sebu7887-19 s

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SAFETYOperation and Maintenance Manual Excerpt

SEBU7887-19October 2012

Operation andMaintenanceManual966H and 972H Wheel LoadersGTA1-Up (972H)LCC1-Up (972H)A6D1-Up (966H)A7D1-Up (972H)RYF1-Up (966H)A6G1-Up (966H)A7G1-Up (972H)A6J1-Up (966H)A7J1-Up (972H)TAL1-Up (966H)

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6 SEBU7887-19Safety SectionSafety Messages

Safety Sectioni03651216

Safety MessagesSMCS Code: 7000

There are several specific safety messages on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all safetymessages.

Make sure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if you cannot read the words. Replacethe illustrations if the illustrations are not legible.When you clean the safety messages, use a cloth,water and soap. Do not use solvent, gasoline, orother harsh chemicals to clean the safety signs.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the warning sign. Looseadhesive will allow the warning sign to fall.

Replace any safety message that is damaged, ormissing. If a safety message is attached to a partthat is replaced, install a safety message on thereplacement part. Any Caterpillar dealer can providenew safety messages.

SEBU7887-19 7Safety Section

Safety Messages

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Do Not Operate (1)This warning label is located inside the cab of themachine on the front left post.

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

Operation Around A Blast Area (2)If your machine is equipped with Product Link, thiswarning label is located in the cab on the front leftpost.

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This machine is equipped with a CaterpillarProduct Link communication device. When elec-tric/electronic detonators are used, this com-munication device should be deactivated within12 m (40 ft) of a blast site, or within the distancemandated under applicable legal requirements.Failure to do so could cause interference withblasting operations and result in serious injury ordeath.


Safety Messages

Pressurized System (3)This warning is located next to the hydraulic tankfiller cap.

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At operating temperature, the hydraulic tank is hotand under pressure.

Hot oil and components can cause personal in-jury. Do not allow hot oil or components to contactskin.

Remove the filler cap only when the engine isstopped, and the filler cap is cool enough to touchwith your bare hand. Remove the filler cap slowlyto relieve pressure.

Rotating Fan (4)This warning label is located behind the access dooron each side of the machine.

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

Pressurized System (5)This warning label is located near the cooling systempressure cap.

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

Flying Debris (6) for variable pitchfan (If Equipped)This message is located at the rear of the hood onboth sides of the machine.

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Flying Debris Hazard! During operation of the en-gine fan, flying debris could be discharged fromthe radiator which could result in personal injuryor death. Stay clear of the fan discharge area untilthe engine is stopped.


Battery (7)This warning is located under the left ladder behindthe top step of the ladder.

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

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

Crush Hazard (8)This warning is located on the side face of the loaderframe near the steering frame lock.

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Crushing Hazard. There is no clearance for a per-son in this area when the machine turns. Severeinjury or death from crushing could occur. Con-nect the steering frame lock between front andrear frames before lifting, transporting, or servic-ing the machine in the articulation area.

Disconnect the steering lock and secure beforeresuming operation.

No Clearance (9)This warning is located on the side face of the loaderframe near the articulation hitch on both sides of themachine.

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


Safety Messages

Seat Belt (10)This warning is located inside the cab on the RH cabpost.

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A seat belt should be worn at all times during ma-chine operation to prevent serious injury or deathin the event of an accident or machine overturn.Failure to wear a seat belt during machine opera-tion may result in serious injury or death.

ROPS/FOPS Structure (11)This warning label is located above the platform onthe right side of the cab to the left of the door.

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Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture's protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. This will void the certification. Consulta Caterpillar dealer to determine this structure'slimitations without voiding its certification.

Certification for Rollover Protective Structure(ROPS) and for Falling Object ProtectiveStructure (FOPS)

When the ROPS or the FOPS is properly installedon a machine which is not altered to exceed thecertification test mass, this structure meets thefollowing standards for the ROPS at the time ofinstallation: SAE J1040 MAY94, ISO 3471:1994, SAEJ397 OCT95, and ISO 3164:1995. Also, the FOPScanopy meets the following standards at the time ofinstallation: SAE/ISO3449 APR98 LEVEL II and ISO3449:1992 LEVEL II.

12 SEBU7887-19Safety SectionAdditional Messages

High Pressure Cylinder (12)This warning is located on the accumulator in thefollowing three places: the service center on the rightside of the machine, the right control (accumulator) inthe right side of the non-engine end frame, and nearthe main hydraulic control valve.

