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®© 2010 CaterpillarAll Rights Reserved

SAFETYOperation and MaintenanceManual Excerpt

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SEBU8135-10

February 2012

Operation andMaintenance

ManualD11T Track-Type Tractor

GEB1-Up (Standard)TPB1-Up (Carrydozer)

SAFETY.CAT.COM

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6 SEBU8135-10Safety SectionSafety Messages

Safety Section

i03653821

Safety Messages

SMCS Code: 7000; 7405

g01401377Illustration 2

Machine with access ladder (if equipped)

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SEBU8135-10 7Safety Section

Safety Messages

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Illustration 3

There are several specific safety messages on thismachine. The exact location of the safety messagesand the description of the safety messages arereviewed in this section. Please become familiarizedwith all safety messages.

Make sure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if you cannot read the words. Replace thesafety messages 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 loosenthe adhesive that secures the safety message. Looseadhesive will allow the safety message to fall.

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Replace any saf ety message that is damaged, or missing. 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)

This message is located on the left post on the insideof the cab.

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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.

Seat Belt (2)

This safety message is located on the left side postabove the steering control.

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A seat belt should be worn at all times during ma-chine operation to prevent serious injury or deathin 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.

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Safety Messages

Improper Connections for JumpStart Cables (3)

This message is located on the underside of eachbattery compartment cover.

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Improper jumper cable connections can cause ex-plosion resulting in personal injury.

If equipped, use the auxiliary starting receptacle toinsure proper cable connection. Follow procedurein the Operation and Maintenance Manual.

Batteries may be located in separate compart-ments. When using jumper cables, always con-

nect positive (+) cable to positive (+) terminal of battery connected to starter solenoid, then, neg-ative (-) terminal (if machine not equipped withstarter negative terminal, connect to engine blockor a designated ground stud). Follow procedurein the Operation and Maintenance Manual.

Safety Messages for Engine (4)

This safety message is located on the left side andthe right side of the engine. The message alsoappears on the front of the engine ECM on the rightside of the engine.

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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 authorized dealer for replacement man-uals. Proper care is your responsibility.

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Hot Coolant Under Pressure (5)

This message is located on the underside of theaccess cover for the radiator cap.

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Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

Do Not Weld or Drill the ROPSStructural Members (6)

This safety message (ROPS) is located on the topright corner of the ROPS.

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Structural damage, an overturn, modification, al-teration, or improper repair, can impair this struc-ture's protective capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. Consult a Caterpillar dealer to deter-mine this structure's limitations without voidingits certification.

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Safety Messages

Do Not Weld or Drill the FOPSCanopy (7)

This safety message (FOPS) is located on theoutside of the right side of the cab.

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The impact from objects that strike the front of thecab or the top of the cab could result in a crush-ing hazard with the potential for personal injury or death.

The front guard and the top guard should be in-stalled on the cab for applications where the haz-ard of falling objects exist. Read theOperation andMaintenance Manual.

Shock Hazard (8)

This safety message is located on the cover to thealternator circuit breaker just below the main fusepanel.

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WARNING! Shock/Electrocution Hazard! Read andunderstand the instructions and warnings in theOperation and Maintenance Manual. Failure to fol-low the instructions or heed the warnings couldcause serious injury or death.

Compressed Recoil Spring (9)

This message is located on the end of the tube of the

front track roller frames.

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Recoil spring force, if not relieved, can result inpersonal injury or death. Relieve spring force be-fore removing the threaded retainer, performingr epairs on the recoil spring housing, or removingthe recoil spring. Consult a Caterpillar dealer for disassembly instructions.

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Compressed Recoil Spring (10)

This message is located on the underside of thecover for the guides on the track roller frames.

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Stop disassembly if evidence of a crack exists inthe tube or slot beneath this guide. A cracked tubecan break suddenly expelling pieces with greatforce that could result in serious injury or death.Contact a Caterpillar dealer for special disassem-bly instructions.

High Pressure Cylinder (11)

This safety message is located inside the track roller frame on both sides of the machine.

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High Pressure Cylinder. Do not remove any partsuntil all pressure has been relieved to avoid pos-sible personal injury. Relieve pressure by openingrelief valve one turn maximum. See the Operationand Maintenance Manual for correct procedure.

Refer to Operation and Maintenance Manual, “Track- Check/Adjust”.

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Additional Messages

Accumulator Location (12)

This safety message is attached to the front floorplatethat is located in the cab. Remove the front floorplatein order to access the accumulator cylinder.

