Cs 533e Seguridad

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SAFETYOperation and Maintenance Manual Excerpt

KEBU7519-08July 2009

Operation andMaintenanceManualCP-533E and CS-533E Vibratory SoilCompactorsBZE1-Up (Machine)TBE1-Up (Machine)BZG1-Up (Machine)TLH1-Up (Machine)DAK1-Up (Machine)ASL1-Up (Machine)TJL1-Up (Machine)ASM1-Up (Machine)DAM1-Up (Machine)

SAFETY.CAT.COM

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

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such asDANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by NOTICE labelson the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

6 KEBU7519-08Safety SectionSafety Messages

Safety Sectioni01985458

Safety MessagesSMCS Code: 7000; 7405

g01028855Illustration 2

KEBU7519-08 7Safety Section

Safety Messages



Do Not Operate (1)This safety message is located on the steeringconsole.

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DO NOT OPERATE OR WORK ON THIS MACHINEUNLESS YOU HAVE READ AND UNDERSTANDTHE INSTRUCTIONS AND WARNINGS IN THEOPERATION AND MAINTENANCE MANUALS.FAILURE TO FOLLOW THE INSTRUCTIONS ORHEED THE WARNINGS COULD RESULT IN IN-JURY OR DEATH. CONTACT ANY CATERPILLARDEALER FOR REPLACEMENT MANUALS. PROP-ER CARE IS YOUR RESPONSIBILITY.

Seat Belt (2)This safety message is located on the side post forthe cab or the ROPS/FOPS guard.

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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.

Do Not Weld or Drill (3)This safety message is located on the side of the cabor the ROPS/FOPS guard.

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


Safety Messages

No Clearance (4)This safety message is located on the frame betweenthe cab and the drum.

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No clearance for a man in this area when the ma-chine turns. Severe injury or death from crushingcould occur.

Install the steering frame lock pin into the lockedposition before lifting the machine, transportingthe machine on another vehicle, or performingservice near the center of the machine.

Disengage the steering lock pin from articulationjoint and store in retainer before resuming opera-tion or the machine will not steer.

No Ether (5)This safety message is located on the top of theradiator.

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


Pressurized System (6)This safety message is located on the top of theradiator.

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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.


Additional Messages

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Additional MessagesSMCS Code: 1000; 7000; 7405


Door Latch (1)

This message is located on the inside of the door.

12 KEBU7519-08Safety SectionGeneral Hazard Information


Alternate Exit (2) (If Equipped)

This message is located on the right side window forthe cab.


Jacking Up Location (3)

This message is located on both sides of themachines.


This is the recommended location for jacking up themachine.

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General Hazard InformationSMCS Code: 7000


Attach a Do Not Operate warning tag or a similarwarning 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 yourCaterpillar 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 powercables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.


General Hazard Information


Wear a hard hat, protective glasses, and otherprotective 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 conditionerrefrigerant 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 allnecessary 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 leveluse appropriate devices such as ladders or man liftmachines. If equipped, use the machine anchoragepoints and use approved fall arrest harnesses andlanyards.

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal 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 forcleaning purposes must be below 275 kPa (40 psi).

Trapped PressurePressure 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 hose towhip. High pressure oil that is released can cause oilto spray. Fluid penetration can cause serious injuryand possible death.

Fluid PenetrationPressure 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.

14 KEBU7519-08Safety SectionGeneral Hazard Information


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.

Containing Fluid SpillageCare 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 ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer 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 from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement 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 thatcontains 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 highefficiency particulate air filter (HEPA) can also beused.

Use exhaust ventilation on permanent machiningjobs.

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


Crushing Prevention and Cutting Prevention

Comply with applicable rules and regulationsfor 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.

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 PreventionSMCS 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 terminalsin 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 retainerpin 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 PreventionSMCS Code: 7000

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

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

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

Check the coolant level only after the engine hasbeen stopped.

16 KEBU7519-08Safety SectionFire Prevention and Explosion Prevention

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

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

OilsHot oil and hot components can cause personalinjury. Do not allow hot oil to contact the skin. Also,do not allow hot components to contact the skin.

