Caterpillar 422E Operator Manual Instant Download by The Service Repair Manual

Operationand Maintenance Manual

422E,428E,432E,434E,442E,444E

BackhoeLoaders

JBA1-Up(432E)

NBA1-Up(444E)

EME1-Up(442E)

SEF1-Up(434E)

DPH1-Up(428E)

SJL1-Up(434E)

MAW1-Up(422E)

ImportantSafetyInformation

Mostaccidentsthatinvolveproductoperation,maintenanceandrepairarecausedbyfailuretoobserve basicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentiallyhazardous situationsbeforeanaccidentoccurs.Apersonmustbealerttopotentialhazards,includinghumanfactors thatcanaffectsafety.Thispersonshouldalsohavethenecessarytraining,skillsandtoolstoperformthese functionsproperly.

Improperoperation,lubrication,maintenanceorrepairofthisproductcanbedangerousandcould resultininjuryordeath.

Donotoperateorperformanylubrication,maintenanceorrepaironthisproduct,untilyouverify thatyouareauthorizedtoperformthiswork,andhavereadandunderstoodtheoperation, lubrication,maintenanceandrepairinformation.

Safetyprecautionsandwarningsareprovidedinthismanualandontheproduct.Ifthesehazardwarnings arenotheeded,bodilyinjuryordeathcouldoccurtoyouortootherpersons.

Thehazardsareidentifiedbythe“SafetyAlertSymbol”andfollowedbya“SignalWord”suchas “DANGER”,“WARNING”or“CAUTION”.TheSafetyAlert“WARNING”labelisshownbelow.

Themeaningofthissafetyalertsymbolisasfollows:

Themessagethatappearsunderthewarningexplainsthehazardandcanbeeitherwrittenorpictorially presented.

Anon-exhaustivelistofoperationsthatmaycauseproductdamageareidentifiedby “NOTICE” labelson theproductandinthispublication.

Caterpillarcannotanticipateeverypossiblecircumstancethatmightinvolveapotentialhazard. Thewarningsinthispublicationandontheproductare,therefore,notallinclusive.Youmustnot usethisproductinanymannerdifferentfromthatconsideredbythismanualwithoutfirst satisfyingyourselfthatyouhaveconsideredallsafetyrulesandprecautionsapplicabletothe operationoftheproductinthelocationofuse,includingsite-specificrulesandprecautions applicabletotheworksite.Ifatool,procedure,workmethodoroperatingtechniquethatisnot specificallyrecommendedbyCaterpillarisused,youmustsatisfyyourselfthatitissafeforyou andforothers.Youshouldalsoensurethatyouareauthorizedtoperformthiswork,andthatthe productwillnotbedamagedorbecomeunsafebytheoperation,lubrication,maintenanceorrepair proceduresthatyouintendtouse.

Theinformation,specifications,andillustrationsinthispublicationareonthebasisofinformationthatwas availableatthetimethatthepublicationwaswritten.Thespecifications,torques,pressures, measurements,adjustments,illustrations,andotheritemscanchangeatanytime.Thesechangescan affecttheservicethatisgiventotheproduct.Obtainthecompleteandmostcurrentinformationbeforeyou startanyjob.Catdealershavethemostcurrentinformationavailable.

Whenreplacementpartsarerequiredforthis productCaterpillarrecommendsusingCatreplacementparts.

Failuretofollowthiswarningmayleadtoprematurefailures,productdamage,personalinjuryordeath.

IntheUnitedStates,themaintenance,replacement,orrepairoftheemissioncontroldevicesand systemsmaybeperformedbyanyrepairestablishmentorindividualoftheowner'schoosing.

Foreword

CaliforniaProposition65Warning

Dieselengineexhaustandsomeofits constituentsareknowntotheStateof Californiatocausecancer,birthdefects, andotherreproductiveharm.

WARNING –Thisproductcan exposeyoutochemicals includingethyleneglycol,which isknowntotheStateofCaliforniato causebirthdefectsorotherreproductive harm.Formoreinformationgoto:

www.P65Warnings.ca.gov

Donotingestthischemical.Washhands afterhandlingtoavoidincidental ingestion.

WARNING –Thisproductcan exposeyoutochemicals includingleadandlead compounds,whichareknowntothe StateofCaliforniatocausecancer,birth defects,orotherreproductiveharm.For moreinformationgoto:

www.P65Warnings.ca.gov

Washhandsafterhandlingcomponents thatmaycontainlead.

LiteratureInformation

Thismanualshouldbestoredintheoperator's compartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operation instructions,transportationinformation,lubrication information,andmaintenanceinformation.

Somephotographsorillustrationsinthispublication showdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthave beenremovedforillustrativepurposes.

Continuingimprovementandadvancementof productdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication. Read,study,andkeepthismanualwiththemachine.

Wheneveraquestionarisesregardingyourmachine, orthispublication,pleaseconsultyourCatdealerfor thelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.In addition,thissectionidentifiesthetextandlocations ofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedin thesafetysectionbeforeoperatingorperforming lubrication,maintenance,andrepaironthismachine.

Operation

Theoperationsectionisareferenceforthenew operatorandarefresherfortheexperienced operator.Thissectionincludesadiscussionof gauges,switches,machinecontrols,attachment controls,transportation,andtowinginformation.

Photographsandillustrationsguidetheoperator throughcorrectproceduresofchecking,starting, operating,andstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationare basic.Skillandtechniquesdevelopastheoperator gainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipment care.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificservice interval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.The MaintenanceIntervalScheduleliststhepagenumber forthestep-by-stepinstructionsrequiredto accomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"one safesource"forallmaintenanceprocedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicing intervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehour meterintervalsifthecalendarintervalsprovidemore convenientservicingschedulesandapproximatethe indicatedservicehourmeterreading.Performthe recommendedserviceattheintervalthatoccursfirst.

Undersevere,dusty,orwetoperatingconditions, morefrequentlubricationthanisspecifiedinthe maintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginal requirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslisted underevery250servicehoursormonthlyandevery 10servicehoursordaily.

CertifiedEngineMaintenance

Propermaintenanceandrepairareessentialtokeep theengineandmachinesystemsoperatingcorrectly. Astheheavy-dutyoff-roaddieselengineowner,you areresponsiblefortheperformanceoftherequired maintenancelistedintheOwnerManual,Operation andMaintenanceManual,andServiceManual.

Itisprohibitedforanypersonengagedinthe businessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orto renderinoperative,anyemission-relateddeviceor elementofdesigninstalledonorinanengineor machinethatisincompliancewithallapplicable regulationsoftheintendedcountrytowhichithas beenshipped.Certainelementsofthemachineand enginesuchastheexhaustsystem,fuelsystem, electricalsystem,intakeairsystem,andcooling systemmaybeemission-relatedandshouldnotbe alteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceed machinedesigncapacitywhichcanadverselyaffect performancecharacteristics.Includedwouldbe stabilityandsystemcertificationssuchasbrakes, steering,androlloverprotectivestructures(ROPS). ContactyourCatdealerforfurtherinformation.

ProductIdentificationNumber

EffectiveFirstQuarter2001theProductIdentification Number(PIN)haschangedfrom8to17characters. Toprovideuniformequipmentidentification, constructionequipmentmanufacturersaremovingto complywiththelatestversionoftheproduct identificationnumberingstandard.Non-roadmachine PINsaredefinedbyISO10261.ThenewPINformat willapplytoallmachinesandgeneratorsets.The PINplatesandframemarkingwilldisplaythe17 characterPIN.Thenewformatwilllooklikethe following:

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProduct SequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirst Quarter2001willmaintaintheir8characterPIN format.

Componentssuchasengines,transmissions,axles, andworktoolswillcontinuetousean8character SerialNumber(S/N).

1.WorldManufacturingCode(characters1-3)

SafetySection SafetyMessages

SafetySection

SafetyMessages

SMCSCode: 7000;7405

Thereareseveralspecificsafetymessagesonthis machine.Theexactlocationofthehazardsandthe descriptionofthehazardsarereviewedinthis section.Pleasebecomefamiliarizedwithallsafety messages.

Illustration2

g01912973

Makesurethatallofthesafetymessagesarelegible. Cleanthesafetymessagesorreplacethesafety messagesifyoucannotreadthewords.Replacethe illustrationsiftheillustrationsarenotlegible.When youcleanthesafetymessages,useacloth,water, andsoap.Donotusesolvent,gasoline,orother harshchemicalstocleanthesafetymessages. Solvents,gasoline,orharshchemicalscouldloosen theadhesivethatsecuresthesafetymessage.Loose adhesivewillallowthesafetymessagetofall.

Replaceanysafetymessagethatisdamaged,or missing.Ifasafetymessageisattachedtoapartthat isreplaced,installasafetymessageonthe replacementpart.AnyCaterpillardealercanprovide newsafetymessages.