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Gas under pressure. Rapid discharge from dis-connecting or disassembly could cause personalinjury or death. See service manual before reliev-ing pressure or charging.

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Additional MessagesSMCS Code: 7000

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

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

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


Additional Messages


Alternate Exit (1)

This message is located on the latch of the right sidewindow in the cab.


14 SEBU7887-19Safety SectionAdditional Messages

If the primary exit is blocked, pull the pin fromthe latch and release the latch. Push the windowoutward. Exit the machine through the window.

Alternate Exit (2)

This message is located on the glass of the righthand door just above the latch.


If the primary exit is blocked, pull the pin fromthe latch and release the latch. Push the windowoutward. Exit the machine through the window.

Alternate Exit (3)

If equipped,this message is located on the bracketassembly for the payload control system near theright hand door.


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

Machine Security System (4)

If equipped, this message is located on the left sideof the instrument panel above the engine start switch.


This machine is equipped with a security system.Read the Operation and Maintenance Manual beforeyou operate the machine.

Air Conditioner (5)

This message is located inside the cab on the rightrear post.


Read the service manual before you perform anymaintenance on the air conditioner.No Step(6)

These messages are located on the fenders and onthe hood behind the cab.


General Hazard Information


Do not step in these locations. Do not stand in theselocations.

If your machine is equipped with Product Link thefollowing message will be located in the cab.


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General Hazard InformationSMCS Code: 7000


Typical example

Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controls.Attach the warning tag before you service theequipment or before you repair the equipment. Thesewarning tags (Special Instruction, SEHS7332) areavailable from your Cat dealer.

Operating the machine while distracted can resultin the loss of machine control. Use extreme cau-tion when using any device while operating themachine. Operating the machine while distractedcan result in personal injury or death.

Know the width of your equipment in order to maintainproper clearance when you operate the equipmentnear fences or near boundary obstacles.

Be aware of high voltage power lines and powercables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the equipment.

Make sure that all protective guards and all coversare secured in place on the equipment.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools,and other items that are not a part of the equipment.

Know the appropriate work site hand signals andthe personnel that are authorized to give the handsignals. Accept hand signals from one person only.

16 SEBU7887-19Safety SectionGeneral Hazard Information

Do not smoke when you service an air conditioner.Also, do not smoke if refrigerant gas may be present.Inhaling the fumes that are released from a flame thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditionerrefrigerant through a lighted cigarette can causebodily harm or death.

Never put maintenance fluids into glass containers.Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and Maintenance Manualfor the procedure for placing the equipment in theservicing position.

When you perform maintenance above ground level,use appropriate devices such as ladders or man liftmachines. If equipped, use the machine anchoragepoints and use approved fall arrest harnesses andlanyards.

Pressurized Air and WaterPressurized air and/or water can cause debris and/orhot water to be blown out. The debris and/or hotwater could result in personal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when thenozzle is deadheaded and the nozzle is used withan effective chip deflector and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Trapped PressurePressure can be trapped in a hydraulic system.Releasing trapped pressure can cause suddenmachine movement or attachment movement. Usecaution if you disconnect hydraulic lines or fittings.High-pressure oil that is released can cause a hoseto whip. High-pressure oil that is released can causeoil to spray. Fluid penetration can cause seriousinjury and possible death.

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting, and repair of theequipment. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for the following items:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.


Crushing Prevention and Cutting Prevention

Inhalation


Exhaust

Use caution. Exhaust fumes can be hazardousto your health. If you operate the machine in anenclosed area, adequate ventilation is necessary.

Asbestos Information

Cat equipment and replacement parts that areshipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCat replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is boundin a resin or sealed in some way. Normal handlingis not hazardous unless airborne dust that containsasbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”. In Japan,use the requirements found in the “Ordinance onPrevention of Health Impairment due to Asbestos”in addition to the requirements of the IndustrialSafety and Health Act.

• Obey environmental regulations for the disposalof asbestos.

• Stay away from areas that might have asbestosparticles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

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Crushing Prevention andCutting PreventionSMCS Code: 7000

Support the equipment properly before you performany work or maintenance beneath that equipment.Do not depend on the hydraulic cylinders to holdup the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

18 SEBU7887-19Safety SectionBurn Prevention

Do not work beneath the cab of the machine unlessthe cab is properly supported.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or whilethe engine is running.