Remove the hydraulic tank filler cap only after theengine has been stopped. The filler cap must becool enough to touch with a bare hand. Follow thestandard procedure in this manual in order to removethe hydraulic tank filler cap.

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

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Fire Prevention and ExplosionPreventionSMCS Code: 7000


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

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

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operatea machine when a fire hazard exists. Contact yourCaterpillar dealer for service.

Understand the use of the primary exit and alternativeexit on the machine. Refer to Operation andMaintenance Manual, Alternative Exit.

Do not operate a machine with a fluid leak. Repairleaks 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, etc. These items may accumulate inthe engine compartment or around other hot areasand 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 forstoring flammable materials.


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.

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 yourCaterpillar 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 ora hydrometer.

Daily inspect battery cables that are in visible areas.Identify cables, clips, straps, and other restraints fordamage. Replace these items if necessary. Look forsigns of the following, which can occur over time dueto 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.

18 KEBU7519-08Safety 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 componentsbefore 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 Caterpillardealer.

WiringCheck 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 forreplacement parts.

Keep wiring and electrical connections free of debris.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bent ordamaged. Use the appropriate backup wrenches inorder to tighten all connections to the recommendedtorque.


Check lines, tubes and hoses carefully. WearPersonal Protection Equipment (PPE) in order tocheck for leaks. Always use a board or cardboardwhen you check for a leak. Leaking fluid that is underpressure 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 otherparts, 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 forreplacement parts. Use genuine Caterpillar parts orthe equivalent, for capabilities of both the pressurelimit and temperature limit.


Fire Extinguisher Location

EtherEther (if equipped) is commonly used in cold weatherapplications. Ether is flammable and poisonous.

Follow the correct cold engine starting procedures.Refer to the section in the Operation and MaintenanceManual with the label Engine Starting.

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

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

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49 C (120.2 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 ExtinguisherAs an additional safety measure, keep a fireextinguisher on the machine.

Be familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher 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 LocationSMCS Code: 7000; 7419

g01007658Illustration 17This is the recommended location for a machine that is equippedwith a cab.

g01007659Illustration 18This is the recommended location for a machine that is equippedwith an open ROPS canopy.

Do not weld the ROPS in order to install the fireextinguisher. Also, do not drill holes in the ROPS inorder to mount the fire extinguisher on the ROPS.

If the fire extinguisher is mounted on the ROPS, strapthe mounting plate to a leg of the ROPS. If the weightof the fire extinguisher is more than 4.5 kg (10 lb),mount the fire extinguisher as low as possible on oneleg. Do not mount the fire extinguisher on the upperone-third area of the leg.

20 KEBU7519-08Safety SectionTire Information

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Tire InformationSMCS Code: 7000

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

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


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

Do not approach a warm tire. Maintain a minimumdistance, as shown. Stay outside the shaded area inIllustration 19.

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

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

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Electrical Storm InjuryPreventionSMCS Code: 7000

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

Mount the machine.

Dismount the machine.

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

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Before Starting EngineSMCS Code: 1000; 7000

Make sure that the steering frame lock link is storedin the unlocked position. The steering frame locklink must be removed in order to steer the machine.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.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Make sure that all machine lights are workingproperly. Before you start the engine and beforeyou move the machine, make sure that no one isunderneath the machine, around the machine, oron the machine. Make sure that the area is free ofpersonnel.

KEBU7519-08 21Safety SectionEngine Starting

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Engine StartingSMCS Code: 1000; 7000


Do not start the engine or move any controls if thereis a Do Not Operate or similar warning tag attachedto the start switch or controls.

Before you start the engine, check for the presenceof bystanders or maintenance personnel. Ensure thatall personnel are clear of the machine. Briefly soundthe forward horn before you start the engine.

Move the parking brake switch to the ON position.

Start the engine and operate the engine in a wellventilated area. In an enclosed area, vent the exhaustto the outside.

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Before OperationSMCS Code: 7000

Clear all personnel from the machine and from thearea.

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

Make sure that the machine horn, the backup alarm(if equipped) and all other warning devices areworking properly.