DoNotOperate(1)

Thissafetymessageislocatedundertheenginestart switch.

Donotoperateorworkonthismachineunless youhavereadandunderstandtheinstructions andwarningsintheOperationandMaintenance Manuals.Failuretofollowtheinstructionsor heedthewarningscouldresultininjuryordeath. ContactyourCatdealerforreplacementmanuals. Propercareisyourresponsibility.

NoEtherInAirInlet(2)

Thissafetymessageislocatedontheairfiltercover.

Illustration3

g01370904

Illustration4

g01372254

SafetySection SafetyMessages

Ifequippedwithanairinletheater(AIH)forcold weatherstarting,donotuseaerosaltypesof startingaidssuchasether.Suchusecouldresult inanexplosionandpersonalinjury.

ProperConnectionsforJumpStart Cables(3)

Illustration5

g01370909

Thissafetymessageislocatedontheinsideofthe doorforthebatterycompartment.

ExplosionHazard!Improperjumpercableconnectionscancauseanexplosionresultinginseriousinjuryordeath.Batteriesmaybelocatedin separatecompartments.Whenusingjumpstart cables,alwaysconnectthepositive(+)cable fromthesourcetothepositive(+)terminalofthe batterythatisconnectedtothestartersolenoid. Connectthenegative(−)cablefromthesourceto thenegative(−)terminalofthestarter.Ifthemachineisnotequippedwithastarternegativeterminal,connectthenegative(−)cabletothe engineblock.FollowtheprocedureintheOperationandMaintenanceManual.

HighPressureAccumulator(4)

Thissafetymessageislocatedontheaccumulator forthepilotoperatedhydrauliccontrols.This accumulatorislocatedontheframeontherightrear ofthemachine.

Hydraulicaccumulatorcontainsgasandoil underhighpressure.Improperremovalorrepair procedurescouldcausesevereinjury.Toremove orrepair,instructionsintheservicemanualmust befollowed.Specialequipmentisrequiredfor testingandcharging.

ROPS(5)

Illustration7

g01113333

Thissafetymessageislocatedonthecabnexttothe leftsidedoor.

Illustration6

g01374065

Structuraldamage,anoverturn,modification,alteration,orimproperrepaircanimpairthisstructure'sprotectioncapabilitytherebyvoidingthis certification.Donotweldonordrillholesinthe structure.ConsultaCaterpillardealertodeterminethisstructure'slimitationswithoutvoiding itscertification.

CrushHazard(6)

Thissafetymessageislocatedontheboomabove theboomfootpin.

CrushingHazard!Staybackasafedistance. Thereisnoclearanceforapersoninthisarea whenthemachineturns.Failuretofollowthese instructionscouldcauseseriousinjuryordeath.

NoExit(7)

Thissafetymessageislocatedontherearofthe slideframe.

Crushhazard;Thisisnotanentranceorexit. Stayclearofthisareawhenthemachineisoperating.Startandoperatethebackhoefromtheoperatorseatonly.Failuretofollowthesewarnings couldresultininjuryordeath.

BraceTheLiftCylinder(8)

Thissafetymessageislocatedonthebraceforthe loaderliftarm.

Illustration8

Illustration9

Whenperforminganyworkunderneatharaised loaderliftarm,theloaderliftarmbracemustbe inplace.Installtheloaderliftarmbraceas follows.

1. Emptyloaderbucket.Removepinthatsecures loaderliftarmbracetoleftloaderarm.Raise theloaderarmswiththebucketinthedump position.

2. Positionservicebraceoverleftliftcylinderwith flatendagainstcylinderend.

3. Pushpinthroughholesofloaderliftarmbrace andinstallcotterpin.

4. Slowlylowerloaderarmsuntilbracecontacts thetopoftheliftcylinderandbossesonloader arm.

5. Toremoveloaderliftarmbrace,reverse procedure.

Failuretofollowthisprocedurecanresultin deathorseriousinjuryiftheloaderarmsareaccidentallylowered.

RefertoOperationandMaintenanceManual,“Lift CylinderBrace-ConnectandDisconnect” formore information.

PressurizedSystem(9)

Thissafetymessageislocatedonthecoolingsystem fillercap.

ousburn.Toopencap,stopengine,waituntilradiatoriscool.Thenloosencapslowlytorelieve thepressure.

HighCylinderPressure(10)

Thissafetymessageislocatedonbothsidesofthe boomneartheconnectionwiththestick.

Illustration11

g01370913

Pressurizedsystem:Hotcoolantcancauseseri-

HighPressureCylinder.Failuretoreadandfollow theseinstructionscancauserapidlydischarging gasand/orhydraulicfluidwhichcanresultin death,personalinjuryandpropertydamage.

SeatBelt(11)

Thissafetymessageislocatedabovetheengine startswitch.

Aseatbeltshouldbewornatalltimesduringmachineoperationtopreventseriousinjuryordeath intheeventofanaccidentormachineoverturn. Failuretowearaseatbeltduringmachineoperationmayresultinseriousinjuryordeath.

QuickCoupler(12)(IfEquipped)

Thissafetymessageislocatedinthefrontofthecab ontherightside.

CRUSHINJURY.COULDCAUSESERIOUSINJURYORDEATH.ALWAYSCONFIRMQUICK COUPLERPINSAREENGAGED.REFERTOTHE OPERATIONANDMAINTENANCEMANUAL

HighPressureAccumulator(13)

Thissafetymessageislocatednexttothe accumulatorifthemachineisequippedwiththe optionforridecontrol.Theaccumulatorislocated behindthebatterybox.

Illustration12 g01407379

Illustration13

Illustration14

g01411137

ProductLink(14)(IfEquipped)

Thissafetymessageislocatedinthefrontofthecab ontheleftpost.

ThismachineisequippedwithaCaterpillarProductLinkcommunicationdevice.Whenelectric detonatorsareused,thiscommunicationdevice shouldbedeactivatedwithin12m (40ft) ofa blastsiteforsatellite-basedsystemsandwithin 3m (10ft) ofablastsiteforcellularbasedsystems,orwithinthedistancemandatedunderapplicablelegalrequirements.Failuretodoso couldcauseinterferencewithblastingoperations andresultinseriousinjuryordeath.

IncaseswherethetypeofProductLinkmodule cannotbeidentified,Caterpillarrecommendsthat thedevicebedisablednolessthan12m (40ft) fromtheblastperimeter.

ObjectHandlingStability(15)(If Equipped)

Thissafetymessageislocatedontherightofthecab ontheconsole.

Illustration15

g01370912

Illustration16

g01370917

Overloadingthemachinecouldimpactthemachine'sstabilitywhichcouldresultinatipover hazard.Atipoverhazardcouldresultinserious injuryordeath.Alwaysactivatethestabilityalarm switchbeforeyouhandleorliftobjects.

AdditionalMessages

SMCSCode: 7000;7405

i03694560

Ifequipped,thismessageislocatedonthestick.

Illustration17 g01957323

Illustration18

TheE-Stickmustbepinnedbeforeusing attachments,topreventmovementwhichcould causepersonalinjury.

Two-Way(Combination)Flow Control(2)

Thismessageislocatedonthecoverplate.

Theflowcontrolhandlepositionwillindicate worktoolcontrolortheflowcontrolhandle positionwillindicatecylindercontrol.

Typicalexample

Attacha “DoNotOperate” warningtagorasimilar warningtagtothestartswitchortothecontrols. Attachthewarningtagbeforeyouservicethe equipmentorbeforeyourepairtheequipment. WarningtagSEHS7332isavailablefromyourCat dealer.

Operatingthemachinewhiledistractedcanresult inthelossofmachinecontrol.Useextremecautionwhenusinganydevicewhileoperatingthe machine.Operatingthemachinewhiledistracted canresultinpersonalinjuryordeath.

Knowthewidthofyourequipmenttomaintainproper clearancewhenyouoperatetheequipmentnear fencesornearboundaryobstacles.

Beawareofhigh-voltagepowerlinesandpower cablesthatareburied.Ifthemachinecomesin contactwiththesehazards,seriousinjuryordeath mayoccurfromelectrocution.

Illustration19

Illustration21

Wearahardhat,protectiveglasses,andother protectiveequipment,asrequired.

Donotwearlooseclothingorjewelrythatcansnag oncontrolsoronotherpartsoftheequipment.

Makesurethatallprotectiveguardsandallcovers aresecuredinplaceontheequipment.

Keeptheequipmentfreefromforeignmaterial. Removedebris,oil,tools,andotheritemsfromthe deck,fromwalkways,andfromsteps.

Securealllooseitemssuchaslunchboxes,tools, andotheritemsthatarenotapartoftheequipment.

