SAFETY.CAT.

COM

320D RR and 320D LRR

EXCAVATORS
Machine Safety

Excerpted from Operation & Maintenance Manual (SEBU8044-01-01)

© 2007 Caterpillar
All Rights Reserved
 SEBU8044-01
March 2006

Operation and
Maintenance
Manual
320D RR and 320D LRR Excavator
FXK1-Up (Machine)
GKL1-Up (Machine)
EBY1-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or 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 pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was 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 can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications 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 or
death.
SEBU8044-01 3
Table of Contents

Table of Contents Operation .............................................................. 99

Operating Techniques ......................................... 103

Foreword ................................................................. 4
Parking ................................................................. 116
Safety Section Transportation Information .................................. 120
Safety Messages .................................................... 6
Towing Information .............................................. 124
Additional Messages ............................................. 12
Engine Starting (Alternate Methods) ................... 126
General Hazard Information ................................. 15
Maintenance Section
Crushing Prevention and Cutting Prevention ........ 17
Maintenance Access ........................................... 129
Burn Prevention .................................................... 18
Lubricant Viscosities and Refill Capacities ......... 130
Fire Prevention and Explosion Prevention ............ 18
Maintenance Support .......................................... 133
Fire Extinguisher Location .................................... 20
Maintenance Interval Schedule .......................... 134
Track Information .................................................. 20
Reference Information Section
Electrical Storm Injury Prevention ......................... 20
Reference Materials ............................................ 190
Before Starting Engine .......................................... 21
Index Section
Engine Starting ..................................................... 21
Index ................................................................... 192
Before Operation .................................................. 21

Operation .............................................................. 21

Engine Stopping ................................................... 22

Lifting Objects ....................................................... 23

Parking .................................................................. 23

Equipment Lowering with Engine Stopped ........... 23

Sound Information and Vibration Information ....... 23

Operator Station ................................................... 26

Guards (Operator Protection) ............................... 26

Product Information Section

General Information .............................................. 28

Identification Information ....................................... 39

Operation Section
Before Operation .................................................. 42

Machine Operation ............................................... 45

Engine Starting ..................................................... 97

4 SEBU8044-01
Foreword

Foreword Maintenance
The maintenance section is a guide to equipment
Literature Information care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
This manual should be stored in the operator’s interval. Items without specific intervals are listed
compartment in the literature holder or seat back under the "When Required" service interval. The
literature storage area. Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
This manual contains safety information, operation accomplish the scheduled maintenance. Use the
instructions, transportation information, lubrication Maintenance Interval Schedule as an index or "one
information and maintenance information. safe source" for all maintenance procedures.
Some photographs or illustrations in this publication
show details or attachments that can be different Maintenance Intervals
from your machine. Guards and covers might have
been removed for illustrative purposes. Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
Continuing improvement and advancement of monthly, etc.) can be used instead of service hour
product design might have caused changes to your meter intervals if they provide more convenient
machine which are not included in this publication. servicing schedules and approximate the indicated
Read, study and keep this manual with the machine. service hour meter reading. Recommended service
should always be performed at the interval that
Whenever a question arises regarding your machine, occurs first.
or this publication, please consult your Caterpillar
dealer for the latest available information. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
Safety be necessary.
The safety section lists basic safety precautions. In Perform service on items at multiples of the original
addition, this section identifies the text and locations requirement. For example, at every 500 service
of warning signs and labels used on the machine. hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
Read and understand the basic precautions listed 10 service hours or daily.
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
California Proposition 65 Warning
Operation Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
The operation section is a reference for the new birth defects, and other reproductive harm.
operator and a refresher for the experienced
operator. This section includes a discussion of Battery posts, terminals and related accessories
gauges, switches, machine controls, attachment contain lead and lead compounds. Wash hands
controls, transportation and towing information. after handling.
Photographs and illustrations guide the operator
through correct procedures of checking, starting, Certified Engine Maintenance
operating and stopping the machine.
Proper maintenance and repair is essential to keep
Operating techniques outlined in this publication are the engine and machine systems operating correctly.
basic. Skill and techniques develop as the operator As the heavy duty off-road diesel engine owner, you
gains knowledge of the machine and its capabilities. are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
SEBU8044-01 5
Foreword

It is prohibited for any person engaged in the 3. Check Character (character 9)

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or 4. Machine Indicator Section (MIS) or Product
render inoperative any emission related device or Sequence Number (characters 10-17). These were
element of design installed on or in an engine or previously referred to as the Serial Number.
machine that is in compliance with the regulations
(40 CFR Part 89). Certain elements of the machine Machines and generator sets produced before First
and engine such as the exhaust system, fuel system, Quarter 2001 will maintain their 8 character PIN
electrical system, intake air system and cooling format.
system may be emission related and should not be
altered unless approved by Caterpillar. Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Machine Capacity Serial Number (S/N).

