Page 1
Operation and
Maintenance
Manual
SEBU7858-03
July 2009
627G Wheel Tracto r-Scraper
DBD1-Up
DBZ1-Up (Scraper)
(Machine)
SAFETY.CAT.COM
Page 2
i03602780
Important Safety Information
Most accidents
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 neces
Improper operation, lubrication, maintenance or repair of this product can be da ngerous and
could result in injury or dea th.
Do not operat
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 heed
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exh
on the product and in this publication.
that involve product operation, maintenance and repair are caused by failure to observe
sary training, skills and tools to perform these functions properly.
e or perform any lubrication, maintenance or repair on this product, until you have
ed, bodily injury or death could occur to you or to other persons.
! Become Alert! Your Safety is Involved.
austive list of operations that may cause product damage are identified by “NOTICE” labels
Caterpillar cannot anticipate every possible c ircumstance that might involve a potential hazard.
The warn
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operat
applicable to the worksite. 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
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was av
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
ings in this publication and on the product are, therefore, not all inclusive. You must
ion of the product in the location of use, including site-specific rules and precautions
others. You should also ensure that the product will not be damaged or become unsafe by
ailable at the time that the publication was written. The specifications, torques, pressures,
any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this
product Caterpillar recommends u si ng Caterpil-
replacement parts or parts with equivalent
lar
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
ath.
de
Page 3
6 SEBU7858-03
Safety Section
Safety Messages
Safety Section
i03640971
Safety Messages
SMCS Code: 7000; 7405
There are se
machine. The exact location of the safety messages
and the description of the safety messages are
reviewed i
with all safety messages.
Make sure t
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
safety me
When you clean the safety messages, use a cloth,
water and soap. Do not use solvent, gasoline, or
other ha
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesiv
Replace any safety message that is damaged, or
missin
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new saf
veral specific safety messages on this
n this section. Please become familiarized
hat all of the safety messages are legible.
ssages if the illustrations are not legible.
rsh chemicals to clean the safety messages.
e will allow the safety message to fall.
g. If a safety message is attached to a part
ety messages.
Page 4
SEBU7858-03 7
Safety Section
Safety Messages
Illustration 2
g01953867
Page 5
8 SEBU7858-03
Safety Section
Safety Messages
Illustration 3
g01954945
Page 6
SEBU7858-03 9
Safety Section
Safety Messages
Do Not Operate (1)
This safety message is positioned on the right side of
the ROPS. This safety message is also positioned in
the engine compartment of the machine. This safety
message is also positioned on the scraper engine
on the left side.
g01370904
Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or heed
the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.
Crushing Hazard (2)
This safety message is positioned on each side of
the hitch link.
g01379133
Hitch and steering movement can reduce clearances suddenly and cause personal injury...
Stop engine before servicing.
No Clearance (3)
This safety message is positioned on each side of
the steering link.
g01371644
Stay back a safe distance. No clearance for a person in this area when the machine turns. Severe
njury or death from crushing could occur.
i
Page 7
10 SEBU7858-03
Safety Section
Safety Messages
DoNotWeldOnTheROPS/FOPS
Structure (4)
This safety message is positioned outside of the cab
to the left of the rear window.
g01118646
Structural da mage, an overturn, modification, alteration, or improper r epair can impair this structure's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to determine this structure's limitations without voiding
its certification.
Do Not Weld On The ROPS/FOPS
Structure (5)
This safety message is positioned on the right side of
the ROPS.
g01132602
Structural damage, an overturn, modification, alteration,orimproperrepaircanimpairthisstructure's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to determine this structure's limitations without voiding
its certification.
This machine has been certified to the standards
thatarelistedonthecertification film. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification film.
Refer to Operation and Maintenance Manual,
“Guards (Operator Protection)” for more information.
Refer to Operation and Maintenance Manual,
“Guards (Operator Protection)” for more information.
Page 8
SEBU7858-03 11
Safety Section
Safety Messages
Seat Belt (6)
This safety message is positioned on the right side of
the ROPS.
g01370908
A seat belt should be worn at all times during machine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine operation may result in serious injury or death.
High C ompressed Spring (7)
Improper Connections For Jump
Start Cables (8)
This safety message is positioned inside the battery
compartmentofthetractor.
g01370909
Explosion Hazard! Improper jumper c able connections can cause an explosion resulting in serious
injury or death. Batteries may be located in separate compartments. Refer to the Operation and
Maintenance Manual for the correct jump starting
procedure.
This safety message is positioned on each brake
actuator.
g01379131
Highly compressed spring inside this housing can
ause serious physical injury or death.
c
Do not service until you read and understand the
nformation in the service manual when servicing
i
the parking/secondary brake actuator.
Refer to Operation and Maintenance Manual, “Engine
Starting with Jump Start Cables” for more information.
Page 9
12 SEBU7858-03
Safety Section
Safety Messages
Engine Coolant (9)
This safety message is positioned on the top of the
radiator tank.
g01371640
The coolant is hot and the coolant is under pressure. Do not touch the hot surfaces. Refer to the
Operation and Maintenance Manual for the procedure to follow when you check the radiator.
Engage The Apron Locking Pi n (10)
This safety message is positioned on the right side
of the bowl.
g01132609
Apron movement could cause serious injury or
death. Rea d the Operation and Maintenance Manual for the proper procedure to engage the apron
pin.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Level - Check” for more
information.
Refer to Operation and Maintenance Manual,
“Blocking the Bowl and Apron” for more information.
Page 10
SEBU7858-03 13
Safety Section
Safety Messages
Engine Coolant (11)
This message is located to the right hand side of
the access door that is on the top of the rear engine
hood for the scraper.
g0137164
The coolant is hot and the coolant is under pressure. Do not touch the hot surfaces. Refer to the
Operation and Maintenance Manual for the procedure to follow when you check the radiator.