Knowtheappropriateworksitehandsignalsandthe personnelthatareauthorizedtogivethehand signals.Accepthandsignalsfromonepersononly.

Donotsmokewhenyouserviceanairconditioner. Also,donotsmokeifrefrigerantgasmaybepresent.

Inhalingthefumesthatarereleasedfromaflamethat contactsairconditionerrefrigerantcancausebodily harmordeath.Inhalinggasfromairconditioner refrigerantthroughalightedcigarettecancause bodilyharmordeath.

Neverputmaintenancefluidsintoglasscontainers. Drainallliquidsintoasuitablecontainer.

Obeyalllocalregulationsforthedisposalofliquids.

Useallcleaningsolutionswithcare.Reportall necessaryrepairs.

Donotallowunauthorizedpersonnelonthe equipment.

Unlessyouareinstructedotherwise,perform maintenancewiththeequipmentintheservicing position.RefertoOperationandMaintenance Manualfortheprocedureforplacingtheequipment intheservicingposition.

Whenyouperformmaintenanceabovegroundlevel, useappropriatedevicessuchasladdersormanlift machines.Ifequipped,usethemachineanchorage pointsanduseapprovedfallarrestharnessesand lanyards.

PressurizedAirandWater

Pressurizedairand/orwatercancausedebrisand/or hotwatertobeblownout.Thedebrisand/orhot watercouldresultinpersonalinjury.

Whenpressurizedairand/orpressurizedwateris usedforcleaning,wearprotectiveclothing,protective shoes,andeyeprotection.Eyeprotectionincludes gogglesoraprotectivefaceshield.

Themaximumairpressureforcleaningpurposes mustbereducedto205kPa (30psi) whenthe nozzleisdeadheadedandthenozzleisusedwithan effectivechipdeflectorandpersonalprotective equipment.Themaximumwaterpressurefor cleaningpurposesmustbebelow275kPa (40psi)

Avoiddirectsprayingofwateronelectrical connectors,connections,andcomponents.When usingairforcleaning,allowthemachinetocoolto reducethepossibilityoffinedebrisignitingwhenredepositedonhotsurfaces.

TrappedPressure

Pressurecanbetrappedinahydraulicsystem. Releasingtrappedpressurecancausesudden machinemovementorattachmentmovement.Use cautionifyoudisconnecthydrauliclinesorfittings. High-pressureoilthatisreleasedcancauseahose towhip.High-pressureoilthatisreleasedcancause oiltospray.Fluidpenetrationcancauseserious injuryandpossibledeath.

FluidPenetration

Pressurecanbetrappedinthehydrauliccircuitlong afterthemachinehasbeenstopped.Thepressure cancausehydraulicfluidoritemssuchaspipeplugs toescaperapidlyifthepressureisnotrelieved correctly.

Donotremoveanyhydrauliccomponentsorparts untilpressurehasbeenrelievedorpersonalinjury mayoccur.Donotdisassembleanyhydraulic componentsorpartsuntilpressurehasbeenrelieved orpersonalinjurymayoccur.RefertotheService Manualforanyproceduresthatarerequiredto relievethehydraulicpressure.

Obeyalllocalregulationsforthedisposalofliquids.

Inhalation

Alwaysuseaboardorcardboardwhenyoucheckfor aleak.Leakingfluidthatisunderpressurecan penetratebodytissue.Fluidpenetrationcancause seriousinjuryandpossibledeath.Apinholeleakcan causesevereinjury.Iffluidisinjectedintoyourskin, youmustgettreatmentimmediately.Seektreatment fromadoctorthatisfamiliarwiththistypeofinjury.

ContainingFluidSpillage

Caremustbetakeninordertoensurethatfluidsare containedduringperformanceofinspection, maintenance,testing,adjusting,andrepairofthe equipment.Preparetocollectthefluidwithsuitable containersbeforeopeninganycompartmentor disassemblinganycomponentthatcontainsfluids.

RefertoSpecialPublication, NENG2500,“Catdealer ServiceToolCatalog” forthefollowingitems:

• Toolsthataresuitableforcollectingfluidsand equipmentthatissuitableforcollectingfluids

• Toolsthataresuitableforcontainingfluidsand equipmentthatissuitableforcontainingfluids

Exhaust

Usecaution.Exhaustfumescanbehazardousto yourhealth.Ifyouoperatethemachineinan enclosedarea,adequateventilationisnecessary.

AsbestosInformation

Catequipmentandreplacementpartsthatare shippedfromCaterpillarareasbestosfree. CaterpillarrecommendstheuseofonlygenuineCat replacementparts.Usethefollowingguidelineswhen youhandleanyreplacementpartsthatcontain asbestosorwhenyouhandleasbestosdebris.

Usecaution.Avoidinhalingdustthatmightbe generatedwhenyouhandlecomponentsthatcontain asbestosfibers.Inhalingthisdustcanbehazardous toyourhealth.Thecomponentsthatmaycontain asbestosfibersarebrakepads,brakebands,lining material,clutchplates,andsomegaskets.The asbestosthatisusedinthesecomponentsisbound inaresinorsealedinsomeway.Normalhandlingis nothazardousunlessairbornedustthatcontains asbestosisgenerated.

Ifdustthatmaycontainasbestosispresent,there areseveralguidelinesthatshouldbefollowed:

• Neverusecompressedairforcleaning.

• Avoidbrushingmaterialsthatcontainasbestos.

• Avoidgrindingmaterialsthatcontainasbestos.

• Useawetmethodinordertocleanupasbestos materials.

• Avacuumcleanerthatisequippedwithahigh efficiencyparticulateairfilter(HEPA)canalsobe used.

Illustration23 g00687600

Illustration24

g02159053

• Useexhaustventilationonpermanentmachining jobs.

• Wearanapprovedrespiratorifthereisnoother waytocontrolthedust.

• Complywithapplicablerulesandregulationsfor theworkplace.IntheUnitedStates,use OccupationalSafetyandHealthAdministration (OSHA)requirements.TheseOSHArequirements canbefoundin “29CFR1910.1001”.InJapan, usetherequirementsfoundinthe “Ordinanceon PreventionofHealthImpairmentduetoAsbestos” inadditiontotherequirementsoftheIndustrial SafetyandHealthAct.

• Obeyenvironmentalregulationsforthedisposalof asbestos.

• Stayawayfromareasthatmighthaveasbestos particlesintheair.

DisposeofWasteProperly

Improperlydisposingofwastecanthreatenthe environment.Potentiallyharmfulfluidsshouldbe disposedofaccordingtolocalregulations.

Alwaysuseleakproofcontainerswhenyoudrain fluids.Donotpourwasteontotheground,downa drain,orintoanysourceofwater.

i01359664

CrushingPreventionand CuttingPrevention

SMCSCode: 7000

Supporttheequipmentproperlybeforeyouperform anyworkormaintenancebeneaththatequipment. Donotdependonthehydrauliccylinderstoholdup theequipment.Equipmentcanfallifacontrolis moved,orifahydrauliclinebreaks.

Donotworkbeneaththecabofthemachineunless thecabisproperlysupported.

Unlessyouareinstructedotherwise,neverattempt adjustmentswhilethemachineismovingorwhilethe engineisrunning.

Neverjumpacrossthestartersolenoidterminalsin ordertostarttheengine.Unexpectedmachine movementcouldresult.

Wheneverthereareequipmentcontrollinkagesthe clearanceinthelinkageareawillchangewiththe movementoftheequipmentorthemachine.Stay clearofareasthatmayhaveasuddenchangein clearancewithmachinemovementorequipment movement.

Stayclearofallrotatingandmovingparts.

Ifitisnecessarytoremoveguardsinordertoperform maintenance,alwaysinstalltheguardsafterthe maintenanceisperformed.

Keepobjectsawayfrommovingfanblades.Thefan bladewillthrowobjectsorcutobjects.

Donotuseakinkedwirecableorafrayedwirecable. Weargloveswhenyouhandlewirecable.

Whenyoustrikearetainerpinwithforce,theretainer pincanflyout.Thelooseretainerpincaninjure personnel.Makesurethattheareaisclearofpeople whenyoustrikearetainerpin.Toavoidinjurytoyour eyes,wearprotectiveglasseswhenyoustrikea retainerpin.

Chipsorotherdebriscanflyoffanobjectwhenyou striketheobject.Makesurethatnoonecanbe injuredbyflyingdebrisbeforestrikinganyobject.

i07746334

BurnPrevention

SMCSCode: 7000

Donottouchanypartofanoperatingengine.Allow theenginetocoolbeforeanymaintenanceis performedontheengine.Relieveallpressureinthe airsystem,intheoilsystem,inthelubrication system,inthefuelsystem,orinthecoolingsystem beforeanylines,fittings,orrelateditemsare disconnected.

