C•TERPILLAR®
`
`KEBU6879-02
`June 2003
`
`Operation and
`Maintenance
`Manual
`
`PM-465 Cold Planer
`
`5ZS1-Up (Machine)
`
`CATERPILLAR EXHIBIT 1038
`CATERPILLAR v. WIRTGEN
`IPR2018-01091
`
`Page 1 of 150
`
`

`

`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.
`A WARNING
`
`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.
`
`A WARNING
`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.
`
`Page 2 of 150
`
`

`

`3
`Table of Contents
`
`Parking .................................................................. 70
`
`Machine Cleanup .................................................. 72
`
`Transportation Information .................................... 73
`
`Engine Starting (Alternate Methods) .................... 76
`
`Maintenance Section
`
`Maintenance Access ............................................. 78
`
`Maintenance Support ........................................... 82
`
`Lubricant Viscosities and Refill Capacities ........... 83
`
`Maintenance Interval Schedule ............................ 85
`
`Reference Information Section
`
`Reference Materials ............................................ 144
`
`Index Section
`
`Index ................................................................... 146
`
`Table of Contents
`
`Foreword ................................................................. 4
`
`Safety Section
`
`Safety Messages .................................................... 6
`
`Additional Messages ............................................. 12
`
`General Hazard Information ................................. 14
`
`Crushing Prevention and Cutting Prevention ........ 15
`
`Burn Prevention .................................................... 16
`
`Fire Prevention and Explosion Prevention ............ 16
`
`Fire Extinguisher Location .................................... 18
`
`Electrical Storm Injury Prevention ......................... 18
`
`Before Starting Engine .......................................... 18
`
`Engine Starting ..................................................... 19
`
`Before Operation ................................................... 19
`
`Operation .............................................................. 19
`
`Parking .................................................................. 20
`
`Equipment Lowering with Engine Stopped ........... 20
`
`Sound Information and Vibration Information ....... 20
`
`Operator Station ................................................... 21
`
`Product Information Section
`
`General Information .............................................. 22
`
`Identification Information ....................................... 23
`
`Operation Section
`
`Before Operation ................................................... 25
`
`Machine Operation ............................................... 28
`
`Machine Controls .................................................. 37
`
`Engine Starting ..................................................... 56
`
`Operation .............................................................. 58
`
`Adjustments .......................................................... 62
`
`Machine Service ................................................... 68
`
`Page 3 of 150
`
`

`

`Maintenance
`
`The maintenance section is a guide to equipment
`care. The Maintenance Interval Schedule (MIS) lists
`the items to be maintained at a specific service
`interval. Items without specific intervals are listed
`under the "When Required" service interval. The
`Maintenance Interval Schedule lists the page
`number for the step-by-step instructions required to
`accomplish the scheduled maintenance. Use the
`Maintenance Interval Schedule as an index or "one
`safe source" for all maintenance procedures.
`
`Maintenance Intervals
`
`Use the service hour meter to determine servicing
`intervals. Calendar intervals shown (daily, weekly,
`monthly, etc.) can be used instead of service hour
`meter intervals if they provide more convenient
`servicing schedules and approximate the indicated
`service hour meter reading. Recommended service
`should always be performed at the interval that
`occurs first.
`
`Under extremely severe, dusty or wet operating
`conditions, more frequent lubrication than is
`specified in the maintenance intervals chart might
`be necessary.
`
`Perform service on items at multiples of the original
`requirement. For example, at every 500 service
`hours or 3 months, also service those items listed
`under every 250 service hours or monthly and every
`10 service hours or daily.
`
`California Proposition 65 Warning
`
`Diesel engine exhaust and some of its constituents
`are known to the State of California to cause cancer,
`birth defects, and other reproductive harm.
`
`Battery posts, terminals and related accessories
`contain lead and lead compounds. Wash hands
`after handling.
`
`Certified Engine Maintenance
`
`Proper maintenance and repair is essential to
`keep the engine and machine systems operating
`correctly. As the heavy duty off-road diesel engine
`owner, you are responsible for the performance
`of the required maintenance listed in the Owner
`Manual, Operation and Maintenance Manual, and
`Service Manual.
`
`4F
`
`oreword
`
`Foreword
`
`Literature Information
`
`This manual should be stored in the operator’s
`compartment in the literature holder or seat back
`literature storage area.
`
`This manual contains safety information, operation
`instructions, transportation information, lubrication
`information and maintenance information.
`
`Some photographs or illustrations in this publication
`show details or attachments that can be different
`from your machine. Guards and covers might have
`been removed for illustrative purposes.
`
`Continuing improvement and advancement of
`product design might have caused changes to your
`machine which are not included in this publication.
`Read, study and keep this manual with the machine.
`
`Whenever a question arises regarding your
`machine, or this publication, please consult your
`Caterpillar dealer for the latest available information.
`
`Safety
`
`The safety section lists basic safety precautions. In
`addition, this section identifies the text and locations
`of warning signs and labels used on the machine.
`
`Read and understand the basic precautions listed
`in the safety section before operating or performing
`lubrication, maintenance and repair on this machine.
`
`Operation
`
`The operation section is a reference for the new
`operator and a refresher for the experienced
`operator. This section includes a discussion of
`gauges, switches, machine controls, attachment
`controls, transportation and towing information.
`
`Photographs and illustrations guide the operator
`through correct procedures of checking, starting,
`operating and stopping the machine.
`
`Operating techniques outlined in this publication are
`basic. Skill and techniques develop as the operator
`gains knowledge of the machine and its capabilities.
`
`Page 4 of 150
`
`

