Service Manual for the correct To relieve pressure:
method of dissipating hydraulic system
pressure. 1. Refer to the Service Manual for the correct
method of dissipating hydraulic system
2. Relieve gas pressure in the accumulator pressure.
cylinder by opening the charging valve one
turn only. 2. Relieve gas pressure in the accumulator
cylinder by opening the charging valve one
Charge the cylinder with dry nitrogen gas. turn only.
See your Caterpillar dealer for tools and detailed Charge the cylinder with dry nitrogen gas.
information required for charging cylinders.
See your Caterpillar dealer for tools and detailed
information required for charging cylinders.
High Pressure Cylinder (Ride
Control)
Batteries

g00950493
Illustration 18 g00950499
Illustration 20
 11
Safety Section
Safety Signs and Labels

This safety label is located on the right side above Unit Injectors
the battery compartment.

g00950495
Illustration 22

This safety label is located on the engine valve

cover base.

g00892563
Illustration 21

IMPROPER JUMPER CABLE CONNECTIONS CAN Illustration 23 g00892579

CAUSE EXPLOSION RESULTING IN PERSONAL
INJURY.

BATTERIES MAY BE LOCATED IN SEPARATE

COMPARTMENTS. WHEN USING JUMPER CA- Electrical Shock Hazard. Unit Injector System. 90
BLES, ALWAYS CONNECT POSITIVE (+) CABLE - 120 Volts.
TO POSITIVE (+) TERMINAL OF BATTERY CON-
NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO Engine Coolant
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH STARTER NEGATIVE TER-
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL.

g00950494
Illustration 24
12
Safety Section
General Hazard Information

This safety label is located near the cooling system i01426767

pressure cap.
General Hazard Information
SMCS Code: 7000

g00104545
Illustration 26

Attach a “Do Not Operate” warning tag or a similar

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

Know the width of your equipment in order to

g00892607 maintain proper clearance when you operate the
Illustration 25
equipment near fences or near boundary obstacles.

Be aware of high voltage power lines and power

cables that are buried. If the machine comes in
PRESSURIZED SYSTEM: HOT COOLANT CAN contact with these hazards, serious injury or death
CAUSE SERIOUS BURN. TO OPEN CAP, STOP may occur from electrocution.
ENGINE, WAIT UNTIL RADIATOR IS COOL. THEN
LOOSEN CAP SLOWLY TO RELIEVE THE PRES-
SURE.

g00702020
Illustration 27

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.
 13
Safety Section
General Hazard Information

Keep the equipment free from foreign material. Trapped Pressure

Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps. Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
Secure all loose items such as lunch boxes, tools, machine movement or attachment movement. Use
and other items that are not a part of the equipment. caution if you disconnect hydraulic lines or fittings.
High pressure oil that is released can cause a hose
Know the appropriate work site hand signals and to whip. High pressure oil that is released can
the personnel that are authorized to give the hand cause oil to spray. Fluid penetration can cause
signals. Accept hand signals from one person only. serious injury and possible death.

Do not smoke when you service an air conditioner.

Also, do not smoke if refrigerant gas may be
Fluid Penetration
present. Inhaling the fumes that are released from a
Pressure can be trapped in the hydraulic circuit
flame that contacts air conditioner refrigerant can
long after the engine has been stopped. The
cause bodily harm or death. Inhaling gas from air
pressure can cause hydraulic fluid or items such
conditioner refrigerant through a lighted cigarette
as pipe plugs to escape rapidly if the pressure is
can cause bodily harm or death.
not relieved correctly.
Never put maintenance fluids into glass containers.
Do not remove any hydraulic components or parts
Drain all liquids into a suitable container.
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
Obey all local regulations for the disposal of liquids.
components or parts until pressure has been
relieved or personal injury may occur. Refer to the
Use all cleaning solutions with care. Report all
Service Manual for any procedures that are required
necessary repairs.
to relieve the hydraulic pressure.
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.

