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SAFETYOperation and Maintenance Manual Excerpt

SEBU7172-04March 2005

Operation andMaintenanceManual539 Knuckleboom Loader1PZ1-Up (Machine)

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis 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 Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications 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 ordeath.

6 SEBU7172-04Safety SectionSafety Messages

Safety Sectioni02282818

Safety MessagesSMCS Code: 7000

There are several specific safety messages on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all safetymessages.

Make sure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if you cannot read the words. Replacethe illustrations if the illustrations are not legible.When you clean the safety messages, use a cloth,water and soap. Do not use solvent, gasoline, orother harsh chemicals to clean the safety signs.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the warning sign. Looseadhesive will allow the warning message to fall.

Replace any safety message that is damaged, ormissing. If a safety message is attached to a partthat is replaced, install a safety message on thereplacement part. Any Caterpillar dealer can providenew safety messages.

Do Not Operate (1)

g00643757Illustration 2

This warning label is located next to the left sidespeaker assembly in the operator compartment.

Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact your Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

SEBU7172-04 7Safety Section

Safety Messages

Electric Power Lines (2)


This warning label is located next to the right sidespeaker assembly in the operator compartment.

Know the maximum height and reach of yourmachine. Serious injury or death by electrocutioncan occur if machine, work tools, or attachmentsare not kept a safe distance from electrical powerlines. Keep distance at least 3 m (10 ft) Plus ad-ditional 10 mm (.4 inch) for each 1,000 volts over50,000 volts.

Battery (3)


This warning label is located on the batterycompartment cover on the right front of the machine.

Improper jumper cable connections may cause anexplosion resulting in personal injury. Batteriesmay be located in separate compartments. Whenusing jumper cables, always connect positive (+)cable to positive (+) terminal of battery connect-ed to starter solenoid and negative (−) cable fromexternal source to starter negative (−) terminal. (Ifnot equipped with starter negative terminal, con-nect to engine block.) Follow procedure in the Op-eration and Maintenance Manual.

8 SEBU7172-04Safety SectionSafety Messages

Lift Eyes Can Fail (4)


This warning label is located on the top of thehydraulic tank.

LIFT EYES OR TANK CAN FAIL WHEN LIFTINGTANK CONTAINING FLUIDS RESULTING IN POS-SIBLE PERSONAL INJURY. DRAIN TANK OF ALLFLUIDS BEFORE LIFTING.

Relieve Hydraulic Tank Pressure (5)


This warning label is located on top of the hydraulictank.

At operating temperature, the hydraulic tank is hotand under pressure.

Hot oil and components can cause personal in-jury. Do not allow hot oil or components to contactskin.

Remove the filler cap only when the engine isstopped, and the filler cap is cool enough totouch with your bare hand. Remove the filler capslowly to relieve pressure.


Additional Messages

Pressurized System (6)


This warning label is located on top of the enginecompartment on the right side of the machine.

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

No Ether in Air Inlet (7)


This warning label is located on the rear of the aircleaner housing.

If equipped with an air inlet heater (AIH) for coldweather starting, do not use aerosal types of start-ing aids such as ether. Such use could result in anexplosion and personal injury.

ROPS/FOPS Structure (10)


This warning label is located on the LH side of thecab below the side window in front of the entrancefor the operator.

Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture’s protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. This will void the certification. Consulta Caterpillar dealer to determine this structure’slimitations without voiding its certification.

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Additional MessagesSMCS Code: 7000

There are several specific messages on thismachine. The exact location of the messages andthe description of the messages are reviewed inthis section. Please become familiarized with allmessages.

10 SEBU7172-04Safety SectionGeneral Hazard Information

Make sure that all of the messages are legible.Clean the messages or replace the messages ifyou cannot read the words. Replace the illustrationsif the illustrations are not legible. When you cleanthe messages, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures themessages. Loose adhesive will allow the messagesto fall.

Replace any message that is damaged, or missing.If a message is attached to a part that is replaced,install a message on the replacement part. AnyCaterpillar dealer can provide new messages.