Additional attachments or modifications may exceed

machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Caterpillar dealer for further information.

Caterpillar Product Identification

Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:

g00751314
Illustration 1

Where:

1. Caterpillar’s World Manufacturing Code

(characters 1-3)

2. Machine Descriptor (characters 4-8)

6 SEBU8044-01
Safety Section
Safety Messages

Safety Section
i02437636

Safety Messages
SMCS Code: 7000; 7405

There are several specific safety messages on this

machine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.

Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
the illustrations if the illustrations are not visible.
When you clean the safety messages, use a cloth,
water and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.

Replace any safety message that is damaged, or

missing. If a safety message is attached to a part
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.

g01160643
Illustration 2
SEBU8044-01 7
Safety Section
Safety Messages

g01217966
Illustration 3
8 SEBU8044-01
Safety Section
Safety Messages

(1) Do Not Operate (3) Seat Belt

This safety message is located in the cab. This safety message is located in the cab.

g00930652 g01067563

Do not operate or work on this machine unless A seat belt should be worn at all times during ma-
you have read and understand the instructions chine operation to prevent serious injury or death
and warnings in the Operation and Maintenance in the event of an accident or machine overturn.
Manuals. Failure to follow the instructions or heed Failure to wear a seat belt during machine opera-
the warnings could result in injury or death. Con- tion may result in serious injury or death.
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
(4) Electrical Power Lines
(2) Crushing Hazard This safety message is located in the cab.

This safety message is located in the cab.

g01067566

g01109331

Electrocution Hazard! Keep the machine and at-

tachments a safe distance from electrical power.
Personal injury can result if the window is not Stay clear 3 m (10 ft) plus twice the line insulator
latched in the overhead position; ensure the au- length. Read and understand the instructions and
to lock is engaged. warnings in the Operation and Maintenance Manu-
al. Failure to follow the instructions and warnings
will cause serious injury or death
SEBU8044-01 9
Safety Section
Safety Messages

(5) Crushing Hazard (6) Pressurized System

This safety message is located on top of the radiator,
next to the filler cap.

g01130693
Illustration 4

This safety message is located in the cab. g01067344

The impact from objects that strike the front of the Pressurized system! Hot coolant can cause seri-
cab or the top of the cab could result in a crush- ous burns, injury or death. To open the cooling
ing hazard with the potential for personal injury or system filler cap, stop the engine and wait until
death. the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to
The front guard and the top guard should be in- relieve the pressure. Read and understand the Op-
stalled on the cab for applications where the haz- eration and Maintenance Manual before perform-
ard of falling objects exist. Read the Operation and ing any cooling system maintenance.
Maintenance Manual.

Refer to Operation and Maintenance Manual,

“Guards” for further information.
10 SEBU8044-01
Safety Section
Safety Messages

(7) Aerosol Starting Aid (8) High Pressure Gas

g01067549
Illustration 6

This safety message is located on the accumulator in

the right back compartment.

g01067463
Illustration 5
This system contains high pressure gas. Failure to
This safety message is located inside the left front follow the instructions and warnings could cause
compartment on the engine air filter. an explosion, resulting in possible injury or death.

Do not expose to fire. Do not weld. Do not drill.

Relieve pressure before discharging.
Explosion hazard! Do not use ether! This machine
See Operation and Maintenance Manual for charg-
is equipped with an air inlet heater. Using ether
ing and discharging. See your Caterpillar Dealer
can create explosions or fires that can cause per-
for tools and detailed information.
sonal injury or death. Read and follow the starting
procedure in the Operation and Maintenance Man-
ual. Refer to Operation and Maintenance Manual,
“Equipment Lowering with Engine Stopped” for
further information.
Refer to Operation and Maintenance Manual, “Engine
Starting” for further information.
SEBU8044-01 11
Safety Section
Safety Messages

(9) Jump Start Cables (11) High Pressure Cylinder

This safety message is located inside the left front
compartment.

g01076729
Illustration 7

g01067366
This safety message is located on the track adjuster.

