Cat 627G Users Manual

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SEBU7858-03

July 2009

Operation and

Maintenance

Manual

627G Wheel Tractor-Scraper

DBD1-Up (Machine)

DBZ1-Up (Scraper)

SAFETY.CAT.COM

i03602780

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe

basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous

situations before an accident occurs. A person must be alert to potential hazards. This person should also

have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and

could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have

read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings

are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as

“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially

presented.

A non-exhaustive list of 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. You must

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

operation of the product in the location of use, including site-specific rules and precautions

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 others. You should also ensure that the product will not be damaged or become unsafe by

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 available at the time that the publication was written. The specifications, torques, pressures,

measurements, adjustments, illustrations, and other items can change at any time. These changes can

affect the service that is given to the product. Obtain the complete and most current information before you

start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-

lar replacement parts or parts with equivalent

specifications including, but not limited to, phys-

ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

6SEBU7858-03

Safety Section

Safety Messages

Safety Section

i03640971

Safety Messages

SMCS Code: 7000; 7405

There are several specific safety messages on this

machine. The exact location of the safety messages

and the description of the safety messages are

reviewed in this section. Please become familiarized

with all safety messages.

Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety

messages if you cannot read the words. Replace the

safety messages 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.

SEBU7858-03 7

Safety Section

Safety Messages

g01953867

Illustration 2

8SEBU7858-03

Safety Section

Safety Messages

g01954945

Illustration 3

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. Con-

tact your Caterpillar dealer for replacement manu-

als. 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 clear-

ances 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 per-

son in this area when the machine turns. Severe

injury or death from crushing could occur.

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 damage, an overturn, modification, al-

teration, or improper repair can impair this struc-

ture's protection capability thereby voiding this

certification. Do not weld on or drill holes in the

structure. Consult a Caterpillar dealer to deter-

mine 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.

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, al-

teration,orimproperrepaircanimpairthisstruc-

ture's protection capability thereby voiding this

certification. Do not weld on or drill holes in the

structure. Consult a Caterpillar dealer to deter-

mine this structure's limitations without voiding

its certification.

Refer to Operation and Maintenance Manual,

“Guards (Operator Protection)” for more information.

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 ma-

chine operation to prevent serious injury or death

in the event of an accident or machine overturn.

Failure to wear a seat belt during machine opera-

tion may result in serious injury or death.

High Compressed Spring (7)

This safety message is positioned on each brake

actuator.

g01379131

Highly compressed spring inside this housing can

cause serious physical injury or death.

Do not service until you read and understand the

information in the service manual when servicing

the parking/secondary brake actuator.

Improper Connections For Jump

Start Cables (8)

This safety message is positioned inside the battery

compartmentofthetractor.

g01370909

Explosion Hazard! Improper jumper cable connec-

tions can cause an explosion resulting in serious

injury or death. Batteries may be located in sep-

arate compartments. Refer to the Operation and

Maintenance Manual for the correct jump starting

procedure.

Refer to Operation and Maintenance Manual, “Engine

Starting with Jump Start Cables” for more information.

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 pres-

sure. Do not touch the hot surfaces. Refer to the

Operation and Maintenance Manual for the proce-

dure to follow when you check the radiator.

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Level - Check” for more

information.

Engage The Apron Locking Pin (10)

This safety message is positioned on the right side

of the bowl.

g01132609

Apron movement could cause serious injury or

death. Read the Operation and Maintenance Man-

ual for the proper procedure to engage the apron

pin.

Refer to Operation and Maintenance Manual,

“Blocking the Bowl and Apron” for more information.

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.

g01371640

The coolant is hot and the coolant is under pres-

sure. Do not touch the hot surfaces. Refer to the

Operation and Maintenance Manual for the proce-

dure to follow when you check the radiator.

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Level - Check” for more

information.

Engage The Apron Locking Pin (12)

This safety message is positioned on the left side

of the bowl.

g01633733

Apron movement could cause serious injury or

death. Read the Operation and Maintenance Man-

ual for the proper procedure to engage the apron

pin.

Refer to Operation and Maintenance Manual,

“Blocking the Bowl and Apron” for more information.

