416E, 422E, and 428E Backhoe Loaders - Safety
Contents
1. Illustration 2 90 1799213 1 Do Not Operate 6 Crushing Hazard 12 Quick Coupler Crushing Hazard 2 No Ether in Air Inlet 7 No Exit 13 Crushing Hazard 3 Jump Starting 8 Brace for the Lift Cylinder 14 Product Link 4 High Pressure Accumulator 9 Pressurized System 5 Rollover Protective Structure Falling 10 High Cylinder Pressure Object Protective Structure 11 Seat Belt 8 Safety Section Safety Messages SEBU7970 12 Do Not Operate 1 This safety message is located under the engine start switch 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 injury or death Contact your Cat dealer for replacement manuals Proper care is your responsibility No Ether In Air Inlet 2 This safety message is located on the air filter cover E g01372254 A WARNING If equipped with an air inlet heater AIH for cold weather starting do not use aerosal types of start ing aids such as ether Such use could result in an explosion and personal injury Proper Connections for Jump Start Cables 3 This safety message is located on the inside of the door for the battery compartment g01370909 Explosion Hazard Improper jumper cable connec tions can cause an explosio2. e Fraying e Abrasion e Cracking 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 on 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 cli
3. Then loosen cap slowly to relieve the pressure SEBU7970 12 11 Safety Section Safety Messages High Cylinder Pressure 10 This safety message is located on both sides of the boom near the connection with the stick g01407379 High Pressure Cylinder Failure to read and fol low these instructions can cause rapidly discharg ing gas and or hydraulic fluid which can result in death personal injury and property damage Seat Belt 11 This safety message is located under the engine start switch 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 seat belt during machine opera tion may result in serious injury or death Quick Coupler 12 This safety message is located in the front of the cab on the right side 901411137 CRUSH INJURY COULD CAUSE SERIOUS IN JURY OR DEATH ALWAYS CONFIRM QUICK COUPLER PINS ARE ENGAGED REFER TO THE OPERATION AND MAINTENANCE MANUAL 12 Safety Section Safety Messages SEBU7970 12 Crush Hazard 13 If Equipped This safety message is located on the sides of the coupler on the backhoe LL g01803414 A crushing hazard exists when the boom sections are being retracted or extended Stay clear of the boom when the machine is in operation Failure to stay clear of the boom when the machine is oper a
4. 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 Typical Operating Vibration Levels Scenario Factors Machine Type Activity X axis Y axis Z axis X axis Y axis Z axis Backhoe Loader excavating 0 28 0 26 0 20 0 09 0 16 0 06 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 publ
5. 10 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 e Never use compressed air for cleaning e Avoid brushing materials that contain asbestos e Avoid grinding materials that contain asbestos e Use a wet method in order to clean up asbestos materials e A vacuum cleaner that is equipped with a high efficiency particulate air filter HEPA can also be used e Use exhaust ventilation on permanent machining jobs Wear an approved respirator if there
6. Make sure the bucket pins are con nected properly Data Privacy 3 This message is located in the cab 14 Safety Section General Hazard Information SEBU7970 12 K Illustration 6 g01418953 104010649 General Hazard Information SMCS Code 7000 Illustration 7 g00104545 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 awaa 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 obstacles 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 3D BES Illustration 8 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 c
7. 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 103571438 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 SEBU7970 12 23 Safety Section Visibility Information Move all hydraulic controls to the HOLD position before you start the engine Move the transmission direction control lever to the NEUTRAL position Engage the parking brake Diesel engine exhaust contains products of combustion which can be harmful to your health Always 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 Briefly sound the horn before you start the engine 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
8. 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 Never use the work tool for a work platform 101439117 Parking SMCS Code 7000 Park on a level surface If you must park on a grade chock the machine Apply the service brake in order to stop the machine Move the transmission control lever to the NEUTRAL position Move the speed control lever to the LOW IDLE position Engage the parking brake Engage the transmission neutral lock Lower all work tools to the ground 26 Safety Section Equipment Lowering with Engine Stopped SEBU7970 12 Stop the engine Turn the engine start switch key to the OFF position for 4 seconds Turn the engine start switch key back to the ON position Press the hydraulic shutoff switch to the UNLOCKED position Move the hydraulic control levers back and forth in order to relieve hydraulic pressure Move the hydraulic control levers to the HOLD position Turn the engine start switch to OFF position and remove the key 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
