SAFETY INFORMATION Caterpillar

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read 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 warnings are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as shown below.

Show/hide table

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.

Operations that may cause product damage are identified by NOTICE labels on 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. If a tool, procedure, work method or operating technique not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

Safety Information

Proper repair is important to the safe and reliable operation of this product. This Service Manual outlines basic recommended procedures, some of which require special tools, devices or work methods.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in this Service Manual and in the descriptions of operations where hazards exist.

Labels

Labels are used to provide instructions and identify specific hazards in the Service Manual and on the product.

The hazards are identified by the"Safety Alert Symbol" and followed by a "Single Word" such as "WARNING" as shown below.

Show/hide table

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

Show/hide table

Warning labels are used to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons. These labels identify hazards which may not be apparent to a trained mechanic. There are many potential hazards during repair for an untrained mechanic and there is no way to label the product against all such hazards. Improper repair procedures can be dangerous and could result in injury or death.

Operations that may result only in mechanical damage are identified by labels on the product and in the Service Manual by the word NOTICE.

NOTICE

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this Service Manual are therefore not all inclusive. If a procedure, tool device or work method not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the procedures you choose.

Current Information

The information, specifications and illustrations in this book are on the basis of information available at the time it was written. The specifications, torques, pressures of operation, measurements, adjustments, illustrations and other items can change at any time. These changes can affect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information available. For a list of the most current modules and form numbers available for each Service Manual, see the Service Manual Contents Microfiche REG1139F.

General Safety Information

Show/hide table

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read 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 warnings are not heeded, bodily injury or death could occur to you or other persons.

The person servicing the product may be unfamiliar with many of the systems on the product. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

Because of the size of some components, the service person should check the weights noted in this Manual. Use proper lifting procedures when removing any components.

Basic Precautions

Following is a list of basic precautions that should always be observed.

1. Read and understand all Warning signs on the product before operating, lubricating or repairing this product. Replace any damaged, illegible or missing warning plates, signs or decals.

2. If an engine must be started to make pressure or rpm checks, be sure all guards are installed. To help prevent an accident caused by parts in rotation, work carefully around machinery that has been put in operation.

3. Make sure the work area around the product is made safe and be aware of hazardous conditions that may exist.

4. Use steps and handholds when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using steps, handholds and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

Corrosion Inhibitor

Corrosion inhibitor contains alkali. Avoid contact with eyes. Avoid prolonged or repeated contact with skin. Do not take internally. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. CALL PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

Batteries

Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not let electrolyte solution make contact with skin or eyes. Electrolyte solution is an acid. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. CALL PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

Protective Equipment

Always wear a hard hat, protective glasses, protective shoes and other protective equipment as required by job conditions when working around this product. In particular, wear protective glasses when pounding on any part of the product or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose clothing or jewelry that can catch on parts of the product.

Pressurized Items

1. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

2. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Check lines, tubes and hoses carefully. Do not use your hand to check for leaks. Pin hole leaks can result in a high velocity fluid stream that will be invisible close to the hose, tube or line. This fluid can penetrate the skin and cause personal injury. Use a board or cardboard to check for leaks.

Hot Fluids and Parts

1. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

2. Be careful when removing fill caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

Lifting

Use a hoist when lifting components which weigh 23 kg (50 lb.) or more, to avoid back injury. Make sure all chains, hooks, slings, etc., are in good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

Repair

1. Disconnect battery and discharge any capacitors before starting any repair work. Hang "Do Not Operate" tag in the Operator's compartment or on the controls.

2. If possible, make all repairs with the machine parked on a level, hard surface. Block machine to prevent it from rolling while working on or under machine.

3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the product before performing any service or disassembly.

4. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device. Then, pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

5. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

6. Replace all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary.

7. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Make reference to "Techniques of Structural Repair Course" form number SEGV2549. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

8. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

9. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

10. Always use lift arm supports to keep lift arms raised. Keep the attachment tilted down when maintenance or repair work is being performed which requires the lift arms in the raised position.

11. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in the event of a line, tube or seal failure must be installed correctly.

12. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. Make sure all protective devices including guards and shields are properly installed and functioning correctly before starting the engine or operating the machine.

Asbestos Information

Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. Components in Caterpillar products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets. The asbestos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not generated.

If dust which may contain asbestos is present, there are several common sense guidelines that should be followed.

1. Never use compressed air for cleaning.

2. Avoid brushing or grinding of asbestos containing materials.

3. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter.

4. Use exhaust ventilation on permanent machining jobs.

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

6. Comply with applicable rules and regulations for the work place (for example in the U.S.A., OSHA requirements as set forth in 29 CFR 1910.1001).

7. Follow environmental rules and regulations for disposal of asbestos.

8. Avoid areas where asbestos particles may be in the air.

Show/hide table

Disconnect batteries before performance of any service work.