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®© 2010 CaterpillarAll Rights Reserved

SAFETYOperation and MaintenanceManual Excerpt

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SEBU7864-16

July 2010

Operation andMaintenance

Manual325D and 329D Excavators

GPB1-Up (Machine)XDB1-Up (Machine)BFC1-Up (Machine)NAC1-Up (Machine)

PKE1-Up (Machine)CZF1-Up (Machine)LAL1-Up (Machine)MCL1-Up (Machine)PAL1-Up (Machine)EBM1-Up (Machine)TPM1-Up (Machine)GBR1-Up (Machine)T2S1-Up (Machine)WLT1-Up (Machine)CYW1-Up (Machine)SCY1-Up (Machine)

SAFETY.CAT.COM

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6 SEBU7864-16Safety SectionSafety Messages

Safety Section

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Safety Messages

SMCS Code: 7000; 7405

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 visible.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.

Replace any safety 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 saf ety messages.

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SEBU7864-16 7Safety Section

Safety Messages

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Safety Messages


Do Not Operate (1)

This safety message is located in the cab on the rightside window.

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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 any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

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Crushing Hazard (2)


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Crushing Hazard! Certain machine front linkagecombinations (boom, stick, quick coupler, worktool) may require keeping the work tool away fromthe cab during operation. Personal injury or deathmay result if the work tool contacts the cab duringoperation.

Refer to Operation and Maintenance Manual,“Operating Technique Information” for further information.

Crushing Hazard (3)

This safety message is located in rear of the cab.

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Personal injury can result if the window is notlatched in the overhead position; ensure the au-to lock is engaged.

Refer to Operation and Maintenance Manual,“Window (Front)” for further information.

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Safety Messages

Product Link (4)

If Equipped, this safety message is positioned in thecab on the left side door post.

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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 within12 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.

Refer to Operation and Maintenance Manual ,“Product Link” for further information.

Do Not Weld or Drill on ROPS (5)

If equipped, this safety message is located on theleft side pillar in the cab.

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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 the

structure. Consult a Caterpillar dealer to deter-mine this structure's limitations without voidingits certification.

This machine has been certified to the standards thatare listed on the certification plate. The maximummass of the machine, which includes the operator and the attachments without a payload, should notexceed the mass on the certification plate.

Refer to Operation and Maintenance Manual,“Guards (Operator Protection)” for more information.

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Safety Messages

Electrical Power Lines (8)


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Electrocution Hazard! Keep the machine and at-tachments a safe distance from electrical power.Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions andwarnings in the Operation and Maintenance Manu-al. Failure to follow the instructions and warningswill cause serious injury or death

Refer to Operation and Maintenance Manual,“Specifications” for further information.

Crushing Hazard (9)


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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.

Refer to Operation and Maintenance Manual,“Guards” for further information.

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Overload Warning Device (If Equipped) (10)


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Overloading the machine could impact the ma-chine's stability which could result in a tipover hazard. A tipover hazard could result in serious in-

jury or death. Always activate the overload warn-ing device before you handle or lift objects.

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

Joystick Controls AlternatePatterns (11)

If Equipped, this safety message is located in the cabon the right side window.

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Crush Hazard. Improper joystick setting couldcause possible unexpected movement of theboom, stick, or worktool which could result inserious injury or death. Confirm that the joy-stick settings are properly configured before youoperate the machine. Read the Operation andMaintenance Manual.

Refer to Operation and Maintenance Manual,

“Joystick Controls Alternate Patterns” for further information.

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Safety Messages

Hot Surface (12)

This safety message is located in two locations onthe engine hood.

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Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or compo-nents to contact your skin. Use protective clothingor protective equipment to protect your skin.

Aerosol Starting Aid (13)

This safety message is located inside the left frontcompartment on the engine air filter.

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Explosion hazard! Do not use ether! This machineis equipped with an air inlet heater. Using ether can create explosions or fires that can cause per-sonal injury or death. Read and follow the startingprocedure in the Operation and Maintenance Man-ual.