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

Product Link communication device. When elec-

tric/electronic detonators are used, this com-

munication device should be deactivated within

12 m (40 ft) of a blast site, or within the distance

mandated under applicable legal requirements.

Failure to do so could cause interference with

blasting operations and result in serious injury or

death.

Refer to Operation and Maintenance Manual,

“Product Link” for more information.

Crushing Hazard (14)

This safety message is located on the right rear

ROPS post.

g01953898

There is restricted visibility to the area directly be-

hind the machine. Failure to make sure the area is

clear could result in injury or death. Use a second

person on the ground to make sure that the area

is clear before you operate the machine in the RE-

VERSE position. Refer to the Operation and Main-

tenance Manual, “Operation Information” for more

information.

Refer to Operation and Maintenance Manual,

“Restricted Visibility” for more information.

SEBU7858-03 15

Safety Section

Additional Messages

i03200484

Additional Messages

SMCS Code: 7000; 7405

g01633794

Illustration 4

16 SEBU7858-03

Safety Section

Additional Messages

g01633796

Illustration 5

g01633797

Illustration 6

g01633799

Illustration 7

g01633801

Illustration 8

g01633802

Illustration 9

Alternate Exit (1)

This message is located on the ROPS support

assembly behind the operator and to the right of the

operator.

g00907967

Illustration 10

If the primary exit is blocked, use the hammer to

break the window. Exit the machine through the

window.

Air Conditioner (2)

SEBU7858-03 17

Safety Section

Additional Messages

This message is located on the discharge line of the

air conditioner compressor.

g00924082

Illustration 11

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.

g01119007

Illustration 12

Data Privacy (4)

This message is located in the cab.

g01418953

Illustration 13

Hood Brace (5)

This message is located on the right side of the

engine hood.

g01132926

Illustration 14

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.

g00941222

Illustration 15

Some oil may be lost during shipment. Fill to the top

with 90 wt. E.P. gear oil.

Cat ELC (Extended Life Coolant) (7)

This message is located inside the engine

compartment on top of the coolant tank for the tractor.

This message is also located under the access cover

for the coolant tank of the scraper.

18 SEBU7858-03

Safety Section

General Hazard Information

g01132922

Illustration 16

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.

g01132923

Illustration 17

i03559343

General Hazard Information

SMCS Code: 7000

g00104545

Illustration 18

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 equipment. 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.

g00702020

Illustration 19

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.

Never put maintenance fluids into glass containers.

Drain all liquids into a suitable container.

SEBU7858-03 19

Safety Section

General Hazard Information

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report all

necessary repairs.

Do not allow unauthorized personnel on the

equipment.

Unless you are instructed otherwise, perform

maintenance with the equipment in the servicing

position. Refer to Operation and Maintenance Manual

for the procedure for placing the equipment in the

servicing position.

When you perform maintenance above ground level

use appropriate devices such as ladders or man lift

machines. If equipped, use the machine anchorage

points and use approved fall arrest harnesses and

lanyards.

Pressurized Air and Water

Pressurized air and/or water can cause debris

and/or hot water to be blown out. This could result in

personal injury.

When pressurized air and/or pressurized water is

used for cleaning, wear protective clothing, protective

shoes, and eye protection. Eye protection includes

goggles or a protective face shield.

The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the

nozzle is deadheaded and the nozzle is used with

an effective chip deflector and personal protective

equipment. The maximum water pressure for

cleaning purposes must be below 275 kPa (40 psi).

Trapped Pressure

Pressure can be trapped in a hydraulic system.

Releasing 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

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure can

cause hydraulic fluid or items such as pipe plugs to

escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury

may occur. Do not disassemble any hydraulic

components or parts until pressure has been relieved

or personal injury may occur. Refer to the Service

Manual for any procedures that are required to

relieve the hydraulic pressure.

g00687600

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.

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

Obey all local regulations for the disposal of liquids.

