sebu7970-08 s

®© 2010 CaterpillarAll Rights Reserved

®

SAFETYOperation and Maintenance Manual Excerpt

SEBU7970-08April 2009

Operation andMaintenanceManual416E, 422E and 428E Backhoe LoadersSHA1-Up (416E)CBD1-Up (416E)CST1-Up (416E)HBE1-Up (422E)SNL1-Up (428E)

SAFETY.CAT.COM

i01658146

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

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

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

The meaning of this safety alert symbol is as follows:

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

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

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

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

6 SEBU7970-08Safety SectionSafety Messages

Safety Sectioni03452324

Safety MessagesSMCS 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 legible.When you clean the safety messages, use a cloth,water and soap. Do not use solvent, gasoline, orother harsh chemicals to clean the safety 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, ormissing. If a safety message is attached to a partthat is replaced, install a safety message on thereplacement part. Any Caterpillar dealer can providenew safety messages.

SEBU7970-08 7Safety Section

Safety Messages

g01799213Illustration 2(1) Do Not Operate.(2) No Ether in Air Inlet(3) Jump Starting(4) High Pressure Accumulator(5) Rollover Protective Structure/Falling

Object Protective Structure

(6) Crushing Hazard(7) No Exit(8) Brace for the Lift Cylinder(9) Pressurized System(10) High Cylinder Pressure(11) Seat Belt

(12) Quick Coupler - Crushing Hazard(13) Crushing Hazard(14) Product Link


Do Not Operate (1)This safety message is located under the enginestart switch.

g01370904

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

No Ether In Air Inlet (2)This safety message is located on the air filter cover.

g01372254

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.

Proper Connections for Jump StartCables (3)This safety message is located on the inside of thedoor for the battery compartment.

g01370909

Explosion Hazard! Improper jumper cable connec-tions can cause an explosion resulting in seriousinjury or death. Batteries may be located in sep-arate compartments. When using jump start ca-bles, always connect the positive (+) cable fromthe source to the positive (+) terminal of the bat-tery that is connected to the starter solenoid. Con-nect the negative (−) cable from the source to thenegative (−) terminal of the starter. If the machineis not equipped with a starter negative terminal,connect the negative (−) cable to the engine block.Follow the procedure in the Operation and Main-tenance Manual.


Safety Messages

High Pressure Accumulator (4)This safety message is located on the accumulatorif the machine is equipped with the option for ridecontrol.

g01370912

Hydraulic accumulator contains gas and oil underhigh pressure. Improper removal or repair proce-dures could cause severe injury. To remove or re-pair, instructions in the service manual must befollowed. Special equipment is required for test-ing and charging.

ROPS (5)This safety message is located on the cab next tothe left side door.

g01799348

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


Crush Hazard (6)This safety message is located on the boom abovethe boom foot pin.

g01371644

Crushing Hazard! Stay back a safe distance. Thereis no clearance for a person in this area when themachine turns. Failure to follow these instructionscould cause serious injury or death.

No Exit (7)This safety message is located on the back of thecab.

g01407377

Crush hazard; This is not an entrance or exit. Stayclear of this area when the machine is operating.Start and operate the backhoe from the operatorseat only. Failure to follow these warnings couldresult in injury or death.

Brace The Lift Cylinder (8)This safety message is located on the brace for theloader lift arm.

g01407376

Loader lift arm brace must be in place when work-ing under raised lift arms.

Failure to follow the instructions or heed the warn-ings could result in injury or death.

Pressurized System (9)This safety message is located on the cooling systemfiller cap.

g01407380

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


Safety Messages

High Cylinder Pressure (10)This safety message is located on both sides of theboom near the connection with the stick.

g01407379

High Pressure Cylinder. Failure to read and fol-low these instructions can cause rapidly discharg-ing gas and/or hydraulic fluid which can result indeath, personal injury and property damage.

Seat Belt (11)This safety message is located under the enginestart switch.

g01370908

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.

Quick Coupler (12)This safety message is located in the front of the cabon the right side.

g01411137

CRUSH INJURY. COULD CAUSE SERIOUS IN-JURY OR DEATH. ALWAYS CONFIRM QUICKCOUPLER PINS ARE ENGAGED. REFER TO THEOPERATION AND MAINTENANCE MANUAL


Crush Hazard (13) (If Equipped)This safety message is located on the sides of thecoupler on the backhoe.

g01803414

A crushing hazard exists when the boom sectionsare being retracted or extended. Stay clear of theboom when the machine is in operation. Failure tostay clear of the boom when the machine is oper-ation can cause injury or death.