Never jump across the starter solenoid terminalsin order to start the engine. Unexpected machinemovement could result.

Whenever there are equipment control linkages theclearance in the linkage area will change with themovement of the equipment or the machine. Stayclear of areas that may have a sudden change inclearance with machine movement or equipmentmovement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to performmaintenance, always install the guards after themaintenance is performed.

Keep objects away from moving fan blades. The fanblade will throw objects or cut objects.

Do not use a kinked wire cable or a frayed wire cable.Wear gloves when you handle wire cable.

When you strike a retainer pin with force, the retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes, wear protective glasses when you strikea retainer pin.

Chips or other debris can fly off an object when youstrike the object. Make sure that no one can beinjured by flying debris before striking any object.

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Burn PreventionSMCS Code: 7000

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

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

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

Check the coolant level only after the engine hasbeen stopped.

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

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

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

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

BatteriesThe liquid in a battery is an electrolyte. Electrolyte isan acid that can cause personal injury. Do not allowelectrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolytelevels. Batteries give off flammable fumes which canexplode.

Always wear protective glasses when you work withbatteries. Wash hands after touching batteries. Theuse of gloves is recommended.


Fire Prevention and Explosion Prevention

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Fire Prevention and ExplosionPreventionSMCS Code: 7000


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

To minimize the risk of fire or explosion, Caterpillarrecommends the following actions.

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operate amachine when a fire hazard exists. Contact your Catdealer for service.

Understand the use of the primary exit and alternativeexit on the machine. Refer to Operation andMaintenance Manual, “Alternative Exit”.

Do not operate a machine with a fluid leak. Repairleaks and clean up fluids before resuming machineoperation. Fluids that are leaking or spilled onto hotsurfaces or onto electrical components can cause afire. A fire may cause personal injury or death.

Remove flammable material such as leaves,twigs, papers, trash, and so on. These items mayaccumulate in the engine compartment or aroundother hot areas and hot parts on the machine.

Keep the access doors to major machinecompartments closed and access doors in workingcondition in order to permit the use of fire suppressionequipment, in case a fire should occur.

Clean all accumulations of flammable materials suchas fuel, oil, and debris from the machine.

Do not operate the machine near any flame.

Keep shields in place. Exhaust shields (if equipped)protect hot exhaust components from oil spray or fuelspray in case of a break in a line, in a hose, or in aseal. Exhaust shields must be installed correctly.

Do not weld or flame cut on tanks or lines that containflammable fluids or flammable material. Empty andpurge the lines and tanks. Then clean the lines andtanks with a nonflammable solvent prior to weldingor flame cutting. Ensure that the components areproperly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallichoods or fenders may be flammable and/or explosive.Repair such components in a well ventilated areaaway from open flames or sparks. Use suitablePersonal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration.Replace damaged lines and hoses. The lines andthe hoses should have adequate support and secureclamps. Tighten all connections to the recommendedtorque. Damage to the protective cover or insulationmay provide fuel for fires.

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


Use caution when you are fueling a machine. Do notsmoke while you are fueling a machine. Do not fuela machine near open flames or sparks. Always stopthe engine before fueling. Fill the fuel tank outdoors.Properly clean areas of spillage.

Never store flammable fluids in the operatorcompartment of the machine.

20 SEBU7887-19Safety SectionFire Prevention and Explosion Prevention

Battery and Battery Cables


Caterpillar recommends the following in order tominimize the risk of fire or an explosion related tothe battery.

Do not operate a machine if battery cables or relatedparts show signs of wear or damage. Contact yourCat dealer for service.

Follow safe procedures for engine starting withjump-start cables. Improper jumper cable connectionscan cause an explosion that may result in injury.Refer to Operation and Maintenance Manual,“Engine Starting with Jump Start Cables” for specificinstructions.

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

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

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter inorder to check the battery charge.

Daily inspect battery cables that are in areas thatare visible. Inspect cables, clips, straps, and otherrestraints for damage. Replace any damaged parts.Check for signs of the following, which can occurover time due to use and environmental factors:

• Fraying

• Abrasion

• Cracking

• Discoloration

• Cuts on the insulation of the cable

• Fouling

• Corroded terminals, damaged terminals, and looseterminals

Replace damaged battery cable(s) and replaceany related parts. Eliminate any fouling, which mayhave caused insulation failure or related componentdamage or wear. Ensure that all components arereinstalled correctly.