Refer to Operation and Maintenance Manual, “EngineStarting” for further information.

Relieve Hydraulic Tank Pressure(14)

This safety message is located on top of the hydraulictank.

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HYDRAULIC TANK

RELIEVE TANK PRESSURE WITH ENGINE OFF BYREMOVING CAP SLOWLY TO PREVENT BURNSFROM HOT OIL.

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High Pressure Gas (15)

This safety message is located on the accumulator inthe right back compartment.

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This system contains high pressure gas. Failure tofollow the instructions and warnings could causean explosion, resulting in possible injury or death.

Do not expose to fire. Do not weld. Do not drill.Relieve pressure before discharging.

See Operation and Maintenance Manual for charg-ing and discharging. See your Caterpillar Dealer for tools and detailed information.

Refer to Operation and Maintenance Manual,“Equipment Lowering with Engine Stopped” for further information.

Pressurized System (16)

This safety message is located on top of the radiator,next to the filler cap.

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Pressurized system! Hot coolant can cause seri-ous burns, injury or death. To open the coolingsystem filler cap, stop the engine and wait untilthe cooling system components are cool. Loosenthe cooling system pressure cap slowly in order torelieve the pressure. Read and understand the Op-eration and Maintenance Manual before perform-ing any cooling system maintenance.

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Level - Check” for further information.

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Safety Messages

Crushing Hazard (17)

This safety message is located on the rear of eachside of the machine. This safety message is alsolocated on each side of the counterweight.

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Machine swings. Stay back. Crushing hazardcould cause serious injury or death.

Jump Start Cables (18)

This safety message is located inside the left frontcompartment.

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Explosion Hazard! Improper jumper cable connec-tions can cause an explosion resulting in seriousinjury or death. Batteries may be located in sep-arate compartments. Refer to the Operation andMaintenance Manual for the correct jump startingprocedure.

Refer to Operation and Maintenance Manual,“Engine Starting with Jump Start Cables” for further information.

High Pressure Cylinder (19)

This safety message is positioned on the trackadjuster on both sides of the machine.

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High Pressure Cylinder. Do not remove any partsfrom the cylinder until all of the pressure has beenrelieved. This will prevent possible personal injuryor death.

Refer to Operation and Maintenance Manual, “Track Adjustment - Adjust” for the adjustment procedure.

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18 SEBU7864-16Safety Section

Additional Messages

Crushing Hazard (20)

This safety message is located on both sides of thestick.

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A crushing hazard exists when the stick and boomare in motion and when the machine is being usedin object handling applications. Failure to stayclear of the stick and boom when the machine

is in operation can result in personal injury or death. Stay clear of the stick and boom when themachine is in operation.

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Additional Messages

SMCS Code: 7000; 7405

There are several specific messages on thismachine. The exact location of the messages andthe description of the information are reviewed in this

section. 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.

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.

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Additional Messages



Cleaning Windows (1)

This message is located in three places on the cabwindows.

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20 SEBU7864-16Safety Section

Additional Messages


NOTICEClean windows with a wet cloth or sponge. Dry clothor sponge may scratch window material.

Alternate Exit (2)

This message is located on the back window of thecab in the lower left hand corner.


Break glass in order to exit.

Refer to Operation and Maintenance Manual,“Alternate Exit” for further information.

Machine Security System (3)

This message is located on the window on the rightside of the cab.


This machine may be equipped with a securitysystem. Read the Operation and MaintenanceManual before you operate the machine.

Refer to Operation and Maintenance Manual,“Machine Security System” for more information.

Data Privacy (4)


The Product Link System is a satellite communicationdevice that transmits information regarding themachine back to Caterpillar and Caterpillar dealersand customers. All logged events and diagnosticcodes 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,“Product Link” for more information.

Radial Seal Air Filters (5)

This message is located on the air cleaner.

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General Hazard Information


To avoid engine damage, use only Caterpillar radialseal air filters. Other filters will not seal properly.Read the operation and maintenance manual.

Refer to Operation and Maintenance Manual, “Engine Air Filter Primary Element - Clean/Replace”.

