12K Motor Grader - Machine Safety

12KMOTOR GRADERMachine Safety

Excerpted from Operation & Maintenance Manual (SEBU8250-01)

®© 2010 CaterpillarAll Rights Reserved

®

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 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.

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 SEBU8250-01Safety SectionSafety Messages

Safety Sectioni02947653

Safety MessagesSMCS Code: 7000

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SEBU8250-01 7Safety Section

Safety Messages


There are several specific safety messages on thismachine. The exact location of the messages andthe description of the messages 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.


Do Not Operate (1)This safety message is located on the right side ofthe operator compartment.

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

Do Not Weld On The ROPS/FOPSStructure (2)This safety message is positioned on the ROPS.

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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.

This machine has been certified to the standardsthat are listed on the certification film. The maximummass of the machine, which includes the operatorand the attachments without a payload, should notexceed the mass on the certification film.

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


Safety Messages

Seat Belt (3)This safety message is located on the left side of theoperator compartment.

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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.

Refer to Operation and Maintenance Manual, “SeatBelt” for more information.

No Clearance (4)This safety message is positioned at the front rightand the front left of the engine compartment.

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Stay back a safe distance. No clearance for a per-son in this area when the machine turns. Severeinjury or death from crushing could occur.

Improper Connections For JumpStart Cables (5)This safety message is positioned below the batteriesinside the service center.

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

Refer to Operation and Maintenance Manual, “EngineStarting with Jump Start Cables” for more information.

Radiator Fan (6)This safety message is positioned on the fuel tankand the side panels on each side of the machine.

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Keep hands clear of fan while engine is running.May cause serious injury or death.


Fall Hazard (7)This safety message is positioned on the battery boxon each side of the machine.

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Do not use this surface as a step or platform. Thissurface may not support additional weight or maybe slippery. Serious injury or death could occurfrom a fall.

Engine Coolant (8)This safety message is positioned on the undersideof the radiator cap access cover on top of the enginecompartment.

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

Refer to Operation and Maintenance Manual,“Cooling System Coolant Level - Check” for moreinformation.


Safety Messages

No Clearance (9)This safety message is positioned near the centerpivot on both sides of the machine.

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Connect the steering frame lock between the frontand the rear frames before lifting, transporting, orservicing the machine in the articulation area. Dis-connect the steering frame lock and secure thesteering frame lock before resuming operation.Severe injury or death could occur.

Refer to Operation and Maintenance Manual,“Steering Frame Lock” for more information.

Accumulator (10)This safety message is positioned on the brakeaccumulators. The brake accumulators are located atthe rear of the cab.

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Cold ambient temperatures could result in the lossof secondary braking capability due to inadequatehydraulic accumulator nitrogen pre-charge. Theloss of the secondary braking system as well asthe main hydraulic pressure will result in little orno braking capability and a potential for injury ordeath.

It is recommended to perform a brake accumula-tor check anytime the machine has been idle forlonger than two hours below −25 °C (−13 °F). Referto Operation and Maintenance Manual beforeperforming any check of the brake accumulator.

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.


Product Link (11) (If Equipped)This safety message is attached to the dash or toanother area of the cab that is visible to the operator.

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This machine is equipped with a Caterpillar Prod-uct Link communication device which must be de-activated within 12 m (40 ft) of a blast zone. Failureto do so could result in serious injury or death.


Additional Messages

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Additional MessagesSMCS Code: 7000


14 SEBU8250-01Safety SectionAdditional Messages



There are several specific messages on thismachine. The exact location of the messages andthe description of the messages are reviewed inthis section. Please become familiarized with allmessages.

Make sure that all of the messages are legible.Clean the messages or replace the messages ifyou cannot read the words. Replace the illustrationsif the illustrations are not legible. When you cleanthe messages, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures themessages. Loose adhesive will allow the messagesto fall.

Replace any message that is damaged, or missing.If a message is attached to a part that is replaced,install a message on the replacement part. AnyCaterpillar dealer can provide new messages.

Air Conditioner (1)

This message is located inside the enginecompartment near the hinges of the right front accessdoor.


Additional Messages


Read the service manual before you perform anymaintenance on the air conditioner.

Cat Extended Life Coolant (ELC) (2)

This message is located on the underside of theradiator cap access cover on top of the enginecompartment.


Refer to Operation and Maintenance Manual,“Cooling System Coolant (ELC) - Change” andOperation and Maintenance Manual, “CoolingSystem Coolant Extender (ELC) - Add” for moreinformation.

Alternate Exit (3)

This message is located on the door latch for theright door.


If the primary exit is blocked, exit the machinethrough the door on the right side of the machine.

Do Not Weld and Do Not Drill. (4)

This message is located on the left hand side of thefront frame.


Do not weld or drill the frame. Refer to Operation andMaintenance Manual, “Guards (Operator Protection)”for more information.

Alternate Exit (5)

If your machine is equipped with a snow wing, thismessage is located on the left ROPS support at therear of the operator's compartment.