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.
g00687600
Illustration 28
When pressure air and/or pressure water is used
for cleaning, wear protective clothing, protective Always use a board or cardboard when you check
shoes, and eye protection. Eye protection includes for a leak. Leaking fluid that is under pressure can
goggles or a protective face shield. penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak
The maximum air pressure for cleaning purposes can cause severe injury. If fluid is injected into your
must be below 205 kPa (30 psi). The maximum skin, you must get treatment immediately. Seek
water pressure for cleaning purposes must be treatment from a doctor that is familiar with this type
below 275 kPa (40 psi). 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.
14
Safety Section
Crushing Prevention and Cutting Prevention

Refer to Special Publication, NENG2500, “Tools and • A vacuum cleaner that is equipped with a high
Shop Products Guide” for the following items: efficiency particulate air filter (HEPA) can also be
used.
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids • Use exhaust ventilation on permanent machining
jobs.
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids • Wear an approved respirator if there is no other
way to control the dust.
Obey all local regulations for the disposal of liquids.
• Comply with applicable rules and regulations
for the work place. In the United States, use
Asbestos Information 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

g00702022
Illustration 29

Caterpillar equipment and replacement parts that

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

Use caution. Avoid inhaling dust that might be

generated when you handle components that Illustration 30
g00706404
contain asbestos fibers. Inhaling this dust can
be hazardous to your health. The components Improperly disposing of waste can threaten the
that may contain asbestos fibers are brake pads, environment. Potentially harmful fluids should be
brake bands, lining material, clutch plates, and disposed of according to local regulations.
some gaskets. The asbestos that is used in these
components is usually bound in a resin or sealed in Always use leakproof containers when you drain
some way. Normal handling is not hazardous unless fluids. Do not pour waste onto the ground, down a
airborne dust that contains asbestos is generated. drain, or into any source of water.
If dust that may contain asbestos is present, there
are several guidelines that should be followed: i01359664

• Never use compressed air for cleaning. Crushing Prevention and

Cutting Prevention
• Avoid brushing materials that contain asbestos.
SMCS Code: 7000
• Avoid grinding materials that contain asbestos.
Support the equipment properly before you perform
• Use a wet method in order to clean up asbestos any work or maintenance beneath that equipment.
materials. 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.
 15
Safety Section
Burn Prevention

Do not work beneath the cab of the machine unless Any contact with hot coolant or with steam
the cab is properly supported. can cause severe burns. Allow cooling system
components to cool before the cooling system is
Unless you are instructed otherwise, never attempt drained.
adjustments while the machine is moving or while
the engine is running. Check the coolant level only after the engine has
been stopped.
Never jump across the starter solenoid terminals
in order to start the engine. Unexpected machine Ensure that the filler cap is cool before removing
movement could result. the filler cap. The filler cap must be cool enough
to touch with a bare hand. Remove the filler cap
Whenever there are equipment control linkages the slowly in order to relieve pressure.
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay Cooling system conditioner contains alkali. Alkali
clear of areas that may have a sudden change in can cause personal injury. Do not allow alkali to
clearance with machine movement or equipment contact the skin, the eyes, or the mouth.
movement.

Stay clear of all rotating and moving parts.

Oils
Hot oil and hot components can cause personal
If it is necessary to remove guards in order to
injury. Do not allow hot oil to contact the skin. Also,
perform maintenance, always install the guards do not allow hot components to contact the skin.
after the maintenance is performed.
Remove the hydraulic tank filler cap only after the
Keep objects away from moving fan blades. The engine has been stopped. The filler cap must be
fan blade will throw objects or cut objects.
cool enough to touch with a bare hand. Follow
the standard procedure in this manual in order to
Do not use a kinked wire cable or a frayed wire remove the hydraulic tank filler cap.
cable. Wear gloves when you handle wire cable.