Alternate Joystick Control Patterns(6)

This message is located behind the front left sideaccess door.


The machine control pattern can easily be changedto the SAE system or to the standard backhoe loader hydraulic system (BHL) by changing the position of the two-way valve (if equipped).

Refer to Operation and Maintenance Manual,“Joystick Controls Alternate Patterns” for further information.

No Step (7)

This message is located on the engine cover on thetop of the machine.


Do not step in this area.

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SMCS Code: 7000


Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment. These warning tags (SpecialInstruction, SEHS7332) are available from your Caterpillar dealer.

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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Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can cause

serious 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.

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 suitablecontainers 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.

Asbestos Information


Caterpillar equipment and replacement parts that areshipped f rom Caterpillar are asbestos free. Caterpillar

recommends the use of only genuine Caterpillar 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. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust that

contains asbestos 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.

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24 SEBU7864-16Safety SectionCrushing Prevention and Cutting Prevention

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requir ements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

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

Dispose of Waste Properly


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

any 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 terminalsin order to start the engine. Unexpected machinemovement could result.

Whenever there are equipment control linkages theclearance in the linkage area will change with the

movement 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.

CoolantWhen 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.

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26 SEBU7864-16Safety SectionFire 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.

Follow practices for safe fueling that are describedin the “Operation” section of the Operation andMaintenance Manual section and follow localregulations. Never store flammable fluids in theoperator 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

Caterpillar dealer for service.

Follow safe procedures for engine starting with jumpstart cables. Improper jumper cable connections cancause an explosion that may result in injury. Refer toOperation and Maintenance Manual, “Engine Startingwith Jump Start Cables” for specific instructions.

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 inorder 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 may

have 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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Fire 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 Caterpillar 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 Caterpillar dealer for repair or for replacement parts.

Keep wiring and electrical connections free of debris.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike highpr essure lines. Do not install any lines that are bent or damaged. Use the appropriate backup wrenches inorder to tighten all connections to the recommendedtorque.


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, looseor damaged. Leaks may provide fuel for fires.Consult your Caterpillar dealer for repair or for replacement parts. Use genuine Caterpillar parts or the equivalent, for capabilities of both the pressurelimit and temperature limit.

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Before Starting Engine

• 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 the

ground during an electrical storm, stay away fromthe vicinity of the machine.

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Before Starting Engine

SMCS Code: 1000; 7000

Start the engine only from the operator compartment.Never short across the starter terminals or acrossthe batteries. Shorting could damage the electricalsystem by bypassing the engine neutral start system.

Inspect the condition of the seat belt and of themounting hardware. Replace any parts that are wornor damaged. Regardless of appearance, replace theseat belt after three years of use. Do not use a seatbelt extension on a retractable seat belt.

Adjust the seat so that full pedal travel can beachieved with the operator's back against the backof the seat.

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

properly.

Before you start the engine and before you move themachine, make sure that no one is underneath themachine, around the machine, or on 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 switch

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

Make sure that you are seated before you start theengine.

Move all hydraulic controls to the HOLD positionbefore you start the engine. Move the hydrauliclockout control to the LOCKED position. For further details on this procedure, refer to Operation andMaintenance Manual, “Operator Controls”.

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.

Briefly sound the horn before you start the engine.

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Before Operation

SMCS Code: 7000

Clear all personnel from the machine and from thearea.

Clear all obstacles from the machine's path. Bewareof hazards (wires, ditches, etc).

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

Adjust the rearview mirrors (if equipped) for the bestvisibility close to the machine. Make sure that thehorn, the travel alarm (if equipped), and all other warning devices are working properly.

Fasten the seat belt securely.

Warm up the engine and the hydraulic oil beforeoperating the machine.

Before moving the machine, check the position of theundercarriage. The normal travel position is with theidler wheels to the front under the cab and the drivesprockets to the rear. When the undercarriage is inthe reversed position, the directional controls mustbe operated in opposite directions.