`

`5
`Foreword
`
`3. Check Character (character 9)
`
`4. Machine Indicator Section (MIS) or Product
`Sequence Number (characters 10-17). These were
`previously referred to as the Serial Number.
`
`Machines and generator sets produced before First
`Quarter 2001 will maintain their 8 character PIN
`format.
`
`Components such as engines, transmissions,
`axles, etc. and work tools will continue to use an 8
`character Serial Number (S/N).
`
`It is prohibited for any person engaged in the
`business of repairing, servicing, selling, leasing, or
`trading engines or machines to remove, alter, or
`render inoperative any emission related device or
`element of design installed on or in an engine or
`machine that is in compliance with the regulations
`(40 CFR Part 89). Certain elements of the machine
`and engine such as the exhaust system, fuel
`system, electrical system, intake air system and
`cooling system may be emission related and should
`not be altered unless approved by Caterpillar.
`
`Machine Capacity
`
`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) will change 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:
`
`*CAT 07898G 6SL12345*
`
`I~J
`
`Illustration 1
`
`Where:
`
`g00751314
`
`1. Caterpillar’s World Manufacturing Code
`(characters 1-3)
`
`2. Machine Descriptor (characters 4-8)
`
`Page 5 of 150
`
`

`

`i01877293
`
`6S
`
`afety Section
`Safety Messages
`
`Safety Section
`
`Safety Messages
`SMCS Code: 7000; 7405
`
`0
`
`0
`
`®
`
`®
`
`0
`
`a'# ~~--r:
`0
`
`g00955417
`
`==----·-(cid:173)
`=:-.:,:i~c:-f=~--.......
`=---lifUiASrllEIBll•--llliM
`©
`
`®
`
`®
`
`0
`
`Illustration 2
`
`Page 6 of 150
`
`