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HIGH PRESSURE CYLINDER AND LINES! Do notremove valve, hydraulic fitting, or valve core, nor disassemble any parts until pressure has been re-lieved. Personal injury or death could occur.

See your Caterpillar dealer who has tools anddetailed information for servicing and chargingcylinders.

Product Link (13) (If Equipped)

This safety message is located inside the cab on theback right post, if equipped.

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This machine is equipped with a Caterpillar Product Link communication device. When elec-tric/electronic detonators are used, this com-munication device should be deactivated within

12 m (40 ft) of a blast site, or within the distancemandated under applicable legal requirements.Failure to do so could cause interference withblasting operations and result in serious injury or death.

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Additional Messages

SMCS Code: 7000; 7405

There are several specific messages on this

machine. The exact location of the messages andthe description of the information are reviewed in thissection. Please become familiar with all messages.

Make sure that all of the messages are legible.Clean the messages or replace the messages if youcannot read the words. Replace the illustrations if the illustrations are not legible. When you clean themessages, 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.

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14 SEBU8135-10Safety Section

Additional Messages


Machine with access ladder (if equipped)

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.

Access Ladder (1) (If Equipped)


The film (1) for the access ladder is located next tothe switch on the ladder control box.

Washer Fluid Bottle (2)


This film (2) is located inside the access door on theleft side of the cab.

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Additional Messages

Engine Lockout Switch (3)

The engine lockout switch is located inside the smallcompartment on the left side of the machine.


Location of engine lockout switch


Film for engine lockout switch

This film (3) is located on the engine lockout switchand is located above the battery disconnect switch.This switch allows the engine to be safely locked outwhile service is performed.

Battery Disconnect Switch (4)


Film for battery disconnect switch

This film (4) is located on the battery disconnect

switch and is located below the engine lockoutswitch. The battery disconnect is inside the smallcompartment on the left side of the machine.

The entire electrical system is disabled when thebatter y disconnect switch is turned to the OFFposition.

Engine Lighting (5)


This film (5) is wall mounted in two places on the rear

side of the engine. Open the engine compartments inorder to locate the light.

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16 SEBU8135-10Safety SectionGeneral Hazard Information

Air Conditioner (6)


This film (6) is located on the left side of the dashpanel near the bottom of the dash.

Product Link (7)


If your machine is equipped with the Product LinkSystem, this additional message is located in the cabon the rear right C post.

The Product Link System is a satellite communicationdevice that transmits information regarding themachine back to Caterpillar and Caterpillar dealersand customers. All logged events and diagnostic

codes that are available to the Caterpillar ElectronicTechnician (ET) on the CAT data link can be sentto the satellite. Information can also be sent to theProduct Link System. The information is used toimprove Caterpillar products and Caterpillar services.

Refer to Operation and Maintenance Manual,“Operator Controls” for more information.

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General Hazard Information

SMCS Code: 7000


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 theequipment or before you repair the equipment. Thesewarning tags (Special Instruction, SEHS7332) areavailable from your Cat dealer.

Operating the machine while distracted can resultin the loss of machine control. Use extreme cau-tion when using any device while operating the

machine. Operating the machine while distractedcan result in personal injury or death.

Know the width of your equipment in order to maintainproper clearance when you operate the equipmentnear fences or near boundary obstacles.

Be aware of high voltage power lines and power cables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.


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General Hazard Information

Wear a hard hat, protective glasses, and other protective equipment, as required.

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

Make sure that all protective guards and all coversare secured in place on the equipment.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, 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 andthe personnel that are authorized to give the handsignals. 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 thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditioner refrigerant through a lighted cigarette can causebodily 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 theequipment.

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and Maintenance Manualfor the procedure for placing the equipment in theservicing position.

When you perform maintenance above ground level,use appropriate devices such as ladders or man liftmachines. If equipped, use the machine anchorage

points and use approved fall arrest harnesses andlanyards.

Pressurized Air and Water

Pr essurized air and/or water can cause debris and/or hot water to be blown out. The debris and/or hotwater could result in personal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when thenozzle is deadheaded and the nozzle is used withan effective chip deflector and personal protectiveequipment. 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 suddenmachine movement or attachment movement. Usecaution if you disconnect hydraulic lines or fittings.High-pressure oil that is released can cause a hoseto whip. High-pressure oil that is released can causeoil to spray. Fluid penetration can cause seriousinjury and possible death.

Fluid Penetration

Pressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

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18 SEBU8135-10Safety SectionGeneral Hazard Information

Containing Fluid Spillage

Care must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting, and repair of theequipment. 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:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Inhalation


Exhaust

Use caution. Exhaust fumes can be hazardousto your health. If you operate the machine in anenclosed 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 genuineCat replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. The

asbestos that is used in these components is boundin a resin or sealed in some way. Normal handlingis not hazardous unless airborne dust that containsasbestos is generated.