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Visibility Information

SMCS Code: 7000

Before you start the machine, perform a walk-aroundinspection in order to ensure that there are nohazards 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.

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30 SEBU7864-16Safety SectionOperation

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 are

located 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:

• Safety instructions

• Controlled patterns of machine movement andvehicle movement

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

• Restricted areas

• Operator training

• 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 theuser that result in a restriction of visibility shall beevaluated.

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Operation

SMCS Code: 7000

Machine Operating TemperatureRange

The machine must function satisfactorily in theanticipated ambient temperature limits that areencountered during operation. The standard machineconfiguration is intended for use within an ambienttemperatur e range of −20 °C (−4 °F) to 43 °C(109 °F). Special configurations for different ambienttemperatures may be available. Consult your Caterpillar dealer for additional information on specialconfigurations of your machine.

Machine Operation

Only oper ate the machine while you are in a seat.The seat belt must be fastened while you operate themachine. Only operate the controls while the engineis running.

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

When the machine is moving watch the clearanceof the boom. Uneven ground can cause the boomto move in all directions.

Make sure that no personnel will be endangeredbefore you move the machine. Do not allow riders onthe machine unless the machine has an additionalseat with a seat belt.

Repor t any machine damage that was noted duringmachine operation. Make any necessary repairs.

Never use the work tool for a work platform.

Hold attachments approximately 40 cm (15 inches)above ground level while you drive the machine. Donot drive the machine close to an overhang, to theedge of a cliff, or to the edge of an excavation.

If the machine begins to sideslip on a grade,immediately dump the load and turn the machinedownhill.

Be careful to avoid any ground condition which couldcause the machine to tip. Tipping can occur whenyou work on hills, on banks, or on slopes. Tipping canalso occur when you cross ditches, ridges, or other unexpected obstructions.

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32 SEBU7864-16Safety SectionParking

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.

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Parking

SMCS Code: 7000

The hydraulic system remains pressurized if theaccumulator is charged. This condition is true evenwhen the engine is not running. This pressure shoulddecrease in a short time (approximately 1 minute).While the hydraulic system maintains a charge, thehydraulic work tools and machine controls remainfunctional.

Machine movement that is sudden and unexpectedwill occur if any of the controls are moved.Unexpected machine movement can cause personalinjury or death.

Always move the hydraulic lockout control to theLOCKED position before you shut off the engine or immediately after the engine stops running.

Park the machine on a level surface. If you mustpark the machine on a grade, chock the tracks of themachine.


Place the machine in the servicing position.

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34 SEBU7864-16Safety SectionSound Information and Vibration Information

Note: All vibration levels are in meter per secondsquared.

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

excavating 0,44 0,27 0,30 0,24 0,16 0,17

hydraulic breaker application

0,53 0,31 0,55 0,30 0,18 0,28

mining application 0,65 0,42 0,61 0,21 0,15 0,32

Track TypeExcavator

transfer 0,48 0,32 0,79 0,19 0,20 0,23

Note: Refer to “ISO/TR 25398 Mechanical Vibration -Guideline for the assessment of exposure to wholebody vibration of ride on operated earthmoving

machines” 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 Caterpillar suspension seat meets the criteria of “ISO 7096”. This represents vertical vibration levelunder severe operating conditions.

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'srecommendations.

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 it is necessary 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 typeexcavators.

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

d. Haul the machines between workplaces.

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Operator 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, organizationsand 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.

You should check the original directive. Thisdocument summarizes part of the content of theapplicable law. This document is not meant tosubstitute the original sources. Other parts of thesedocuments are based on information from the UnitedKingdom Health and Safety Executive.

Refer to Operation and Maintenance ManualSupplement , SEBU8257 for more information aboutvibration.

Consult your local Caterpillar dealer for moreinformation about machine features that minimizevibration levels. Consult your local Caterpillar dealer about safe machine operation.

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

Caterpillar, Inc.www.cat.com

i03634321

Operator Station

SMCS Code: 7300; 7301; 7325

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

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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36 SEBU7864-16Safety SectionGuards

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 top

• 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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