Coolant

Whentheengineisatoperatingtemperature,the enginecoolantishot.Thecoolantisalsounder pressure.Theradiatorandalllinestotheheatersor totheenginecontainhotcoolant.

Anycontactwithhotcoolantorwithsteamcancause severeburns.Allowcoolingsystemcomponentsto coolbeforethecoolingsystemisdrained.

Checkthecoolantlevelonlyaftertheenginehas beenstopped.

Ensurethatthefillercapiscoolbeforeremovingthe fillercap.Thefillercapmustbecoolenoughtotouch withabarehand.Removethefillercapslowlyto relievepressure.

Coolingsystemconditionercontainsalkali.Alkalican causepersonalinjury.Donotallowalkalitocontact theskin,theeyes,orthemouth.

Oils

Hotoilandhotcomponentscancausepersonal injury.Donotallowhotoiltocontacttheskin.Also, donotallowhotcomponentstocontacttheskin.

Removethehydraulictankfillercaponlyafterthe enginehasbeenstopped.Thefillercapmustbecool enoughtotouchwithabarehand.Followthe standardprocedureinthismanualtoremovethe hydraulictankfillercap.

Batteries

Theliquidinabatteryisanelectrolyte.Electrolyteis anacidthatcancausepersonalinjury.Donotallow electrolytetocontacttheskinortheeyes.

Donotsmokewhilecheckingthebatteryelectrolyte levels.Batteriesgiveoffflammablefumeswhichcan explode.

Alwayswearprotectiveglasseswhenyouworkwith batteries.Washhandsaftertouchingbatteries.The useofglovesisrecommended.

FirePreventionandExplosion Prevention

SMCSCode: 7000

General

Allfuels,mostlubricants,andsomecoolantmixtures areflammable.

Tominimizetheriskoffireorexplosion,Caterpillar recommendsthefollowingactions.

AlwaysperformaWalk-AroundInspection,which mayhelpyouidentifyafirehazard.Donotoperatea machinewhenafirehazardexists.ContactyourCat dealerforservice.

Understandtheuseoftheprimaryexitand alternativeexitonthemachine.RefertoOperation andMaintenanceManual,“AlternativeExit”

Donotoperateamachinewithafluidleak.Repair leaksandcleanupfluidsbeforeresumingmachine operation.Fluidsthatareleakingorspilledontohot surfacesorontoelectricalcomponentscancausea fire.Afiremaycausepersonalinjuryordeath.

Removeflammablematerialsuchasleaves,twigs, papers,trash,andsoon.Theseitemsmay accumulateintheenginecompartmentoraround otherhotareasandhotpartsonthemachine.

Keeptheaccessdoorstomajormachine compartmentsclosedandaccessdoorsinworking conditioninordertopermittheuseoffire suppressionequipment,incaseafireshouldoccur.

Cleanallaccumulationsofflammablematerialssuch asfuel,oil,anddebrisfromthemachine.

Illustration26 g00704000

Donotoperatethemachinenearanyflame.

Keepshieldsinplace.Exhaustshields(ifequipped) protecthotexhaustcomponentsfromoilsprayorfuel sprayincaseofabreakinaline,inahose,orina seal.Exhaustshieldsmustbeinstalledcorrectly.

Donotweldorflamecutontanksorlinesthatcontain flammablefluidsorflammablematerial.Emptyand purgethelinesandtanks.Thencleanthelinesand tankswithanonflammablesolventpriortoweldingor flamecutting.Ensurethatthecomponentsare properlygroundedinordertoavoidunwantedarcs.

Dustthatisgeneratedfromrepairingnonmetallic hoodsorfendersmaybeflammableand/or explosive.Repairsuchcomponentsinawell ventilatedareaawayfromopenflamesorsparks. UsesuitablePersonalProtectionEquipment(PPE).

Inspectalllinesandhosesforwearordeterioration. Replacedamagedlinesandhoses.Thelinesandthe hosesshouldhaveadequatesupportandsecure clamps.Tightenallconnectionstotherecommended torque.Damagetotheprotectivecoverorinsulation mayprovidefuelforfires.

Storefuelsandlubricantsinproperlymarked containersawayfromunauthorizedpersonnel.Store oilyragsandflammablematerialsinprotective containers.Donotsmokeinareasthatareusedfor storingflammablematerials.

g03839130

Usecautionwhenyouarefuelingamachine.Donot smokewhileyouarefuelingamachine.Donotfuela machinenearopenflamesorsparks.Donotusecell phonesorotherelectronicdeviceswhileyouare refueling.Alwaysstoptheenginebeforefueling.Fill thefueltankoutdoors.Properlycleanareasof spillage.

Avoidstaticelectricityriskwhenfueling.Ultralow sulfurdiesel(ULSD)posesagreaterstaticignition hazardthanearlierdieselformulationswithahigher sulfurcontent.Avoiddeathorseriousinjuryfromfire orexplosion.Consultwithyourfuelorfuelsystem suppliertoensurethatthedeliverysystemisin compliancewithfuelingstandardsforproper groundingandbondingpractices.

Neverstoreflammablefluidsintheoperator compartmentofthemachine.

BatteryandBatteryCables

g03839133

Caterpillarrecommendsthefollowinginorderto minimizetheriskoffireoranexplosionrelatedtothe battery.

Donotoperateamachineifbatterycablesorrelated partsshowsignsofwearordamage.Contactyour Catdealerforservice.

Followsafeproceduresforenginestartingwithjumpstartcables.Improperjumpercableconnectionscan causeanexplosionthatmayresultininjury.Referto OperationandMaintenanceManual,“EngineStarting withJumpStartCables” forspecificinstructions.

Donotchargeafrozenbattery.Thismaycausean explosion.

Gasesfromabatterycanexplode.Keepanyopen flamesorsparksawayfromthetopofabattery.Do notsmokeinbatterychargingareas.Donotusecell phonesorotherelectronicdevicesinbattery chargingareas.

Nevercheckthebatterychargebyplacingametal objectacrosstheterminalposts.Useavoltmeterin ordertocheckthebatterycharge.

Illustration27

Illustration28

Dailyinspectbatterycablesthatareinareasthatare visible.Inspectcables,clips,straps,andother restraintsfordamage.Replaceanydamagedparts. Checkforsignsofthefollowing,whichcanoccur overtimeduetouseandenvironmentalfactors:

• Fraying

• Abrasion

• Cracking

• Discoloration

• Cutsontheinsulationofthecable

• Fouling

• Corrodedterminals,damagedterminals,and looseterminals

Replacedamagedbatterycable(s) andreplaceany relatedparts.Eliminateanyfouling,whichmayhave causedinsulationfailureorrelatedcomponent damageorwear.Ensurethatallcomponentsare reinstalledcorrectly.

Anexposedwireonthebatterycablemaycausea shorttogroundiftheexposedareacomesinto contactwithagroundedsurface.Abatterycable shortproducesheatfromthebatterycurrent,which maybeafirehazard.

Anexposedwireonthegroundcablebetweenthe batteryandthedisconnectswitchmaycausethe disconnectswitchtobebypassediftheexposedarea comesintocontactwithagroundedsurface.This mayresultinanunsafeconditionforservicingthe machine.Repaircomponentsorreplacecomponents beforeservicingthemachine.

Fireonamachinecanresultinpersonalinjuryor death.Exposedbatterycablesthatcomeinto contactwithagroundedconnectioncanresultin fires.Replacecablesandrelatedpartsthatshow signsofwearordamage.ContactyourCat dealer.

Wiring

Checkelectricalwiresdaily.Ifanyofthefollowing conditionsexist,replacepartsbeforeyouoperatethe machine.

• Fraying

• Signsofabrasionorwear

• Cracking

• Discoloration

• Cutsoninsulation

• Otherdamage

Makesurethatallclamps,guards,clips,andstraps arereinstalledcorrectly.Thiswillhelptoprevent vibration,rubbingagainstotherparts,andexcessive heatduringmachineoperation.

Attachingelectricalwiringtohosesandtubesthat containflammablefluidsorcombustiblefluidsshould beavoided.

ConsultyourCatdealerforrepairorforreplacement parts.

Keepwiringandelectricalconnectionsfreeofdebris.

Lines,Tubes,andHoses

Donotbendhigh-pressurelines.Donotstrikehighpressurelines.Donotinstallanylinesthatarebent ordamaged.Usetheappropriatebackupwrenches inordertotightenallconnectionstothe recommendedtorque.

Checklines,tubes,andhosescarefully.Wear PersonalProtectionEquipment(PPE)inorderto checkforleaks.Alwaysuseaboardorcardboard whenyoucheckforaleak.Leakingfluidthatisunder pressurecanpenetratebodytissue.Fluidpenetration cancauseseriousinjuryandpossibledeath.Apin holeleakcancausesevereinjury.Iffluidisinjected intoyourskin,youmustgettreatmentimmediately. Seektreatmentfromadoctorthatisfamiliarwiththis typeofinjury.