Radial Seal Air Filter

This message is located on the rear of the air cleanerhousing.


Alternative Exit

This message is located on each latch for the rearcab window.


Keep Alternate Exit Unlocked During MachineOperation.

This message is located on LH side and RH side ofthe secondary exit.

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General Hazard InformationSMCS Code: 7000


Before you service the machine or before you repairthe machine, attach a “Do Not Operate” warning tagor a similar warning tag to the start switch or to thecontrols. These warning tags Special Instruction,SEHS7332 are available from your Caterpillar dealer.

Know the width of your equipment in order to maintainproper clearance near fences, boundary obstacles,etc.

Wear a hard hat, protective glasses and otherprotective equipment in order to accommodate jobconditions.

Do not wear loose clothing or jewelry that can catchon controls or on other parts of the machine.


General Hazard Information

Ensure that all protective guards and all covers aresecured in place on the machine.

Keep the machine free from foreign material. Checkthe deck, the walkways and the steps. Removedebris, oil, tools and other items.

Secure all loose items that are not a part of themachine. Secure lunch boxes, tools and other items.

Know the appropriate work site hand signals. Also,know the personnel that are authorized to give thehand signals. Accept 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 emitted from a flame thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditionerrefrigerant through a lighted cigarette can causebodily harm or death.

Never put maintenance fluids into glass containers.Drain all liquids into a suitable container.

When you discard liquids, obey all local regulations.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on the machine.

Unless you are instructed otherwise, perform themaintenance with the following conditions:

• The machine is parked on level ground.

• The hydraulic controls are in the NEUTRALposition.

• The stabilizers are lowered.

• Lower the boom until the head exerts a slightdownward pressure on the ground.

• The engine is stopped.

• The engine start switch in the OFF position andthe key is removed.

• The battery disconnect switch is in the OFFposition.

Pressure AirPressure air can cause personal injury. Whenpressure air is used for cleaning, wear a protectiveface shield, protective clothing and protective shoes.

The maximum air pressure must be below 205 kPa(30 psi) for cleaning purposes.

Trapped PressurePressure can be trapped in a hydraulic system.Trapped pressure can cause sudden machinemovement or attachment movement. Use cautionif you disconnect hydraulic lines or fittings. Highpressure oil that is released can cause a hose towhip. High pressure oil that is released can cause oilto spray. Fluid penetration can cause serious injuryand possible death.

Fluid PenetrationWhen you check for a leak, use a board or cardboard.Leaking fluid that is under pressure can penetratebody tissue. Fluid penetration can cause seriousinjury and possible death. A pin hole leak can causesevere injury. If fluid is injected into your skin, youmust obtain treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of themachine. Be prepared to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Tools andShop Products Guide” for the following items:

• Equipment that is suitable for collecting fluids

• Equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Asbestos InformationCaterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCaterpillar replacement parts. If any replacementparts that contain asbestos are used, the followingguidelines should be used in handling these partsand asbestos debris.

12 SEBU7172-04Safety SectionCrushing Prevention and Cutting Prevention

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. If this dust is inhaled, it can behazardous to your health. The components that maycontain asbestos fibers are brake pads, brake bands,lining material, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous, unless airborne dust thatcontains asbestos is generated.

If dust which can contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Also avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter can also be used.

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulations forthe work place. In the USA, use OccupationalSafety and Health Administration requirements.These OSHA requirements can be found in “29CFR 1910.1001”.

• Obey environmental rules for the disposal ofasbestos and obey environmental regulations forthe disposal of asbestos.

• Stay away from areas that might have asbestosparticles in the air.

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Crushing Prevention andCutting PreventionSMCS Code: 7000

Support the equipment properly when you workbeneath the equipment. Do not depend on thehydraulic cylinders to hold up the equipment. Anattachment can fall if a control is moved, or if ahydraulic line breaks.