16 SEBU8250-01Safety SectionAdditional Messages


If the primary exits are blocked, use the hammerto break the window. Exit the machine through thewindow.

Data Privacy (6)

This message is located in the cab.


Hydraulic Tank Drain (7)

This message is located at the left rear of the machinenear the drain valve for the hydraulic system.


Air Tank (8)

This message is located on the left rear side of themachine.


Refer to Operation and Maintenance Manual, “AirTank Moisture and Sediment - Drain” for furtherinformation.

Engine Oil Drain (9)

This message is located at the left rear of themachine near the drain valve for the engine oil.


Cooling System Drain (10)

This message is located at the left rear of themachine near the drain valves for the cooling system.


General Hazard Information


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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.


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.

18 SEBU8250-01Safety SectionGeneral 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.


Crushing 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.

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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.

20 SEBU8250-01Safety SectionBurn 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.

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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.

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.


Fire Prevention and Explosion Prevention

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.


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


22 SEBU8250-01Safety SectionFire Prevention and Explosion Prevention

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.

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.


Fire Extinguisher Location


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.

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

Do not weld a bracket on the Rollover ProtectiveStructure (ROPS) in order to install the fireextinguisher. Also, do not drill holes in the ROPS inorder to mount the fire extinguisher on the ROPS.

Strap the mounting plate to a leg of the ROPSin order to mount the fire extinguisher. If the fireextinguisher weighs more than 4.5 kg (10 lb), mountthe fire extinguisher low on one leg of the ROPS. Donot mount the fire extinguisher on the upper one-thirdportion of the leg.

24 SEBU8250-01Safety 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 26.

Do not use water or calcium as a ballast for the tires.Dry nitrogen gas is recommended for inflation of tires.If the tires were originally inflated with air, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

Nitrogen inflated tires reduce the potential ofa tire explosion because nitrogen does not aidcombustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration of rubber, and corrosion ofrim components.

To avoid overinflation, proper nitrogen inflationequipment and training in the usage of the equipmentare necessary. A tire blowout or a rim failure canresult from improper equipment or from misusedequipment.

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.

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.

i02957742

Before Starting EngineSMCS Code: 1000; 7000


Place frame lock link (1) in the storage bracket. Theframe lock link must be removed from the lockedposition in order to articulate the machine.


Before Starting Engine


Remove wheel lean bolt (2) from the locked position.The wheel lean bolt must be removed in order to leanthe wheels.

Start the engine only from the operator'scompartment. Never short across the starterterminals or across the batteries. Shorting couldbypass the engine neutral start system. Shortingcould also damage the electrical system.


Make sure that the machine horn works properly.


The mirrors on your machine may be different. Adjustthe mirrors for the best operator vision. Adjust theinside mirror or the inside mirrors before you operatethe machine. If the machine is equipped with outsidemirrors, adjust the outside mirrors before you operatethe machine.

Inspect the condition of the seat belt and the conditionof mounting hardware. Replace any damaged partsand any worn parts. Regardless of appearance,replace the seat belt after three years of use. Do notuse a seat belt extension on a retractable seat belt.

Adjust the seat in order to achieve full pedal travelwhen the operator's back is against the back of theseat. Adjust the steering column tilt lever in orderto enhance the operation of the machine from theoperator's seat. Adjust the steering wheel tilt lock inorder to enhance the operation of the machine fromthe operator's seat.

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

Before you start the engine or before you move themachine, make sure that no one is on the machine,underneath the machine, or around the machine.Make sure that there are no personnel in the area.

26 SEBU8250-01Safety SectionEngine Starting

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Engine StartingSMCS Code: 1000; 7000

If a warning tag is attached to the engine start switchor to the machine controls, do not start the engine.Also, do not move any machine controls.

Move all hydraulic controls to the HOLD position or tothe OFF position before you start the engine.

Move the transmission control (lever) to theNEUTRAL position.

Engage the parking brake control.

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.

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Before OperationSMCS Code: 7000; 7600

Clear all personnel from the machine and from thearea.

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

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.

Remove the wheel lean locking bolt from the wheellean lock bracket. Make sure that the frame lock pinis stored in the unlocked position. The frame lock pinmust be removed in order to steer the machine.

For the best vision of the area that is close to themachine, adjust the rear view 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.

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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.


Operation

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OperationSMCS Code: 7000; 7600

Machine Operating TemperatureRangeThe standard machine configuration is intendedfor use within an ambient temperature rangeof −40 °C (−40 °F) to 50 °C (122 °F). Specialconfigurations for different ambient temperaturesmay be available. Consult your Caterpillar dealer foradditional information on special configurations ofyour machine.

Machine OperationOnly 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.

Before you operate the machine, remove the wheellean locking bolt from the wheel lean lock bracket.Make sure that the frame lock pin is stored in theunlocked position. The steering frame lock link mustbe removed in order to steer the machine.

Do not use the wheel lean locking bolt and the wheellean lock bracket in order to center the wheel leanof the machine.