9. large area Remember that nearly all of the fluids on the machine are flammable including coolant and oils Additionally plastics rubbers fabrics and resins in fiberglass panels are also flammable i00980571 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 extinguisher Obey the recommendations on the instruction plate Mount the fire extinguisher in the battery box Do not weld the ROPS in order to install the fire extinguisher Also do not drill holes in the ROPS in order to mount the fire extinguisher on the ROPS 104160129 Tire Information SMCS Code 7000 Explosions of air inflated tires have resulted from heat induced gas combustion inside the tires Explosions can be caused by heat that is generated by welding by heating rim components by external fire or by excessive use of brakes A tire explosion is much more violent than a blowout The explosion can propel the tire the rim components and the axle components from the machine Stay out of the trajectory path Both the force of the explosion and the flying debris can cause property damage personal injury or death 22 Safety Section Electrical Storm Injury Prevention SEBU7970 12 Illustration 16 g02166933 Typical example of tire is shown Do not approach a h
10. used for servicing tires and rims the assemblies could burst with explosive force This explosive force can cause serious personal injury or death Carefully obey the specific instructions from your tire dealer 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 i00771840 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 Before you start the
11. 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 103894906 Sound Information and Vibration Information SMCS Code 7000 Sound Level Information The operator Equivalent Sound Pressure Level Leq is 80 dB A when ANSI SAE J1166 OCT 98 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 properly maintained or when the doors and windows are open for extended periods or in a noisy environment The average exterior sound pressure level is 80 dB A when the SAE J88Apr95 Constant Speed Moving Test procedure is used to measure the value for the standard machine The measurement was conducted under the following conditions distanc
12. 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 e Safety instructions e Controlled patterns of machine movement and vehicle movement e Workers that direct traffic to move when it is safe e Restricted areas e Operator training e Warning symbols or warning signs on machines or on vehicles e A system of communication e 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 103164423 Restricted Visibility SMCS Code 7000 The operator has areas near this machine that have restrictions in visibility Job site organization will need to be used in order to minimize the hazards of restricted visibility For more information regardi
13. B Make sure that all windows are clean Secure the doors in the open position or in the shut position Secure the windows in the open position or in the shut position For the best visibility of the area that is close to the machine adjust the rearview mirrors if equipped Make sure that the machine horn the backup alarm if equipped and all other warning devices are working properly Fasten the seat belt securely 104632311 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 all protective devices Before you move the machine make sure that no one will be endangered Do not allow riders on the machine unless the machine has an additional seat with a seat belt The rider must be seated and the seat belt must be fastened Never use the work tool for a work platform Note any needed repairs during machine operation Report any needed repairs Carry work tools at approximately 40 cm 15 inches above ground level Do not go close to the edge of a cliff an excavation or an overhang Avoid operating the machine across the slope When possible operate the machine up the slopes and down the slopes If the machine begins to sideslip on a downgrade immediately r
14. SAFETY Operation and Maintenance Manual Excerpt 2010 Caterpillar All Rights Reserved CATERPILLAR CATERPILLAR Set L Operation and Maintenance Manual 416E 422E and 428E Backhoe Loaders 1 U SNET gies chine SAFETY CAT COM 6 Safety Section Safety Messages SEBU7970 12 Safety Section 104571236 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 that 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 SEBU7970 12 7 Safety Section Safety Messages
15. at are attached to the engine or pumps If possible turn the battery disconnect switch to the OFF position Disconnecting the battery will remove the ignition source in the event of an electrical short Disconnecting the battery will eliminate a second ignition source if electrical wiring is damaged by the fire resulting in a short circuit Notify emergency personnel of the fire and your location If your machine is equipped with a fire suppression system follow the manufacturers procedure for activating the system Note Fire suppression systems need to be regularly inspected by qualified personnel You must be trained to operate the fire suppression system Use the on board fire extinguisher and use the following procedure 1 Pull the pin 2 Aim the extinguisher or nozzle at the base of the fire 3 Squeeze the handle and release the extinguishing agent 4 Sweep the extinguisher from side to side across the base of the fire until the fire is out Remember if you are unable to do anything else shut off the machine before exiting By shutting off the machine fuels will not continue to be pumped into the fire If the fire grows out of control be aware of the following risks Tires on wheeled machines pose a risk of explosion as tires burn Hot shrapnel and debris can be thrown great distances in an explosion Tanks accumulators hoses and fittings can rupture in a fire spraying fuels and shrapnel over a