When you strike a retainer pin with force, the Batteries

retainer pin can fly out. The loose retainer pin can
injure personnel. Make sure that the area is clear Electrolyte is an acid. Electrolyte can cause
of people when you strike a retainer pin. To avoid personal injury. Do not allow electrolyte to contact
injury to your eyes, wear protective glasses when the skin or the eyes. Always wear protective glasses
you strike a retainer pin. for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is
Chips or other debris can fly off an object when recommended.
you strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i01359795

i01329099
Fire Prevention and Explosion
Burn Prevention Prevention
SMCS Code: 7000
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 g00704000
to the engine contain hot coolant. Illustration 31
16
Safety Section
Fire Prevention and Explosion Prevention

All fuels, most lubricants, and some coolant mixtures

are flammable.

Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.

Remove all flammable materials such as fuel, oil,

and debris from the machine. Do not allow any
flammable materials to accumulate on the machine.

Store fuels and 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.

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 Illustration 32 g00704059
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly. Use caution when you are refueling a machine. Do
not smoke while you are refueling a machine. Do
Do not weld on lines or on tanks that contain not refuel a machine near open flames or sparks.
flammable fluids. Do not flame cut lines or tanks Always stop the engine before refueling. Fill the fuel
that contain flammable fluid. Clean any such lines tank outdoors.
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.

g00704135
Illustration 33

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.
 17
Safety Section
Fire Extinguisher Location

Improper jumper cable connections can cause • Wires are exposed.

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific • Outer coverings are ballooning.
instructions.
• Flexible part of the hoses are kinked.
Do not charge a frozen battery. This may cause
an explosion. • Outer covers have embedded armoring.

Fire Extinguisher • End fittings are displaced.

Make sure that all clamps, guards, and heat shields
Make sure that a fire extinguisher is available. Be
are installed correctly. During machine operation,
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire this will help to prevent vibration, rubbing against
other parts, and excessive heat.
extinguisher regularly. Obey the recommendations
on the instruction plate.
i01829285
Ether Fire Extinguisher Location
Ether is flammable and poisonous.
SMCS Code: 7000; 7419
Use ether in well ventilated areas. Do not smoke
Make sure that a fire extinguisher is on the machine.
while you are replacing an ether cylinder or while
Make sure that you are familiar with the operation
you are using an ether spray.
of the fire extinguisher. Inspect the fire extinguisher
and service the fire extinguisher on a regular basis.
Do not store ether cylinders in living areas or in the
Obey the recommendations on the instruction plate.
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
If equipped, know how to use the machine fire
above 49 C (120 F). Keep ether cylinders away
suppression system.
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.

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.
g00950479
Illustration 34
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for The recommended place to mount a fire extinguisher
repair or for replacement parts. on a machine is on the left side of the radiator
guard.
Check lines, tubes and hoses carefully. Do not
use your bare hand to check for leaks. Use a Do not weld the ROPS/FOPS to install the fire
board or cardboard to check for leaks. Tighten all extinguisher. Also, do not drill holes in the
connections to the recommended torque. ROPS/FOPS to mount the fire extinguisher.

Replace the parts if any of the following conditions

are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.
18
Safety Section
Tire Information

Do not use water or calcium as a ballast for the

tires. Dry nitrogen gas is recommended for inflation
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.

Nitrogen inflated tires reduce the potential of a

tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation of
the rubber, deterioration of rubber, and corrosion
of rim components.

To avoid overinflation, proper nitrogen inflation

equipment and training in the usage of the
g00950480
equipment are necessary. A tire blowout or a rim
Illustration 35 failure can result from improper equipment or from
misused equipment.
If more than one fire extinguisher is required,
the recommended place to mount a second fire When you inflate a tire, stand behind the tread and
extinguisher is on the right side of the front frame use a self-attaching chuck.
behind the fender.
Servicing tires and rims can be dangerous. Only
i01557411 trained personnel that use proper tools and proper
procedures should perform this maintenance. If
Tire Information correct procedures are not used for servicing tires
and rims, the assemblies could burst with explosive
SMCS Code: 7000 force. This explosive force can cause serious
personal injury or death. Carefully obey the specific
Explosions of air inflated tires have resulted from instructions from your tire dealer.
heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated
i01122596
by welding, by heating rim components, by external
fire, or by excessive use of brakes. Electrical Storm Injury
A tire explosion is much more violent than a Prevention
blowout. The explosion can propel the tire, the rim
components, and the axle components as far as SMCS Code: 7000
500 m (1500 ft) or more from the machine. Both the
force of the explosion and the flying debris can When lightning is striking in the vicinity of the
cause property damage, personal injury, or death. machine, the operator should never attempt the
following procedures:

• Mount the machine.