Engage The Apron Locking Pi n (12)
This safety message is positioned on the left side
of the bowl.
g01633733
0
Apron movement could cause serious injury or
death. Rea d the Operation and Maintenance Manual for the proper procedure to engage the apron
pin.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Level - Check” for more
information.
Refer to Operation and Maintenance Manual,
“Blocking the Bowl and Apron” for more information.
Page 11
14 SEBU7858-03
Safety Section
Safety Messages
Product Link (13) (If Equipped)
This safety message is positioned in the cab.
g01381177
This machine is equipped with a Caterpillar
Produc
tric/electronic detonators are used, this communication device should be deactivated within
12 m (4
mandated under applicable legal requirements.
Failure to do so could cause interference with
blast
death.
t Link communication device. When elec-
0 ft) of a blast site, or within the distance
ing operations and result in serious injury or
Crushing Hazard (14)
This safety message is located on the right rear
ROPS post.
g01953898
There is restricted visibility to the area directly behind the machine. Failure to make sure the area is
clear could result in injury or death. Use a s econd
person on the ground to make sure that the area
is clear before you operate the machine in the REVERSE position. Refer to the Operation and Maintenance Manual, “Operation I n formation” for more
information.
Refer to Operation and Maintenance Manual,
“Restricted Visibility” for more information.
r to Operation and Maintenance Manual,
Refe
“Product Link” for more information.
Page 12
SEBU7858-03 15
Safety Section
Additional Messages
i03200484
Additional Messages
SMCS Code: 7000; 7405
Illustration 4
g01633794
Page 13
16 SEBU7858-03
Safety Section
Additional Messages
Illustration 5
Illustration 6
g01633796
g01633797
Illustration 8
Illustration 9
g01633801
g01633802
Alternate Exit (1)
This message is located on the ROPS support
assembly behind the operator and to the right of the
operator.
Illustration 7
g01633799
Illustration 10
g00907967
If the primary exit is blocked, use the hammer to
break the window. Exit the machine through the
window.
Air Conditioner (2)
Page 14
SEBU7858-03 17
Safety Section
Additional Messages
This message is
located on the discharge line of the
air conditioner compressor.
Illustration 11
g00924082
Air Tank (3)
This message is located at the bottom of the left side
access door on the tractor. This message is also
located at the right rear of the scraper.
Illustration 14
g01132926
Release the hood brace before attempting to lower
the engine hood.
Auger Bearing (6)
This message is located on the lower bearing of the
auger behind the access door for the auger bearing.
Illustration 12
g01119007
Data Privacy (4)
This message is located in the cab.
Illustration 13
g01418953
Hood Brace (5)
This message is located on the right side of the
engine hood.
stration 15
Illu
g00941222
Some oil may be lost during shipment. Fill to the top
90 wt. E.P. gear oil.
with
Cat ELC (Extended Life Coolant) (7)
This message is located inside the engine
compartment on top of the coolant tank for the tractor.
s message is also located under the access cover
Thi
for the coolant tank of the scraper.
Page 15
18 SEBU7858-03
Safety Section
General Hazard Information
Illustration 16
g01132922
Engine Coolant (8)
This message is located inside the engine
compartment on the top of the coolant tank for the
tractor. This message is also located above the sight
glass for the cooling system on the right side of the
scraper.
Attach a “Do Not
Operate” warning tag or a similar
warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equ
ipment. These warning tags (Special
Instruction, SEHS7332) are available from your
Caterpillar dealer.
Know the width of your equipment in order to maintain
proper clearance when you operate the equipment
near fences
or near boundary obstacles.
Be aware of high voltage power lines and power
cables that
are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.
Illustration 17
g01132923
General Hazard Information
SMCS Code: 7000
i03559343
Illustration 19
g00702020
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
Keep the equipment free from foreign material.
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Know the appropriate work site hand signals and
the personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
Do not smoke when you service an air conditioner.
Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause
bodily harm or death.
Illustration 18
g00104545
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Page 16
SEBU7858-03 19
Safety Section
General Hazard Information
Obey all local r
Use all cleaning solutions with care. Report all
necessary rep
Do not allow unauthorized personnel on the
equipment.
Unless you are instructed otherwise, perform
maintenanc
position. Refer to Operation and Maintenance Manual
for the procedure for placing the equipment in the
servicing p
When you perform maintenance above ground level
use approp
machines. If equipped, use the machine anchorage
points and use approved fall arrest harnesses and
lanyards.
Pressuri
Pressurized air and/or water can cause debris
and/or ho
personal injury.
When pre
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles
The maximum air pressure for cleaning purposes
must be
nozzle is deadheaded and the nozzle is used with
an effective chip deflector and personal protective
ment. The maximum water pressure for
equip
cleaning purposes must be below 275 kPa (40 psi).
egulations for the disposal of liquids.
airs.
e with the equipment in the servicing
osition.
riate devices such as ladders or man lift
zed Air and Water
t water to be blown out. This could result in
ssurized air and/or pressurized water is
or a protective face shield.
reduced to 205 kPa (30 psi) when the
Trapped Pressure
ure can be trapped in a hydraulic system.
Press
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
ion if you disconnect hydraulic lines or fittings.
caut
High pressure oil that is released can cause a hose to
whip. High pressure oil that is released can cause oil
ray . Fluid penetration can cause serious injury
to sp
and possible death.