Replacetheaffectedpartsifanyofthefollowing conditionsarepresent:

• Endfittingsaredamagedorleaking.

• Outercoveringsarechafedorcut.

• Wiresareexposed.

• Outercoveringsareswellingorballooning.

• Flexiblepartsofthehosesarekinked.

Illustration29

g00687600

• Outercovershaveexposedembeddedarmoring.

• Endfittingsaredisplaced.

Makesurethatallclamps,guards,andheatshields areinstalledcorrectly.Duringmachineoperation,this willhelptopreventvibration,rubbingagainstother parts,excessiveheat,andfailureoflines,tubes,and hoses.

Donotoperateamachinewhenafirehazardexists. Repairanylinesthatarecorroded,loose,or damaged.Leaksmayprovidefuelforfires.Consult yourCatdealerforrepairorforreplacementparts. UsegenuineCatpartsortheequivalent,for capabilitiesofboththepressurelimitand temperaturelimit.

Ether

Ether(ifequipped)iscommonlyusedincold-weather applications.Etherisflammableandpoisonous.

OnlyuseapprovedEthercanistersfortheEther dispensingsystemfittedtoyourmachine,donot sprayEthermanuallyintoanengine,followthe correctcoldenginestartingprocedures.Refertothe sectionintheOperationandMaintenanceManual withthelabel “EngineStarting” .

Useetherinventilatedareas.Donotsmokewhile youarereplacinganethercylinder.

Donotstoreethercylindersinlivingareasorinthe operatorcompartmentofamachine.Donotstore ethercylindersindirectsunlightorintemperatures above49°C (120.2°F).Keepethercylindersaway fromopenflamesorsparks.

Disposeofusedethercylindersproperly.Donot punctureanethercylinder.Keepethercylinders awayfromunauthorizedpersonnel.

FireExtinguisher

Asanadditionalsafetymeasure,keepafire extinguisheronthemachine.

Befamiliarwiththeoperationofthefireextinguisher. Inspectthefireextinguisherandservicethefire extinguisherregularly.Followtherecommendations ontheinstructionplate.

ConsiderinstallationofanaftermarketFire SuppressionSystem,iftheapplicationandworking conditionswarranttheinstallation.

i07041871

FireSafety

SMCSCode: 7000

Note: Locatesecondaryexitsandhowtousethe secondaryexitsbeforeyouoperatethemachine.

Note: Locatefireextinguishersandhowtouseafire extinguisherbeforeyouoperatethemachine.

Ifyoufindthatyouareinvolvedinamachinefire, yoursafetyandthatofothersonsitearethetop priority.Thefollowingactionsshouldonlybe performediftheactionsdonotpresentadangeror risktoyouandanynearbypeople.Assesstheriskof personalinjuryandmoveawaytoasafedistanceas soonasyoufeelunsafe.

Movethemachineawayfromnearbycombustible materialsuchasfuel/oilstations,structures,trash, mulch,andtimber.

Loweranyimplementsandturnofftheengineas soonaspossible.Ifyouleavetheenginerunning,the enginewillcontinuetofeedafire.Thefirewillbefed fromanydamagedhosesthatareattachedtothe engineorpumps.

Ifpossible,turnthebatterydisconnectswitchtothe OFFposition.Disconnectingthebatterywillremove theignitionsourceintheeventofanelectricalshort. Disconnectingthebatterywilleliminateasecond ignitionsourceifelectricalwiringisdamagedbythe fire,resultinginashortcircuit.

Notifyemergencypersonnelofthefireandyour location.

Ifyourmachineisequippedwithafiresuppression system,followthemanufacturersprocedurefor activatingthesystem.

Note: Firesuppressionsystemsneedtoberegularly inspectedbyqualifiedpersonnel.Youmustbe trainedtooperatethefiresuppressionsystem.

Ifyouareunabletodoanythingelse,shutoffthe machinebeforeexiting.Byshuttingoffthemachine, fuelswillnotcontinuetobepumpedintothefire.

Ifthefiregrowsoutofcontrol,beawareofthe followingrisks:

• Tiresonwheeledmachinesposeariskof explosionastiresburn.Hotshrapnelanddebris canbethrowngreatdistancesinanexplosion.

• Tanks,accumulators,hoses,andfittingscan ruptureinafire,sprayingfuelsandshrapnelover alargearea.

• Rememberthatnearlyallthefluidsonthe machineareflammable,includingcoolantandoils. Additionally,plastics,rubbers,fabrics,andresins infiberglasspanelsarealsoflammable.

FireExtinguisherLocation

SMCSCode: 7000;7419

Makesurethatafireextinguisherisonthemachine. Makesurethatyouarefamiliarwiththeoperationof thefireextinguisher.Inspectthefireextinguisherand servicetheextinguisher.Obeytherecommendations ontheinstructionplate.

Mountthefireextinguisherinthebatterybox.Donot weldtheROPSinordertoinstallthefireextinguisher. Also,donotdrillholesintheROPSinordertomount thefireextinguisherontheROPS. i06164462

TireInformation

SMCSCode: 7000

Explosionsofairinflatedtireshaveresultedfrom heat-inducedgascombustioninsidethetires. Explosionscanbecausedbyheatthatisgenerated bywelding,byheatingrimcomponents,byexternal fire,orbyexcessiveuseofbrakes.

Atireexplosionismuchmoreviolentthanablowout. Theexplosioncanpropelthetire,therim components,andtheaxlecomponentsfromthe machine.Stayoutofthetrajectorypath.Boththe forceoftheexplosionandtheflyingdebriscancause propertydamage,personalinjury,ordeath.

Illustration30

Typicalexampleoftireisshown

g02166933

Donotapproachahotoranapparentlydamaged tire.

Caterpillarrecommendsagainstusingwateror calciumasaballastforthetiresexceptinmachines designedforthisadditionalmass.Forthose applicablemachines,themaintenancesectionwill containinstructionsonthecorrecttireinflationand fillingprocedures.Ballast,suchasfluidinthetires, increasesoverallmachineweightandmayaffect braking,steering,powertraincomponents,orthe certificationoftheprotectivestructuresuchasthe ROPS.Theuseoftire/rimrustpreventativesorother liquidadditivesisnotrequired.

Propernitrogeninflationequipment,andtraining inusingtheequipment,arenecessarytoavoid overinflation.Atireblowoutorrimfailurecanresultfromimproperormisusedequipmentand personalinjuryordeathcanoccur.

Atireblowoutand/orrimfailurecanoccurifthe inflationequipmentisnotusedcorrectly,dueto thefactthatafullychargednitrogencylinder's pressureisapproximately15000kPa (2200psi).

Drynitrogengasisrecommendedforinflationof tires.Ifthetireswereoriginallyinflatedwithair, nitrogenisstillpreferredforadjustingthepressure. Nitrogenmixesproperlywithair.

Nitrogeninflatedtiresreducethepotentialofatire explosionbecausenitrogendoesnotaidcombustion. Nitrogenhelpstopreventoxidationoftherubber, deteriorationofrubber,andcorrosionofrim components.

Toavoidoverinflation,propernitrogeninflation equipmentandtrainingintheusageoftheequipment arenecessary.Atireblowoutorarimfailurecan resultfromimproperequipmentorfrommisused equipment.

Whenyouinflateatire,standbehindthetreadand useaself-attachingchuck.

Servicingtiresandrimscanbedangerous.Only trainedpersonnelthatusepropertoolsandproper proceduresshouldperformthismaintenance.If correctproceduresarenotusedforservicingtires andrims,theassembliescouldburstwithexplosive force.Thisexplosiveforcecancauseserious personalinjuryordeath.Carefullyobeythespecific instructionsfromyourtiredealer.

i01122596

ElectricalStormInjury Prevention

SMCSCode: 7000

Whenlightningisstrikinginthevicinityofthe machine,theoperatorshouldneverattemptthe followingprocedures:

• Mountthemachine.

• Dismountthemachine.

Ifyouareintheoperator'sstationduringanelectrical storm,stayintheoperator'sstation.Ifyouareonthe groundduringanelectricalstorm,stayawayfromthe vicinityofthemachine.

i00771840

BeforeStartingEngine

SMCSCode: 1000;7000

Starttheengineonlyfromtheoperatorcompartment. Nevershortacrossthestarterterminalsoracrossthe batteries.Shortingcoulddamagetheelectrical systembybypassingtheengineneutralstartsystem.

Inspecttheconditionoftheseatbeltandofthe mountinghardware.Replaceanypartsthatareworn ordamaged.Regardlessofappearance,replacethe seatbeltafterthreeyearsofuse.Donotuseaseat beltextensiononaretractableseatbelt.