Product Link (14) (If Equipped)This safety message is located in the front of the cabon the right side.

g01381177

This machine is equipped with a CaterpillarProduct Link radio communication device whichmust be deactivated within 6.0 m (20 ft) of a blastzone. Failure to do so could result in seriousinjury or death.


Additional Messages

i02897596

Additional MessagesSMCS Code: 7000; 7405

g01442834Illustration 3

Pinning of the Extendable Stick (1)

If equipped, this message is located on the stick.


The E-Stick must be pinned before using attach-ments, to prevent movement which could causepersonal injury.

Improper Location of the Backhoe Bucket (2)

This message is located by the linkage for thebackhoe bucket.


Improper bucket pin connection can cause ma-chine damage. Make sure the bucket pins are con-nected properly.

Data Privacy (3)

This message is located in the cab.

14 SEBU7970-08Safety SectionGeneral Hazard Information


i03559343

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.


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.


General Hazard Information

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.


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.

16 SEBU7970-08Safety SectionCrushing Prevention and Cutting Prevention

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.

• 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.

i01359664

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.


Burn Prevention

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.

i01329099

Burn PreventionSMCS Code: 7000

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

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

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

Check the coolant level only after the engine hasbeen stopped.

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

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

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

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

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

i01359795

Fire Prevention and ExplosionPreventionSMCS Code: 7000


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

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

18 SEBU7970-08Safety SectionFire Prevention and Explosion Prevention

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

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

Do not operate the machine near any flame.

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

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

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

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

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


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


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

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

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

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

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

EtherEther is flammable and poisonous.

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


Fire Extinguisher Location

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

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

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

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

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

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

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

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

i00980571

Fire Extinguisher LocationSMCS Code: 7000; 7419

Make sure that a fire extinguisher is on the machine.Make sure that you are familiar with the operation ofthe fire extinguisher. Inspect the fire extinguisher andservice the extinguisher. Obey the recommendationson the instruction plate.

Mount the fire extinguisher in the battery box. Do notweld the ROPS in order to install the fire extinguisher.Also, do not drill holes in the ROPS in order to mountthe fire extinguisher on the ROPS.

i01943386

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 15.

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

20 SEBU7970-08Safety SectionElectrical Storm Injury Prevention

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.

i01122596

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.

i00771840

Before Starting EngineSMCS 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 workingproperly.

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.

i03571438

Engine StartingSMCS Code: 1000; 7000

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

Move all hydraulic controls to the HOLD positionbefore you start the engine.

Move the transmission direction control lever to theNEUTRAL position.

Engage the parking brake.

Diesel engine exhaust contains products ofcombustion which can be harmful to your health.Always start the engine in a well ventilated area.Always operate the engine in a well ventilated area.If you are in an enclosed area, vent the exhaust tothe outside.

Briefly sound the horn before you start the engine.

i03162317

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:


Restricted Visibility

• 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.

i03164423

Restricted VisibilitySMCS Code: 7000

The operator has areas near this machine that haverestrictions in visibility. Job site organization willneed to be used in order to minimize the hazards ofrestricted visibility. For more information regardingjob site organization, refer to this Operation andMaintenance Manual, “Visibility Information”

The illustration below provides a visual indicationof the areas of restricted visibility near the machinein two locations. One location is on a rectangularline 1.00 m (3.28 ft) from the outside of the machineprofile at a height of 1.5 m (4.92 ft). The secondlocation is on the ground level at a radius of 12.00 m(39.37 ft) from the operator.


Top view of the machine

Note: This illustration does not show all areas ofrestricted visibility that are inside the two locations orrestricted visibility that may exist at further distancesfrom the machine.

• (A) 1 m (3 ft)

• (B) 2 m (6 ft 6 in)

• (C) 1 m (3 ft)

i01388947

Before OperationSMCS Code: 7000

Clear all personnel from the machine and from thearea.

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

The stabilizers must be in the correct positionbefore you operate the machine. Completely raisethe stabilizers for transporting the machine or forloader operation. Lower the stabilizers before youoperate the backhoe. DO NOT DIG UNDER THESTABILIZERS!

22 SEBU7970-08Safety SectionOperation

Stand on the outside of the machine on the groundin order to reposition the flip-over stabilizer pads. DONOT REPOSITION THE STABILIZER PADS WHILEYOU ARE IN THE CAB!