`

`@
`
`,~
`
`®
`
`®
`
`it.WARNING
`
`ntS MACHINE MAY FALL AND CAUSE
`Pl!!RSONAL NJIJln' OR DEATH~ ALWAYS
`INITALL SUPPORT LIEGfl BEFORE
`WORKING BENEATH MACHIN!, SEE
`OPIMIOR9 MANUAL FOA IN8'f'AUCTION,
`
`0
`
`1;;;.;m1i::,
`
`c n
`
`®
`
`0
`
`=~·mt"rl'rn1~--(cid:173)
`=r•1 .... ,,_, ___ _
`lil'==i."l'illlw•---·-
`
`®
`
`®
`
`7
`Safety Section
`Safety Messages
`
`®
`
`TIIIS IUCHNi IIAY MU. AND CMISE
`P&R90NAL ~ OR tJEI01t. AlYfAV8
`INSTALL &UPPORT LEGS IKFORe
`WORKING BENEATH MACHINE. SO:
`OPIFUll'CRIMANla&.FORIC'l'AUCn0N.
`
`0
`
`© ..
`
`THII DOOR IUl't MI.L. BIULTIIIG IN
`Pl!AIONAL l&ILNff 011 IIKATH, IIA(cid:173)
`DOOR TO IWDIIIUM OPl!N POIITION
`ANDAr'UICHMlllaPOMSN11illlNG
`NIIA~OIIINDOCII.
`
`0
`
`g00955418
`
`Illustration 3
`
`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. Become familiar with all of the 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
`legible. 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.
`
`Do Not Operate (1)
`
`This safety message is located above both steering
`wheels.
`
`A WARNING
`
`DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE
`READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE
`OPERATION AND MAINTIENANCE MANUALS. FAILURE TO FOLLOW THE
`INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR
`DEATH. CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT
`MANUALS. PROPER CARE IS YOUR RESPONSIBIUTY.
`
`g00788977
`
`A WARNING
`Do not operate or work on this machine unless
`you have read and understand the instructions
`and warnings in the Operation and Maintenance
`Manual. Failure to follow the instructions or heed
`the warnings could result in injury or death. Con-
`tact any Caterpillar dealer for replacement manu-
`als. Proper care is your responsibility.
`
`Page 7 of 150
`
`

`

`8S
`
`afety Section
`Safety Messages
`
`Do Not Propel (2)
`
`Moving Belt (4)
`
`This safety message is located above both steering
`wheels.
`
`This safety message is located on the doors for the
`rotor drive belt. This safety message is located on
`both sides of the upper and lower conveyors.
`
`A WARNING
`
`DO NOT PROPEL OR OPERATE THE MACHINE IN
`THE FULLY RAISED (SERVICE HEIGHT) POSITION.
`FAILURE TO FOLLOW THIS INSTRUCTION COULD
`CAUSE A SUDDEN TILT OF THE MACHINE
`RESULTING IN PERSONAL INJURY OR DEATH.
`
`A WARNING
`
`CONTACT WITH MOVING BELT CAN
`RESULT IN PERSONAL INJURY OR
`DEATH. STAY CLEAR IF ENGINE IS
`RUNNING.
`
`g00792838
`
`A WARNING
`Do not propel or operate the machine in the fully
`raised (SERVICE HEIGHT) position. Failure to fol-
`low this instruction could cause a sudden tilt of
`the machine resulting in personal injury or death.
`
`Mounting the Machine (3)
`
`This safety message is located at each track
`assembly.
`
`A WARNING
`
`CONTACT WITH MOVING TRACK
`CAN RESULT IN PERSONAL INJURY
`OR DEATH. STAY CLEAR OF TRACK
`WHEN MACHINE IS MOVING.
`
`g00792856
`
`A WARNING
`Contact with moving belt can result in personal
`injury or death. Stay clear if engine is running.
`
`Machine Support Legs (5)
`
`This safety message is located at the front and rear
`at both sides by the legs.
`
`AWARNING
`
`THIS MACHINE MAY FALL AND CAUSE
`PERSONAL INJURY OR DEATH~ ALWAYS
`INSTALL SUPPORT LEGS BEFORE
`WORKING BENEATH MACHJNE. SEE
`OPERATORS MANUAL FOR INSTRUCTION.
`
`g00791189
`
`A WARNING
`Contact with moving track can result in personal
`injury or death. Stay clear of track when machine
`is moving.
`
`g00792848
`
`A WARNING
`This machine may fall and cause personal injury
`or death. Always install support legs before work-
`ing beneath machine. See Operators Manual for
`instruction.
`
`Page 8 of 150
`
`