An exposed wire on the battery cable may causea short to ground if the exposed area comes intocontact with a grounded surface. A battery cableshort produces heat from the battery current, whichmay be a fire hazard.

An exposed wire on the ground cable between thebattery and the disconnect switch may cause thedisconnect switch to be bypassed if the exposed areacomes into contact with a grounded surface. Thismay result in an unsafe condition for servicing themachine. Repair components or replace componentsbefore servicing the machine.

Fire on a machine can result in personal injuryor death. Exposed battery cables that come intocontact with a grounded connection can result infires. Replace cables and related parts that showsigns of wear or damage. Contact your Cat dealer.

WiringCheck electrical wires daily. If any of the followingconditions exist, replace parts before you operatethe machine.

• Fraying

• Signs of abrasion or wear

• Cracking

• Discoloration

• Cuts on insulation

• Other damage

Make sure that all clamps, guards, clips, and strapsare reinstalled correctly. This will help to preventvibration, rubbing against other parts, and excessiveheat during machine operation.


Fire Prevention and Explosion Prevention

Attaching electrical wiring to hoses and tubes thatcontain flammable fluids or combustible fluids shouldbe avoided.

Consult your Cat dealer for repair or for replacementparts.

Keep wiring and electrical connections free of debris.

Lines, Tubes, and HosesDo not bend high-pressure lines. Do not strikehigh-pressure lines. Do not install any lines thatare bent or damaged. Use the appropriate backupwrenches in order to tighten all connections to therecommended torque.


Check lines, tubes, and hoses carefully. WearPersonal Protection Equipment (PPE) in order tocheck for leaks. Always use a board or cardboardwhen you check for a leak. Leaking fluid that is underpressure can penetrate body tissue. Fluid penetrationcan cause serious injury and possible death. A pinhole leak can cause severe injury. If fluid is injectedinto your skin, you must get treatment immediately.Seek treatment from a doctor that is familiar with thistype of injury.

Replace the affected parts if any of the followingconditions are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are swelling or ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have exposed embedded armoring.

• End fittings are displaced.

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

Do not operate a machine when a fire hazardexists. Repair any lines that are corroded, loose,or damaged. Leaks may provide fuel for fires.Consult your Cat dealer for repair or for replacementparts. Use genuine Cat parts or the equivalent, forcapabilities of both the pressure limit and temperaturelimit.

EtherEther (if equipped) is commonly used in cold-weatherapplications. Ether is flammable and poisonous.

Follow the correct cold engine starting procedures.Refer to the section in the Operation and MaintenanceManual with the label “Engine Starting”.

Do not spray ether manually into an engine if themachine is equipped with a thermal starting aid forcold weather starting.

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

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49° C (120.2° F). Keep ether cylinders awayfrom open flames or sparks.

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

Fire ExtinguisherAs an additional safety measure, keep a fireextinguisher on the machine.

Be familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Follow the recommendationson the instruction plate.

Consider installation of an aftermarket FireSuppression System, if the application and workingconditions warrant the installation.

22 SEBU7887-19Safety SectionFire Safety

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Fire SafetySMCS Code: 7000

Note: Locate secondary exits and how to use thesecondary exits before you operate the machine.

Note: Locate fire extinguishers and how to use a fireextinguisher before you operate the machine.

If you find that you are involved in a machine fire, yoursafety and that of others on site is the top priority.The following actions should only be performed if theactions do not present a danger or risk to you andany nearby people. At all times you should assessthe risk of personal injury and move away to a safedistance as soon as you feel unsafe.

Move the machine away from nearby combustiblematerial such as fuel/oil stations, structures, trash,mulch, and timber.

Lower any implements and turn off the engine assoon as possible. If you leave the engine running,the engine will continue to feed a fire. The fire willbe fed from any damaged hoses that are attachedto the engine or pumps.

If possible, turn the battery disconnect switch to theOFF position. Disconnecting the battery will removethe ignition source in the event of an electrical short.Disconnecting the battery will eliminate a secondignition source if electrical wiring is damaged by thefire, resulting in a short circuit.

Notify emergency personnel of the fire and yourlocation.

If your machine is equipped with a fire suppressionsystem, follow the manufacturers procedure foractivating the system.

Note: Fire suppression systems need to be regularlyinspected by qualified personnel. You must be trainedto operate the fire suppression system.