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

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

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

• A vacuum cleaner that is equipped with a highef ficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machining jobs.

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

• Comply with applicable rules and regulations

for the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

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

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Crushing Prevention and Cutting Prevention

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should be

disposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

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Crushing Prevention andCutting Prevention

SMCS Code: 7000

Support the equipment properly before you performany work or maintenance beneath that equipment.Do not depend on the hydraulic cylinders to holdup the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Do not work beneath the cab of the machine unlessthe cab is properly supported.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or whilethe engine is running.

Never jump across the starter solenoid terminals

in order to start the engine. Unexpected machinemovement could result.

Whenever there are equipment control linkages theclearance in the linkage area will change with themovement of the equipment or the machine. Stayclear of areas that may have a sudden change inclearance with machine movement or equipmentmovement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to performmaintenance, always install the guards after themaintenance is performed.

Keep objects away from moving fan blades. The fanblade 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 injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes, wear protective glasses when you strikea retainer pin.

Chips or other debris can fly off an object when youstrike the object. Make sure that no one can beinjured by flying debris before striking any object.

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Burn Prevention

SMCS 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.

Coolant

When the engine is at operating temperature, theengine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.

Any contact with hot coolant or with steam can 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.

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20 SEBU8135-10Safety SectionFire Prevention and Explosion Prevention

Oils

Hot 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.

Batteries

The liquid in a battery is an electrolyte. Electrolyte isan acid that can cause personal injury. Do not allowelectrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolyte

levels. Batteries give off fl

ammable fumes which canexplode.

Always wear protective glasses when you work withbatteries. Wash hands after touching batteries. Theuse of gloves is recommended.

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Fire Prevention and ExplosionPrevention

SMCS Code: 7000


General

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

To minimize the risk of fire or explosion, Caterpillar recommends the following actions.

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operate amachine when a fire hazard exists. Contact your Catdealer for ser vice.

Understand the use of the primary exit and alternative

exit on the machine. Refer to Operation andMaintenance Manual, “Alternative Exit”.

Do not operate a machine with a fluid leak. Repair leaks and clean up fluids before resuming machineoperation. Fluids that are leaking or spilled onto hotsurfaces or onto electrical components can cause afire. A fire may cause personal injury or death.

Remove flammable material such as leaves,twigs, papers, trash, and so on. These items mayaccumulate in the engine compartment or aroundother hot areas and hot parts on the machine.

Keep the access doors to major machinecompartments closed and access doors in workingcondition in order to permit the use of fire suppressionequipment, in case a fire should occur.

Clean all accumulations of flammable materials suchas fuel, oil, and debris from the machine.

Do not operate the machine near any flame.

Keep shields in place. Exhaust shields (if equipped)protect hot exhaust components from oil spray or fuelspray in case of a break in a line, in a hose, or in aseal. Exhaust shields must be installed correctly.

Do not weld or flame cut on tanks or lines that containflammable fluids or flammable material. Empty andpurge the lines and tanks. Then clean the lines andtanks with a nonflammable solvent prior to weldingor flame cutting. Ensure that the components areproperly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallichoods or fenders may be flammable and/or explosive.Repair such components in a well ventilated areaaway from open flames or sparks. Use suitablePersonal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration.Replace damaged lines and hoses. The lines andthe hoses should have adequate support and secureclamps. Tighten all connections to the recommendedtorque. Damage to the protective cover or insulationmay provide fuel for fires.

Store fuels and lubricants in properly markedcontainers away from unauthorized personnel. Storeoily rags and flammable materials in protectivecontainers. Do not smoke in areas that are used for storing flammable materials.

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Fire Prevention and Explosion Prevention


Use caution when you are fueling a machine. Do notsmoke while you are fueling a machine. Do not fuela machine near open flames or sparks. Always stopthe engine before fueling. Fill the fuel tank outdoors.Properly clean areas of spillage.

Never store flammable fluids in the operator compartment of the machine.

Battery and Battery Cables


Caterpillar recommends the following in order tominimize the risk of fire or an explosion related tothe battery.

Do not operate a machine if battery cables or relatedparts 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 specificinstructions.

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

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 in

order to check the battery charge.

Daily inspect battery cables that are in areas thatare 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:

• Fraying

• Abrasion

• Cracking

• Discoloration

• Cuts on the insulation of the cable

• Fouling

• Corroded terminals, damaged terminals, and looseterminals

Replace damaged battery cable(s) and replaceany related parts. Eliminate any fouling, which mayhave caused insulation failure or related componentdamage or wear. Ensure that all components arereinstalled correctly.