Do not remove an
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
relieve the h
Illustration 20
Always use a board or cardboard when you check
for a leak. 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 get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
y hydraulic components or parts
parts until pressure has been relieved
ydraulic pressure.
g00687600
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for the following items:
Tools that are suitable for collecting fluids and
•
equipment that is suitable for collecting fluids
Tools that are suitable for containing fluids and
•
equipment that is suitable for containing fluids
Fluid Penetration
ssure can be trapped in the hydraulic circuit long
Pre
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
cape rapidly if the pressure is not relieved correctly.
es
Obey all local regulations for the disposal of liquids.
Page 17
20 SEBU7858-03
Safety Section
Crushing Prevention and Cutting Prevention
Asbestos Information
ion 21
Illustrat
Caterpillar equipment and replacement parts that are
shipped f
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you
asbestos or when you handle asbestos debris.
Use caut
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbest
boundinaresinorsealedinsomeway.Normal
handling is not hazardous unless airborne dust that
conta
If dust that may contain asbestos is present, there
are se
rom Caterpillar are asbestos free. Caterpillar
handle any replacement parts that contain
ion. Avoid inhaling dust that might be
health. The components that may contain
os that is used in these components is usually
ins asbestos is generated.
veral guidelines that should be followed:
g00702022
Comply with app
•
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requir
can be found in “29 CFR 1910.1001”.
Obey environ
•
of asbestos.
Stay away fr
•
particles in the air.
licable rules and regulations
ements. These OSHA requirements
mental regulations for the disposal
om areas that might have asbestos
Dispose of Waste Properly
Illustration 22
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
g00706404
Never use compressed air for cleaning.
•
Avoid brushing materials that contain asbestos.
•
d grinding materials that contain asbestos.
Avoi
•
Useawetmethodinordertocleanupasbestos
•
erials.
mat
A vacuum cleaner that is equipped with a high
•
ciency particulate air filter (HEPA) can also be
effi
used.
e exhaust ventilation on permanent machining
Us
•
jobs.
ar an approved respirator if there is no other
We
•
way to control the dust.
i01359664
Crushing Prevention and
Cutting Prevention
SMCS Code: 7000
port the equipment properly before you perform
Sup
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold
the equipment. Equipment can fall if a control is
up
moved, or if a hydraulic line breaks.
not work beneath the cab of the machine unless
Do
the cab is properly supported.
nless you are instructed otherwise, never attempt
U
adjustments while the machine is moving or while
the engine is running.
Page 18
SEBU7858-03 21
Safety Section
Burn Prevention
Never jump acro
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 t
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
maintenan
Keep objects away from moving fan blades. The fan
blade will
Do not use a kinked wire cable or a frayed wire cable.
Wear glov
When you strike a retainer pin with force, the retainer
pin can fly
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to
your eye
a retainer pin.
throw objects or cut objects.
s, wear protective glasses when you strike
ss the starter solenoid terminals
he equipment or the machine. Stay
ce is performed.
es when you handle wire cable.
out. The loose retainer pin can injure
Ensure that the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relie
Cooling system conditioner contains alkali. Alkali can
cause person
the skin, the eyes, or the mouth.
filler cap is cool before removing the
ve pressure.
al injury. Do not allow alkali to contact
Oils
Hot oil and h
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 enoug
standard procedure in this manual in order to remove
the hydraulic tank filler cap.
ot components can cause personal
h to touch with a bare hand. Follow the
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
. Always wear protective glasses for servicing
Chips or
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
other debris can fly off an object when you
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.
i03605020
Fire Prevention an d Explosion
Prevention
SMCS Code: 7000
0704000
Illustration 23
General
All fuels, most lubricants, and some coolant mixtures
are flammable.
g0
Check the coolant level only after the engine has
been stopped.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Page 19
22 SEBU7858-03
Safety Section
Fire Prevention and Explosion Prevention
Always perform
a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate
a machine when a fire hazard exists. Contact your
Caterpillar d
ealer for service.
Understand the use of the primary exit and alternative
exit on the ma
chine. Refer to Operation and
Maintenance Manual, “Alternative Exit”.
Do not opera
te a machine with a fluid leak. Repair
leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or
onto electrical components can cause a
fire. A fire may cause personal injury or death.
Remove flam
mable material such as leaves, twigs,
papers, trash, etc. These items may accumulate in
the engine compartment or around other hot areas
and hot par
ts on the machine.
Keep the access doors to major machine
compartm
ents closed and access doors in working
conditioninordertopermittheuseoffire suppression
equipment, in case a fire should occur.
Clean all accumulations of flammable materials such
as fuel, oil and debris from the machine.
Do not operate the machine near any flame.
Keep shi
elds in place. 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. E
xhaust shields must be installed correctly.
Illustration 24
g00704059
Usecautionwhenyouarefuelingamachine.Donot
smoke while you are fueling a machine. Do not fuel
a machine near open flames or sparks. Always stop
the engine before fueling. Fill the fuel tank outdoors.
Properly clean areas of spillage.
Follow practices for safe fueling that are described
in the “Operation” section of the Operation and
Maintenance Manual section and follow local
regulations. Never store flammable fluids in the
operator compartment of the machine.
Do not weld or flame cut on tanks or lines that contain
flamma
ble fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding
or flam
e cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
that is generated from repairing nonmetallic
Dust
hoods or fenders may be flammable and/or explosive.
Repair such components in a well ventilated area
from open flames or sparks. Use suitable
away
Personal Protection Equipment (PPE).
pect all lines and hoses for wear or deterioration.
Ins
Replace damaged lines and hoses. The lines and
the hoses should have adequate support and secure
mps. Tighten all connections to the recommended
cla
torque. Damage to the protective cover or insulation
may provide fuel for fires.