20 SEBU7858-03

Safety Section

Crushing Prevention and Cutting Prevention

Asbestos Information

g00702022

Illustration 21

Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar

recommends the use of only genuine Caterpillar

replacement parts. Use the following guidelines

when you handle any replacement parts that contain

asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be

generated when you handle components that contain

asbestos fibers. Inhaling this dust can be hazardous

to your health. The components that may contain

asbestos fibers are brake pads, brake bands, lining

material, clutch plates, and some gaskets. The

asbestos that is used in these components is usually

boundinaresinorsealedinsomeway.Normal

handling is not hazardous unless airborne dust that

contains asbestos is generated.

If dust that may contain asbestos is present, there

are several guidelines that should be followed:

•Never use compressed air for cleaning.

•Avoid brushing materials that contain asbestos.

•Avoid grinding materials that contain asbestos.

•Useawetmethodinordertocleanupasbestos

materials.

•A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be

used.

•Use exhaust ventilation on permanent machining

jobs.

•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 United States, use

Occupational Safety and Health Administration

(OSHA) requirements. These OSHA requirements

can be found in “29 CFR 1910.1001”.

•Obey environmental regulations for the disposal

of asbestos.

•Stay away from areas that might have asbestos

particles in the air.

Dispose of Waste Properly

g00706404

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.

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.

SEBU7858-03 21

Safety Section

Burn Prevention

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.

Keep objects away from moving fan blades. The fan

blade will throw objects or cut objects.

Do not use a kinked wire cable or a frayed wire cable.

Wear gloves when you handle wire cable.

When you strike a retainer pin with force, the retainer

pin can flyout. 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.

i03605020

Fire Prevention and Explosion

Prevention

SMCS Code: 7000

g00704000

Illustration 23

General

All fuels, most lubricants, and some coolant mixtures

are flammable.

To minimize the risk of fire or explosion, Caterpillar

recommends the following actions.

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 dealer for service.

Understand the use of the primary exit and alternative

exit on the machine. Refer to Operation and

Maintenance Manual, “Alternative Exit”.

Do not operate 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 flammable material such as leaves, twigs,

papers, trash, etc. These items may accumulate in

the engine compartment or around other hot areas

and hot parts on the machine.

Keep the access doors to major machine

compartments 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 shields 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. Exhaust shields must be installed correctly.

Do not weld or flame cut on tanks or lines that contain

flammable 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 flame cutting. Ensure that the components are

properly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallic

hoods or fenders may be flammable and/or explosive.

Repair such components in a well ventilated area

away from open flames or sparks. Use suitable

Personal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration.

Replace damaged lines and hoses. The lines and

the hoses should have adequate support and secure

clamps. Tighten all connections to the recommended

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

oily rags and flammable materials in protective

containers. Do not smoke in areas that are used for

storing flammable materials.

g00704059

Illustration 24

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.

Battery and Battery Cables

g00704135

Illustration 25

SEBU7858-03 23

Safety Section

Fire Prevention and Explosion Prevention

Caterpillar recommends the following in order to

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 dealer for service.

Follow safe procedures for engine starting with jump

start cables. Improper jumper cable connections can

cause an explosion that may result in injury. Refer to

Operation and Maintenance Manual, “Engine Starting

with Jump Start Cables” for specific instructions.

Do not charge a frozen battery. This may cause an

explosion.

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do

not smoke in battery charging areas.

Never check the battery charge by placing a metal

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. Replace these items if necessary. Look for

signs of the following, which can occur over time due

to use and environmental factors:

•Fraying

•Abrasion

•Cracking

•Discoloration

•Cuts on the insulation of the cable

•Fouling

•Corroded terminals, damaged terminals, and loose

terminals

Replace damaged battery cable(s) and replace

any related parts. Eliminate any fouling, which may

have caused insulation failure or related component

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

contact with a grounded surface. A battery cable

short produces heat from the battery current, which

may be a fire hazard.

An exposed wire on the ground cable between the

battery and the disconnect switch may cause the

disconnect switch to be bypassed if the exposed area

comes into contact with a grounded surface. This

may result in an unsafe condition for servicing the

machine. Repair components or replace components

before servicing the machine.

Fire on a machine can result in personal injury

or death. Exposed battery cables that come into

contact with a grounded connection can result in

fires. Replace cables and related parts that show

signs of wear or damage. Contact your Caterpillar

dealer.