Mechanically connected controls will causemovement of components at all times, even if thepump or engine is not operating. Always be certainthat the boom and grapple are properly supported orresting on firm ground before stopping the engine.This will minimize the possibility of accidentalmovement of components.

Do not use a boom attachment for a work platformor personnel carrier.

Do not move loads over the heads of other persons.

Always lower the boom to the ground or to the trailerbefore leaving the cab. If it is necessary to work ona machine with a lifted boom, securely support themachine or attachment.

Do not support the machine on cinder blocks, hollowtiles, or props that may crumble under continuousload. Do not work under a machine that is supportedsolely by a jack.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving. Also, neverattempt adjustments while the engine is running.

Whenever there are attachment linkages, theclearance in the linkage area will increase or theclearance in the linkage area will decrease withmovement of the attachment.

Stay clear of all rotating parts and all moving parts.

Keep objects away from moving fan blades. Thefan blade will throw objects or the fan blade will cutobjects.

Do not use a kinked wire rope cable or a frayed wirerope cable. Wear gloves when you handle wire ropecable.

When you strike a retainer pin with force, the retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin.

In order to avoid injury to your eyes, Wear protectiveglasses when you strike a retainer pin.

Chips or other debris can fly off objects when youstrike the objects. Ensure that an injury will not occurfrom flying debris before you hit any object.


Burn Prevention

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Burn PreventionSMCS Code: 7000

Do not touch any part of an operating engine.Allow the engine to cool before any maintenance isperformed on the engine. Relieve all pressure in theair system, in the oil system, in the lubrication system,in the fuel system, or in the cooling system beforeany lines, fittings or related items are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level only after the engine hasbeen stopped.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot components can cause personalinjury. 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 theengine has been stopped. The filler cap must becool enough to touch with a bare hand. Follow thestandard procedure in this manual in order to removethe hydraulic tank filler cap.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

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Fire Prevention and ExplosionPreventionSMCS Code: 7000


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

Remove all flammable materials such as fuel, oil, anddebris from the machine. Do not allow any flammablematerials to accumulate on the machine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not operate the machine near any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil spray or fuel spray in case ofa break in a line, in a hose, or in a seal. Exhaustshields must be installed correctly.

Do not weld on lines or on tanks that containflammable fluids. Do not flame cut lines or tanksthat contain flammable fluid. Clean any such lines ortanks thoroughly with a nonflammable solvent priorto welding or flame cutting.

Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate themachine. Clean all electrical connections and tightenall electrical connections.

14 SEBU7172-04Safety SectionFire Prevention and Explosion Prevention

Dust that is generated from repairing nonmetallichoods or nonmetallic fenders can be flammableand/or explosive. Repair such components in a wellventilated area away from open flames or sparks.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and the hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.


Use caution when you are refueling a machine. Donot smoke while you are refueling a machine. Donot refuel a machine near open flames or sparks.Always stop the engine before refueling. Fill the fueltank outdoors.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

EtherEther is flammable and poisonous.

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

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49 °C (120 °F). Keep ether cylinders awayfrom open flames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the machine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

SEBU7172-04 15Safety SectionTire Information

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During machine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

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Tire InformationSMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.

A tire explosion is much more violent than ablowout. The explosion can propel the tire, the rimcomponents, and the axle components as far as500 m (1500 ft) or more from the machine. Both theforce of the explosion and the flying debris can causeproperty damage, personal injury, or death.

g00337832Illustration 17(A) At least 15 m (50 ft)(B) At least 500 m (1500 ft)

Do not approach a warm tire. Maintain a minimumdistance, as shown. Stay outside the shaded area inIllustration 17.

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, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

Nitrogen inflated tires reduce the potential ofa tire explosion because nitrogen does not aidcombustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration of rubber, and corrosion ofrim components.

To avoid overinflation, proper nitrogen inflationequipment and training in the usage of the equipmentare necessary. A tire blowout or a rim failure canresult from improper equipment or from misusedequipment.

When you inflate a tire, stand behind the tread anduse a self-attaching chuck.