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
ly rags and flammable materials in protective
oi
containers. Do not smoke in areas that are used for
storing flammable materials.
Battery and Battery Cables
Illustration 25
g00704135
Page 20
SEBU7858-03 23
Safety Section
Fire Prevention and Explosion Prevention
Caterpillar re
minimize the risk of fire or an explosion related to
the battery.
Do not operate a machine if battery cables or related
parts show signs of wear or damage. Contact your
Caterpillar
Follow safe procedures for engine starting with jump
start cable
cause an explosion that may result in injury. Refer to
Operation and Maintenance Manual, “Engine Starting
with Jump St
Do not charge a frozen battery. This may cause an
explosion
Gases from a battery can explode. Keep any open
flames or sp
not smoke in battery charging areas.
Never che
object across the terminal posts. Use a voltmeter or
ahydrometer.
Daily inspect battery cables that are in visible areas.
Identify cables, clips, straps, and other restraints for
damage.
signs of the following, which can occur over time due
to use and environmental factors:
commends the following in order to
dealer for service.
s. Improper jumper cable connections can
art Cables” for specific instructions.
.
arks away from the top of a battery. Do
ck the battery charge by placing a metal
Replace these items if necessary. Look for
An exposed wire
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into con
may result in an unsafe condition for servicing the
machine. Repair components or replace components
before servi
Fire on a machine can result in personal injury
or death. Exposed battery cables that come into
contact wit
fires. Replace cables and related parts that show
signs of wear or damage. Contact y our Caterpillar
dealer.
on the ground cable between the
tact with a grounded surface. This
cing the machine.
h a grounded connection can result in
Wiring
Check electrical wires daily. If any of the following
conditio
the machine.
•
•
•
ns exist, replace parts before you operate
Fraying
Signs of abrasion or wear
Cracking
Fraying
•
on
Abrasi
•
Cracking
•
Discoloration
•
n the insulation of the cable
Cuts o
•
Fouling
•
Corroded terminals, damaged terminals, and loose
•
terminals
Replace damaged battery cable(s) and replace
any related parts. Eliminate any fouling, which may
e caused insulation failure or related component
hav
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause
a short to ground if the exposed area comes into
ntact with a grounded surface. A battery cable
co
short produces heat from the battery current, which
may be a fire hazard.
oration
Discol
•
Cuts on insulation
•
Other damage
•
Make s
are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat
Attachingelectricalwiringtohosesandtubesthat
cont
be avoided.
Cons
replacement parts.
Kee
Lin
Donotbendhighpressurelines.Donotstrikehigh
pr
damaged. Use the appropriate backup wrenches in
order to tighten all connections to the recommended
to
ure that all clamps, guards, clips, and straps
during machine operation.
ain flammable fluids or combustible fluids should
ult your Caterpillar dealer for repair or for
p wiring and electrical connections free of debris.
es, Tubes and Hoses
essure lines. Do not install any lines that are bent or
rque.
Page 21
24 SEBU7858-03
Safety Section
Fire Extinguisher Location
Ether
Illustration 26
Check lines, tubes and hoses carefully. Wear
Personal Protection Equipment (PPE) in order to
check for leaks. Always use a board or cardboard
when you check for a leak. 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 get treatment immediately.
Seek treatment from a doctor that is familiar with this
type of injury.
Replace the affected parts if any of the following
conditions are present:
End fittings are damaged or leaking.
•
g00687600
Ether (if equi
applications. Ether is flammable and poisonous.
Follow the cor
Refer to the section in the Operation and Maintenance
Manual with the label “Engine Starting”.
Do not spray ether into an engine if the machine is
equipped with a thermal starting aid for cold weather
starting.
Use ether in well ventilated areas. Do not smoke
while you ar
are using an ether spray.
Do not stor
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49°
from open flames or sparks.
Dispose o
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
pped) is commonly used in cold weather
rect cold engine starting procedures.
e replacing an ether cylinder or while you
e ether cylinders in living areas or in the
C (120.2° F). Keep ether cylinders away
f used ether cylinders properly. Do not
Fire Extinguisher
As an additional safety measure, keep a fire
extinguisher on the machine.
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 shields
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes and
hoses.
Do not operate a machine when a fire hazard
exists. Repair any lines that are corroded, loose
or damaged. Leaks may provide fuel for fires.
Consult your Caterpillar dealer for repair or for
replacement parts. Use genuine Caterpillar parts or
the equivalent, for capabilities of both the pressure
limit and temperature limit.
Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
uisher regularly. Follow the recommendations
exting
on the instruction plate.
der installation of an aftermarket Fire
Consi
Suppression System, if the application and working
conditions warrant the installation.
70502
i023
Fire Extinguisher Location
SMCS Code: 7000
esurethatafire extinguisher is available. Be
Mak
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
inguisher regularly. Obey the recommendations
ext
on the instruction plate.
e fire extinguisher may be mounted to the grab
Th
handle that is located on the right platform near the
front of the engine hood. Do not block access to the
llowing items:
fo
handrails
•
ladders
•
Page 22
SEBU7858-03 25
Safety Section
Tire Information
walkways
•
front side door of engine hood
•
Do not weld a bracket on the Rollover Protective
Structure (ROPS) in order to install the fire
extinguishe
order to mount the fire extinguisher on the ROPS.
r. Also, do not drill holes in the ROPS in
i01557411
Tire Information
SMCS Code: 7000
Explosions of air inflated tires have resulted from
heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated
by welding, by heating rim components, by external
fire, or by excessive use of brakes.
A tire explosion is much more violent than a
blowout. The explosion can propel the tire, the rim
components, and the axle components as far as
500 m (1500 ft) or more from the machine. Both the
force of the explosion and the flying debris can cause
property damage, personal injury, or death.