16. e 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 80 dB A when ISO 6396 1992 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 Backhoe 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 vibration level for backhoe loaders Note Vibration levels are influenced by many different parameters Many items are listed below e Operator training behavior mode and stress SEBU7970 12 27 Safety Section Sound Information and Vibration Information e Job site organization preparation environment weather and material e Machine type
17. ed 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 can cause oil to spray Fluid penetration can cause serious injury and possible death 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 pers
18. emove the load and turn the machine downhill SEBU7970 12 25 Safety Section Engine Stopping Avoid any conditions that can lead to tipping the machine The machine can tip when you work on hills on banks and on slopes Also the machine can tip when you cross ditches ridges or other unexpected obstructions Maintain control of the machine Do not overload the machine beyond the machine capacity Never straddle a wire cable Never allow other personnel to straddle a wire cable Know the maximum dimensions of your machine Always keep the Rollover Protective Structure ROPS installed during machine operation 102624835 Engine Stopping SMCS Code 1000 7000 Do not stop the engine immediately after the machine has been operated under load This can cause overheating and accelerated wear of engine components After the machine is parked and the parking brake is engaged allow the engine to run for two minutes before shutdown This allows hot areas of the engine to cool gradually 104159629 Work Tools SMCS Code 6700 Only use work tools that are recommended by Caterpillar for use on Cat machines Use of work tools including buckets which are outside of Caterpillar s recommendations or specifications for weight dimensions flows pressures and so on may result in less than optimal vehicle performance including but not limited to reductions in production stability reliability and component durabil
19. erate 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 Store fuels and lubricants in properly 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 13 g00704059 Use caution when you are fueling a machine Do not smoke while you are fueling a machine Do not fuel a machine near o
20. exible parts of the hoses are kinked e Outer covers have exposed 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 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 engine 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 no
21. ication 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 EM5 The seat has a transmissibility factor of SEAT lt 0 7 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 68 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 following 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 condit
22. ion a Remove any large rocks or obstacles b Fill any ditches and holes 28 Safety Section Sound Information and Vibration Information SEBU7970 12 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 compact backhoe loaders c If no ride control system is available reduce speed in order to prevent bounce d Haul the machines between workplaces 9 Less 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 i
23. 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 11 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 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 SEBU7970 12 17 Safety Section Burn Prevention 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 equipmen
24. ity Caterpillar recommends appropriate work tools for our machines to maximize the value our customers receive from our products Caterpillar understands that special circumstances may lead a customer to use tools outside of our specifications In these cases customers must be aware that such choices can reduce vehicle performance and will affect their ability to claim warranty in the event of what a customer may perceive as a premature failure Work tools and work tool control systems that are compatible with your Cat machine are required for safe machine operation and or reliable machine operation If you are in doubt about the compatibility of a particular work tool with your machine consult your Cat dealer Make sure that all necessary guarding is in place on the host machine and on the work tool Keep all windows and doors closed on the host machine A polycarbonate shield must be used when the host machine is not equipped with windows and when a work tool could throw debris Do not exceed the maximum operating weight that is listed on the ROPS certification If your machine is equipped with an extendable stick install the transport pin when you are using the following work tools hydraulic hammers augers and compactors Always wear protective glasses Always wear the protective equipment that is recommended in the operation manual for the work tool Wear any other protective equipment that is required for the operating