Wiring

Check electrical wires daily. If any of the following

conditions exist, replace parts before you operate

the machine.

•Fraying

•Signs of abrasion or wear

•Cracking

•Discoloration

•Cuts on insulation

•Other damage

Make sure that all clamps, guards, clips, and straps

are reinstalled correctly. This will help to prevent

vibration, rubbing against other parts, and excessive

heat during machine operation.

Attachingelectricalwiringtohosesandtubesthat

contain flammable fluids or combustible fluids should

be avoided.

Consult your Caterpillar dealer for repair or for

replacement parts.

Keep wiring and electrical connections free of debris.

Lines, Tubes and Hoses

Donotbendhighpressurelines.Donotstrikehigh

pressure lines. Do not install any lines that are bent or

damaged. Use the appropriate backup wrenches in

order to tighten all connections to the recommended

torque.

24 SEBU7858-03

Safety Section

Fire Extinguisher Location

g00687600

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.

•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.

Ether

Ether (if equipped) is commonly used in cold weather

applications. Ether is flammable and poisonous.

Follow the correct cold engine starting procedures.

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 are replacing an ether cylinder or while you

are using an ether spray.

Do not store ether cylinders in living areas or in the

operator compartment of a machine. Do not store

ether cylinders in direct sunlight or in temperatures

above 49° C (120.2° F). Keep ether cylinders away

from open flames or sparks.

Dispose of used ether cylinders properly. Do not

puncture an ether cylinder. Keep ether cylinders

away from unauthorized personnel.

Fire Extinguisher

As an additional safety measure, keep a fire

extinguisher on the machine.

Be familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire

extinguisher regularly. Follow the recommendations

on the instruction plate.

Consider installation of an aftermarket Fire

Suppression System, if the application and working

conditions warrant the installation.

i02370502

Fire Extinguisher Location

SMCS Code: 7000

Makesurethatafire extinguisher is available. Be

familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire

extinguisher regularly. Obey the recommendations

on the instruction plate.

Thefire extinguisher may be mounted to the grab

handle that is located on the right platform near the

front of the engine hood. Do not block access to the

following items:

•handrails

•ladders

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

extinguisher. Also, do not drill holes in the ROPS in

order to mount the fire extinguisher on the ROPS.

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.

g00337832

Illustration 27

(A)Atleast15m(50ft)

(B) At least 500 m (1500 ft)

Do not approach a warm tire. Maintain a minimum

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.

If the tires were originally inflated with air, nitrogen

is still preferred for adjusting the pressure. Nitrogen

mixes properly with air.

Nitrogen inflated tires reduce the potential of

a tire explosion because nitrogen does not aid

combustion. Nitrogen helps to prevent oxidation of

the rubber, deterioration of rubber, and corrosion of

rim components.

To avoid overinflation, proper nitrogen inflation

equipment and training in the usage of the equipment

are necessary. A tire blowout or a rim failure can

result from improper equipment or from misused

equipment.

When you inflate a tire, stand behind the tread and

use a self-attaching chuck.

Servicing tires and rims can be dangerous. Only

trained personnel that use proper tools and proper

procedures should perform this maintenance. If

correct procedures are not used for servicing tires

and rims, the assemblies could burst with explosive

force. This explosive force can cause serious

personal injury or death. Carefully obey the specific

instructions from your tire dealer.

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:

•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

SMCS Code: 1000; 7000

Start the engine only from the operator's

compartment. Never short across the starter

terminals or across the batteries. Shorting could

bypass the engine neutral start system. Shorting

could also damage the electrical system.

26 SEBU7858-03

Safety Section

Engine Starting

g00927804

Illustration 28

Depress the machine horn (1) in order to make sure

that the machine horn works properly.

g01120628

Illustration 29

Typical example

Adjust the mirrors (2) on your machine for the best

operator vision. Adjust both the inside mirror and the

outside mirror before you operate the machine.

Inspect the condition of the seat belt and the condition

of mounting hardware. Replace any damaged parts

and any worn parts. Regardless of appearance,

replace the seat belt after three years of use. Do not

use a seat belt extension on a retractable seat belt.