`

`9
`Safety Section
`Safety Messages
`
`Service Doors (6)
`
`Cutting Depth (8)
`
`This safety message is located on the service door
`for the rotor.
`
`This safety message is located near the top of both
`right and left rear legs.
`
`A WARNING
`
`THlS DOOR MAY FALL RESULTING IN
`PERSONAL INJURY OR DEATH . RAISE
`DOOR TO MAXIMUM OPEN POSITION
`AND ATTACH BAR BEFORE ENTERING
`AREA BENEATH OPEN DOOR.
`
`........ '
`
`.4~ WARNING
`
`PERSONAL.1NJURY OR DEATH CAN RESULT FROM CHECKING CUTTING
`DEPTH TOO CLOSE TO REAR OF MACHINE.
`CLEARANCE BETWEEN TRACK ANO CUTTER HOUSING IS INSUFFICIENT
`FOR CHECKING DEPTlt.
`CHECK COTTING DEPTH AT LEAST 8 METERS (25 FEET) FROM.REAR 0
`MACHINE,
`
`g00792870
`
`g00792986
`
`.A, WARNING
`This door may fall resulting in personal injury
`or death. Raise door to maximum open position
`and attach bar before entering area beneath open
`door.
`
`Machine Movement (7)
`
`This safety message is located on both sides at the
`left rear and right rear of the machine.
`
`A WARNING
`THIS MACHINE MAY LUNGE BACK(cid:173)
`WARD WHICH COULD RESULT IN
`PERSONAL INJURY OR DEATH.
`STAY AT LEAST SM (25 FEET)
`CLEAR OF THE AREA BEHIND
`THE MACHINE.
`
`g00792892
`
`.A, WARNING
`This machine may lunge backward which could
`result in personal injury or death. Stay a least 8 m
`(25 ft) clear of the area behind the machine.
`
`.A, WARNING
`Personal injury or death can result from checking
`cutting depth too close to rear of machine.
`
`Clearance between track and cutter housing is in-
`sufficient for checking depth.
`
`Check cutting depth at least 8 m (25 ft) from rear
`of machine.
`
`Rotor (9)
`
`This safety message is located on both sides and
`on the rotor door.
`
`A WARNING
`
`ROTOR MOVEMENT CAN
`CAUSE INJURY OR
`DEATH. STAY CLEAR OF
`ROTOR WHEN ENGINE
`IS RUNNING. SHUT
`ENGINE OFF BEFORE
`PERFORMING ANY
`SERVICE ON ROTOR OR
`ITS HOUSING .
`
`g00792915
`
`.A, WARNING
`Rotor movement can cause injury or death. Stay
`clear of the rotor when the engine is running. Shut
`off the engine before performing any service on
`the rotor or its housing.
`
`Page 9 of 150
`
`

`

`10
`Safety Section
`Safety Messages
`
`No Clearance (10)
`
`This safety message is located at the pivot area of
`the secondary conveyor.
`
`A WARNING
`
`NO CLEARANCE FOR MAN IN THIS
`AREA WHEN CONVEYOR TURNS;
`SEVERE INJURY OR DEATH FROM
`CRUSHING COULD OCCUR.
`
`g00792917
`
`A WARNING
`No clearance for man in this area when conveyor
`turns; Severe injury or death from crushing could
`occur.
`
`Improper Connections for Jump
`Start Cables (11)
`
`This safety message is located at the battery
`compartment.
`
`A WARNING
`
`CABLE
`JUMPER
`IMPROPER
`CAUSE
`CONNECTIONS
`CAN
`IN
`EXPLOSION
`RESULTING
`PERSONAL INJURY.
`
`BATTERIES MAY BE LOCATED IN SEPA(cid:173)
`RATE COMPARTMENTS. WHEN USING
`JUMPER CABLES, ALWAYS CONNECT
`POSITIVE ( + ) CABLE TO POSITIVE ( + )
`TERMINAL OF BATTERY CONNECTED
`TO STARTER SOLENOID AND NEGA(cid:173)
`TIVE ( -
`) CABLE FROM EXTERNAL
`SOURCE TO STARTER NEGATIVE ( - )
`TERMINAL (IF MACHINE NOT EQUIPPED
`WITH STARTER NEGATIVE TERMINAL,
`CONNECT TO ENGINE BLOCK.) FOL(cid:173)
`LOW PROCEDURE IN THE OPERATION
`MANUAL.
`
`&V-4611 4
`
`g00038786
`
`A WARNING
`IMPROPER JUMPER CABLE CONNECTIONS CAN
`CAUSE EXPLOSION RESULTING IN PERSONAL
`INJURY.
`
`BATTERIES MAY BE LOCATED IN SEPARATE
`COMPARTMENTS. WHEN USING JUMPER CA-
`BLES, ALWAYS CONNECT POSITIVE (+) CABLE
`TO POSITIVE (+) TERMINAL OF BATTERY CON-
`NECTED TO STARTER SOLENOID AND NEGA-
`TIVE (-) CABLE FROM EXTERNAL SOURCE TO
`STARTER NEGATIVE (-) TERMINAL (IF MACHINE
`NOT EQUIPPED WITH STARTER NEGATIVE TER-
`MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
`PROCEDURE IN THE OPERATION MANUAL.
`
`Page 10 of 150
`
`