Use the on-board fire extinguisher and use thefollowing procedure:

1. Pull the pin.

2. Aim the extinguisher or nozzle at the base of thefire.

3. Squeeze the handle and release the extinguishingagent.

4. Sweep the extinguisher from side to side acrossthe base of the fire until the fire is out.

Remember, if you are unable to do anything else,shut off the machine before exiting. By shutting offthe machine, fuels will not continue to be pumpedinto the fire.

If the fire grows out of control, be aware of thefollowing risks:

• Tires on wheeled machines pose a risk of explosionas tires burn. Hot shrapnel and debris can bethrown great distances in an explosion.

• Tanks, accumulators, hoses, and fittings canrupture in a fire, spraying fuels and shrapnel over alarge area.

• Remember that nearly all of the fluids on themachine are flammable, including coolant and oils.Additionally, plastics, rubbers, fabrics, and resinsin fiberglass panels are also flammable.

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Fire Extinguisher LocationSMCS Code: 7000

Make sure that a fire extinguisher is on the machine.Make sure that you are familiar with the operation ofthe fire extinguisher. Inspect the fire extinguisher andservice the fire extinguisher on a regular basis. Obeythe recommendations on the instruction plate.

The recommended location for mounting the fireextinguisher is on the platform behind the cab.

If the fire extinguisher is mounted on the ROPS, strapthe mounting plate to a leg of the ROPS. If the weightof the fire extinguisher is more than 4.5 kg (10 lb),mount the fire extinguisher as low as possible on oneleg. Do not mount the fire extinguisher on the upperone-third area of the leg.

Note: Do not weld the ROPS in order to install thefire extinguisher. Also, do not drill holes in the ROPSin order to mount the fire extinguisher on the ROPS.

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Tire InformationSMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.


Electrical Storm Injury Prevention

A tire explosion is much more violent than ablowout. The explosion can propel the tire, the rimcomponents, and the axle components from themachine. Stay out of the trajectory path. Both theforce of the explosion and the flying debris can causeproperty damage, personal injury, or death.


Typical example of tire is shown

Do not approach a hot or an apparently damaged tire.

Caterpillar recommends against using water orcalcium as a ballast for the tires except in machinesdesigned for this additional mass. For thoseapplicable machines, the maintenance section willcontain instructions on the correct tire inflation andfilling procedures. Ballast, such as fluid in the tires,increases overall machine weight and may affectbraking, steering, power train components, or thecertification of the protective structure such as theROPS. The use of tire/rim rust preventatives or otherliquid additives is not required.

Dry nitrogen gas is recommended for inflation of tires.If the tires were originally inflated with air, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

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

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

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

Servicing tires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tiresand rims, the assemblies could burst with explosiveforce. This explosive force can cause seriouspersonal injury or death. Carefully obey the specificinstructions from your tire dealer.

i01122596

Electrical Storm InjuryPreventionSMCS Code: 7000

When lightning is striking in the vicinity of themachine, the operator should never attempt thefollowing procedures:

• Mount the machine.

• Dismount the machine.

If you are in the operator's station during an electricalstorm, stay in the operator's station. If you are on theground during an electrical storm, stay away fromthe vicinity of the machine.

i00934890

Before Starting EngineSMCS Code: 1000; 7000

The steering frame lock must be in the unlockedposition in order to steer the machine.

Start the engine only from the operator compartment.Never short across the starter terminals or acrossthe batteries. Shorting could bypass the engineneutral start system. Shorting could also damage theelectrical system.

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

Adjust the seat so that there is full pedal travel whilethe operator's back is against the back of the seat.

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

24 SEBU7887-19Safety SectionVisibility Information

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

i04862936

Visibility InformationSMCS Code: 7000

Before you start the machine, perform a walk-aroundinspection in order to ensure that there are nohazards around the machine.

While the machine is in operation, constantly surveythe area around the machine in order to identifypotential hazards as hazards become visible aroundthe machine.

Your machine may be equipped with visual aids.Some examples of visual aids are Closed CircuitTelevision (CCTV) and mirrors. Before operating themachine, ensure that the visual aids are in properworking condition and that the visual aids are clean.Adjust the visual aids using the procedures that arelocated in this Operation and Maintenance Manual.If equipped, the Work Area Vision System shall beadjusted according to Operation and MaintenanceManual, SEBU8157, “Work Area Vision System”.If equipped, the Cat Detect Object Detectionshall be adjusted according to the Operation andMaintenance Manual, “Cat Detect Object Detection”for your machine.