Explosion Hazard! Improper jumper cable connec- High Pressure Cylinder. Do not remove any parts
tions can cause an explosion resulting in serious from the cylinder until all of the pressure has been
injury or death. Batteries may be located in sep- relieved. This will prevent possible personal injury
arate compartments. Refer to the Operation and or death.
Maintenance Manual for the correct jump starting
procedure. Refer to Operation and Maintenance Manual , “Track
Adjustment - Adjust” for the proper service procedure.
(10) Crushing Hazard
(12) Relieve Hydraulic Tank
This safety message is located on both sides of the Pressure
back end of the machine.
This safety message is located on top of the hydraulic
tank.

g01067376

g01067344

Machine swings. Stay back. Crushing hazard

could cause serious injury or death.
HYDRAULIC TANK

RELIEVE TANK PRESSURE WITH ENGINE OFF BY

REMOVING CAP SLOWLY TO PREVENT BURNS
FROM HOT OIL.
12 SEBU8044-01
Safety Section
Additional Messages

(13) Hot Surface

This safety message is located in two locations on
the engine hood.

g00921005

Hot parts or hot components can cause burns or

personal injury. Do not allow hot parts or compo-
nents to contact your skin. Use protective clothing
or protective equipment to protect your skin.

i02437756

Additional Messages
SMCS Code: 7000; 7405

There are several specific messages on this

machine. The exact location of the messages and
the description of the information are reviewed in this
section. Please become familiar with all messages.

Make sure that all of the messages are legible.

Clean the messages or replace the messages if you
cannot read the words. Replace the illustrations if
the illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to 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. Any
Caterpillar dealer can provide new messages.
SEBU8044-01 13
Safety Section
Additional Messages

g01162416
Illustration 8

g01218009
Illustration 9

(1) Cleaning Windows

This message is located in three places on the cab

windows.
14 SEBU8044-01
Safety Section
Additional Messages

g01134495 g00915912
Illustration 10 Illustration 12

NOTICE Pull the ring in order to open the alternate exit.

Clean windows with a wet cloth or sponge. Dry cloth
or sponge may scratch window material. (4) Radial Seal Air Filters

This message is located on the air cleaner.

(2) Alternate Exit

This message is located on the rear window in the

cab.

g00915906
Illustration 11

If the primary exits are blocked, pull the ring in order

g01134494
to open the rear window. Exit the machine through Illustration 13
the window.
To avoid engine damage, use only Caterpillar radial
(3) Ring for the Alternate Exit seal air filters. Other filters will not seal properly.
Read the operation and maintenance manual.
This message is located on the ring for the alternate
exit. Refer to Operation and Maintenance Manual, “Engine
Air Filter Primary Element - Clean/Replace”.

(5)No Step

This message is located on the engine cover on the

top of the machine.
SEBU8044-01 15
Safety Section
General Hazard Information

g00911158 g00702020
Illustration 14 Illustration 16

Do not step in this area. Wear a hard hat, protective glasses, and other
protective equipment, as required.
i02443908
Do not wear loose clothing or jewelry that can snag
General Hazard Information on controls or on other parts of the equipment.

SMCS Code: 7000 Make sure that all protective guards and all covers
are secured in place on the equipment.

Keep the equipment free from foreign material.

Remove debris, oil, tools, and other items from the
deck, 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 and

the personnel that are authorized to give the hand
signals. 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.
g00104545 Inhaling the fumes that are released from a flame that
Illustration 15
contacts air conditioner refrigerant can cause bodily
Attach a “Do Not Operate” warning tag or a similar harm or death. Inhaling gas from air conditioner
warning tag to the start switch or to the controls refrigerant through a lighted cigarette can cause
before you service the equipment or before you bodily harm or death.
repair the equipment. These warning tags (Special
Instruction, SEHS7332) are available from your Never put maintenance fluids into glass containers.
Caterpillar dealer. Drain all liquids into a suitable container.

Know the width of your equipment in order to maintain Obey all local regulations for the disposal of liquids.
proper clearance when you operate the equipment
near fences or near boundary obstacles. Use all cleaning solutions with care. Report all
necessary repairs.
Be aware of high voltage power lines and power
cables that are buried. If the machine comes in Do not allow unauthorized personnel on the
contact with these hazards, serious injury or death equipment.
may occur from electrocution.
Unless you are instructed otherwise, perform
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance Manual
for the procedure for placing the equipment in the
servicing position.
16 SEBU8044-01
Safety Section
General Hazard Information