Fasten the seat belt securely.

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Visibility InformationSMCS 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.

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 properworking 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 orderto 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 traffic 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.

22 KEBU7519-08Safety SectionOperation

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OperationSMCS Code: 7000

Machine Operating Temperature Range. Themachine must function satisfactorily in the anticipatedambient temperature limits that are encounteredduring operation. The minimum limits of items thatwill effect the safe operation of the machine tobe considered are 0-100% relative humidity for40 C (40 F) to 50 C (122 F) temperaturesunless otherwise specified in marketing functionalspecification.

Only operate 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.

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

Make sure that no personnel will be endangeredbefore you move the machine.

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

additional seat

additional seat belt

Never use the work tool as a work platform.

Note any needed repairs during machine operation.Report any needed repairs.

Carry attachments approximately 40 cm (15 inches)above ground level. Do not go close to the edge of acliff, an excavation, or an overhang.

If the machine begins to sideslip downward on agrade, immediately remove the load and turn themachine downhill.

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

Avoid operating the machine across the slope. Whenpossible, operate the machine up the slopes anddown the slopes.

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

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

Know the maximum dimensions of your machine.

i02624835

Engine StoppingSMCS Code: 1000; 7000

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

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

i01985552

ParkingSMCS Code: 7000

Park on a level surface. If you must park on a grade,chock the machine's wheels.

Move the propel control lever to the NEUTRALposition. Engage the parking brake.

Lower all attachments to the ground.

Stop the engine.

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

Note: If you are parking the machine for an extendedperiod of time, turn the battery disconnect switchto the OFF position. This will prevent drainage ofthe battery. A battery short circuit, any current drawfrom certain components, and vandalism can causedrainage of the battery.


Equipment Lowering with Engine Stopped

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Equipment Lowering withEngine StoppedSMCS Code: 7000

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

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Sound Information andVibration InformationSMCS Code: 7000

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

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the EU DirectivesThe operator sound pressure level is 82 dB(A).The operator sound pressure level was measuredaccording to the static test procedures and conditionsthat are specified in ISO 6394.

The exterior sound power level is 111 dB(A). Theexterior sound power level was measured accordingto the static test procedures and conditions that arespecified in ISO 6393.

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

Vibration Data for Single Drum VibratoryCompactor

Information Concerning Hand/Arm VibrationLevel

When the machine is operated according to theintended use, the hand/arm vibration of this machineis below 2.5 meter per second squared.

Information Concerning Whole Body VibrationLevel

This section provides vibration data and a methodfor estimating the vibration level for Single DrumVibratory Compactors.

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 ofthe equipment

It is not possible to get precise vibration levels forthis machine. The expected vibration levels can beestimated with the information in Table 1 in orderto 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 order to obtain the estimated vibration level. Foraggressive 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.

24 KEBU7519-08Safety SectionSound 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

compaction (boulder) 0,47 0,53 0,41 0,17 0,22 0,12Single DrumVibratoryCompactor compaction (silt) 0,29 0,28 0,28 0,08 0,17 0,11

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 ofearthmoving 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 ofISO 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. Maintainmachines according to themanufacturer'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 orderto 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 orderto minimize the vibration level.

a. Drive around obstacles and rough terrain.

b. Slow down when it is necessary to go overrough 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.

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

d. Haul the machines between workplaces.

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 orderto achieve good posture.

b. Adjust the mirrors in order to minimize twistedposture.

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


Operator Station

d. Avoid jumping from the cab.

e. Minimize repeated handling of loads and liftingof loads.

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

SourcesThe 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 ofearthmoving 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 Manual,SEBU8257, The European Union PhysicalAgents (Vibration) Directive 2002/44/EC for moreinformation about vibration.

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

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

Caterpillar, Inc.www.cat.com

i03634321

Operator StationSMCS Code: 7000; 7300; 7301; 7325

Any modifications 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 otherequipment 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.

i01992325

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

26 KEBU7519-08Safety SectionGuards

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

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

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

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

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

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

Demolition applications

Rock quarries

Forestry products

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

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