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i01658146
Table of Contents
Safety Information ................................................. 4
Index Section
Index ..................................................................... 13
4 SENR7733-09
Safety Messages
There are several specific safety messages on this
i02145477 machine. The exact location of the hazards and
the description of the hazards are reviewed in this
Safety Information section. Please become familiarized with all safety
messages.
SMCS Code: 7000
Make sure that all of the safety messages are legible.
Introduction Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
Proper repair is important to the safe operation and the illustrations if the illustrations are not legible.
the reliable operation of this machine. This document When you clean the safety messages, use a cloth,
outlines basic recommended procedures. Some of water, and soap. Do not use solvent, gasoline, or
the procedures require special tools, devices, or work other harsh chemicals to clean the safety messages.
methods. Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages.
Before you perform any repairs or before Loose adhesive will allow the safety messages to fall.
you perform any maintenance, read all safety
information. Understand all safety information Replace any safety message that is damaged, or
before you perform any repairs or before you missing. If a safety message is attached to a part
perform any maintenance. that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
Safety information can be found in this document and new safety messages.
the following documents for your machine:
Protective Equipment
• Operation and Maintenance Manual
• Testing and Adjusting Manual
• Disassembly and Assembly Manual
• Warning labels that are located on the machine
and engine
Basic Precautions
g00702020
Illustration 1
Improper operation, lubrication, maintenance or When you work around the machine, always wear
repair of this product can be dangerous and could protective equipment that is required by the job
result in injury or death. conditions. Protective equipment includes the
items that follow: hard hat, protective glasses, and
Do not operate or perform any lubrication, main- protective shoes. In particular, wear protective
tenance or repair on this product, until you have glasses when you use a hammer or when you use a
read and understood the operation, lubrication, sledge hammer. When you weld use the appropriate
maintenance and repair information. protective equipment that is required by the job
conditions. Protective equipment for welding includes
the items that follow: gloves, welding hood, goggles,
Always observe the list of basic precautions that
and apron. Do not wear loose clothing or jewelry that
follows:
can catch on parts of the machine.
SENR7733-09 5
Mounting and Dismounting Make sure that all chains, hooks, slings, and any
other lifting devices are in good condition.
g00037860
Illustration 2
g00687600
Illustration 4
SENR7733-09 7
General Hazard Information Use all cleaning solutions with care. Report all
necessary repairs.
Do not damage wiring during the removal operations. Refer to Special Publication, NENG2500, “Tools and
Wiring should be reinstalled so that the wiring is not Shop Products Guide” for the following items:
damaged. Wiring should also be installed so that the
wiring will not be damaged during normal operation • Tools that are suitable for collecting fluids and
of the equipment. Do not connect wiring to a line that equipment that is suitable for collecting fluids
may contain fluid.
• Tools that are suitable for containing fluids and
Always use lift arm supports in order to keep the lift equipment that is suitable for containing fluids
arms raised. Keep all work tools tilted downward
when repair work is being formed with the lift arms Obey all local regulations for the disposal of liquids.
in the raised position. Prior to performing any
maintenance or repairs, ensure that all hydraulic Asbestos Information
pressure has been relieved.
Unless you are instructed otherwise, perform If dust that may contain asbestos is present, there
maintenance with the equipment in the servicing are several guidelines that should be followed:
position. Refer to Operation and Maintenance Manual
for the procedure for placing the equipment in the • Never use compressed air for cleaning.
servicing position.
• Avoid brushing materials that contain asbestos.
Containing Fluid Spillage
• Avoid grinding materials that contain asbestos.
Care must be taken in order to ensure that fluids
are contained during performance of inspection, • Use a wet method in order to clean up asbestos
maintenance, testing, adjusting and repair of the materials.
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
SENR7733-09 9
• A vacuum cleaner that is equipped with a high Unless you are instructed otherwise, never attempt
efficiency particulate air filter (HEPA) can also be adjustments while the machine is moving or while
used. the engine is running.
• Use exhaust ventilation on permanent machining Never jump across the starter solenoid terminals
jobs. in order to start the engine. Unexpected machine
movement could result.