`

`11
`Safety Section
`Safety Messages
`
`Adjustment for the Mirror (12)
`
`This safety message is located on both sides of the
`machine next to the mirror.
`
`.&WARNING m
`
`g00867409
`
`A WARNING
`Do not adjust the mirrors when the machine is
`moving. Refer to the Operation and Maintenance
`Manual for complete instructions for adjusting the
`mirrors. Personal injury or death may result from
`adjusting the mirrors when the machine is mov-
`ing.
`
`Page 11 of 150
`
`

`

`12
`Safety Section
`Additional Messages
`
`Additional Messages
`SMCS Code: 1000; 7000; 7405
`
`i01878399
`
`0
`
`NOTICE
`
`ffll ,ou._G l'IIACTICUIIILLALIOl'lltl'I .. Tl1'1WCTUIIAL -H I
`(l'AIUJ!le)TQ'ffl!OIINWYOIIM!MfflNIIIIIU_,.S'!Sl'l!I,
`
`1.--0111~ntl-,Kll~1141-•MLIYILM
`-m.l!TO-Tffl!-1'111111-NIICINTACITIIIITH'llt!
`
`-·
`
`l,WMINLONIUIG11WOIW,l'llln'PIIIGMfflCIMIHCIUUl•-TO~_,.ffll
`-~-HlfflNll'ffl!00N-.
`
`G
`!LC w
`0
`
`Illustration 4
`
`g00955954
`
`Page 12 of 150
`
`

`

`13
`Safety Section
`Additional Messages
`
`0000000
`'
`
`g00955955
`
`NOTICE
`
`DO NOT SHIP THIS MACHINE WITHOUT USING THE CONVEYOR SHIPPING
`SUPPORTS. FAILURE TO SUPPORT THE CONVEYOR DURING SHIPPING WILL
`RESULT IN STRUCTURAL DAMAGE (OR FAILURE) OF THE CONVEYOR
`MOUNTING SUPPORT SYSTEM.
`
`THE FOLLOWING PRACTICES WILL ALSO PREVENT STRUCTURAL DAMAGE I
`(FAILURE} TO THE CONVEYOR MOUNTING SUPPORT SYSTEM.
`
`1. WHEN RAISING OR LOWERING THE MACHINE, KEEP THE MACHINE AS LEVEL AS
`POSSIBLE TO PREVENT THE CONVEYOR FROM COMING IN CONTACT WITH THE
`GROUND.
`
`2, WHEN LOADING TRUCKS, EVERY PRECAUTION SHOULD BE MADE TO PREVENT THE
`TRUCKS FROM HITTING THE CONVEYOR.
`
`Illustration 6
`
`ELC Cooling System (2)
`
`g00956001
`
`This message is located on the reservoir for the
`radiator.
`
`0
`
`NOTICE
`DO NOT SHIP 11-111 MACHINE WffllOUT USING THI! CONVEYOR ltlPPING
`SUPPOl't'l'I. FALURE TO SUPPORT THE CONYEY0Ft DURINOi SHIPPING WILL
`RESULT IN STRUCTURAL DAMAGE (OR FAILURE) OF THE CONVEYOR
`MOUNTING SUPPORT SYSTEM.
`
`THI! ll'OLLOWING ll'lltACTICl!8 WILL AL80 ll'RMNT 8TllUCTUML DAMAGl!I
`(FAIWRE) TO THE CONVEYOR MOIMTING SUPPORT SYITEM.
`
`1-:o;~o~~=~~=~~:.t:.Kl!c":r.:::fC=~~L,.:
`
`1-:~~i.:H=~TH~TIDNIIHDULDll!IWJl!!TOl'll!VM'THI!
`
`Illustration 5
`
`There are several specific messages on this
`machine. The exact location of the messages and
`the description of the messages are reviewed in
`this section. Please become familiarized 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.
`
`Notice for Shipping (1)
`
`This message is located on both sides of the
`conveyor.
`
`Page 13 of 150
`
`