To avoid overin
equipment and training in the usage of the equipment
are necessary. A tire blowout or a rim failure can
result from im
equipment.
When you infla
use a self-attaching chuck.
Servicing t
trained personnel that use proper tools and proper
procedures should perform this maintenance. If
correct pro
and rims, the assemblies could burst with explosive
force. This explosive force can cause serious
personal i
instructions from your tire dealer.
flation, proper nitrogen inflation
proper equipment or from misused
te a tire, stand behind the tread and
ires and rims can be dangerous. Only
cedures are not used for servicing tires
njury or death. Carefully obey the specific
i01122596
Electrical Storm Injury
Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
37832
Illustration 27
(A)Atleast15m(50ft)
(B) At least 500 m (1500 ft)
ot approach a warm tire. Maintain a minimum
Do n
distance, as shown. Stay outside the shaded area in
Illustration 27.
Do not use water or calcium as a ballast for the tires.
Dry nitrogen gas is recommended for inflation of tires.
the tires were originally inflated with air, nitrogen
If
is still preferred for adjusting the pressure. Nitrogen
mixes properly with a ir.
g003
Mount the machine.
•
Dismount the machine.
•
If you are in the operator's station during an electrical
storm, stay in the operator's station. If you are on the
ground during an electrical storm, stay away from
the vicinity of the machine.
i03140043
Before Starting Engine
S Code: 1000; 7000
SMC
Start the engine only from the operator's
partment. Never short across the starter
com
terminals or across the batteries. Shorting could
bypass the engine neutral start system. Shorting
uld also damage the electrical system.
co
Nitrogen inflated tires reduce the potential of
a tire explosion because nitrogen does not aid
ombustion. Nitrogen helps to prevent oxidation of
c
the rubber, deterioration of rubber, and corrosion of
rim components.
Page 23
26 SEBU7858-03
Safety Section
Engine Starting
i03565626
Engine Starting
SMCS Code: 1000; 7000
Illustration 28
g00927804
Depress the machine horn (1) in order to make sure
that the machine horn works properly.
If a warning ta
g is attached to the engine start switch
or to the machine controls, do not start the engine.
Also, do not move any machine controls.
Move all hydraulic controls to the HOLD position or to
the OFF position before you start the engine.
Move the transmission control (lever) to the
NEUTRAL position.
Engage the parking brake control.
Diesel eng
ine exhaust contains products of
combustion which can be harmful to your health.
Always start the engine in a well ventilated area.
Always op
erate the engine in a well ventilated area.
If you are in an enclosed area, vent the exhaust to
the outside.
Briefly sound the horn before you start the engine.
i01349075
Before Operation
SMCS Code: 7000
Illustration 29
al example
Typic
g01120628
Adjust the mirrors (2) on your machine for the best
ator vision. Adjust both the inside mirror and the
oper
outside mirror before you operate the machine.
ect the condition of the seat belt and the condition
Insp
of mounting hardware. Replace any damaged parts
and any worn parts. Regardless of appearance,
lace the seat belt after three years of use. Do not
rep
use a seat belt e xtension on a retractable seat belt.
ust the seat in order to achieve full pedal travel
Adj
when the operator's back is against the back of the
seat.
Make sure that the machine is equipped with a
lighting system that is adequate for the job conditions.
ke sure that all lights are working properly.
Ma
Before you start the engine or before you move the
chine, make sure that no one is on the machine,
ma
underneath the machine, or around the machine.
Make sure that there are no personnel in the area.
Clear all personnel from the machine and from the
area.
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 the
doors in the open position or in the shut position.
Secure the windows in the open position or in the
shut position.
For the best vision of the area that is close to the
machine, adjust the rear view mirrors (if equipped).
Make sure that the machine horn, the backup alarm
(if equipped) and all other warning devices are
working properly.
Fasten the seat belt securely.
Page 24
SEBU7858-03 27
Safety Section
Visibility Information
i03162317
Visibility Information
SMCS Code: 7000
Before you sta
inspection in order to ensure that there are no
hazards around the machine.
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential h
the machine.
Your machi
Some examples of visual aids are Closed Circuit
Television (CCTV) and mirrors. Before operating the
machine, e
working condition and that the visual aids are clean.
Adjust the visual aids using the procedures that are
located i
If equipped, the Work Area Vision System shall be
adjusted according to Operation and Maintenance
Manual, S
It may not be possible to provide direct visibility on
large ma
Appropriate job site organization is required in order
to minimize hazards that are caused by restricted
ity. Job site organization is a collection of rules
visibil
and procedures that coordinates machines and
people that work together in the same area. Examples
of job s
ite organization include the following:
rt the machine, perform a walk-around
azards as hazards become visible around
ne may be equipped with visual aids.
nsure that the visual aids are in proper
n this Operation and Maintenance Manual.
EBU8157, “Work Area Vision System”.
chines to all areas around the machine.
i03641204
Restricted Visibility
SMCS Code: 7000
Thesizeandth
result in areas that can not be seen when the operator
is seated. Illustration 30 provides an approximate
visual indic
visibility. Illustration 30 indicates restricted visibility
areas at ground level inside a radius of 12.00 m
(40 ft) from
use of optional visual aids. This illustration does not
provide areas of restricted visibility for distances
outside a r
This machine may be equipped with optional visual
aids that m
restricted visibility areas. Refer to this Operation and
Maintenance Manual, “Mirror” for more information on
addition
cameras, refer to this Operation and Maintenance
Manual, “Camera” for more information on additional
visibili
optional visual aids, the job site organization must
be utilized to minimize hazards of this restricted
visibil
organization refer to Operation and Maintenance
Manual, “Visibility Information”.
al visibility. If your machine is equipped with
ty. For areas that are not covered by the
ity. For more information regarding job site
econfiguration of this machine may
ation of areas of significant restricted
the operator on a machine without the
adius of 12.00 m (40 ft).
ay provide visibility to some of the
Safety instructions
•
Controlled patterns of machine movement and
•
vehicle movement
Workers that direct traffictomovewhenitissafe
•
ricted areas
Rest
•
Operator training
•
Warning symbols or warning signs on machines
•
or on vehicles
A system of communication
•
munication between workers and operators
Com
•
prior to approaching the machine
difications of the machine configuration by the
Mo
user that result in a restriction of visibility shall be
evaluated.