• Wear an approved respirator if there is no other
way to control the dust. Whenever there are equipment control linkages the
clearance in the linkage area will change with the
• Comply with applicable rules and regulations movement of the equipment or the machine. Stay
for the work place. In the United States, use clear of areas that may have a sudden change in
Occupational Safety and Health Administration clearance with machine movement or equipment
(OSHA) requirements. These OSHA requirements movement.
can be found in “29 CFR 1910.1001”.
Stay clear of all rotating and moving parts.
• Obey environmental regulations for the disposal
of asbestos. If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
• Stay away from areas that might have asbestos maintenance is performed.
particles in the air.
Keep objects away from moving fan blades. The fan
Dispose of Waste Properly blade will throw objects or cut objects.
g00706404
Illustration 7 Burn Prevention
Improperly disposing of waste can threaten the Do not touch any part of an operating engine.
environment. Potentially harmful fluids should be Allow the engine to cool before any maintenance is
disposed of according to local regulations. performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication system,
Always use leakproof containers when you drain in the fuel system, or in the cooling system before
fluids. Do not pour waste onto the ground, down a any lines, fittings or related items are disconnected.
drain, or into any source of water.
Coolant
Crushing Prevention and Cutting
Prevention When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
Support the equipment properly before you perform pressure. The radiator and all lines to the heaters or
any work or maintenance beneath that equipment. to the engine contain hot coolant.
Do not depend on the hydraulic cylinders to hold
up the equipment. Equipment can fall if a control is Any contact with hot coolant or with steam can cause
moved, or if a hydraulic line breaks. severe burns. Allow cooling system components to
cool before the cooling system is drained.
Do not work beneath the machine component of the
machine unless the machine component is properly Check the coolant level only after the engine has
supported. been stopped.
10 SENR7733-09
Ensure that the filler cap is cool before removing the Exhaust shields (if equipped) protect hot exhaust
filler cap. The filler cap must be cool enough to touch components from oil spray or fuel spray in case of
with a bare hand. Remove the filler cap slowly in a break in a line, in a hose, or in a seal. Exhaust
order to relieve pressure. shields must be installed correctly.
Cooling system conditioner contains alkali. Alkali can Do not weld on lines or on tanks that contain
cause personal injury. Do not allow alkali to contact flammable fluids. Do not flame cut lines or tanks
the skin, the eyes, or the mouth. that contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior
Oils to welding or flame cutting.
Hot oil and hot components can cause personal Check all electrical wires daily. Repair any wires
injury. Do not allow hot oil to contact the skin. Also, that are loose or frayed before you operate the
do not allow hot components to contact the skin. machine. Clean all electrical connections and tighten
all electrical connections.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be Dust that is generated from repairing nonmetallic
cool enough to touch with a bare hand. Follow the hoods or nonmetallic fenders can be flammable
standard procedure in this manual in order to remove and/or explosive. Repair such components in a well
the hydraulic tank filler cap. ventilated area away from open flames or sparks.
g00704000
Illustration 8
Gases from a battery can explode. Keep any open Replace the parts if any of the following conditions
flames or sparks away from the top of a battery. Do are present:
not smoke in battery charging areas.
• End fittings are damaged or leaking.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or • Outer coverings are chafed or cut.
a hydrometer.
• Wires are exposed.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the • Outer coverings are ballooning.
Operation and Maintenance Manual for specific
instructions. • Flexible part of the hoses are kinked.
Do not charge a frozen battery. This may cause an • Outer covers have embedded armoring.
explosion.
• End fittings are displaced.
Fire Extinguisher
Make sure that all clamps, guards, and heat shields
Make sure that a fire extinguisher is available. Be are installed correctly. During machine operation, this
familiar with the operation of the fire extinguisher. will help to prevent vibration, rubbing against other
Inspect the fire extinguisher and service the fire parts, and excessive heat.
extinguisher regularly. Obey the recommendations
on the instruction plate. Tire Information
g00337832
Illustration 11
(A) At least 15 m (50 ft)
(B) At least 500 m (1500 ft)
Work Tools
Make sure that all necessary guarding is in place on
the host machine and on the work tool.