Adjust the seat in order to achieve full pedal travel

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.

Make sure that all lights are working properly.

Before you start the engine or before you move the

machine, make sure that no one is on the machine,

underneath the machine, or around the machine.

Make sure that there are no personnel in the area.

i03565626

Engine Starting

SMCS Code: 1000; 7000

If a warning tag 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 engine exhaust contains products of

combustion which can be harmful to your health.

Always start the engine in a well ventilated area.

Always operate 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

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.

SEBU7858-03 27

Safety Section

Visibility Information

i03162317

Visibility Information

SMCS Code: 7000

Before you start the machine, perform a walk-around

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 hazards as hazards become visible around

the machine.

Your machine may be equipped with visual aids.

Some examples of visual aids are Closed Circuit

Television (CCTV) and mirrors. Before operating the

machine, ensure that the visual aids are in proper

working condition and that the visual aids are clean.

Adjust the visual aids using the procedures that are

located in this Operation and Maintenance Manual.

If equipped, the Work Area Vision System shall be

adjusted according to Operation and Maintenance

Manual, SEBU8157, “Work Area Vision System”.

It may not be possible to provide direct visibility on

large machines to all areas around the machine.

Appropriate job site organization is required in order

to minimize hazards that are caused by restricted

visibility. Job site organization is a collection of rules

and procedures that coordinates machines and

people that work together in the same area. Examples

of job site organization include the following:

•Safety instructions

•Controlled patterns of machine movement and

vehicle movement

•Workers that direct traffictomovewhenitissafe

•Restricted areas

•Operator training

•Warning symbols or warning signs on machines

or on vehicles

•A system of communication

•Communication between workers and operators

prior to approaching the machine

Modifications of the machine configuration by the

user that result in a restriction of visibility shall be

evaluated.

i03641204

Restricted Visibility

SMCS Code: 7000

Thesizeandth

econfiguration of this machine may

result in areas that can not be seen when the operator

is seated. Illustration 30 provides an approximate

visual indication of areas of significant restricted

visibility. Illustration 30 indicates restricted visibility

areas at ground level inside a radius of 12.00 m

(40 ft) from the operator on a machine without the

use of optional visual aids. This illustration does not

provide areas of restricted visibility for distances

outside a radius of 12.00 m (40 ft).

This machine may be equipped with optional visual

aids that may provide visibility to some of the

restricted visibility areas. Refer to this Operation and

Maintenance Manual, “Mirror” for more information on

additional visibility. If your machine is equipped with

cameras, refer to this Operation and Maintenance

Manual, “Camera” for more information on additional

visibility. For areas that are not covered by the

optional visual aids, the job site organization must

be utilized to minimize hazards of this restricted

visibility. For more information regarding job site

organization refer to Operation and Maintenance

Manual, “Visibility Information”.

g01635673

Illustration 30

Top view of the machine

28 SEBU7858-03

Safety Section

Operation

Note: The shaded areas indicate the approximate

location of areas with significant restricted visibility.

There is restricted visibility to the area directly be-

hind the machine. Failure to make sure the area is

clear could result in injury or death. Use a second

person on the ground to make sure that the area

is clear before you operate the machine in the RE-

VERSE position. Refer to the Operation and Main-

tenance Manual, “Operation Information” for more

information.

i03565616

Operation

SMCS Code: 7000

Machine Operating Temperature

Range

The standard machine configuration is intended

for use within an ambient temperature range

of −40 °C (−40 °F) to 50 °C (122 °F). Special

configurations for different ambient temperatures

may be available. Consult your Caterpillar dealer for

additional information on special configurations of

your machine.

MachineOperation

Only operate the machine while you are in a seat.

The seat belt must be fastened while you operate the

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

protective devices.

Before you move the machine, you must make sure

that no one will be endangered.

Do not allow riders on the machine unless the

machine has the following equipment:

•additional seat

•additional seat belt

•Rollover Protective Structure (ROPS)

Never use the work tool for a work platform.

Note any needed repairs during machine operation.

Report any needed repairs.