Illustration 30
Top v iew of the m achine
1635673
g0
Page 25
28 SEBU7858-03
Safety Section
Operation
Note: The shade
location of areas with significant restricted visibility.
There is restricted visibility to the area directly behind the mach
clear could result in injury or death. Use a second
person on the ground to make sure that the area
is clear bef
VERSE position. Refer to the Operation a nd Maintenance Manual, “Operation Information” for more
informatio
d areas indicate the approximate
ine. Failure to make sure the area is
ore you operate the machine in the RE-
n.
i03565616
Operation
SMCS Code: 7000
Machine Operating Temperature
Range
The stan
for use within an ambient temperature range
of −40 °C (−40 °F) to 50 °C (122 °F). Special
configur
may be available. Consult your Caterpillar dealer for
additional information on special configurations of
your ma
Machin
Only operate the machine while you are in a seat.
The se
machine. Only operate the controls while the engine
is running.
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
prot
Before you move the machine, you must make sure
tha
dard machine configuration is intended
ations for different ambient temperatures
chine.
eOperation
at belt must be fastened while you operate the
ective devices.
t no one will be endangered.
Do not operate t
that could result in the seat suspension travel stops
being contacted and do not operate the machine at
travel speeds
travel stops being contacted. Operating this machine
in very rough ground conditions or at travels speeds
not suitable
in excessive seat vertical travel with impact of the
suspension against the travel stops, which may
cause injur
the operator, properly adjust the seat controls for the
operator weight and height. Refer to Operation and
Maintenanc
Carry attachments approximately 40 cm (15 inches)
above grou
cliff, an excavation, or an overhang.
If the mach
grade, immediately remove the load and turn the
machine downhill.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on
can tip when you cross ditches, ridges or other
unexpected obstructions.
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and
down the
Maintain control of the machine. Do not overload the
machin
Never straddle a wire cable. Never allow other
perso
Before you maneuver the machine, make sure
that n
attachments.
Know
Always keep the Rollover Protective Structure
(ROP
banks and on slopes. Also, the machine
e beyond the machine capacity.
nnel to straddle a wire cable.
o personnel are between the machine and
the maximum dimensions of your machine.
S) installed during machine operation.
he machine on ground conditions
that could result in the seat suspension
for the ground conditions may result
y. In order to minimize impact loading on
e Manual, “Seat” for more information.
nd level. Do not go close to the edge of a
ine begins to sideslip downward on a
slopes.
Do not allow riders on the machine unless the
hine has the following equipment:
mac
additional seat
•
additional seat belt
•
llover Protective Structure (ROPS)
Ro
•
Never use the work tool for a work platform.
Note any needed repairs during machine operation.
Report any needed repairs.
i02624835
Engine St opp ing
SMCS Code: 1000; 7000
Do not stop the engine immediately after the
machine has been operated under load. This can
cause overheating and accelerated wear of engine
components.
Page 26
SEBU7858-03 29
Safety Section
Parking
After the machi
is engaged, allow the engine to run for two minutes
before shutdown. This allows hot areas of the engine
to cool gradua
ne is parked and the parking brake
lly.
i03370980
Parking
SMCS Code: 7000
Park the machine on a level surface. If you must park
on a grade, chock the machine's wheels with suitable
chocks. Take into account the following:
tire size
•
machine weight
•
ground conditions
•
Apply the service brake in order to stop the
machine. Move the transmission control (lever) to
the NEUTRAL position. Move the throttle control to
the LOW IDLE position.
Engage the parking brake.
Lower all equipment to the ground. Activate any
control locks.
Stop the engine.
Awelltrainedo
in the Operation and Maintenance Manual has
the greatest impact on stability. Operator training
provides a per
observation of working and environmental conditions,
feel for the machine, identification of potential
hazards, and
appropriate decisions.
When you wor
slopes, consider the following important points:
Speed of tra
tend to make the machine less stable.
Roughness
maybelessstablewithuneventerrain.
Direction
across the slope. When possible, operate the
machine up the slopes and operate the machine
down the s
machine uphill when you are working on an incline.
Mounted e
may be impeded by the following components:
equipment that is mounted on the machine, machine
configur
Nature of surface – Ground that has been newly
filled wi
machine.
ation, weights, and counterweights.
th earth may collapse from the weight of the
perator that follows the instructions
sonwiththefollowingabilities:
operating the machine safely by making
k on side hills and when you work on
vel – At higher speeds, forces of inertia
of terrain or surface – The machine
of travel – Avoid operating the machine
lopes. Place the heaviest end of the
quipment – Balance of the machine
Turn the engine start switch to the OFF position and
remove the engine start switch key.
Turn the battery disconnect switch to the OFF
position. Remove the disconnect switch key if you
do not operate the machine for an extended period
of time. This will prevent drainage of the battery. A
battery short circuit, any current draw from certain
components, and vandalism can cause drainage of
the battery.
i02780235
Slope Operation
CS Code: 7000
SM
Machines that are operating safely in various
plications depend on these criteria: the machine
ap
model, configuration, machine maintenance,
operating speed of the machine, conditions of the
errain, fluid levels, and tire inflation pressures. The
t
most important criteria are the skill and judgment of
the operator.