Adjusttheseatsothatfullpedaltravelcanbe achievedwiththeoperator'sbackagainstthebackof theseat.

Makesurethatthemachineisequippedwitha lightingsystemthatisadequateforthejob conditions.Makesurethatallmachinelightsare workingproperly.

Beforeyoustarttheengineandbeforeyoumovethe machine,makesurethatnooneisunderneaththe machine,aroundthemachine,oronthemachine. Makesurethattheareaisfreeofpersonnel.

i03571438

EngineStarting

SMCSCode: 1000;7000

Ifawarningtagisattachedtothestartswitchorto thecontrols,donotstarttheengine.Also,donot moveanycontrols.

MoveallhydrauliccontrolstotheHOLDposition beforeyoustarttheengine.

Movethetransmissiondirectioncontrollevertothe NEUTRALposition.

Engagetheparkingbrake.

Dieselengineexhaustcontainsproductsof combustionwhichcanbeharmfultoyourhealth. Alwaysstarttheengineinawellventilatedarea. Alwaysoperatetheengineinawellventilatedarea.If youareinanenclosedarea,venttheexhausttothe outside.

Brieflysoundthehornbeforeyoustarttheengine.

VisibilityInformation

SMCSCode: 7000

i07746368

Beforeyoustartthemachine,performawalk-around inspectioninordertoensurethatthereareno hazardsaroundthemachine.

Whilethemachineisinoperation,constantlysurvey theareaaroundthemachineinordertoidentify potentialhazardsashazardsbecomevisiblearound themachine.

Yourmachinemaybeequippedwithvisualaids. SomeexamplesofvisualaidsareClosedCircuit Television(CCTV)andmirrors.Beforeoperatingthe machine,ensurethatthevisualaidsareinproper workingconditionandthatthevisualaidsareclean. Adjustthevisualaidsusingtheproceduresthatare locatedinthisOperationandMaintenanceManual.If equipped,theWorkAreaVisionSystemshallbe adjustedaccordingtoOperationandMaintenance Manual, SEBU8157,“WorkAreaVisionSystem”.If equipped,theCatDetectObjectDetectionshallbe adjustedaccordingtotheOperationand MaintenanceManual,“CatDetectObjectDetection” foryourmachine.

Itmaynotbepossibletoprovidedirectvisibilityon largemachinestoallareasaroundthemachine. Appropriatejobsiteorganizationisrequiredinorder tominimizehazardsthatarecausedbyrestricted visibility.Jobsiteorganizationisacollectionofrules andproceduresthatcoordinatesmachinesand peoplethatworktogetherinthesamearea. Examplesofjobsiteorganizationincludethe following:

• Safetyinstructions

• Controlledpatternsofmachinemovementand vehiclemovement

• Workersthatdirectsafemovementoftraffic

• Restrictedareas

• Operatortraining

• Warningsymbolsorwarningsignsonmachinesor onvehicles

• Asystemofcommunication

• Communicationbetweenworkersandoperators priortoapproachingthemachine

Modificationsofthemachineconfigurationbythe userthatresultinarestrictionofvisibilityshallbe evaluated.

i03105380

RestrictedVisibility

SMCSCode: 7000

Thesizeandtheconfigurationofthismachinemay resultinareasthatcannotbeseenwhenthe operatorisseated.Illustration 31 providesan approximatevisualindicationofareasofsignificant restrictedvisibility.Illustration 31 indicatesrestricted visibilityareasatgroundlevelinsidearadiusof 12.00m (39.37ft) fromtheoperatoronamachine withouttheuseofoptionalvisualaids.This illustrationdoesnotprovideareasofrestricted visibilityfordistancesoutsidearadiusof12.00m (39.37ft).

Thismachinemaybeequippedwithoptionalvisual aidsthatmayprovidevisibilitytosomeofthe restrictedvisibilityareas.Forareasthatarenot coveredbytheoptionalvisualaids,jobsite organizationmustbeutilizedtominimizehazardsof thisrestrictedvisibility.Formoreinformation regardingjobsiteorganizationrefertoOperationand MaintenanceManual,“VisibilityInformation”

BeforeOperation

SMCSCode: 7000

Clearallpersonnelfromthemachineandfromthe area.

Clearallobstaclesfromthepathofthemachine. Bewareofhazardssuchaselectricalwires,ditches, etc.

Thestabilizersmustbeinthecorrectpositionbefore youoperatethemachine.Completelyraisethe stabilizersfortransportingthemachineorforloader operation.Lowerthestabilizersbeforeyouoperate thebackhoe. DONOTDIGUNDERTHE

STABILIZERS!

Makesurethatallwindowsareclean.Securethe doorsintheopenpositionorintheshutposition. Securethewindowsintheopenpositionorinthe shutposition.

Forthebestvisibilityoftheareathatisclosetothe machine,adjusttherearviewmirrors(ifequipped).

Makesurethatthemachinehorn,thebackupalarm (ifequipped)andallotherwarningdevicesare workingproperly.

Fastentheseatbeltsecurely.

Operation

SMCSCode: 7000

i07443772

Note: Theshadedareasindicatetheapproximate locationofareaswithsignificantrestrictedvisibility.

Onlyoperatethemachinewhileyouaresittingina seat.Theseatbeltmustbefastenedwhileyou operatethemachine.Onlyoperatethecontrolswhile theengineisrunning.

Whileyouoperatethemachineslowlyinanopen area,checkforproperoperationofallcontrolsandall protectivedevices.

Beforeyoumovethemachine,makesurethatno onewillbeendangered.

Donotallowridersonthemachineunlessthe machinehasanadditionalseatwithaseatbelt.The ridermustbeseatedandtheseatbeltmustbe fastened.

Neverusetheworktoolforaworkplatform.

Noteanyneededrepairsduringmachineoperation. Reportanyneededrepairs.

Carryworktoolsatapproximately40cm (15inches) abovegroundlevel.

Donotgoclosetotheedgeofacliff,anexcavation, oranoverhang.

Avoidoperatingthemachineacrosstheslope.When possible,operatethemachineuptheslopesand downtheslopes.Ifthemachinebeginstosideslipon adowngrade,immediatelyremovetheloadandturn themachinedownhill.

Avoidanyconditionsthatcanleadtotippingthe machine.Themachinecantipwhenyouworkon hills,onbanksandonslopes.Also,themachinecan tipwhenyoucrossditches,ridges,orother unexpectedobstructions.

Maintaincontrolofthemachine.Donotoverloadthe machinebeyondthemachinecapacity.

Neverstraddleawirecable.Neverallowother personneltostraddleawirecable.

Knowthemaximumdimensionsofyourmachine.

AlwayskeeptheRolloverProtectiveStructure (ROPS)installedduringmachineoperation.

FuelingMachine

UltraLowSulfurDiesel(ULSD)posesagreater staticignitionhazardthanearlierdieselformulations,withahigherSulfurcontent,whichmayresultinafireorexplosion.Consultwithyourfuel orfuelsystemsupplierfordetailsonproper groundingandbondingpractices.

Fuelcapmaybehot.Toavoidinjury,usepersonal protectiveequipment.Allowthecaptocoolbefore fuelingthemachine.

LimitingConditionsandCriteria

Limitingconditionsareimmediateissueswiththis machinethatmustbeaddressedpriortocontinuing operation.

TheSafetySectionoftheOperationand MaintenanceManualdescribeslimitingcondition criteriaforreplacingitemssuchassafetymessages, seatbeltandmountinghardware,lines,tubes,hoses, batterycablesandrelatedparts,electricalwires,and repairinganyfluidleak.

TheMaintenanceIntervalScheduleintheOperation andMaintenanceManualdescribeslimitingcondition criteriathatrequirerepairorreplacementforitems(if equipped)suchasalarms,horns,brakingsystem, steeringsystem,androlloverprotectivestructures.

TheMonitoringSystem(ifequipped)describedinthe OperationSectionoftheOperationandMaintenance Manualprovidesinformationonlimitingcondition criteria,includingawarninglevelthatrequires immediateshutdownofthemachine.

i06299648

EngineStopping

SMCSCode: 1000;7000

Toavoidpossibleinjuryordeath,donotsmoke whileinanareathatcontainsflammableliquids.

Allfuels,mostlubricants,andsomecoolantsare flammable.

Keepallfuelsandlubricantsstoredinproperly markedcontainersandawayfromunauthorized persons.

Fuelleakedorspilledontohotsurfacesorelectricalcomponentscancauseafire.

Storealloilyragsorotherflammablematerialsin aprotectivecontainerinasafeplace.

Removeallflammablematerialssuchasfuel,oil, andotherdebrisbeforetheyaccumulateonthe machine.