Do not operate the machine on ground conditions

that could result in the seat suspension travel stops

being contacted and do not operate the machine at

travel speeds that could result in the seat suspension

travel stops being contacted. Operating this machine

in very rough ground conditions or at travels speeds

not suitable for the ground conditions may result

in excessive seat vertical travel with impact of the

suspension against the travel stops, which may

cause injury. In order to minimize impact loading on

the operator, properly adjust the seat controls for the

operator weight and height. Refer to Operation and

Maintenance Manual, “Seat” for more information.

Carry attachments approximately 40 cm (15 inches)

above ground level. Do not go close to the edge of a

cliff, an excavation, or an overhang.

If the machine begins to sideslip downward on a

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 banks and on slopes. Also, the machine

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 slopes.

Maintain control of the machine. Do not overload the

machine beyond the machine capacity.

Never straddle a wire cable. Never allow other

personnel to straddle a wire cable.

Before you maneuver the machine, make sure

that no personnel are between the machine and

attachments.

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure

(ROPS) installed during machine operation.

i02624835

Engine Stopping

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.

SEBU7858-03 29

Safety Section

Parking

After the machine is parked and the parking brake

is engaged, allow the engine to run for two minutes

before shutdown. This allows hot areas of the engine

to cool gradually.

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.

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

SMCS Code: 7000

Machines that are operating safely in various

applications depend on these criteria: the machine

model, configuration, machine maintenance,

operating speed of the machine, conditions of the

terrain, fluid levels, and tire inflation pressures. The

most important criteria are the skill and judgment of

the operator.

Awelltrainedo

perator that follows the instructions

in the Operation and Maintenance Manual has

the greatest impact on stability. Operator training

provides a personwiththefollowingabilities:

observation of working and environmental conditions,

feel for the machine, identification of potential

hazards, and operating the machine safely by making

appropriate decisions.

When you work on side hills and when you work on

slopes, consider the following important points:

Speed of travel – At higher speeds, forces of inertia

tend to make the machine less stable.

Roughness of terrain or surface – The machine

maybelessstablewithuneventerrain.

Direction of travel – Avoid operating the machine

across the slope. When possible, operate the

machine up the slopes and operate the machine

down the slopes. Place the heaviest end of the

machine uphill when you are working on an incline.

Mounted equipment – Balance of the machine

may be impeded by the following components:

equipment that is mounted on the machine, machine

configuration, weights, and counterweights.

Nature of surface – Ground that has been newly

filled with earth may collapse from the weight of the

machine.

Surface material – Rocks and moisture of the

surface material may drastically affect the machine's

traction and machine's stability. Rocky surfaces may

promote side slipping of the machine.

Slippage due to excessive loads – This may cause

downhill tracks or downhill tires to dig into the ground,

which will increase the angle of the machine.

Widthoftracksortires –Narrower tracks or

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

also decrease the weight on the uphill tires. The

decreased weight will cause the machine to be less

stable.

Height of the working load of the machine –

When the working loads are in higher positions, the

stability of the machine is reduced.

Operated equipment – Be aware of performance

features of the equipment in operation and the effects

on machine stability.

30 SEBU7858-03

Safety Section

Equipment Lowering with Engine Stopped

Operating techniques – Keep all attachments or

pulled loads low to the ground for optimum stability.

Machine systems have limitations on slopes –

Slopes can affect the proper function and operation

of the various machine systems. These machine

systems are needed for machine control on slopes.

Note: Safe operation on steep slopes may require

special machine maintenance. Excellent skill of

the operator and proper equipment for specific

applications are also required. Consult the Operation

and Maintenance Manual sections for the proper fluid

level requirements and intended machine use.

i01329161

EquipmentLoweringwith

Engine Stopped

SMCS Code: 7000

Before lowering any equipment with the engine

stopped, clear the area around the equipment of

all personnel. The procedure to use will vary with

the type of equipment to be lowered. Keep in mind

most systemsuseahighpressurefluid or air to

raise or lower equipment. The procedure will cause

high pressure air, hydraulic, or some other media

to be released in order to lower the equipment.