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

Before you move the machine, you must make surethat no one will be endangered.

Do not allow riders on the machine.

Reduce engine speed when you maneuver in tightquarters or when you are going over a hill.

When you operate the machine downhill, use twotransmission gears less than the transmission gearthat is used when you operate the machine up thesame hill.

Do not allow the engine to overspeed when youoperate the machine downhill. If overspeed exists,use the service brake control to decrease the speedto a level that will allow you to downshift. Repeat thisprocess until a stable speed is obtained.

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.

Before you maneuver the machine, make surethat no personnel are between the machine andattachments.

Know the maximum dimensions of your machine.

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

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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.

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ParkingSMCS Code: 7000

Park the machine on a level surface. If you must parkon a grade, chock the machine's wheels with suitablechocks. Take into account the following:

• tire size

28 SEBU8250-01Safety SectionSlope Operation

• machine weight

• ground conditions

Apply the service brake in order to stop themachine. Move the transmission control (lever) tothe NEUTRAL position. Move the throttle control tothe LOW IDLE position.

Engage the parking brake.

Lower all equipment to the ground. Activate anycontrol locks.

Stop the engine.

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

Turn the battery disconnect switch to the OFFposition. Remove the disconnect switch key if youdo not operate the machine for an extended periodof time. This will prevent drainage of the battery. Abattery short circuit, any current draw from certaincomponents, and vandalism can cause drainage ofthe battery.

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Slope OperationSMCS Code: 7000

Machines that are operating safely in variousapplications depend on these criteria: the machinemodel, configuration, machine maintenance,operating speed of the machine, conditions of theterrain, fluid levels, and tire inflation pressures. Themost important criteria are the skill and judgment ofthe operator.

A well trained operator that follows the instructionsin the Operation and Maintenance Manual hasthe greatest impact on stability. Operator trainingprovides a person with the following abilities:observation of working and environmental conditions,feel for the machine, identification of potentialhazards, and operating the machine safely by makingappropriate decisions.

When you work on side hills and when you work onslopes, consider the following important points:

Speed of travel – At higher speeds, forces of inertiatend to make the machine less stable.

Roughness of terrain or surface – The machinemay be less stable with uneven terrain.

Direction of travel – Avoid operating the machineacross the slope. When possible, operate themachine up the slopes and operate the machinedown the slopes. Place the heaviest end of themachine uphill when you are working on an incline.

Mounted equipment – Balance of the machinemay be impeded by the following components:equipment that is mounted on the machine, machineconfiguration, weights, and counterweights.

Nature of surface – Ground that has been newlyfilled with earth may collapse from the weight of themachine.

Surface material – Rocks and moisture of thesurface material may drastically affect the machine'straction and machine's stability. Rocky surfaces maypromote side slipping of the machine.

Slippage due to excessive loads – This may causedownhill tracks or downhill tires to dig into the ground,which will increase the angle of the machine.

Width of tracks or tires – Narrower tracks ornarrower tires further increase the digging into theground which causes the machine to be less stable.

Implements attached to the drawbar – This maydecrease the weight on the uphill tracks. This mayalso decrease the weight on the uphill tires. Thedecreased weight will cause the machine to be lessstable.

Height of the working load of the machine –When the working loads are in higher positions, thestability of the machine is reduced.

Operated equipment – Be aware of performancefeatures of the equipment in operation and the effectson machine stability.

Operating techniques – Keep all attachments orpulled loads low to the ground for optimum stability.

Machine systems have limitations on slopes –Slopes can affect the proper function and operationof the various machine systems. These machinesystems are needed for machine control on slopes.

Note: Safe operation on steep slopes may requirespecial machine maintenance. Excellent skill ofthe operator and proper equipment for specificapplications are also required. Consult the Operationand Maintenance Manual sections for the proper fluidlevel requirements and intended machine use.


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 InformationThe operator Equivalent Sound Pressure Level(Leq) is 78 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 84dB(A) when the “SAE J88Feb2006 - 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”.

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the “EU Directives”The dynamic operator sound pressure level is 77dB(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 Motor Graders

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 motor graders.

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.

30 SEBU8250-01Safety SectionSound Information and Vibration Information

Note: All vibration levels are in meter per secondsquared.

Table 1

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

Vibration Levels Scenario FactorsMachineType

Typical OperatingActivity X axis Y axis Z axis X axis Y axis Z axis

finish grading 0,41 0,48 0,38 0,22 0,26 0,14

hard grading 0,61 0,64 0,78 0,21 0,21 0,30MotorGraders

transfer 0,39 0,36 0,58 0,25 0,25 0,34

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 EM4”. The seat has atransmissibility factor of “SEAT<1.1”.

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 0.63 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 motor graders.


Operator Station

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.

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 the calculationprocedure is based on “ISO/TR 25398 MechanicalVibration - 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

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Operator StationSMCS Code: 7000

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.

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Guards(Operator Protection)SMCS Code: 7000

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.

32 SEBU8250-01Safety 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.

12K Motor Grader - Machine Safety

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