Pressurized Air and Water Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
Pressurized air and/or water can cause debris penetrate body tissue. Fluid penetration can cause
and/or hot water to be blown out. This could result in serious injury and possible death. A pin hole leak can
personal injury. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
When pressurized air and/or pressurized water is from a doctor that is familiar with this type of injury.
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes Containing Fluid Spillage
goggles or a protective face shield.
Care must be taken in order to ensure that fluids
The maximum air pressure for cleaning purposes are contained during performance of inspection,
must be reduced to 205 kPa (30 psi) when the maintenance, testing, adjusting and repair of the
nozzle is deadheaded and the nozzle is used with equipment. Prepare to collect the fluid with suitable
an effective chip deflector and personal protective containers before opening any compartment or
equipment. The maximum water pressure for disassembling any component that contains fluids.
cleaning purposes must be below 275 kPa (40 psi).
Refer to Special Publication, NENG2500, “Caterpillar
Trapped Pressure Dealer Service Tool Catalog” for the following items:

Pressure can be trapped in a hydraulic system. • Tools that are suitable for collecting fluids and
Releasing trapped pressure can cause sudden equipment that is suitable for collecting fluids
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings. • Tools that are suitable for containing fluids and
High pressure oil that is released can cause a hose to equipment that is suitable for containing fluids
whip. High pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury Obey all local regulations for the disposal of liquids.
and possible death.
Asbestos Information
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
relieve the hydraulic pressure.
g00702022
Illustration 18

Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

g00687600
Illustration 17
SEBU8044-01 17
Safety Section
Crushing Prevention and Cutting Prevention

Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.

If dust that may contain asbestos is present, there

are several guidelines that should be followed:

• Never use compressed air for cleaning.

g00706404
• Avoid brushing materials that contain asbestos. Illustration 19

• Avoid grinding materials that contain asbestos. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
• Use a wet method in order to clean up asbestos disposed of according to local regulations.
materials.
Always use leakproof containers when you drain
• A vacuum cleaner that is equipped with a high fluids. Do not pour waste onto the ground, down a
efficiency particulate air filter (HEPA) can also be drain, or into any source of water.
used.
i01359664
• Use exhaust ventilation on permanent machining
jobs. Crushing Prevention and
• Wear an approved respirator if there is no other Cutting Prevention
way to control the dust.
SMCS Code: 7000
• Comply with applicable rules and regulations
for the work place. In the United States, use Support the equipment properly before you perform
Occupational Safety and Health Administration any work or maintenance beneath that equipment.
(OSHA) requirements. These OSHA requirements Do not depend on the hydraulic cylinders to hold
can be found in “29 CFR 1910.1001”. up the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
• Obey environmental regulations for the disposal
of asbestos. Do not work beneath the cab of the machine unless
the cab is properly supported.
• Stay away from areas that might have asbestos
particles in the air. Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while
the engine is running.

Never jump across the starter solenoid terminals

in order to start the engine. Unexpected machine
movement could result.

Whenever there are equipment control linkages the

clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.

Stay clear of all rotating and moving parts.

18 SEBU8044-01
Safety Section
Burn Prevention

If it is necessary to remove guards in order to perform Oils

maintenance, always install the guards after the
maintenance is performed. Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
Keep objects away from moving fan blades. The fan do not allow hot components to contact the skin.
blade will throw objects or cut objects.
Remove the hydraulic tank filler cap only after the
Do not use a kinked wire cable or a frayed wire cable. engine has been stopped. The filler cap must be
Wear gloves when you handle wire cable. cool enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
When you strike a retainer pin with force, the retainer the hydraulic tank filler cap.
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to
Batteries
your eyes, wear protective glasses when you strike
Electrolyte is an acid. Electrolyte can cause personal
a retainer pin.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
Chips or other debris can fly off an object when you
batteries. Wash hands after touching the batteries
strike the object. Make sure that no one can be
and connectors. Use of gloves is recommended.
injured by flying debris before striking any object.

i01359795
i01329099

Burn Prevention Fire Prevention and Explosion

Prevention
SMCS Code: 7000
SMCS Code: 7000
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication system,
in the fuel system, or in the cooling system before
any lines, fittings or related items are disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause Illustration 20
g00704000
severe burns. Allow cooling system components to
cool before the cooling system is drained. All fuels, most lubricants, and some coolant mixtures
are flammable.
Check the coolant level only after the engine has
been stopped. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
Ensure that the filler cap is cool before removing the a fire. Fire may cause personal injury and property
filler cap. The filler cap must be cool enough to touch damage.
with a bare hand. Remove the filler cap slowly in
order to relieve pressure. Remove all flammable materials such as fuel, oil, and
debris from the machine. Do not allow any flammable
Cooling system conditioner contains alkali. Alkali can materials to accumulate on the machine.
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
SEBU8044-01 19
Safety Section
Fire Prevention and Explosion Prevention

Do not operate the machine near any flame.