Donotexposethemachinetoflames,burning brush,etc.,ifatallpossible.

Locatefuelfillonmachine,andremovethefuelcap. Whenfuelingthemachineiscomplete,replacethe fuelcapandlockintoplace.

Donotstoptheengineimmediatelyafterthemachine hasbeenoperatedunderload.Stoppingtheengine immediatelycancauseoverheatingandaccelerated wearofenginecomponents.

Afterthemachineisparkedandtheparkingbrakeis engaged,allowtheenginetorunatlowidlefor5 minutesbeforeshutdown.Runningtheengineallows hotareasoftheenginetocoolgradually.

i04159629

WorkTools

SMCSCode: 6700

Onlyuseworktoolsthatarerecommendedby CaterpillarforuseonCatmachines.

Useofworktools,includingbuckets,whichare outsideofCaterpillar'srecommendationsor specificationsforweight,dimensions,flows, pressures,andsoon.mayresultinless-than-optimal vehicleperformance,includingbutnotlimitedto reductionsinproduction,stability,reliability,and componentdurability.Caterpillarrecommends appropriateworktoolsforourmachinestomaximize thevalueourcustomersreceivefromourproducts. Caterpillarunderstandsthatspecialcircumstances mayleadacustomertousetoolsoutsideofour specifications.Inthesecases,customersmustbe awarethatsuchchoicescanreducevehicle performanceandwillaffecttheirabilitytoclaim warrantyintheeventofwhatacustomermay perceiveasaprematurefailure.

Worktoolsandworktoolcontrolsystems,thatare compatiblewithyourCatmachine,arerequiredfor safemachineoperationand/orreliablemachine operation.Ifyouareindoubtaboutthecompatibility ofaparticularworktoolwithyourmachine,consult yourCatdealer.

Makesurethatallnecessaryguardingisinplaceon thehostmachineandontheworktool.

Keepallwindowsanddoorsclosedonthehost machine.Apolycarbonateshieldmustbeusedwhen thehostmachineisnotequippedwithwindowsand whenaworktoolcouldthrowdebris.

Donotexceedthemaximumoperatingweightthatis listedontheROPScertification.

Ifyourmachineisequippedwithanextendablestick, installthetransportpinwhenyouareusingthe followingworktools:hydraulichammers,augersand compactors

Alwayswearprotectiveglasses.Alwayswearthe protectiveequipmentthatisrecommendedinthe operationmanualfortheworktool.Wearanyother protectiveequipmentthatisrequiredforthe operatingenvironment.

Topreventpersonnelfrombeingstruckbyflying objects,ensurethatallpersonnelareoutofthework area.

Whileyouareperforminganymaintenance,any testing,oranyadjustmentstotheworktoolstayclear ofthefollowingareas:cuttingedges,pinching surfacesandcrushingsurfaces.

Neverusetheworktoolforaworkplatform.

Parking

SMCSCode: 7000

i03112589

Parkonalevelsurface.Ifyoumustparkonagrade, chockthemachine.

Applytheservicebrakeinordertostopthemachine. MovethetransmissioncontrollevertotheNEUTRAL position.

MovethespeedcontrollevertotheLOWIDLE position.

Engagetheparkingbrake.

Engagethetransmissionneutrallock.

Lowerallworktoolstotheground.

Stoptheengine.

TurntheenginestartswitchkeytotheOFFposition for4seconds.

TurntheenginestartswitchkeybacktotheON position.

PressthehydraulicshutoffswitchtotheUNLOCKED position.

Movethehydrauliccontrolleversbackandforthin ordertorelievehydraulicpressure.

MovethehydrauliccontrolleverstotheHOLD position.

TurntheenginestartswitchtoOFFpositionand removethekey.

Stowthesteeringcolumniftheadjustablesteering columnisavailableonthemachine.

i07746366

SlopeOperation

SMCSCode: 7000

Machinesthatareoperatingsafelyinvarious applicationsdependonthesecriteria:themachine model,configuration,machinemaintenance, operatingspeedofthemachine,conditionsofthe terrain,fluidlevels,andtireinflationpressures.The mostimportantcriteriaaretheskillandjudgmentof theoperator.

Awelltrainedoperatorthatfollowstheinstructionsin theOperationandMaintenanceManualhasthe greatestimpactonstability.Operatortraining providesapersonwiththefollowingabilities: observationofworkingandenvironmentalconditions, feelforthemachine,identificationofpotential hazardsandoperatingthemachinesafelybymaking appropriatedecisions.

Whenyouworkonsidehillsandwhenyouworkon slopes,considerthefollowingimportantpoints:

Speedoftravel – Athigherspeeds,forcesofinertia tendtomakethemachinelessstable.

Roughnessofterrainorsurface – Themachine maybelessstablewithuneventerrain.

Directionoftravel – Avoidoperatingthemachine acrosstheslope.Whenpossible,operatethe machineuptheslopesandoperatethemachine downtheslopes.Placetheheaviestendofthe machineuphillwhenyouareworkingonanincline.

Mountedequipment – Balanceofthemachinemay beimpededbythefollowingcomponents:equipment thatismountedonthemachine,machine configuration,weights,andcounterweights.

Natureofsurface – Groundthathasbeennewly filledwithearthmaycollapsefromtheweightofthe machine.

Surfacematerial – Rocksandmoistureofthe surfacematerialmaydrasticallyaffectthemachine's tractionandmachine'sstability.Rockysurfacesmay promotesideslippingofthemachine.

Slippageduetoexcessiveloads – Thismaycause downhilltracksordownhilltirestodigintotheground, whichwillincreasetheangleofthemachine.

Widthoftracksortires – Narrowertracksor narrowertiresfurtherincreasethediggingintothe groundwhichcausesthemachinetobelessstable.

Implementsattachedtothedrawbar – Thismay decreasetheweightontheuphilltracks.Thismay alsodecreasetheweightontheuphilltires.The decreasedweightwillcausethemachinetobeless stable.

Heightoftheworkingloadofthemachine – When theworkingloadsareinhigherpositions,thestability ofthemachineisreduced.

Operatedequipment – Beawareofperformance featuresoftheequipmentinoperationandtheeffects onmachinestability.

Operatingtechniques – Keepallattachmentsor pulledloadslowtothegroundforoptimumstability.

Machinesystemshavelimitationsonslopes –Slopescanaffecttheproperfunctionandoperation ofthevariousmachinesystems.Thesemachine systemsareneededformachinecontrol.

Note: Operatorswithlotsofexperienceandproper equipmentforspecificapplicationsarealsorequired. Safeoperationonsteepslopesmayalsorequire specialmachinemaintenance.RefertoLubricant ViscositiesandRefillCapacitiesinthismanualforthe properfluidlevelrequirementsandintendedmachine use.Fluidsmustbeatthecorrectlevelstoensure thatsystemswilloperateproperlyonaslope.

SafetySection

EquipmentLoweringwithEngineStopped

EquipmentLoweringwith EngineStopped

SMCSCode: 7000

i01329161

Beforeloweringanyequipmentwiththeengine stopped,cleartheareaaroundtheequipmentofall personnel.Theproceduretousewillvarywiththe typeofequipmenttobelowered.Keepinmindmost systemsuseahighpressurefluidorairtoraiseor lowerequipment.Theprocedurewillcausehigh pressureair,hydraulic,orsomeothermediatobe releasedinordertolowertheequipment.Wear appropriatepersonalprotectiveequipmentandfollow theestablishedprocedureintheOperationand MaintenanceManual,“EquipmentLoweringwith EngineStopped” intheOperationSectionofthe manual.

i03696989

SoundInformationand VibrationInformation

SMCSCode: 7000

SoundLevelInformation

TheoperatorEquivalentSoundPressureLevel(Leq) is78dB(A)when “ANSI/SAEJ1166OCT98” isused tomeasurethevalueforanenclosedcab.Thisisa workcyclesoundexposurelevel.Thecabwas properlyinstalledandmaintained.Thetestwas conductedwiththecabdoorsandthecabwindows closed.

Hearingprotectionmaybeneededwhenthe machineisoperatedwithanopenoperatorstationfor extendedperiodsorinanoisyenvironment.Hearing protectionmaybeneededwhenthemachineis operatedwithacabthatisnotproperlymaintainedor whenthedoorsandwindowsareopenforextended periodsorinanoisyenvironment.

Theaverageexteriorsoundpressurelevelis80dB (A)whenthe “SAEJ88Apr95-ConstantSpeed MovingTest” procedureisusedtomeasurethevalue forthestandardmachine.Themeasurementwas conductedunderthefollowingconditions:distanceof 15m (49.2ft) and“themachinemovingforwardinan intermediategearratio”.