Servicing tires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tiresand rims, the assemblies could burst with explosiveforce. This explosive force can cause seriouspersonal injury or death. Carefully obey the specificinstructions from your tire dealer.

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Electrical Storm InjuryPreventionSMCS Code: 7000

When lightning is striking in the vicinity of themachine, the operator should never attempt thefollowing procedures:

• Mount the machine.

• Dismount the machine.

If you are in the operator’s station during an electricalstorm, stay in the operator’s station. If you are on theground during an electrical storm, stay away fromthe vicinity of the machine.

16 SEBU7172-04Safety SectionMounting and Dismounting

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Mounting and DismountingSMCS Code: 7000


Mount the machine and dismount the machine onlyat locations that have steps and/or handholds. Beforeyou mount the machine, clean the steps and thehandholds. Inspect the steps and handholds. Makeany necessary repairs.

Face the machine whenever you mount the machineand whenever you dismount the machine.

Maintain a three-point contact with the steps and withthe handholds.

Note: Three-point contact can be two feet and onehand. Three-point contact can also be one foot andtwo hands.

Never mount a moving machine. Never dismount amoving machine. Never jump off the machine.

Do not carry tools or supplies when you mount themachine or when you dismount the machine. Use ahand line to raise and lower tools or supplies.

Do not use any controls as handholds when youenter the operator compartment or when you exit theoperator compartment.

Alternate ExitMachines that are equipped with cabs may havealternate exits. For additional information onmachines that are equipped with alternate exits, seeOperation and Maintenance Manual, “Alternate Exit”.

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Before Starting EngineSMCS Code: 1000; 7000

Start the engine only from the operator’scompartment. Never short across the starterterminals or across the batteries. Shorting couldbypass the engine neutral start system. Shortingcould also damage the electrical system.

Inspect the condition of the seat belt and the conditionof mounting hardware. Replace any damaged partsor worn parts. Regardless of appearance, replacethe seat belt after three years of use. Do not use anextension for a seat belt on a retractable seat belt.

Adjust the seat so that full pedal travel can beachieved. Make sure that the operator’s back isagainst the back of the seat. Adjust the seat onlywhen the controls are de-energized.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Ensure that all lights are in proper working condition.

Make sure that there are no personnel in the areabefore you start the engine. Make sure that thereare no personnel in the area before you move themachine. Make sure that there are no personnel onthe machine, underneath the machine, or around themachine.

Check for worn wires or for frayed wires. Check forloose connections in the electrical system.

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Engine StartingSMCS Code: 1000; 7000

Perform the walk-around inspection before startingthe engine.

If a warning tag is attached to the start switch or tothe controls, do not start the engine. Also, do notmove any controls.

Ensure that all hydraulic controls are in the HOLDposition before you start the engine.

Make sure that the hydraulic activation control leveris in the LOCKED position.

Ensure that the cab door is shut.


Before Operation

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Before OperationSMCS Code: 7000

Make sure that there are no personnel on themachine or in the area around the machine.

Clear all obstacles from the path of the machine.Beware of hazards such as wires, ditches, etc.

Make sure that all windows are clean. Secure thedoors and the windows in the open position or in theshut position.

Adjust the rear view mirrors (if equipped) for the bestvision of the area near the machine.

Ensure that the horn, the backup alarm (if equipped),and all other warning devices are working properly.

Fasten the seat belt securely.

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OperationSMCS Code: 7000

Machine Operating TemperatureRangeThe standard machine configuration is intendedfor use within an ambient temperature rangeof −40 °C (−40 °F) to 50 °C (122 °F). Specialconfigurations for different ambient temperaturesmay be available. Consult your Caterpillar dealer foradditional information on special configurations ofyour machine.

Machine OperationOnly operate the machine while you are sitting ina seat. The seat belt must be fastened while youoperate the machine. Only operate the controls whilethe engine is running.

While you operate the machine slowly in an openarea, check for proper operation of all controls and allprotective devices.