It may not be possible to provide direct visibility onlarge machines to all areas around the machine.Appropriate job site organization is required in orderto minimize hazards that are caused by restrictedvisibility. Job site organization is a collection of rulesand procedures that coordinates machines andpeople that work together in the same area. Examplesof job site organization include the following:

• Safety instructions

• Controlled patterns of machine movement andvehicle movement

• Workers that direct safe movement of traffic

• Restricted areas

• Operator training

• Warning symbols or warning signs on machinesor on vehicles

• A system of communication

• Communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration by theuser that result in a restriction of visibility shall beevaluated.

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Restricted VisibilitySMCS Code: 7000

The size and the configuration of this machine mayresult in areas that can not be seen when the operatoris seated. Illustration 21 provides an approximatevisual indication of areas of significant restrictedvisibility. Illustration 21 indicates restricted visibilityareas at ground level inside a radius of 12 m (40 ft)from the operator on a machine without the use ofoptional visual aids. This illustration does not provideareas of restricted visibility for distances outside aradius of 12 m (40 ft).

This machine may be equipped with optional visualaids that may provide visibility to some of therestricted visibility areas. Refer to this Operation andMaintenance Manual, “Mirror” for more information onadditional visibility. If your machine is equipped withcameras, refer to this Operation and MaintenanceManual, “Camera” for more information on additionalvisibility. For areas that are not covered by theoptional visual aids, the job site organization mustbe utilized to minimize hazards of this restrictedvisibility. For more information regarding job siteorganization refer to Operation and MaintenanceManual, “Visibility Information”.

SEBU7887-19 25Safety SectionEngine Starting


Top view of the machine

Note: The shaded areas indicate the approximatelocation of areas with significant restricted visibility.

i03690423

Engine StartingSMCS Code: 1000; 7000

If a warning tag is attached to the engine start switchor to the controls, do not start the engine and do notmove any controls.

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

Move the transmission control to the NEUTRALposition.

Engage the parking brake.

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

Briefly sound the horn before you start the engine.

Check for the presence of personnel. Ensure that allpersonnel are clear of the machine.

i01943255

Before OperationSMCS Code: 7000

Make sure that there are no personnel on themachine or in the area around the machine.

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

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

Adjust the rear view mirrors (if equipped) for the bestvision of the area near the machine.

Ensure that the horn, the backup alarm (if equipped),and all other warning devices are working properly.

Fasten the seat belt securely.

i04632311

OperationSMCS Code: 7000

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

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

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

Do not allow riders on the machine unless themachine has an additional seat with a seat belt.The rider must be seated and the seat belt must befastened.

Never use the work tool for a work platform.

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

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

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

26 SEBU7887-19Safety SectionEngine Stopping

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

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

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

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

Know the maximum dimensions of your machine.

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

i02624835

Engine StoppingSMCS Code: 1000; 7000

Do not stop the engine immediately after themachine has been operated under load. This cancause overheating and accelerated wear of enginecomponents.

After the machine is parked and the parking brakeis engaged, allow the engine to run for two minutesbefore shutdown. This allows hot areas of the engineto cool gradually.

i03832349

ParkingSMCS Code: 7000

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

• tire size

• machine weight

• ground conditions

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

Engage the parking brake.

Lower all equipment to the ground. Activate anycontrol locks.

Stop the engine.

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

Always turn the battery disconnect switch to the OFFposition before leaving the machine.

If the machine will not be operated for a month ormore, remove the battery disconnect switch key.

i03745198

Slope OperationSMCS Code: 7000

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

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

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

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

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

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

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

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

SEBU7887-19 27Safety SectionWork Tools

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

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

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

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

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

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

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

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

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

i04159629

Work ToolsSMCS Code: 6700

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

Use of work tools, including buckets, whichare outside of Caterpillar's recommendationsor specifications for weight, dimensions, flows,pressures, and so on. may result in less-than-optimalvehicle performance, including but not limited toreductions in production, stability, reliability, andcomponent durability. Caterpillar recommendsappropriate work tools for our machines to maximizethe value our customers receive from our products.Caterpillar understands that special circumstancesmay lead a customer to use tools outside of ourspecifications. In these cases, customers mustbe aware that such choices can reduce vehicleperformance and will affect their ability to claimwarranty in the event of what a customer mayperceive as a premature failure.

Work tools and work tool control systems, that arecompatible with your Cat machine, are required forsafe machine operation and/or reliable machineoperation. If you are in doubt about the compatibilityof a particular work tool with your machine, consultyour Cat dealer.