SoundLevelInformationfor MachinesinEuropeanUnion CountriesandinCountriesthat Adoptthe “EUDirectives”

Thedynamicoperatorsoundpressurelevelis78dB (A)when “ISO6396:2008” isusedtomeasurethe valueforanenclosedcab.Thecabwasproperly installedandmaintained.Thetestwasconducted withthecabdoorsandthecabwindowsclosed.

“TheEuropeanUnionPhysical

Agents(Vibration)Directive2002/ 44/EC”

VibrationDataforBackhoeLoaders

InformationConcerningHand/ArmVibration Level

Whenthemachineisoperatedaccordingtothe intendeduse,theweightedrootmeansquare(RMS) accelerationemissionofthemachinetowhichthe armsaresubjectedhavebeenmeasuredasfollows:

Table1

Note: Allvibrationlevelsareinmeterpersecond squared.

InformationConcerningWholeBodyVibration Level

Thissectionprovidesvibrationdataandamethodfor estimatingthevibrationlevelforbackhoeloaders.

Note: Vibrationlevelsareinfluencedbymany differentparameters.Manyitemsarelistedbelow.

• Operatortraining,behavior,modeandstress

• Jobsiteorganization,preparation,environment, weatherandmaterial

• Machinetype,qualityoftheseat,qualityofthe suspensionsystem,attachmentsandconditionof theequipment

Itisnotpossibletogetprecisevibrationlevelsforthis machine.Theexpectedvibrationlevelscanbe estimatedwiththeinformationinTable 3 inorderto calculatethedailyvibrationexposure.Asimple evaluationofthemachineapplicationcanbeused.

Estimatethevibrationlevelsforthethreevibration directions.Fortypicaloperatingconditions,usethe averagevibrationlevelsastheestimatedlevel.With anexperiencedoperatorandsmoothterrain,subtract theScenarioFactorsfromtheaveragevibrationlevel inordertoobtaintheestimatedvibrationlevel.For aggressiveoperationsandsevereterrain,addthe ScenarioFactorstotheaveragevibrationlevelin ordertoobtaintheestimatedvibrationlevel.

Note: Allvibrationlevelsareinmeterpersecond squared.

Table3

“ISOReferenceTableA-Equivalentvibrationlevelsofwholebodyvibrationemissionforearthmovingequipment.”

Note: Referto “ISO/TR25398MechanicalVibrationGuidelinefortheassessmentofexposuretowhole bodyvibrationofrideonoperatedearthmoving machines” formoreinformationaboutvibration.This publicationusesdatathatismeasuredby internationalinstitutes,organizationsand manufacturers.Thisdocumentprovidesinformation aboutthewholebodyexposureofoperatorsof earthmovingequipment.RefertoOperationand MaintenanceManual, SEBU8257,“TheEuropean UnionPhysicalAgents(Vibration)Directive2002/44/ EC” formoreinformationaboutmachinevibration levels.

TheCaterpillarsuspensionseatmeetsthecriteriaof “ISO7096”.Thisrepresentsverticalvibrationlevel undersevereoperatingconditions.Thisseatistested withtheinput “spectralclassEM5”.Theseathasa transmissibilityfactorof“SEAT<0.7”.

Thewholebodyvibrationlevelofthemachinevaries. Thereisarangeofvalues.Thelowvalueis0.5meter persecondsquared.Themachinemeetstheshort termlevelforthedesignoftheseatin “ISO7096” Thevalueis1.68meterpersecondsquaredforthis machine.

GuidelinesforReducingVibrationLevelson EarthmovingEquipment

Properlyadjustmachines.Properlymaintain machines.Operatemachinessmoothly.Maintainthe conditionsoftheterrain.Thefollowingguidelinescan helpreducethewholebodyvibrationlevel:

1. Usetherighttypeandsizeofmachine,equipment, andattachments.

2. Maintainmachinesaccordingtothe manufacturer'srecommendations.

a.Tirepressures

b.Brakeandsteeringsystems

c.Controls,hydraulicsystemandlinkages

3. Keeptheterrainingoodcondition.

a.Removeanylargerocksorobstacles.

b.Fillanyditchesandholes.

c.Providemachinesandscheduletimeinorderto maintaintheconditionsoftheterrain.

4. Useaseatthatmeets “ISO7096”.Keeptheseat maintainedandadjusted.

a.Adjusttheseatandsuspensionfortheweight andthesizeoftheoperator.

b.Inspectandmaintaintheseatsuspensionand adjustmentmechanisms.

5. Performthefollowingoperationssmoothly.

a.Steer

b.Brake

c.Accelerate.

d.Shiftthegears.

6. Movetheattachmentssmoothly.

7. Adjustthemachinespeedandtherouteinorderto minimizethevibrationlevel.

a.Drivearoundobstaclesandroughterrain.

b.Slowdownwhenitisnecessarytogoover roughterrain.

8. Minimizevibrationsforalongworkcycleoralong traveldistance.

a.Usemachinesthatareequippedwith suspensionsystems.

b.Usetheridecontrolsystemoncompact backhoeloaders.

c.Ifnoridecontrolsystemisavailable,reduce speedinordertopreventbounce.

d.Haulthemachinesbetweenworkplaces.

9. Lessoperatorcomfortmaybecausedbyotherrisk factors.Thefollowingguidelinescanbeeffective inordertoprovidebetteroperatorcomfort:

a.Adjusttheseatandadjustthecontrolsinorder toachievegoodposture.

b.Adjustthemirrorsinordertominimizetwisted posture.

c.Providebreaksinordertoreducelongperiods ofsitting.

d.Avoidjumpingfromthecab.

SafetySection

OperatorStation

e.Minimizerepeatedhandlingofloadsandlifting ofloads.

f.Minimizeanyshocksandimpactsduringsports andleisureactivities.

Sources

Thevibrationinformationandcalculationprocedure isbasedon “ISO/TR25398MechanicalVibrationGuidelinefortheassessmentofexposuretowhole bodyvibrationofrideonoperatedearthmoving machines”.Harmonizeddataismeasuredby internationalinstitutes,organizationsand manufacturers.

Thisliteratureprovidesinformationaboutassessing thewholebodyvibrationexposureofoperatorsof earthmovingequipment.Themethodisbasedon measuredvibrationemissionunderrealworking conditionsforallmachines.

Youshouldchecktheoriginaldirective.This documentsummarizespartofthecontentofthe applicablelaw.Thisdocumentisnotmeantto substitutetheoriginalsources.Otherpartsofthese documentsarebasedoninformationfromtheUnited KingdomHealthandSafetyExecutive.

RefertoOperationandMaintenanceManual, SEBU8257,“TheEuropeanUnionPhysicalAgents (Vibration)Directive2002/44/EC” formore informationaboutvibration.

ConsultyourlocalCaterpillardealerformore informationaboutmachinefeaturesthatminimize vibrationlevels.ConsultyourlocalCaterpillardealer aboutsafemachineoperation.

Usethefollowingwebsiteinordertofindyourlocal dealer: Caterpillar,Inc. www.cat.com

i07746362

OperatorStation

SMCSCode: 7000;7300

Anymodificationstotheinsideoftheoperatorstation shouldnotprojectintotheoperatorspaceorintothe spaceforthecompanionseat(ifequipped).The additionofaradio,fireextinguisher,andother equipmentmustbeinstalledsothatthedefined operatorspaceandthespaceforthecompanionseat (ifequipped)ismaintained.Anyitemthatisbrought intothecabshouldnotprojectintothedefined operatorspaceorthespaceforthecompanionseat (ifequipped).Alunchboxorotherlooseitemsmust besecured.Objectsmustnotposeanimpacthazard inroughterrainorintheeventofarollover.

ProductInformation Section

GeneralInformation

Specifications

SMCSCode: 7000

IntendedUse

Thismachineisclassifiedasabackhoeloaderas describedinISO6165:2006.Whenthemachineis usedasaloader,thismachineisattachedwitha frontmountedbucketorCaterpillarapprovedwork tools.Worktoolsareusedfordigging,loading,lifting, andcarryingmaterialsuchasearth,crushedrockor gravel.Whenthemachineisoperatingasabackhoe, theintendeduseofthismachineisforexcavating withabucketorworkingwithCaterpillarapproved worktools.Thismachinecanbeusedinobject handlingapplicationsthatarewithintheliftcapacity ofthemachine.Whenthismachineisusedinobject handlingapplicationsuseapprovedliftingpointsand approvedliftingdevices.

GeneralMachineSpecifications

Note: Basicmachinespecificationsarelistedbelow. Actualmachinespecificationswillvarywithdifferent worktools.

Table4

422EBACKHOELOADER

ApproximateWeight

(16845lb)

Table5

428EBACKHOELOADER

ApproximateWeight

(17211lb) TransportLength 5869mm (19.3ft)