An exposed wire on the battery cable may causea short to ground if the exposed area comes intocontact with a grounded surface. A battery cableshort produces heat from the battery current, whichmay be a fire hazard.

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22 SEBU8135-10Safety SectionFire Prevention and Explosion Prevention

An exposed wire on the ground cable between thebattery and the disconnect switch may cause thedisconnect switch to be bypassed if the exposed areacomes into contact with a grounded surface. Thismay result in an unsafe condition for servicing themachine. Repair components or replace components

before servicing the machine.

Fire on a machine can result in personal injuryor death. Exposed battery cables that come intocontact with a grounded connection can result infires. Replace cables and related parts that showsigns of wear or damage. Contact your Cat dealer.

Wiring

Check electrical wires daily. If any of the followingconditions exist, replace parts before you operatethe machine.

• Fraying

• Signs of abrasion or wear

• Cracking

• Discoloration

• Cuts on insulation

• Other damage

Make sure that all clamps, guards, clips, and strapsare reinstalled correctly. This will help to preventvibration, rubbing against other parts, and excessiveheat during machine operation.

Attaching electrical wiring to hoses and tubes thatcontain flammable fluids or combustible fluids shouldbe avoided.

Consult your Cat dealer for repair or for replacementparts.

Keep wiring and electrical connections free of debris.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strikehigh-pressure lines. Do not install any lines thatar e bent or damaged. Use the appropriate backupwrenches in order to tighten all connections to therecommended torque.


Check lines, tubes, and hoses carefully. Wear Personal Protection Equipment (PPE) in order tocheck 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 penetrationcan cause serious injury and possible death. A pinhole leak can cause severe injury. If fluid is injectedinto your skin, you must get treatment immediately.Seek treatment from a doctor that is familiar with thistype of injury.

Replace the affected parts if any of the followingconditions are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are swelling or ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have exposed 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 other

parts, excessive heat, and failure of lines, tubes, andhoses.

Do not operate a machine when a fire hazardexists. Repair any lines that are corroded, loose,or damaged. Leaks may provide fuel for fires.Consult your Cat dealer for repair or for replacementparts. Use genuine Cat parts or the equivalent, for capabilities of both the pressure limit and temperaturelimit.

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Fire Extinguisher Location

Ether

Ether (if equipped) is commonly used in cold-weather applications. Ether is flammable and poisonous.

Follow the cor rect cold engine starting procedures.

Refer to the section in the Operation and MaintenanceManual with the label “Engine Starting”.

Do not spray ether manually into an engine if themachine is equipped with a thermal starting aid for cold weather starting.

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

Do not stor e ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperatures

above 49° C (120.2° 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.

Fire Extinguisher

As an additional safety measure, keep a fireextinguisher on the machine.

Be familiar with the operation of the fire extinguisher.

Inspect thefi

re extinguisher and service thefi

reextinguisher regularly. Follow the recommendationson the instruction plate.

Consider installation of an aftermarket FireSuppression System, if the application and workingconditions warrant the installation.

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Fire Extinguisher Location

SMCS Code: 7419

Make sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher. Obey the recommendations on theinstruction plate.

Mount the fire extinguisher in the accepted locationper local regulations.

If your machine is equipped with a ROPS structure,strap the mounting plate to the ROPS in order tomount the fire extinguisher. If the weight of the fireextinguisher exceeds 4.5 kg (10 lb), mount the fireextinguisher near the bottom of the ROPS. Do notmount the fire extinguisher at the upper one-third

area of the ROPS.

Do not weld the ROPS structure in order to install thefire extinguisher. Also, do not drill holes in the ROPSstructure in order to mount the fire extinguisher onthe ROPS.

Consult your Cat dealer for the proper procedure for mounting the fire extinguisher.

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Track Information

SMCS Code: 4170; 7000

Track adjusting systems use either grease or oilunder high pressure to keep the track under tension.

Grease or oil under high pressure coming out of therelief valve can penetrate the body causing injury or death. Do not watch the relief valve to see if greaseor oil is escaping. Watch the track or track adjustmentcylinder to see if the track is being loosened.

The pins and bushings in a dry track pin jointcan become very hot. It is possible to burn thefi

ngers if there is more than brief contact with thesecomponents.

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Electrical Storm InjuryPrevention

SMCS 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.