25. n 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 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 Cater
26. n resulting in serious injury or death Batteries may be located in sep arate compartments When using jump start ca bles always connect the positive cable from the source to the positive terminal of the bat tery that is connected to the starter solenoid Con nect the negative cable from the source to the negative terminal of the starter If the machine is not equipped with a starter negative terminal connect the negative cable to the engine block Follow the procedure in the Operation and Main tenance Manual SEBU7970 12 9 Safety Section Safety Messages High Pressure Accumulator 4 This safety message is located on the accumulator if the machine is equipped with the option for ride control g01370912 Hydraulic accumulator contains gas and oil under high pressure Improper removal or repair proce dures could cause severe injury To remove or re pair instructions in the service manual must be followed Special equipment is required for test ing and charging ROPS 5 This safety message is located on the cab next to the left side door ROPS SAEJXXXX MAYXX ISO XXXX 1994 FOPS SAEJ ISOXXXX APR98 LEVE ISOXXXX 1992 LEVEL Il XXXX XXXX XX XXX XX XXX XXXX XXXX XXXX XXXX XX XXX XX XXX CATERPILLAR INC PEORIA ILLINOIS USA g01799348 Structural damage an overturn modification al teration or improper repair can impair this struc ture s
27. ng job site organization refer to this Operation and Maintenance Manual Visibility Information The illustration below provides a visual indication of the areas of restricted visibility near the machine in two locations One location is on a rectangular line 1 00 m 3 28 ft from the outside of the machine profile at a height of 1 5 m 4 92 ft The second location is on the ground level at a radius of 12 00 m 39 37 ft from the operator 24 Safety Section Before Operation SEBU7970 12 Illustration 17 g01622342 Top view of the machine Note This illustration does not show all areas of restricted visibility that are inside the two locations or restricted visibility that may exist at further distances from the machine e A 1m 3 ft B 2 m 6 ft 6 in C 1m 3 ft 101388947 Before Operation SMCS Code 7000 Clear all personnel from the machine and from the area Clear all obstacles from the path of the machine Beware of hazards such as electrical wires ditches etc The stabilizers must be in the correct position before you operate the machine Completely raise the stabilizers for transporting the machine or for loader operation Lower the stabilizers before you operate the backhoe DO NOT DIG UNDER THE STABILIZERS Stand on the outside of the machine on the ground in order to reposition the flip over stabilizer pads DO NOT REPOSITION THE STABILIZER PADS WHILE YOU ARE IN THE CA
28. olant 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 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 The liquid in a battery is an electrolyte Electrolyte is an acid that can cause personal injury Do not allow electrolyte to contact the skin or the eyes Do not smoke while checking the battery electrolyte levels Batteries give off flammable fumes which can explode Always wear protective glasses when you work with batteries Wash hands after touching batteries The u
29. onal 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 9 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 Special 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 16 Safety Section Crushing Prevention and Cutting Prevention SEBU7970 12 Inhalation Illustration
30. ot or an apparently damaged tire Caterpillar recommends against using water or calcium as a ballast for the tires except in machines designed for this additional mass For those applicable machines the maintenance section will contain instructions on the correct tire inflation and filling procedures Ballast such as fluid in the tires increases overall machine weight and may affect braking steering power train components or the certification of the protective structure such as the ROPS The use of tire rim rust preventatives or other liquid additives is not required 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 equipment are necessary A tire blowout or a rim failure can result from improper equipment or from misused equipment When you inflate a tire stand behind the tread and use a self attaching chuck Servicing tires and rims can be dangerous Only trained personnel that use proper tools and proper procedures should perform this maintenance If correct procedures are not
31. overs 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 necessary repairs Do not allow unauthorized personnel on the equipment SEBU7970 12 15 Safety Section General Hazard Information 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 equipp