• 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.

g00337832
Illustration 36
(A) At least 15 m (50 ft)
(B) At least 500 m (1500 ft)

Do not approach a warm tire. Maintain a minimum

distance, as shown. Stay outside the shaded area
in Illustration 36.
 19
Safety Section
Mounting and Dismounting

i01411864 i01829290

Mounting and Dismounting Before Starting Engine

SMCS Code: 7000 SMCS Code: 1000; 7000

g00037860 g00950476
Illustration 37 Illustration 38

Mount the machine and dismount the machine Make sure the steering frame lock is stored in the
only at locations that have steps and/or handholds. unlocked position as shown. The steering frame
Before you mount the machine, clean the steps and lock must be removed to steer the machine.
the handholds. Inspect the steps and handholds.
Make any necessary repairs. Note: Start the engine only from the operator’s
station. Never short across the starter terminals or
Face the machine whenever you mount the machine across the batteries. Shorting could bypass the
and whenever you dismount the machine. engine neutral start system. Shorting could also
damage the electrical system.
Maintain a three-point contact with the steps and
with the handholds. Before you mount the machine, perform a
walk around inspection. Look for any damaged
Note: Three-point contact can be two feet and one components and leaks. Report discrepancies and
hand. Three-point contact can also be one foot and make any necessary repairs before operating the
two hands. machine.

Never mount a moving machine. Never dismount a Reference: For more information, refer to the
moving machine. Never jump off the machine. Operation and Maintenance Manual, “Walk Around
Inspection” for the machine that is being serviced.
Do not carry tools or supplies when you mount the
machine or when you dismount the machine. Use a When you enter the operator’s station, inspect the
hand line to raise and lower tools or supplies. condition of the seat belt and the condition of the
mounting hardware. Replace any damaged parts
Do not use any controls as handholds when you and any worn parts. Regardless of appearance,
enter the operator compartment or when you exit replace the seat belt after three years of use. Do not
the operator compartment. use a seat belt extension on a retractable seat belt.

Alternate Exit Adjust the seat so that full pedal travel can be
achieved when the operator’s back is against the
Machines that are equipped with cabs may have back of the seat.
alternate exits. For additional information on
machines that are equipped with alternate exits, Make sure that the machine is equipped with
see Operation and Maintenance Manual, “Alternate a lighting system that is adequate for the job
Exit”. conditions. Make sure that all lights are working
properly.

Before you start the engine or before you move the

machine, make sure that no one is on the machine,
underneath the machine, or around the machine.
Make sure that there are no personnel in the area.
20
Safety Section
Engine Starting

i01740624 Make sure that the horn, the backup alarm, the
action alarm, the dash indicator lamps and all other
Engine Starting warning devices are working properly.
SMCS Code: 1000; 7000 Fasten the seat belt securely.

i01740813

Operation
SMCS Code: 7000

Only operate the machine while you are sitting in

a seat. The seat belt must be fastened while you
operate the machine. Only operate the controls
while the engine is running.

While you operate the machine slowly in an open

area, check for proper operation of all controls and
Illustration 39
g00104545 all protective devices.