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

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

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

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

Always wear protective glasses. Always wear theprotective equipment that is recommended in theoperation manual for the work tool. Wear any otherprotective equipment that is required for the operatingenvironment.

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

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

Never use the work tool for a work platform.

28 SEBU7887-19Safety SectionEquipment Lowering with Engine Stopped

i01329161

Equipment Lowering withEngine StoppedSMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment ofall personnel. The procedure to use will vary withthe type of equipment to be lowered. Keep in mindmost systems use a high pressure fluid or air toraise or lower equipment. The procedure will causehigh pressure air, hydraulic, or some other mediato be released in order to lower the equipment.Wear appropriate personal protective equipment andfollow the established procedure in the Operationand Maintenance Manual, “Equipment Lowering withEngine Stopped” in the Operation Section of themanual.

i04001726

Sound Information andVibration InformationSMCS Code: 7000

Sound Level Information

966H and 972H

The operator sound pressure level for a standardmachine configuration, measured according to theprocedures specified in “ISO6396:2008”, is 71 dB(A)with the cooling fan speed set at maximum value.Hearing protection may be needed when the machineis operated with windows and/or door opened or withan open operator station.

The machine sound power level for a standardmachine configuration, measured according to theprocedures specified in “ISO6395:2008”, is 111 dB(A)with the cooling fan speed set at maximum value.

The machine sound pressure level for a standardmachine configuration, measured according to theprocedures specified in “SAEJ88 Feb2006”, is 75dB(A) for the 966H and 76 dB(A) for the 972H. Themeasurement was conducted under the followingconditions: distance of 15 m (49.2 ft), moving forwardin an intermediate gear ratio, static hydraulic cycle(with no payload) and with the cooling fan speed setat 70 percent of the maximum value.

The operator sound pressure level for a machineinstalled with a Low Sound package, measuredaccording to the procedures specified in“ISO6396:2008”, is 69 dB(A) with the cooling fanspeed set at 70 percent of the maximum value.Hearing protection may be needed when the machineis operated with windows and/or door opened or withan open operator station.

The machine sound power level for a machineinstalled with a Low Sound package, measuredaccording to the procedures specified in“ISO6395:2008”, is 105 dB(A) with the cooling fanspeed set at 70 percent of the maximum value.

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the “EU Directives”

966H and 972H

The operator sound pressure level for a standardmachine configuration, measured according to theprocedures specified in “ISO6396:2008”, is 69 dB(A)with a cooling fan speed set at 70 percent of themaximum value. Hearing protection may be neededwhen the machine is operated with windows and/ordoor opened.

The labeled sound power level for a standardmachine configuration is 107 dB(A) for the 966H and108 dB(A) for the 972H with a cooling fan speed setat 70 percent of the maximum value, in conformancewith the “2000/14/EC” regulation.

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

Vibration Data for Wheel Loaders

Information Concerning Hand/Arm VibrationLevel

When the machine is operated according to theintended use, the hand/arm vibration of this machineis below 2.5 meter per second squared.

Information Concerning Whole Body VibrationLevel

This section provides vibration data and a method forestimating the vibration level for wheel loaders.

Note: Vibration levels are influenced by manydifferent parameters. Many items are listed below.


Sound Information and Vibration Information

• Operator training, behavior, mode, and stress

• Job site organization, preparation, environment,weather, and material

• Machine type, quality of the seat, quality of thesuspension system, attachments, and condition ofthe equipment

It is not possible to get precise vibration levels forthis machine. The expected vibration levels can beestimated with the information in Table 1 in orderto calculate the daily vibration exposure. A simpleevaluation of the machine application can be used.

Estimate the vibration levels for the three vibrationdirections. For typical operating conditions, use theaverage vibration levels as the estimated level. Withan experienced operator and smooth terrain, subtractthe Scenario Factors from the average vibration levelin order to obtain the estimated vibration level. Foraggressive operations and severe terrain, add theScenario Factors to the average vibration level inorder to obtain the estimated vibration level.

Note: All vibration levels are in meter per secondsquared.