Before you move the machine, make sure that noone will be endangered.

Do not allow riders on the machine unless themachine has an additional seat with a seat belt.

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. Whenpossible, operate the machine up the slopes anddown the slopes. If the machine begins to sideslipon a downgrade, immediately remove the load andturn the machine downhill.

Avoid any conditions that can lead to tipping themachine. The machine can tip when you work onhills, on banks and on slopes. Also, the machinecan tip when you cross ditches, ridges or otherunexpected obstructions.

Maintain control of the machine. Do not overload themachine beyond the machine capacity.

Make sure that the hitches and the towing devicesare adequate. Only connect trailing equipment to adrawbar or to a hitch.

Never straddle a wire cable. Never allow otherpersonnel to straddle a wire cable.

Before you maneuver the machine, make sure thatno personnel are between the machine and thetrailing equipment. Block up the hitch of the trailingequipment in order to align the hitch with the drawbar.Maneuver the machine. Connect the machine to thetrailing equipment.

Know the maximum dimensions of your machine.

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Engine StoppingSMCS Code: 1000; 7000

Do not stop the engine immediately after themachine has been operated under load. This cancause overheating and accelerated wear of enginecomponents.

After the machine is parked and the parking brakeis engaged, allow the engine to run for five minutesbefore shutdown. This allows hot areas of the engineto cool gradually.

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Work ToolsSMCS Code: 6700

Only use work tools that are recommended byCaterpillar for use on Caterpillar machines.

18 SEBU7172-04Safety SectionLifting Objects

If you are in doubt about the compatibility of aparticular work tool with your machine, consult yourCaterpillar dealer.

Make sure that all necessary guarding is in place onthe host machine and on the work tool.

Keep all windows and doors closed on the hostmachine. Always wear protective glasses. Alwayswear the protective equipment that is recommendedin the work tool’s operation manual. Wear any otherprotective equipment that is required for the operatingenvironment.

To prevent personnel from being struck by flyingobjects, ensure that all personnel are out of the workarea.

While you are performing any maintenance, anytesting, or any adjustments to the work tool stayclear of the following areas: cutting edges, pinchingsurfaces, and crushing surfaces.

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Lifting ObjectsSMCS Code: 7000

There may be some local regulations and/orgovernment regulations that govern the use ofmachines which lift heavy objects. Obey thoseregulations.

If this machine is used to lift objects within anarea that is controlled by the European Directive“89/392/EEC”, the machine must be equipped with aboom lowering control valve and an overload warningdevice.

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ParkingSMCS Code: 7000

Park the machine on a level surface. If you must parkthe machine on a downgrade, block the tires.

Apply the service brake in order to stop the machine.Move the transmission control to the NEUTRALposition.

Engage the parking brake.

Lower all work tools to the ground. Activate anycontrol locks.

Stop the engine.

Turn the engine start switch to the OFF position andremove the key.

Turn the battery disconnect switch to the OFFposition. If the machine will not be operated for anextended period of time, remove the key in order toavoid battery discharge that may be caused by abattery short circuit, by the current draw via certaincomponents, or by vandalism.

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Equipment Lowering withEngine StoppedSMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment ofall personnel. The procedure to use will vary withthe type of equipment to be lowered. Keep in mindmost systems use a high pressure fluid or air toraise or lower equipment. The procedure will causehigh pressure air, hydraulic, or some other mediato be released in order to lower the equipment.Wear appropriate personal protective equipment andfollow the established procedure in the Operationand Maintenance Manual, “Equipment Lowering withEngine Stopped” in the Operation Section of themanual.

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Sound Information andVibration InformationSMCS Code: 7000

The operator sound exposure Leq (equivalent soundpressure level) measured according to the work cycleprocedures specified in “ANSI/SAE J1166May90” is81.55 dB(A), for the cab offered by Caterpillar, whenproperly installed, maintained and tested with thedoors and windows closed.