If a warning tag is attached to the engine start Before you move the machine, make sure that no
switch or to the machine controls, do not start the one will be endangered.
engine. Also, do not move any machine controls.
Do not allow riders on the machine unless the
Move all hydraulic controls to the HOLD position machine has the following equipment:
before you start the engine.
• Additional seat.
Move the transmission control to the NEUTRAL
position. • Additional seat belt.
Move the steering and transmission lock control • Falling Object Protective Structure (FOPS).
(STIC steering machines) or the transmission
neutral lock control (wheel steering machines) to Note any needed repairs during machine operation.
the LOCKED position. Report any needed repairs.

Engage the parking brake. Carry work tools at approximately 400 mm

(15 inches) above ground level.
Diesel engine exhaust contains products of
combustion which can be harmful to your health. Do not go close to the edge of a cliff, an excavation,
Always operate the engine in a well ventilated area. or an overhang.
If you are in an enclosed area, vent the exhaust to
the outside. Avoid operating the machine across the slope.
When possible, operate the machine up the slopes
and down the slopes. If the machine begins to
i01740680 sideslip on a downgrade, immediately remove the
load and turn the machine downhill.
Before Operation
Avoid any conditions that can lead to tipping the
SMCS Code: 7000 machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine
Make sure that there are no personnel on the can tip when you cross ditches, ridges or other
machine or in the area around the machine. unexpected obstructions.
Clear all obstacles from the path of the machine. Maintain control of the machine. Do not overload
Beware of hazards such as wires, ditches, etc. the machine beyond the machine capacity.
Make sure that all windows are clean. Secure the Make sure that the hitches and the towing devices
door in the closed position. are adequate. Only connect trailing equipment to
a drawbar or to a hitch.
 21
Safety Section
Engine Stopping

Never straddle a wire cable. Never allow other Park the machine on a level surface. If you must
personnel to straddle a wire cable. park on a grade, block the machine’s wheels.

Before you maneuver the machine, make sure Apply the service brake in order to stop the
that no personnel are between the machine and machine. Move the transmission control to the
the trailing equipment. Block up the hitch of the NEUTRAL position.
trailing equipment in order to align the hitch with
the drawbar. Maneuver the machine. Connect the Engage the parking brake.
machine to the trailing equipment.
Lower all work tools to the ground. Activate any
Know the maximum dimensions of your machine. control locks.

Always keep the Rollover Protective Structure Stop the engine.

(ROPS) or the Falling Object Protective Structure
(FOPS) installed during machine operation. Turn the engine start switch to the OFF position.

Always anticipate the grade and select the proper Turn the battery disconnect switch to the OFF
gear range for the grade. position and remove the engine start switch key.
Remove the disconnect switch key if you do not
Obey all road signs. operate the machine for an extended period of
time. This will prevent drainage of the battery. A
A signalman should be present, when you move the battery short circuit, any current draw from certain
machine in a building or out of a building. components, and vandalism can cause drainage
of the battery.
i01353516
i01329161
Engine Stopping
Equipment Lowering with
SMCS Code: 1000; 7000
Engine Stopped
Do not stop the engine immediately after the
SMCS Code: 7000
machine has been operated under load. This can
cause overheating and accelerated wear of engine
Before lowering any equipment with the engine
components.
stopped, clear the area around the equipment of
all personnel. The procedure to use will vary with
After the machine is parked and the parking brake
the type of equipment to be lowered. Keep in mind
is engaged, allow the engine to run for five minutes
most systems use a high pressure fluid or air to
before shutdown. This allows hot areas of the
raise or lower equipment. The procedure will cause
engine to cool gradually.
high pressure air, hydraulic, or some other media to
be released in order to lower the equipment. Wear
i01829355 appropriate personal protective equipment and
follow the established procedure in the Operation
Parking and Maintenance Manual, “Equipment Lowering
with Engine Stopped” in the Operation Section of
SMCS Code: 7000 the manual.

i01829370

Sound Information and

Vibration Information
SMCS Code: 7000

The operator sound pressure level for an enclosed

cab is 83 dB(A) measured according to the test
procedures and conditions specified in “ISO 6394”
or “98/37/EC”.

g00950487
Illustration 40
22
Safety Section
Operator Station

Vibration Level A daily inspection of the guards is required in order

to check for structures that are bent, cracked or
The hands and arms are exposed to a weighted root loose. Never operate a machine with a damaged
mean square acceleration that is less than 1.7 m/s2. structure.