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24 SEBU8135-10Safety SectionBefore Starting Engine

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Before Starting Engine

SMCS Code: 1000; 7000

Start the engine only from the operator'scompartment. Do not short across the batteryterminals and do not short across the batteries.Bypassing the engine neutral start system candamage the electrical system.

Inspect the condition of the seat belt and mountinghardware. Replace any damaged parts or worn parts.Regardless of appearance, replace the seat belt after three year s of use. Do not use an extension for aseat belt on a retractable seat belt.

Adjust the seat so that full pedal travel can beachieved. Make sure that the operator's back is

against the back of the seat.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Make sure that all lights are working properly. Beforeyou start the engine or before you move the machine,make sure that no one is working on the machine,working underneath the machine or working closeto the machine. Make sure that the area is free of personnel.

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Engine Starting

SMCS Code: 1000; 7000

If a warning tag is attached to the engine start switchor to the controls, do not start the engine. Also, donot move any controls.

Move all hydraulic controls to the HOLD positionbefore you start the engine. Move the transmissioncontrol lever to the NEUTRAL position.

Engage the parking brake.

Diesel engine exhaust contains products of combustion which can be harmful to your health.

Always run the engine in a well ventilated area. If you are in an enclosed area, vent the exhaust to theoutside.

Br iefly sound the horn before starting the engine.

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Before Operation

SMCS Code: 7000

Clear all personnel from the machine and from thearea.

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

Be sure that all windows are clean. Secure the doorsand the windows in either the open position or theshut position.

Adjust the rearview mirrors (if equipped) for bestvision close to the machine. Make sure that themachine horn, the backup alarm (if equipped) and allother warning devices are working properly.

Reference: Refer to Operation and MaintenanceManual, “Walk-Around Inspection” in this manual.

Fasten the seat belt securely.

i03162317

Visibility Information

SMCS Code: 7000

Before you start the machine, perform a walk-aroundinspection in order to ensure that there are no

hazards around the machine.

While the machine is in operation, constantly surveythe area around the machine in order to identifypotential hazards as hazards become visible aroundthe machine.

Your machine may be equipped with visual aids.Some examples of visual aids are Closed CircuitTelevision (CCTV) and mirrors. Before operating themachine, ensure that the visual aids are in proper working condition and that the visual aids are clean.

Adjust the visual aids using the procedures that arelocated in this Operation and Maintenance Manual.If equipped, the Work Area Vision System shall beadjusted according to Operation and MaintenanceManual, SEBU8157, “Work Area Vision System”.

It may not be possible to provide direct visibility onlarge machines to all areas around the machine.

Appropriate job site organization is required in order to minimize hazards that are caused by restrictedvisibility. Job site organization is a collection of rulesand procedures that coordinates machines andpeople that work together in the same area. Examplesof job site organization include the following:

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Restricted Visibility

• Safety instructions

• Controlled patterns of machine movement andvehicle movement

• Workers that direct traf fic to move when it is safe

• Restricted areas

• Operator tr aining

• Warning symbols or warning signs on machinesor on vehicles

• A system of communication

• Communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration by the

user that result in a restriction of visibility shall beevaluated.

i03653889

Restricted Visibility

SMCS Code: 7000

The size and the configuration of this machine mayresult in areas that can not be seen when the operator is seated. Illustration 22 provides an approximatevisual indication of areas of significant restricted

visibility. Illustration 22 indicates restricted visibilityareas at ground level inside a radius of 12 m (40 ft)from the operator on a machine without the use of optional visual aids. This illustration does not provideareas of restricted visibility for distances outside aradius of 12 m (40 ft).

This machine may be equipped with optional visualaids that may provide visibility to some areas withrestricted visibility. Refer to this Operation andMaintenance Manual, “Mirror” for more information onadditional visibility. If your machine is equipped withcameras, refer to this Operation and MaintenanceManual, “Camera” for more information on additional

visibility. For areas that are not covered by theoptional visual aids, the job site organization mustbe utilized to minimize hazards of this restrictedvisibility. For more information regarding job siteorganization refer to Operation and MaintenanceManual, “Visibility Information”.


Top view of the machine

Note: The shaded areas indicate the approximatelocation of areas with significant restricted visibility.

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Operation

SMCS Code: 7000

Note: The “Machine Operating Temperature Range”is noted in the following information.

The standard machine configuration is intended for use within an ambient temperature range of −40 °C(−40.0 °F) to 50 °C (122.0 °F). Special configurationsfor different ambient temperatures may be available.

Consult your Cat dealer for additional information onspecial configurations of your machine.

Only operate the machine while you are in a seat.The seat belt must be fastened while you operatethe machine. Only operate the controls while theengine is running. On machines that are disabled, thecontrols may be used when the engine is not running.