The operator sound pressure level measuredaccording to the procedures specified in “SAEJ919Jun86” is 78.5 dB(A), for the cab offered byCaterpillar, when properly installed, maintained andtested with the doors and windows closed and withthe machine at high idle with all cab fans off.

The exterior sound pressure level for the standardmachine measured at a distance of 15 m (49.2 ft)according to the test procedures specified in “SAEJ88Jun86”, with the machine at high idle is 78.1dB(A).


Operator Station

Vibration LevelThe hands and arms are exposed to a weightedroot mean square acceleration that is less than 1.1m/sec2.

The whole body is exposed to a weighted root meansquare acceleration that is less than 0.2 m/s2.

Measurements are obtained on a representativemachine using the procedures in the followingstandards:

• “SAE J88”

• “SAE J1166”

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Operator StationSMCS Code: 7000

Any modifications to the inside of the operatorstation should not project into the operator space.The addition of a radio, fire extinguisher, and otherequipment must be installed so that the definedoperator space is maintained. Any item that is broughtinto the cab should not project into the definedoperator space. A lunch box or other loose itemsmust be secured. Objects must not pose an impacthazard in rough terrain or in the event of a rollover.

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Guards(Operator Protection)SMCS Code: 7000

There are different types of guards that are used toprotect the operator. The machine and the machineapplication determines the type of guard that shouldbe used.

A daily inspection of the guards is required in order tocheck for structures that are bent, cracked or loose.Never operate a machine with a damaged structure.

The operator becomes exposed to a hazardoussituation if the machine is used improperly or if pooroperating techniques are used. This situation canoccur even though a machine is equipped with anappropriate protective guard. Follow the establishedoperating procedures that are recommended for yourmachine.

Rollover Protective Structure(ROPS), Falling Object ProtectiveStructure (FOPS) or Tip OverProtection Structure (TOPS)The ROPS/FOPS Structure (if equipped) on yourmachine is specifically designed, tested and certifiedfor that machine. Excavators are not equippedwith ROPS structures. Any alteration or anymodification to the ROPS/FOPS Structure couldweaken the structure. This places the operatorinto an unprotected environment. Modifications orattachments that cause the machine to exceed theweight that is stamped on the certification plate alsoplace the operator into an unprotected environment.Excessive weight may inhibit the brake performance,the steering performance and the ROPS. Theprotection that is offered by the ROPS/FOPSStructure will be impaired if the ROPS/FOPSStructure has structural damage. Damage to thestructure can be caused by an overturn, a fallingobject, a collision, etc.

Do not mount items (fire extinguishers, first aidkits, work lights, etc) by welding brackets to theROPS/FOPS Structure or by drilling holes in theROPS/FOPS Structure. Welding brackets or drillingholes in the ROPS/FOPS Structures can weakenthe structures. Consult your Caterpillar dealer formounting guidelines.

The Tip Over Protection Structure (TOPS) isanother type of guard that is used on mini hydraulicexcavators. This structure protects the operator inthe event of a tipover. The same guidelines for theinspection, the maintenance and the modification ofthe ROPS/FOPS Structure are required for the TipOver Protection Structure.

Other Guards (If Equipped)Protection from flying objects and/or falling objects isrequired for special applications. Logging applicationsand demolition applications are two examples thatrequire special protection.

A front guard needs to be installed when a worktool that creates flying objects is used. Meshfront guards that are approved by Caterpillar orpolycarbonate front guards that are approved byCaterpillar are available for machines with a cab oran open canopy. On machines that are equipped withcabs, the windshield should also be closed. Safetyglasses are recommended when flying hazards existfor machines with cabs and machines with opencanopies.

If the work material extends above the cab, topguards and front guards should be used. Typicalexamples of this type of application are listed below:

20 SEBU7172-04Safety SectionGuards

• Demolition applications

• Rock quarries

• Forestry products

Additional guards may be required for specificapplications or work tools. The Operation andMaintenance Manual for your machine or yourwork tool will provide specific requirements for theguards. Consult your Caterpillar dealer for additionalinformation.

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