The whole body is exposed to a maximum weighted The operator becomes exposed to a hazardous
root mean square acceleration of 1.3 m/s2. situation if the machine is used improperly or if poor
operating techniques are used. This situation can
Measurements are obtained on a representative occur even though a machine is equipped with an
machine using the procedures in the following appropriate protective guard. Follow the established
standards: operating procedures that are recommended for
your machine.
• “ISO 2631/1”
Rollover Protective Structure
• “ISO 5349”
(ROPS), Falling Object Protective
i01741439 Structure (FOPS) or Tip Over
Operator Station Protection Structure (TOPS)
The ROPS/FOPS Structure (if equipped) on your
SMCS Code: 7000; 7301; 7325 machine is specifically designed, tested and
certified for that machine. Excavators are not
This Caterpillar machine is equipped with a factory equipped with ROPS structures. Any alteration or
installed operator station that conforms to industry any modification to the ROPS/FOPS Structure could
standards. The standards specify the clearance that weaken the structure. This places the operator
is required in the operator station for the operator. into an unprotected environment. Modifications or
This machine complies with one or more of the attachments that cause the machine to exceed
following standards: the weight that is stamped on the certification
plate also place the operator into an unprotected
• “ISO 3411” environment. Excessive weight may inhibit the
brake performance, the steering performance
• “EN 474-1” and the ROPS. The protection that is offered by
the ROPS/FOPS Structure will be impaired if the
• “EN 23411” ROPS/FOPS Structure has structural damage.
Damage to the structure can be caused by an
Any modifications to the inside of the operator overturn, a falling object, a collision, etc.
station should not project into the defined space.
The addition of a radio, fire extinguisher, and other Do not mount items (fire extinguishers, first aid
equipment must be installed so that the defined kits, work lights, etc) by welding brackets to the
space is maintained. Any item that is brought into ROPS/FOPS Structure or by drilling holes in the
the operator station should not project into the ROPS/FOPS Structure. Welding brackets or drilling
defined space. A lunch box or other loose items holes in the ROPS/FOPS Structures can weaken
must be secured. Objects must not pose an impact the structures. Consult your Caterpillar dealer for
hazard in rough terrain or in the event of a machine mounting guidelines.
rollover.
The Tip Over Protection Structure (TOPS) is another
i01836198 type of guard that is used on mini-hydraulic
excavators. This structure protects the operator in
Guards the event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
(Operator Protection) the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.
SMCS Code: 7000; 7150; 7325

There are different types of guards that are used to Other Guards (If Equipped)
protect the operator. The machine and the machine
application determines the type of guard that should Protection from flying objects and/or falling objects
be used. is required for special applications. Logging
applications and demolition applications are two
examples that require special protection.
 23
Safety Section
Steering Frame Lock

A front guard needs to be installed when a work

tool that creates flying objects is used. Mesh
front guards that are approved by Caterpillar or
polycarbonate front guards that are approved by
Caterpillar are available for machines with a cab or
an open canopy. On machines that are equipped
with cabs, the windshield should also be closed.
Safety glasses are recommended when flying
hazards exist for machines with cabs and machines
with open canopies.

If the work material extends above the cab, top

guards and front guards should be used. Typical
examples of this type of application are listed below:

• Demolition applications
• Rock quarries
• 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.

i01741550

Steering Frame Lock

SMCS Code: 7000; 7506

Install the steering frame lock when the machine

is being lifted and when the machine is being
transported. Also install the steering frame lock
if you are performing service work near the
articulating hitch.

Remove the steering frame lock before the machine

is operated.

Reference: For more detailed information about

the steering frame lock, refer to Operation and
Maintenance Manual, “Steering Frame Lock” in the
Operation Section for the machine that is being
serviced.