`

`14
`Safety Section
`General Hazard Information
`
`G ELC w
`
`Illustration 7
`
`g00955999
`
`i01041641
`
`General Hazard Information
`SMCS Code: 7000
`
`Keep the machine free from foreign material. Check
`the deck, the walkways and the steps. Remove
`debris, oil, tools and other items.
`
`Secure all loose items that are not a part of the
`machine. Secure lunch boxes, tools and other items.
`
`Know the appropriate work site hand signals. Also,
`know the personnel that are authorized to give the
`hand signals. Accept signals from one person only.
`
`Never put maintenance fluids into glass containers.
`Drain all liquids into a suitable container.
`
`When you discard liquids, obey all local regulations.
`
`Use all cleaning solutions with care.
`
`Report all necessary repairs.
`
`Do not allow unauthorized personnel on the
`machine.
`
`Dual controls are always active. Several functions
`may be controlled at both sides of control panel.
`
`When you perform maintenance procedures that
`are not specified, maintenance procedures need to
`be performed, as follows:
`
`• Park the machine on level ground.
`
`• Move the rotary switch to the OFF position.
`Reduce engine speed.
`
`Illustration 8
`
`g00037327
`
`• Raise the machine to the full UP position. Then
`install all four leg supports. Refer to Operation and
`Maintenance Manual, “Installing Leg Supports”.
`
`Before you service the machine or before you repair
`the machine, attach a “Do Not Operate” warning tag
`or a similar warning tag to the start switch or to the
`controls. These warning tags Special Instruction,
`SEHS7332 are available from your dealer.
`
`Know the width of your equipment in order to
`maintain proper clearance near fences, boundary
`obstacles, etc.
`
`Wear a hard hat, protective glasses and other
`protective equipment in order to accommodate job
`conditions.
`
`Do not wear loose clothing in order to avoid
`catching loose clothing in the machine or the
`machine controls. Do not wear jewelry in order
`to avoid catching jewelry in the machine or the
`machine controls.
`
`Ensure that all protective guards and all covers are
`secured in place on the machine.
`
`• Apply the parking Brake. Stop the engine.
`
`• Turn the engine start switch key to the OFF
`position. Then remove the key.
`
`• Turn the disconnect switch key to the OFF
`position. Then remove the key.
`
`Pressure Air
`
`Pressure air can cause personal injury. When
`pressure air is used for cleaning, wear a protective
`face shield, protective clothing and protective
`shoes.
`
`The maximum air pressure must be below 205 kPa
`(30 psi) for cleaning purposes.
`
`Page 14 of 150
`
`