Exhaust shields (if equipped) protect hot exhaust

components from oil spray or fuel spray in case of
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.

Do not weld on lines or on tanks that contain

flammable fluids. Do not flame cut lines or tanks
that contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior
to welding or flame cutting.

Check all electrical wires daily. Repair any wires

that are loose or frayed before you operate the
machine. Clean all electrical connections and tighten
all electrical connections.

Dust that is generated from repairing nonmetallic

hoods or nonmetallic fenders can be flammable
and/or explosive. Repair such components in a well
ventilated area away from open flames or sparks. Illustration 22
g00704135

Inspect all lines and hoses for wear or for Gases from a battery can explode. Keep any open
deterioration. The hoses must be properly routed. flames or sparks away from the top of a battery. Do
The lines and the hoses must have adequate support not smoke in battery charging areas.
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires. Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.

Improper jumper cable connections can cause

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. This may cause an

explosion.

Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Ether
g00704059
Illustration 21
Ether is flammable and poisonous.
Use caution when you are refueling a machine. Do
not smoke while you are refueling a machine. Do Use ether in well ventilated areas. Do not smoke
not refuel a machine near open flames or sparks. while you are replacing an ether cylinder or while you
Always stop the engine before refueling. Fill the fuel are using an ether spray.
tank outdoors.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49 °C (120 °F). Keep ether cylinders away
from open flames or sparks.
20 SEBU8044-01
Safety Section
Fire Extinguisher Location

Dispose of used ether cylinders properly. Do not i01932259

puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel. Fire Extinguisher Location
Do not spray ether into an engine if the machine is SMCS Code: 7000; 7419
equipped with a thermal starting aid for cold weather
starting.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or Illustration 23
g01005330
cardboard to check for leaks. Tighten all connections
to the recommended torque. Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Replace the parts if any of the following conditions Inspect the fire extinguisher and service the fire
are present: extinguisher regularly. Obey the recommendations
on the instruction plate.
• End fittings are damaged or leaking.
The recommended location for mounting the fire
• Outer coverings are chafed or cut. extinguisher is in the storage box.

• Wires are exposed.

i01329108

• Outer coverings are ballooning. Track Information

• Flexible part of the hoses are kinked. SMCS Code: 4170; 7000
• Outer covers have embedded armoring. Track adjusting systems use either grease or oil
under high pressure to keep the track under tension.
• End fittings are displaced.
Grease or oil under high pressure coming out of the
Make sure that all clamps, guards, and heat shields
relief valve can penetrate the body causing injury or
are installed correctly. During machine operation, this
death. Do not watch the relief valve to see if grease
will help to prevent vibration, rubbing against other
or oil is escaping. Watch the track or track adjustment
parts, and excessive heat.
cylinder to see if the track is being loosened.

The pins and bushings in a dry track pin joint

can become very hot. It is possible to burn the
fingers if there is more than brief contact with these
components.

i01122596

Electrical Storm Injury

Prevention
SMCS Code: 7000

When lightning is striking in the vicinity of the

machine, the operator should never attempt the
following procedures:
SEBU8044-01 21
Safety Section
Before Starting Engine

• Mount the machine. i01340061

• Dismount the machine. Before Operation

If you are in the operator’s station during an electrical SMCS Code: 7000
storm, stay in the operator’s station. If you are on the
S/N: FXK2-Up
ground during an electrical storm, stay away from
the vicinity of the machine. S/N: GKL1-Up
S/N: EBY1-Up
i00771840