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

For the best visibility of the area that is close to themachine, adjust the rearview mirrors (if equipped).

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

Fasten the seat belt securely.

i02973608

OperationSMCS Code: 7000

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

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

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

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

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

Carry work tools at approximately 40 cm (15 inches)above ground level.

Do not go close to the edge of a cliff, an excavation,or an overhang.

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

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

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

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

Know the maximum dimensions of your machine.

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

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.

i03562303

Work ToolsSMCS Code: 6700

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

Work tools and work tool control systems, thatare compatible with your Caterpillar machine, arerequired for safe machine operation and/or reliablemachine operation. If you are in doubt about thecompatibility of a particular work tool with yourmachine, consult your Caterpillar dealer.

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

Keep all windows and doors closed on the hostmachine. A polycarbonate shield must be used whenthe host machine is not equipped with windows andwhen a work tool could throw debris.

Do not exceed the maximum operating weight that islisted on the ROPS certification.

If your machine is equipped with an extendable stick,install the transport pin when you are using thefollowing work tools: hydraulic hammers, augers, andcompactors


Parking

Always wear protective glasses. Always wear theprotective equipment that is recommended in thework tool's operation manual. Wear any otherprotective equipment that is required for the operatingenvironment.

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

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

Never use the work tool for a work platform.

i01439117

ParkingSMCS Code: 7000

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

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

Move the speed control lever to the LOW IDLEposition.

Engage the parking brake.

Engage the transmission neutral lock.

Lower all work tools to the ground.

Stop the engine.

Turn the engine start switch key to the OFF positionfor 4 seconds.

Turn the engine start switch key back to the ONposition.

Press the hydraulic shutoff switch to the UNLOCKEDposition.

Move the hydraulic control levers back and forth inorder to relieve hydraulic pressure.

Move the hydraulic control levers to the HOLDposition.

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

i01329161

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.

i02546111

Sound Information andVibration InformationSMCS Code: 7000

Sound Level InformationThe operator Equivalent Sound Pressure Level(Leq) is 80 dB(A) when “ANSI/SAE J1166 OCT 98”is used to measure the value for an enclosed cab.This is a work cycle sound exposure level. The cabwas properly installed and maintained. The test wasconducted with the cab doors and the cab windowsclosed.

Hearing protection may be needed when themachine is operated with an open operator station 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.

The average exterior sound pressure level is 80dB(A) when the “SAE J88Apr95 - Constant SpeedMoving Test” procedure is used to measure the valuefor the standard machine. The measurement wasconducted under the following conditions: distance of15 m (49.2 ft) and “the machine moving forward in anintermediate gear ratio”.

24 SEBU7970-08Safety SectionSound Information and Vibration Information

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the “EU Directives”The dynamic operator sound pressure level is 80dB(A) when “ISO 6396:1992” is used to measure thevalue for an enclosed cab. The cab was properlyinstalled and maintained. The test was conductedwith the cab doors and the cab windows closed.

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

Vibration Data for Backhoe Loaders

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 method forestimating the vibration level for backhoe loaders.

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.


Sound Information and Vibration Information

Table 1

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

Vibration Levels Scenario FactorsMachine Type Typical Operating

Activity X axis Y axis Z axis X axis Y axis Z axis

Backhoe Loader excavating 0,28 0,26 0,20 0,09 0,16 0,06

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 of“ISO 7096”. This represents vertical vibration levelunder severe operating conditions. This seat is testedwith the input “spectral class EM5”. The seat has atransmissibility factor of “SEAT<0.7”.

The whole body vibration level of the machine varies.There is a range of values. The low value is 0.5meter per second squared. The machine meets theshort term level for the design of the seat in “ISO7096”. The value is 1.68 meter per second squaredfor this machine.

Guidelines for Reducing Vibration Levels onEarthmoving Equipment

Properly adjust machines. Properly maintainmachines. Operate machines smoothly. Maintain theconditions of the terrain. The following guidelines canhelp reduce the whole body vibration level:

1. Use the right type and size of machine, equipment,and attachments.

2. 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 on compactbackhoe loaders.

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.

26 SEBU7970-08Safety SectionOperator Station

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 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

i01649970

Operator StationSMCS Code: 7000; 7300

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

sebu7970-08 s

Documents

product operation

product damage

safety precautions

thatthe product

safety alert symbol

safety alert warning

repair information

observebasic safety