Table 1

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

Vibration Levels Scenario FactorsMachineType

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

load and carry motion 0,84 0,81 0,52 0,23 0,20 0,14

mining application(1) 1,27 0,97 0,81 0,47 0,31 0,47

transfer(2) 0,76 0,91 0,49 0,33 0,35 0,17WheelLoader

V-shape motion (3) 0,99 0,84 0,54 0,29 0,32 0,14(1) Loading at the face(2) Travel at high speed on the job site or on public roads(3) Loading a truck in short cycles

Note: Refer to “ISO/TR 25398 Mechanical Vibration -Guideline for the assessment of exposure to wholebody vibration of ride on operated earthmovingmachines” for more information about vibration.This publication uses data that is measuredby international institutes, organizations andmanufacturers. This document provides informationabout the whole body exposure of operators ofearthmoving equipment. Refer to Operation andMaintenance Manual Supplement , SEBU8257 formore information about machine vibration levels.

The Caterpillar suspension seat meets the criteria of“ISO 7096”. This represents vertical vibration levelunder severe operating conditions. This seat is testedwith the input “spectral class EM3”. The seat has atransmissibility factor of “SEAT<1.0”.

The whole body vibration level of the machine varies.There is a range of values. The low value is 0.5meter per second squared. The machine meets theshort term level for the design of the seat in “ISO7096”. The value is 1.13 meter per second squaredfor this machine.

Guidelines for Reducing Vibration Levels onEarthmoving Equipment

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

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

30 SEBU7887-19Safety SectionSound Information and Vibration Information

2. Maintainmachines according to themanufacturer'srecommendations.

a. Tire pressures

b. Brake and steering systems

c. Controls, hydraulic system and linkages

3. Keep the terrain in good condition.

a. Remove any large rocks or obstacles.

b. Fill any ditches and holes.

c. Provide machines and schedule time in orderto maintain the conditions of the terrain.

4. Use a seat that meets “ISO 7096”. Keep the seatmaintained and adjusted.

a. Adjust the seat and suspension for the weightand the size of the operator.

b. Inspect and maintain the seat suspension andadjustment mechanisms.

5. Perform the following operations smoothly.

a. Steer

b. Brake

c. Accelerate.

d. Shift the gears.

6. Move the attachments smoothly.

7. Adjust the machine speed and the route in orderto minimize the vibration level.

a. Drive around obstacles and rough terrain.

b. Slow down when it is necessary to go overrough terrain.

8. Minimize vibrations for a long work cycle or a longtravel distance.

a. Use machines that are equipped withsuspension systems.

b. Use the ride control system on wheel loaders.

c. If no ride control system is available, reducespeed in order to prevent bounce.

d. Haul the machines between workplaces.

9. Less operator comfort may be caused by other riskfactors. The following guidelines can be effectivein order to provide better operator comfort:

a. Adjust the seat and adjust the controls in orderto achieve good posture.

b. Adjust the mirrors in order to minimize twistedposture.

c. Provide breaks in order to reduce long periodsof sitting.

d. Avoid jumping from the cab.

e. Minimize repeated handling of loads and liftingof loads.

f. Minimize any shocks and impacts during sportsand leisure activities.

SourcesThe vibration information and calculation procedureis based on “ISO/TR 25398 Mechanical Vibration- Guideline for the assessment of exposureto whole body vibration of ride on operatedearthmoving machines”. Harmonized data ismeasured by international institutes, organizationsand manufacturers.

This literature provides information about assessingthe whole body vibration exposure of operators ofearthmoving equipment. The method is based onmeasured vibration emission under real workingconditions for all machines.

You should check the original directive. Thisdocument summarizes part of the content of theapplicable law. This document is not meant tosubstitute the original sources. Other parts of thesedocuments are based on information from the UnitedKingdom Health and Safety Executive.

Refer to Operation and Maintenance ManualSupplement , SEBU8257 for more information aboutvibration.

Consult your local Cat dealer for more informationabout machine features that minimize vibrationlevels. Consult your local Cat dealer about safemachine operation.

Use the following web site in order to find your localdealer:

Caterpillar, Inc.www.cat.com


Operator Station

i03634321

Operator StationSMCS Code: 7000

Any modifications to the inside of the operator stationshould not project into the operator space or intothe space for the companion seat (if equipped).The addition of a radio, fire extinguisher, and otherequipment must be installed so that the definedoperator space and the space for the companion seat(if equipped) is maintained. Any item that is broughtinto the cab should not project into the definedoperator space or the space for the companion seat(if equipped). A lunch box or other loose items mustbe secured. Objects must not pose an impact hazardin rough terrain or in the event of a rollover.

sebu7887-19 s

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