Before Starting Engine Clear all personnel from the machine and from the
area.
SMCS Code: 1000; 7000
Clear all obstacles from the machine’s path. Beware
of hazards (wires, ditches, etc).
Start the engine only from the operator compartment.
Never short across the starter terminals or across
Be sure that all windows are clean. Secure the doors
the batteries. Shorting could damage the electrical
and the windows in the open position or in the shut
system by bypassing the engine neutral start system.
position.
Inspect the condition of the seat belt and of the
Adjust the rearview mirrors (if equipped) for the best
mounting hardware. Replace any parts that are worn
visibility close to the machine. Make sure that the
or damaged. Regardless of appearance, replace the
horn, the travel alarm (if equipped), and all other
seat belt after three years of use. Do not use a seat
warning devices are working properly.
belt extension on a retractable seat belt.
Fasten the seat belt securely.
Adjust the seat so that full pedal travel can be
achieved with the operator’s back against the back
Warm up the engine and the hydraulic oil before
of the seat.
operating the machine.
Make sure that the machine is equipped with a
Before moving the machine, check the position of the
lighting system that is adequate for the job conditions.
undercarriage. The normal travel position is with the
Make sure that all machine lights are working
idler wheels to the front under the cab and the drive
properly.
sprockets to the rear. When the undercarriage is in
the reversed position, the directional controls must
Before you start the engine and before you move the
be operated in opposite directions.
machine, make sure that no one is underneath the
machine, around the machine, or on the machine.
Make sure that the area is free of personnel. i01982707

Operation
i02346672

Engine Starting SMCS Code: 7000

SMCS Code: 1000; 7000 Machine Operating Temperature

If a warning tag is attached to the engine start switch
Range
or to the controls, do not start the engine. Also, do The machine must function satisfactorily in the
not move any controls. anticipated ambient temperature limits that are
encountered during operation. The standard
Move all hydraulic controls to the HOLD position machine configuration is intended for use within
before you start the engine. Move the hydraulic an ambient temperature range of −18 °C (0 °F) to
lockout control to the LOCKED position. For further 43 °C (109 °F). Special configurations for different
details on this procedure, refer to Operation and ambient temperatures may be available. Consult
Maintenance Manual, “Operator Controls”. your Caterpillar dealer for additional information on
special configurations of your machine.
Diesel engine exhaust contains products of
combustion which can be harmful to your health.
Always run the engine in a well ventilated area. If
you are in an enclosed area, vent the exhaust to the
outside.
22 SEBU8044-01
Safety Section
Engine Stopping

Machine Operation Only connect trailing equipment to a drawbar or to a

hitch.
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the Never straddle a wire cable. Never allow other
machine. Only operate the controls while the engine personnel to straddle a wire cable.
is running.
When you maneuver in order to connect the
Check for proper operation of all controls and of all equipment, make sure that no personnel are between
protective devices while you operate the machine the machine and trailing equipment. Block up the
slowly in an open area. hitch of the trailing equipment in order to align the
equipment with the drawbar.
When the machine is moving watch the clearance
of the boom. Uneven ground can cause the boom Check the local regulations, state codes, and/or
to move in all directions. directives of the job site for a specific minimum
distance from obstacles.
Make sure that no personnel will be endangered
before you move the machine. Do not allow riders on Before you operate the machine, check with local
the machine unless the machine has an additional utilities for the locations of underground pipes and for
seat with a seat belt. the locations of buried cables.

Report any machine damage that was noted during Know the maximum dimensions of your machine.
machine operation. Make any necessary repairs.
Watch the load at all times.
Hold attachments approximately 40 cm (15 inches)
above ground level while you drive the machine. Do Do not operate the machine without the
not drive the machine close to an overhang, to the counterweight. The machine can tip when the boom
edge of a cliff, or to the edge of an excavation. is over the side.

If the machine begins to sideslip on a grade, The clamshell, the grapple, or the magnet can swing
immediately dump the load and turn the machine in all directions. Move the joysticks in a continuous
downhill. motion. Failure to move the joysticks in a continuous
motion can cause the clamshell, the grapple, or the
Be careful to avoid any ground condition which could magnet to swing into the cab or into a person in the
cause the machine to tip. Tipping can occur when work area. This will result in personal injury.
you work on hills, on banks, or on slopes. Tipping can
also occur when you cross ditches, ridges, or other The boom and the stick linkage can allow the bucket
unexpected obstructions. to contact the undercarriage and/or the cab. Be
aware of the position of the bucket.
When possible, operate the machine up slopes and
down slopes. Avoid operating the machine across
i01353516
the slope.

Keep the machine under control. Do not overload the

Engine Stopping
machine beyond capacity. SMCS Code: 1000; 7000
Avoid changing the direction of travel on a slope. This Do not stop the engine immediately after the
could result in tipping or side slipping of the machine. machine has been operated under load. This can
cause overheating and accelerated wear of engine
Bring the load close to the machine before travelling components.
any distances.
After the machine is parked and the parking brake
Bring the load close to the machine before swinging is engaged, allow the engine to run for five minutes
the load. before shutdown. This allows hot areas of the engine
to cool gradually.
Lifting capacity decreases as the load is moved
further from the machine.