Check for proper operation of all controls andprotective devices while you operate the machineslowly in an open area.

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26 SEBU8135-10Safety SectionParking

Before moving the machine, the operator mustensure that no one will be endangered.

Do not allow riders on the machine unless themachine has the following equipment:

• additional seat

• additional seat belt

• Roll Over Protective Structure (ROPS)

Never use the work tool as a work platform.

Report any repairs that are needed and noted duringoperation.

Carry attachments close to the ground, approximately40 cm (15 inches) above ground level. Do not goclose to the edge of a cliff, an excavation, or an

overhang.

If the machine begins to sideslip, perform thefollowing procedure:

• Discard the load.

• Turn the machine downhill.

Be careful to avoid any condition which could leadto tipping. Tipping can occur when you work onhills, banks, and slopes. Also, tipping can occur when you cross ditches, ridges, or other unexpectedobstructions.

Whenever possible, operate the machine up theslopes and down the slopes. Avoid operating themachine across the slope, when possible.

Keep the machine under control. Do not overload themachine beyond capacity.

Towing devices and eyes that are not part of machinemust be adequate.

Connect trailing equipment to a drawbar or to a hitchonly.

Never straddle a wire cable or allow other personnelto straddle a wire cable.

When you maneuver to connect the equipment, makesure that no personnel are between the machineand trailing equipment. Block the hitch of the trailingequipment in order to align the equipment with thedrawbar.

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure(ROPS) installed during machine operation.

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Parking

SMCS Code: 7000

Park on a level surface. If you must park on a grade,use blocks to prevent the machine from rolling.

Apply the ser vice brake in order to stop the machine.Move the transmission control lever to NEUTRALposition and move the speed control to LOW IDLEposition. Engage the parking brake.

Lower all attachments to the ground.

Activate the implement shutoff control (hydrauliclockout).

Stop the engine.

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

Turn the key for the battery disconnect switch to theOFF position. Remove the key when you exit themachine for an extended period of time.

Turning the battery disconnect switch to the OFFposition will provide the following benefits:

• Prevent battery discharge that is caused by abattery short circuit.

• Prevent battery discharge that is caused by someof the electrical components.

• Prevent battery discharge that is caused byvandalism.

i03745198

Slope Operation

SMCS Code: 7000

Machines that are operating safely in variousapplications depend on these criteria: the machinemodel, configuration, machine maintenance,operating speed of the machine, conditions of theterrain, fluid levels, and tire inflation pressures. Themost important criteria are the skill and judgment of the operator.

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Engine Stopping

A well trained operator that follows the instructionsin the Operation and Maintenance Manual hasthe greatest impact on stability. Operator trainingprovides a per son with the following abilities:observation of working and environmental conditions,feel for the machine, identification of potential

hazards, and operating the machine safely by makingappropriate decisions.

When you wor k on side hills and when you work onslopes, consider the following important points:

Speed of travel – At higher speeds, forces of inertiatend to make the machine less stable.

Roughness of terrain or surface – The machinemay be less stable with uneven terrain.

Direction of travel – Avoid operating the machineacross the slope. When possible, operate the

machine up the slopes and operate the machinedown the slopes. Place the heaviest end of themachine uphill when you are working on an incline.

Mounted equipment – Balance of the machinemay be impeded by the following components:equipment that is mounted on the machine, machineconfigur ation, weights, and counterweights.

Nature of surface – Ground that has been newlyfilled with earth may collapse from the weight of themachine.

Surface material – Rocks and moisture of the

surface material may drastically affect the machine'straction and machine's stability. Rocky surfaces maypromote side slipping of the machine.

Slippage due to excessive loads – This may causedownhill tracks or downhill tires to dig into the ground,which will increase the angle of the machine.

Width of tracks or tires – Narrower tracks or narrower tires further increase the digging into theground which causes the machine to be less stable.

Implements attached to the drawbar – This maydecrease the weight on the uphill tracks. This may

also decrease the weight on the uphill tires. Thedecreased weight will cause the machine to be lessstable.

Height of the working load of the machine –When the working loads are in higher positions, thestability of the machine is reduced.

Operated equipment – Be aware of performancefeatures of the equipment in operation and the effectson machine stability.

Operating techniques – Keep all attachments or pulled loads low to the ground for optimum stability.

Machine systems have limitations on slopes –Slopes can affect the proper function and operationof the various machine systems. These machine

systems are needed for machine control.