32. pen flames or sparks Always stop the engine before fueling Fill the fuel tank outdoors Properly clean areas of spillage Never store flammable fluids in the operator compartment of the machine SEBU7970 12 19 Safety Section Fire Prevention and Explosion Prevention Battery and Battery Cables Illustration 14 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 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
33. pillar Inc www cat com SEBU7970 12 29 Safety Section Operator Station 103634321 Operator Station SMCS Code 7000 7300 Any modifications to the inside of the operator station should not project into the operator space or into the space for the companion seat if equipped The addition of a radio fire extinguisher and other equipment must be installed so that the defined operator space and the space for the companion seat if equipped is maintained Any item that is brought into the cab should not project into the defined operator space or the space for the companion seat if equipped 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 rollover
34. 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 10 Safety Section Safety Messages SEBU7970 12 Crush Hazard 6 This safety message is located on the boom above the boom foot pin g01371644 Crushing Hazard Stay back a safe distance There is no clearance for a person in this area when the machine turns Failure to follow these instructions could cause serious injury or death No Exit 7 This safety message is located on the back of the cab g01407377 Crush hazard This is not an entrance or exit Stay clear of this area when the machine is operating Start and operate the backhoe from the operator seat only Failure to follow these warnings could result in injury or death Brace The Lift Cylinder 8 This safety message is located on the brace for the loader lift arm g01407376 A WARNING 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 Pressurized System 9 This safety message is located on the cooling system filler cap g01407380 A WARNING Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool
35. ps and straps are reinstalled correctly This will help to prevent vibration rubbing against other parts and excessive heat during machine operation 20 Safety Section Fire Prevention and Explosion Prevention SEBU7970 12 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 15 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 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 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 Fl
36. se of gloves is recommended 104218233 Fire Prevention and Explosion Prevention SMCS Code 7000 I Illustration 12 g00704000 18 Safety Section Fire Prevention and Explosion Prevention SEBU7970 12 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 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 op
37. t 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 SEBU7970 12 21 Safety Section Fire Safety 104025591 Fire Safety SMCS Code 7000 Note Locate secondary exits and how to use the secondary exits before you operate the machine Note Locate fire extinguishers and how to use a fire extinguisher before you operate the machine If you find that you are involved in a machine fire your safety and that of others on site is the top priority The following actions should only be performed if the actions do not present a danger or risk to you and any nearby people At all times you should assess the risk of personal injury and move away to a safe distance as soon as you feel unsafe Move the machine away from nearby combustible material such as fuel oil stations structures trash mulch and timber Lower any implements and turn off the engine as soon as possible If you leave the engine running the engine will continue to feed a fire The fire will be fed from any damaged hoses th
38. t 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 104760300 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 Coolant When the engine is at operating temperature the engine co
39. tion can cause injury or death Product Link 14 If Equipped This safety message is located in the front of the cab on the right side g01381177 This machine is equipped with a Caterpillar Prod uct Link communication device When electric detonators are used this communication device should be deactivated within 12 m 40 ft of a blast site for satellite based systems and within 3 m 10 ft of a blast site for cellular based systems or within the distance mandated under applicable legal requirements Failure to do so could cause interference with blasting operations and result in serious injury or death In cases where the type of Product Link module cannot be identified Caterpillar recommends that the device be disabled no less than 12 m 40 ft from the blast perimeter SEBU7970 12 13 Safety Section Additional Messages 102897596 Additional Messages SMCS Code 7000 7405 Illustration 3 Pinning of the Extendable Stick 1 If equipped this message is located on the stick Illustration 4 g01202535 AX CAUTION The E Stick must be pinned before using attach ments to prevent movement which could cause personal injury Improper Location of the Backhoe Bucket 2 This message is located by the linkage for the backhoe bucket g01442834 Illustration 5 g01202537 CAUTION Improper bucket pin connection can cause ma chine damage
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