Make sure that the towing eyes and the towing

devices are adequate for your needs.
SEBU8044-01 23
Safety Section
Lifting Objects

i00697030 Note: Make sure that all work tools are in the
recommended servicing position before servicing the
Lifting Objects machine.
SMCS Code: 7000 Move the hydraulic lockout control to the LOCKED
position.
There may be some local regulations and/or
government regulations that govern the use of Stop the engine.
excavators which lift heavy objects. Obey those
regulations. Turn the engine start switch to the OFF position and
remove the engine start switch key.
If this machine is used to lift objects within an
area that is controlled by the European Directive Turn the battery disconnect switch to the OFF
“89/392/EEC”, the machine must be equipped with a position. Remove the disconnect switch key if you
boom lowering control valve and an overload warning do not operate the machine for an extended period
device. of time. This will prevent drainage of the battery. A
battery short circuit, any current draw from certain
i02252108
components, and vandalism can cause drainage of
the battery.
Parking
i01329161
SMCS Code: 7000

The hydraulic system remains pressurized provided

Equipment Lowering with
that the accumulator is charged. This condition is true Engine Stopped
even when the engine is not running. This pressure
should decrease in a short time (approximately SMCS Code: 7000-II
one minute). While the hydraulic system maintains
a charge, the hydraulic work tools and machine Before lowering any equipment with the engine
controls remain functional. stopped, clear the area around the equipment of
all personnel. The procedure to use will vary with
Machine movement that is sudden and unexpected the type of equipment to be lowered. Keep in mind
will occur if any of the controls are moved. This can most systems use a high pressure fluid or air to
cause personal injury or death. raise or lower equipment. The procedure will cause
high pressure air, hydraulic, or some other media
Always move the hydraulic lockout control to the to be released in order to lower the equipment.
LOCKED position before you shut off the engine or Wear appropriate personal protective equipment and
immediately after the engine stops running. follow the established procedure in the Operation
and Maintenance Manual, “Equipment Lowering with
Park the machine on a level surface. If you must Engine Stopped” in the Operation Section of the
park the machine on a grade, chock the tracks of the manual.
machine.
i02504870

Sound Information and

Vibration Information
SMCS Code: 7000

Sound Level Information

Hearing protection may be needed when the
machine is operated with an open operator station
and an open cab for extended periods or in a noisy
environment. Hearing protection may be needed
g00100836 when the machine is operated with a cab that is
Illustration 24
not properly maintained or when the doors and
windows are open for extended periods or in a noisy
Place the machine in the servicing position.
environment.
24 SEBU8044-01
Safety Section
Sound Information and Vibration Information

“The European Union Physical

Agents (Vibration) Directive
2002/44/EC”
Vibration Data for Track Type Excavator
Information Concerning Hand/Arm Vibration
Level

When the machine is operated according to the

intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.

Information Concerning Whole Body Vibration

Level

This section provides vibration data and a method

for estimating the vibration level for track type
excavators.

Note: Vibration levels are influenced by many

different 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 the

suspension system, attachments, and condition of
the equipment

It is not possible to get precise vibration levels for

this machine. The expected vibration levels can be
estimated with the information in Table 1 in order
to calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.

Estimate the vibration levels for the three vibration

directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.

Note: All vibration levels are in meter per second

squared.
SEBU8044-01 25
Safety Section
Sound Information and Vibration Information

Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Machine Typical Operating Vibration Levels Scenario Factors

Type Activity X axis Y axis Z axis X axis Y axis Z axis
excavating 0,44 0,27 0,30 0,24 0,16 0,17
hydraulic breaker
Track Type 0,53 0,31 0,55 0,30 0,18 0,28
application
Excavator
mining application 0,65 0,42 0,61 0,21 0,15 0,32
transfer 0,48 0,32 0,79 0,19 0,20 0,23

Note: Refer to “ISO/TR 25398 Mechanical Vibration - a. Adjust the seat and suspension for the weight
Guideline for the assessment of exposure to whole and the size of the operator.
body vibration of ride on operated earthmoving
machines” for more information about vibration. b. Inspect and maintain the seat suspension and
This publication uses data that is measured adjustment mechanisms.
by international institutes, organizations and
manufacturers. This document provides information 5. Perform the following operations smoothly.
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and a. Steer
Maintenance Manual Supplement , SEBU8257 for
more information about machine vibration levels. b. Brake

The Caterpillar suspension seat meets the criteria of c. Accelerate.

“ISO 7096”. This represents vertical vibration level
under severe operating conditions. d. Shift the gears.