Note: Safe operation on steep slopes may requirespecial machine maintenance. Excellent skill of the operator and proper equipment for specificapplications are also required. Consult the Operationand Maintenance Manual sections for the proper fluidlevel requirements and intended machine use.

i02624835

Engine Stopping

SMCS 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 two minutesbefore shutdown. This allows hot areas of the engineto cool gradually.

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Equipment Lowering withEngine Stopped

SMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment of all 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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28 SEBU8135-10Safety SectionSound Information and Vibration Information

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Sound Information andVibration Inf ormation

SMCS Code: 7000

Sound Level Information

The operator Equivalent Sound Pressure Level(Leq) is 79 dB(A) when “ISO 6396:1992” is used tomeasure the value for an enclosed cab. This valueis a dynamic cycle sound exposure level. The cabwas properly installed and maintained. The test wasconducted with the cab doors and the cab windowsclosed.

The operator Equivalent Sound Pressure Level (Leq)is 82 dB(A) when “ANSI/SAE J1166 MAY90” is used

to measure the value for an enclosed cab. This valueis a work cycle sound exposure level. The cab wasproperly installed and maintained. The test wasconducted with the cab doors and the cab windowsclosed.

Hearing protection may be needed when themachine is operated with an open operator station for extended periods or in a noisy environment. Hearingprotection may be needed when the machine isoperated with a cab that is not properly maintained or when the doors and windows are open for extendedperiods or in a noisy environment.

The average exterior sound pressure level is 87dB(A) when “SAE J88 APR95” is used to measure thevalue for the standard machine. The measurementwas conducted under the following conditions:distance of 15 m (49.2 ft) and “the machine movingforward in an intermediate gear ratio”.

As this machine is manufactured by Caterpillar, theexternal sound power level of the machine meets thecriteria that are specified in the European Directives“2002/44/EC”. The European Directives are noted onthe document of conformance and on the labels thataccompany the machine.

Sound Level Information for Machines in European UnionCountries and in Countries thatAdopt the “EU Directives”

The dynamic operator sound pressure level is 79dB(A) when “ISO 6396:1992” is used to measure thevalue for an enclosed cab. The cab was properlyinstalled and maintained. The test was conductedwith the cab doors and the cab windows closed.

“The European Union PhysicalAgents (Vibration) Directive2002/44/EC”

Vibration Data for Track-Type Tractors

Information Concerning Hand/Arm VibrationLevel

When the machine is operated according to theintended use, the hand/arm vibration of this machineis below 2.5 m/s2.

Information Concerning Whole Body VibrationLevel

This section provides vibration data and a method for estimating the vibration level for track-type tractors.

Note: Vibration levels are influenced by manydifferent parameters. Many items are listed below.

• Operator training, behavior, mode, and stress

• Job site organization, preparation, environment,weather, and material

• Machine type, quality of the seat, quality of thesuspension system, attachments, and condition of the equipment

It is not possible to get precise vibration levels for this machine. The expected vibration levels can beestimated with the information in Table 1 in order to calculate the daily vibration exposure. A simpleevaluation of the machine application can be used.

Estimate the vibration levels for the three vibrationdirections. For typical operating conditions, use theaverage vibration levels as the estimated level. Withan experienced operator and smooth terrain, subtractthe Scenario Factors from the average vibration levelin or der to obtain the estimated vibration level. For aggressive operations and severe terrain, add theScenario Factors to the average vibration level inorder to obtain the estimated vibration level.

Note: All vibration levels are in meter per secondsquared.

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Sound Information and Vibration Information

Table 1

“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Vibration Levels Scenario FactorsMachineType

Typical OperatingActivity X axis Y axis Z axis X axis Y axis Z axis

dozing 0,74 0,58 0,70 0,31 0,25 0,31

ripping 1,25 1,19 1,02 0,40 0,41 0,28Track-Type

Tractors

transfer 0,87 0,80 0,97 0,43 0,40 0,34

Note: Refer to “ISO/TR 25398 Mechanical Vibration -Guideline for the assessment of exposure to wholebody vibration of ride on operated earthmovingmachines” for more information about vibration.This publication uses data that is measuredby international institutes, organizations, andmanufacturers. This document provides informationabout the whole body exposure of operators of earthmoving equipment. Refer to Operation andMaintenance Manual, SEBU8257, “The EuropeanUnion Physical Agents (Vibration) Directive2002/44/EC” for more information about machinevibration levels.

The Cat suspension seat meets the criteria of “ISO7096”. This criteria represents vertical vibration levelunder severe operating conditions. This seat is testedwith the input “spectral class EM6”. The seat has atransmissibility factor of “SEAT<0.7”.