Surfac
surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
promo
Slippage due to excessive loads – This may cause
downh
which will increase the angle of the machine.
Widt
narrower tires further increase the digging into the
ground which causes the machine to be less stable.
Implements attached to the drawbar – This may
decrease the weight on the uphill tracks. This may
als
decreased weight will cause the machine to be less
stable.
Height of the working load of the m achine –
When the working loads are in higher positions, the
st
Operated equipment – Be aware of performance
fe
on machine stability.
e material – Rocks and moisture of the
te side slipping of the machine.
ill tracks or downhill tires to dig into the ground,
hoftracksortires –Narrower tracks or
o decrease the weight on the uphill tires. The
ability of the machine is reduced.
atures of the equipment in operation and the effects
Page 27
30 SEBU7858-03
Safety Section
Equipment Lowering with Engine Stopped
Operating tech
pulled loads low to the ground for optimum stability.
Machine syste
Slopes can affect the proper function and operation
of the various machine systems. These machine
systems are n
Note: Safe operation on steep slopes may require
special mac
the operator and proper equipment for specific
applications are also required. Consult the Operation
and Mainten
level requirements and intended machine use.
Equipmen
niques – Keep all attachments or
ms have limi tations on slopes –
eeded for machine control on slopes.
hine maintenance. Excellent skill of
ance Manual sections for the proper fluid
i01329161
tLoweringwith
Engine Stopped
SMCS Cod
Before lowering any equipment with the engine
stopped
all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind
most sy
raise or lower equipment. The procedure will cause
high pressure air, hydraulic, or some other media
to be re
Wear appropriate personal protective equipment and
follow the established procedure in the Operation
and Ma
Engine Stopped” in the Operation Section of the
manual.
e: 7000
, clear the area around the equipment of
stemsuseahighpressurefluid or air to
leased in order to lower the equipment.
intenance Manual, “Equipment Lowering with
6373
i0359
Sound Information and
Vibr
ation Inf ormation
Hearing protec
machine is operated with an open operator station for
extended periods or in a noisy environment. Hearing
protection ma
operated with a cab that is not properly maintained or
when the doors and w indows are open for extended
periods or in
The average exterior sound pressure level is 86
dB(A) when t
Moving Test” procedure is used to measure the value
for the standard machine. The measurement was
conducted u
15 m (49.2 ft) and “the machine moving forward in an
intermediate gear ratio”.
The exterior sound power level is 115 dB(A) when the
value is measured according to the static pressure
test proce
in “ISO 6393:2008”.
tion may be needed when the
y be needed when the machine is
a noisy environment.
he “SAE J88Feb06 - Constant Speed
nder the following conditions: distance of
dures and the conditions that are specified
Sound Level Information for
Machines
in European Union
Countries and in Countries that
Adopt the “European Union
Directi
The static operator sound pressure level is 79 dB(A)
when “I
for an enclosed cab. The test was conducted with the
cab doors and the cab windows closed. The cab was
proper
“The E
ves”
SO 6394:2008” is used to measure the value
ly installed and maintained.
uropean Union Physical
Agents (Vibration) Directive
2002/44/EC”
tion D ata for Wheel Scrapers
Vibra
SMCS Code: 7000
S/N: DBD1-Up
Sound Level Information
operator Equivalent Sound Pressure Level
The
(Leq) is 81 dB(A) when “ANSI/SAE J1166 OCT 98”
is used to measure the value for an enclosed cab.
is is a work cycle sound exposure level. The cab
Th
was properly installed and maintained. The test was
conducted with the cab doors and the cab windows
osed.
cl
Information Concerning Hand/Arm Vibration
l
Leve
When the machine is operated according to the
nded use, the hand/arm vibration of this machine
inte
is below 2.5 meter per second squared.
ormation Concerning Whole Body Vibration
Inf
Level
s section provides vibration data and a method for
Thi
estimating the vibration level for wheel scrapers.
te: Vibration levels are influenced by many
No
different parameters. Many items are listed below.
erator training, behavior, mode, and stress
Op
•
Page 28
SEBU7858-03 31
Safety Section
Sound Information and Vibration Information
Jobsiteorgani
•
zation, preparation, environment,
weather, and material
Machine type,
•
quality of the seat, quality of the
suspension system, attachments, and condition of
the equipment
It is not possible to get precise vibration levels for
this machine. The expected vibration levels can be
estimated w
ith the information in Table 1 in order
to calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
average vi
bration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to
obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to o
btain the estimated vibration level.
Note: All vibration levels are in meter per second
squared.
Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Vibration Levels Scenario Factors
X
axisYaxisZaxisXaxisYaxisZaxis
Machine Family Machine Type
Scraper Wheel Scraper
Typical Operating
Activity
work cycle 1,05 1,18 1,12 0,34 0,40 0,42
Note: Refer to “ISO/TR 25398 Mechanical Vibration Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving
machines” for more information about vibration.
This publication uses data that is measured
by international institutes, organizations and
manufacturers. This document provides information
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and
Maintenance Manual, SEBU8257, “The European
Union Physical Agents (Vibration) Directive
2002/44/EC” for more information about machine
vibration levels.
The Caterpillar suspension seat meets the criteria of
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. This seat is tested
with the input “spectral class EM2”. The seat has a
transmissibility factor of “SEAT<1.0”.
The whole body vibration level of the machine varies.