Guidelines for Reducing Vibration Levels on 6. Move the attachments smoothly.

Earthmoving Equipment
7. Adjust the machine speed and the route in order
Properly adjust machines. Properly maintain to minimize the vibration level.
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can a. Drive around obstacles and rough terrain.
help reduce the whole body vibration level:
b. Slow down when it is necessary to go over
1. Use the right type and size of machine, equipment, rough terrain.
and attachments.
8. Minimize vibrations for a long work cycle or a long
2. Maintain machines according to the travel distance.
manufacturer’s recommendations.
a. Use machines that are equipped with
a. Tire pressures suspension systems.

b. Brake and steering systems b. Use the ride control system on track type
excavators.
c. Controls, hydraulic system and linkages
c. If no ride control system is available, reduce
3. Keep the terrain in good condition. speed in order to prevent bounce.

a. Remove any large rocks or obstacles. d. Haul the machines between workplaces.

b. Fill any ditches and holes. 9. Less operator comfort may be caused by other risk
factors. The following guidelines can be effective
c. Provide machines and schedule time in order in order to provide better operator comfort:
to maintain the conditions of the terrain.
a. Adjust the seat and adjust the controls in order
4. Use a seat that meets “ISO 7096”. Keep the seat to achieve good posture.
maintained and adjusted.
26 SEBU8044-01
Safety Section
Operator Station

b. Adjust the mirrors in order to minimize twisted Rollover Protective Structure

posture.
(ROPS), Falling Object Protective
c. Provide breaks in order to reduce long periods Structure (FOPS) or Tip Over
of sitting. Protection Structure (TOPS)
d. Avoid jumping from the cab. The ROPS/FOPS Structure (if equipped) on your
machine is specifically designed, tested and certified
e. Minimize repeated handling of loads and lifting for that machine. Excavators are not equipped
of loads. with ROPS structures. Any alteration or any
modification to the ROPS/FOPS Structure could
f. Minimize any shocks and impacts during sports weaken the structure. This places the operator
and leisure activities. into an unprotected environment. Modifications or
attachments that cause the machine to exceed the
i01649970 weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Operator Station Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
SMCS Code: 7300; 7301; 7325 protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Any modifications to the inside of the operator Structure has structural damage. Damage to the
station should not project into the operator space. structure can be caused by an overturn, a falling
The addition of a radio, fire extinguisher, and other object, a collision, etc.
equipment must be installed so that the defined
operator space is maintained. Any item that is brought Do not mount items (fire extinguishers, first aid
into the cab should not project into the defined kits, work lights, etc) by welding brackets to the
operator space. A lunch box or other loose items ROPS/FOPS Structure or by drilling holes in the
must be secured. Objects must not pose an impact ROPS/FOPS Structure. Welding brackets or drilling
hazard in rough terrain or in the event of a rollover. holes in the ROPS/FOPS Structures can weaken
the structures. Consult your Caterpillar dealer for
mounting guidelines.
i01992325

Guards The Tip Over Protection Structure (TOPS) is

another type of guard that is used on mini hydraulic
(Operator Protection) excavators. This structure protects the operator in
the event of a tipover. The same guidelines for the
SMCS Code: 7000; 7150 inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
There are different types of guards that are used to Over Protection Structure.
protect the operator. The machine and the machine
application determines the type of guard that should
be used. Other Guards (If Equipped)
A daily inspection of the guards is required in order to Protection from flying objects and/or falling objects is
check for structures that are bent, cracked or loose. required for special applications. Logging applications
Never operate a machine with a damaged structure. and demolition applications are two examples that
require special protection.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor A front guard needs to be installed when a work
operating techniques are used. This situation can tool that creates flying objects is used. Mesh
occur even though a machine is equipped with an front guards that are approved by Caterpillar or
appropriate protective guard. Follow the established polycarbonate front guards that are approved by
operating procedures that are recommended for your Caterpillar are available for machines with a cab or
machine. an open canopy. On machines that are equipped with
cabs, the windshield should also be closed. Safety
glasses are recommended when flying hazards exist
for machines with cabs and machines with open
canopies.

If the work material extends above the cab, top

guards and front guards should be used. Typical
examples of this type of application are listed below:
SEBU8044-01 27
Safety Section
Guards

• Demolition applications
• Rock quarries
• Forestry products
Additional guards may be required for specific
applications or work tools. The Operation and
Maintenance Manual for your machine or your
work tool will provide specific requirements for the
guards. Consult your Caterpillar dealer for additional
information.