The whole body vibration level of the machine varies.There is a range of values. The low value is 0.5

m/s2. The machine meets the short-term level for thedesign of the seat in “ISO 7096”. The value is 1.61m/s2 for this machine.

Guidelines for Reducing Vibration Levels onEarthmoving Equipment

Properly adjust machines. Properly maintainmachines. Operate machines smoothly. Maintain theconditions of the terrain. The following guidelines canhelp 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 recommendations.

a. Tire pressures

b. Brake and steering systems

c. Controls, hydraulic system, and linkages

3. Keep the terrain in good condition.

a. Remove any large rocks or obstacles.

b. Fill any ditches and holes.

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 seatmaintained and adjusted.

a. Adjust the seat and suspension for the weightand the size of the operator.

b. Inspect and maintain the seat suspension andadjustment 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 necessary, in order to go over rough terrain.

8. Minimize vibrations for a long work cycle or a longtravel distance.

a. Use machines that are equipped withsuspension systems.

b. Use the ride control system on Track-TypeTractors.

c. If no ride control system is available, reducespeed in order to prevent bounce.

d. Haul the machines between workplaces.

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30 SEBU8135-10Safety SectionOperator Station

9. Less operator comfort may be caused by other riskfactors. The following guidelines can be effectivein 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 twistedposture.

c. Provide breaks in order to reduce long periodsof sitting.

d. Avoid jumping from the cab.

e. Minimize r epeated handling of loads and liftingof loads.

f. Minimize any shocks and impacts during sportsand leisure activities.

Sources

The vibration information and calculation procedureis based on “ISO/TR 25398 Mechanical Vibration- Guideline for the assessment of exposureto whole body vibration of ride on operatedearthmoving machines”. Harmonized data ismeasured by international institutes, organizations,and manufacturers.

This literature provides information about assessingthe whole body vibration exposure of operators of

earthmoving equipment. The method is based onmeasured vibration emission under real workingconditions for all machines.

Check the original directive. This documentsummarizes part of the content of the applicable law.This document is not meant to substitute the originalsources. Other parts of these documents are basedon information from the United Kingdom Health andSafety Executive.

Refer to Operation and Maintenance Manual,SEBU8257, “The European Union Physical

Agents (Vibration) Directive 2002/44/EC” for more

inf ormation about vibration.

Consult your local Cat dealer for more informationabout machine features that minimize vibrationlevels. Consult your local Cat dealer about safemachine operation.

Use the following web site in order to find your localdealer:

Caterpillar, Inc.www.cat.com

i03634321

Operator Station

SMCS Code: 7000; 7301

Any modifi

cations to the inside of the operator stationshould not project into the operator space or intothe space for the companion seat (if equipped).The addition of a radio, fire extinguisher, and other equipment must be installed so that the definedoperator space and the space for the companion seat(if equipped) is maintained. Any item that is broughtinto the cab should not project into the definedoperator space or the space for the companion seat(if equipped). A lunch box or other loose items mustbe secured. Objects must not pose an impact hazardin rough terrain or in the event of a rollover.

i03656846

Guards(Operator Protection)

SMCS Code: 7000; 7150; 7325

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 poor operating techniques are used. This situation canoccur even though a machine is equipped with anappropriate protective guard. Follow the establishedoperating procedures that are recommended for your machine.

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Guards

Rollover Protective Structure(ROPS), Falling Object ProtectiveStructure (FOPS) or Tip Over Protection Structure (TOPS)

The ROPS/FOPS Structure (if equipped) on your machine is specifically designed, tested andcertified for that machine. Any alteration or anymodification to the ROPS/FOPS Structure couldweaken the structure. This places the operator into an unprotected environment. Modifications or attachments 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 for mounting guidelines.

The Tip Over Protection Structure (TOPS) isanother type of guard that is used on mini hydraulic

excavators. This structure protects the operator inthe event of a tipover. The same guidelines for theinspection, the maintenance and the modification of the 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 work tool

that creates flying objects is used. Mesh front guardsthat are approved by Caterpillar or polycarbonatefront guards that are approved by Caterpillar areavailable for machines with a cab or an open canopy.On machines that are equipped with cabs, thewindows should also be closed. Safety glasses arerecommended when flying hazards exist for machineswith cabs and machines with open canopies.

If the work material extends above the cab, topguards and front guards should be used. Typical

• Rock quarries

• Forestry products

Additional guards may be required for specificapplications or work tools. The Operation and

Maintenance Manual for your machine or your work tool will provide specific requirements for theguards. Consult your Caterpillar dealer for additionalinformation.

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