There is a range of values. The low value is 0.5
meter per second squared. The machine meets the
short term level for the design of the seat in “ISO
7096”. The value is 1.34 meter per second squared
for this machine.
Guidelines for Reducing Vibration Levels on
Earthmoving Equipment
Properly adjust machines. Properly maintain
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level:
1. Use the right type and size of machine, equipment,
and attachments.
2. Maintain machines according to the manufacturer's
recommendations.
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.
Page 29
32 SEBU7858-03
Safety Section
Sound Information and Vibration Information
c. Provide machin
to maintain the conditions of the terrain.
4. Use a seat that
maintained and adjusted.
a. Adjust the se
and the size of the operator.
b. Inspect and
adjustment mechanisms.
5. Perform the
a. Steer
b. Brake
c. Accelerat
d. Shift the gears.
6. Move the attachments smoothly.
7. Adjust th
to minimize the vibration level.
a. Drive ar
emachinespeedandtherouteinorder
ound obstacles and rough terrain.
es and schedule time in order
meets “ISO 7096”. Keep the seat
at and suspension for the weight
maintain the seat suspension and
following operations smoothly.
e.
e. Minimize repea
of loads.
f. Minimize any s
and leisure activities.
ted handling of loads and lifting
hocks and impacts during sports
Sources
The vibratio
procedure is based on “ISO/TR 25398 Mechanical
Vibration - Guideline for the assessment of exposure
to whole bod
earthmoving machines”. Harmonized data is
measured by international institutes, organizations
and manufac
This literature provides information about assessing
the whole b
earthmoving equipment. The method is based on
measured vibration emission under real working
conditio
You should check the original directive. This
document
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documen
Kingdom Health and Safety Executive.
n information and the calculation
y vibration of ride on operated
turers.
ody vibration exposure of operators of
ns for all machines.
summarizes part of the content of the
ts are based on information from the United
b. Slow down when it is necessary to go over
rough te
8. Minimize vibrations for a long work cycle or a long
travel
a. Use machines that are equipped with
suspe
b. Use the ride control system on wheel scrapers.
c. If no ride control system is available, reduce
speed in order to prevent bounce.
d. Haul the machines between workplaces.
9. Less
factors. The following guidelines can be effective
in order to provide better operator comfort:
a. Adjust the seat and adjust the controls in order
to achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
c. Provide breaks in order to reduce long periods
of sitting.
rrain.
distance.
nsion systems.
operator comfort may be caused by other risk
Refer to
SEBU8257, “The European Union Physical
Agents (Vibration) Directive 2002/44/EC” for more
inform
Consult your local Caterpillar dealer for more
infor
vibration levels. Consult your local Caterpillar dealer
about safe machine operation.
Use the following web site in order to find your local
dealer:
Operation and Maintenance Manual,
ation about vibration.
mation about machine features that minimize
Caterpillar, Inc.
www.cat.com
d. Avoid jumping from the cab.
Page 30
SEBU7858-03 33
Safety Section
Operator Station
i03634321
Operator Station
SMCS Code: 7000
S/N: DBD1-Up
Any modifications to the inside of the operator station
should not pr
the space for the companion seat (if equipped).
The addition of a radio, fire extinguisher, and other
equipment m
operator space and the space for the companion seat
(if equipped) is maintained. Any item that is brought
into the cab
operator space or the space for the companion seat
(if equipped). A lunch box or other loose items must
be secured
in rough terrain or in the event of a rollover.
oject into the operator space or into
ust be installed so that the defined
should not project into the defined
. Objects must not pose an impact hazard
i01992325
Guards
(Operator Protection)
SMCS Code: 7000
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.
A daily inspection of the guards is required in order to
check for structures that are bent, cracked or loose.
Never operate a machine with a damaged structure.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are recommended for your
machine.
Rollover Protective Structure
(ROPS), Falling Object Protective
Structure (FO PS) or Tip Over
Protection Structure (TOPS)
The ROPS/FOPS Structure (if equipped) on your
machine is specifically designed, tested and certified
for that machine. Excavators are not equipped
with ROPS structures. Any alteration or any
modification to the ROPS/FOPS Structure could
weaken the structure. This places the operator
into an unprotected environment. Modifications or
attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
structure can be caused by an overturn, a falling
object, a collision, etc.
Donotmountitems(fire extinguishers, first aid
kits, work lights, etc) by welding brackets to the
ROPS/FOPS Structure or by drilling holes in the
ROPS/FOPS Structure. Welding brackets or drilling
holes in the ROPS/FOPS Structures can weaken
the structures. Consult your Caterpillar dealer for
mounting guidelines.
The Tip Over Protection Structure (TOPS) is
another type of guard that is used on mini hydraulic
excavators. This structure protects the operator in
the event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.
Other Guards (If Equipped)
Protection from flying objects and/or falling objects is
required for special applications. Logging applications
and demolition applications are two examples that
require special protection.
A front guard needs to be installed when a work
tool that creates flying objects is used. Mesh
front guards that are approved by Caterpillar or
polycarbonate front guards that are approved by
Caterpillar are available for machines with a cab or
an open canopy. On machines that are equipped with
cabs, the windshield should also be closed. Safety
glasses are recommended when flying hazards exist
for machines with cabs and machines with open
canopies.
If the work material extends above the cab, top
guards and front guards should be used. Typical
examples of this type of application are listed below:
Page 31
34 SEBU7858-03
Safety Section
Guards
Demolition app
•
Rock quarries
•
Forestry products
•
Additional g
applications or work tools. The Operation and
Maintenance Manual for your machine or your
work tool wi
guards. Consult your Caterpillar dealer for additional
information.
lications
uards may be required for specific
ll provide specific requirements for the
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