`

`Trapped Pressure
`
`Pressure can be trapped in a hydraulic system.
`Trapped pressure can cause sudden machine
`movement or attachment movement. Use caution
`if you disconnect hydraulic lines or fittings. High
`pressure oil that is released can cause a hose to
`whip. High pressure oil that is released can cause
`oil to spray. Fluid penetration can cause serious
`injury and possible death.
`
`Fluid Penetration
`
`When you check for a leak, use a board or
`cardboard. Leaking fluid that is under pressure can
`penetrate body tissue. Fluid penetration can cause
`serious injury and possible death. A pin hole leak
`can cause severe injury. If fluid is injected into your
`skin, you must obtain treatment immediately. Seek
`treatment from a doctor that is familiar with this type
`of injury.
`
`Asbestos Information
`
`Caterpillar equipment and replacement parts that
`are shipped from Caterpillar are asbestos free.
`Caterpillar recommends the use of only genuine
`Caterpillar replacement parts. If any replacement
`parts that contain asbestos are used, the following
`guidelines should be used in handling these parts
`and asbestos debris.
`
`Use caution. Avoid inhaling dust that might be
`generated when you handle components that
`contain asbestos fibers. If this dust is inhaled, it
`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. In these components, the asbestos
`is bound in a resin or sealed. The normal handling
`of the components is not hazardous unless airborne
`dust that contains asbestos is generated.
`
`If dust which can contain asbestos is present, there
`are several guidelines that should be followed:
`
`• Never use compressed air for cleaning.
`
`• Avoid sweeping materials that contain asbestos.
`
`• Also avoid grinding materials that contain
`asbestos.
`
`15
`Safety Section
`Crushing Prevention and Cutting Prevention
`
`• Wear an approved respirator if there is no other
`way to control the dust.
`
`• Comply with applicable rules and regulations for
`the work place. In the USA, use Occupational
`Safety and Health Administration requirements.
`These OSHA requirements can be found in “29
`CFR 1910.1001”.
`
`• Obey environmental rules for the disposal of
`asbestos. Obey the environmental regulations for
`the disposal of asbestos.
`
`• Stay away from areas that might have asbestos
`particles in the air.
`
`i01359664
`
`Crushing Prevention and
`Cutting Prevention
`SMCS Code: 7000
`
`Support the equipment properly before you perform
`any work or maintenance beneath that equipment.
`Do not depend on the hydraulic cylinders to hold
`up the equipment. Equipment can fall if a control is
`moved, or if a hydraulic line breaks.
`
`Do not work beneath the cab of the machine unless
`the cab is properly supported.
`
`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.
`
`If it is necessary to remove guards in order to
`perform maintenance, always install the guards
`after the maintenance is performed.
`
`• Use a wet method in order to clean up asbestos
`materials.
`
`Keep objects away from moving fan blades. The
`fan blade will throw objects or cut objects.
`
`• You may also use a vacuum that is equipped with
`a highly efficient filter that cleans particulate air.
`
`Do not use a kinked wire cable or a frayed wire
`cable. Wear gloves when you handle wire cable.
`
`• Use exhaust ventilation on permanent machining
`jobs.
`
`Page 15 of 150
`
`

`

`16
`Safety Section
`Burn Prevention
`
`When you strike a retainer pin with force, the
`retainer 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 your eyes, wear protective glasses when
`you strike a retainer pin.
`
`Chips or other debris can fly off an object when
`you strike the object. Make sure that no one can be
`injured by flying debris before striking any object.
`
`i01329099
`
`Burn Prevention
`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 severe burns. Allow cooling system
`components to cool before the cooling system is
`drained.
`
`Check the coolant level only after the engine has
`been stopped.
`
`Ensure that the filler cap is cool before removing
`the filler cap. The filler cap must be cool enough
`to touch with a bare hand. Remove the filler cap
`slowly in order to relieve pressure.
`
`Cooling system conditioner contains alkali. Alkali
`can cause personal injury. Do not allow alkali to
`contact the skin, the eyes, or the mouth.
`
`Oils
`
`Hot oil and hot components can cause personal
`injury. 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 the
`engine has been stopped. The filler cap must be
`cool enough to touch with a bare hand. Follow
`the standard procedure in this manual in order to
`remove the hydraulic tank filler cap.
`
`Batteries
`
`Electrolyte is an acid. Electrolyte can cause
`personal injury. Do not allow electrolyte to contact
`the skin or the eyes. Always wear protective glasses
`for servicing batteries. Wash hands after touching
`the batteries and connectors. Use of gloves is
`recommended.
`
`i01359795
`
`Fire Prevention and Explosion
`Prevention
`SMCS Code: 7000
`
`Illustration 9
`
`g00704000
`
`All fuels, most lubricants, and some coolant mixtures
`are flammable.
`
`Flammable fluids that are leaking or spilled onto hot
`surfaces or onto electrical components can cause
`a fire. Fire may cause personal injury and property
`damage.
`
`Remove all flammable materials such as fuel, oil,
`and debris from the machine. Do not allow any
`flammable materials to accumulate on the machine.
`
`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.
`
`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.
`
`Page 16 of 150
`
`

`

`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 o