Wear appropriate personal protective equipment and

follow the established procedure in the Operation

and Maintenance Manual, “Equipment Lowering with

Engine Stopped” in the Operation Section of the

manual.

i03596373

Sound Information and

Vibration Information

SMCS Code: 7000

S/N: DBD1-Up

Sound Level Information

The operator Equivalent Sound Pressure Level

(Leq) is 81 dB(A) when “ANSI/SAE J1166 OCT 98”

is used to measure the value for an enclosed cab.

This is a work cycle sound exposure level. The cab

was properly installed and maintained. The test was

conducted with the cab doors and the cab windows

closed.

Hearing protection may be needed when the

machine is operated with an open operator station for

extended periods or in a noisy environment. Hearing

protection may be needed when the machine is

operated with a cab that is not properly maintained or

when the doors and windows are open for extended

periods or in a noisy environment.

The average exterior sound pressure level is 86

dB(A) when the “SAE J88Feb06 - Constant Speed

Moving Test” procedure is used to measure the value

for the standard machine. The measurement was

conducted under the following conditions: distance of

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 procedures and the conditions that are specified

in “ISO 6393:2008”.

Sound Level Information for

Machines in European Union

Countries and in Countries that

Adopt the “European Union

Directives”

The static operator sound pressure level is 79 dB(A)

when “ISO 6394:2008” is used to measure the value

for an enclosed cab. The test was conducted with the

cab doors and the cab windows closed. The cab was

properly installed and maintained.

“The European Union Physical

Agents (Vibration) Directive

2002/44/EC”

Vibration Data for Wheel Scrapers

Information Concerning Hand/Arm Vibration

Level

When the machine is operated according to the

intended use, the hand/arm vibration of this machine

is below 2.5 meter per second squared.

Information Concerning Whole Body Vibration

Level

This section provides vibration data and a method for

estimating the vibration level for wheel scrapers.

Note: Vibration levels are influenced by many

different parameters. Many items are listed below.

•Operator training, behavior, mode, and stress

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 with the information in Table 1 in order

to calculate the daily vibration exposure. A simple

evaluation of the machine application can be used.

Estimate the vibration levels for the three vibration

directions. For typical operating conditions, use the

average vibration levels as the estimated level. With

an experienced operator and smooth terrain, subtract

the Scenario Factors from the average vibration level

in order to obtain the estimated vibration level. For

aggressive operations and severe terrain, add the

Scenario Factors to the average vibration level in

order to obtain the estimated vibration level.

Note: All vibration levels are in meter per second

squared.

Table 1

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

Vibration Levels Scenario Factors

Machine Family Machine Type Typical Operating

Activity X

axis

Y

axis

Z

axis

X

axis

Y

axis

Z

axis

Scraper Wheel Scraper 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.

32 SEBU7858-03

Safety Section

Sound Information and Vibration Information

c. Provide machines and schedule time in order

to maintain the conditions of the terrain.

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

maintained and adjusted.

a. Adjust the seat and suspension for the weight

and the size of the operator.

b. Inspect and maintain the seat suspension and

adjustment mechanisms.

5. Perform the following operations smoothly.

a. Steer

b. Brake

c. Accelerate.

d. Shift the gears.

6. Move the attachments smoothly.

7. Adjust themachinespeedandtherouteinorder

to minimize the vibration level.

a. Drive around obstacles and rough terrain.

b. Slow down when it is necessary to go over

rough terrain.

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

travel distance.

a. Use machines that are equipped with

suspension systems.

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 operator comfort may be caused by other risk

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.

d. Avoid jumping from the cab.

e. Minimize repeated handling of loads and lifting

of loads.

f. Minimize any shocks and impacts during sports

and leisure activities.

Sources

The vibration information and the calculation

procedure is based on “ISO/TR 25398 Mechanical

Vibration - Guideline for the assessment of exposure

to whole body vibration of ride on operated

earthmoving machines”. Harmonized data is

measured by international institutes, organizations

and manufacturers.

This literature provides information about assessing

the whole body vibration exposure of operators of

earthmoving equipment. The method is based on

measured vibration emission under real working

conditions for all machines.

You should check the original directive. This

document summarizes part of the content of the

applicable law. This document is not meant to

substitute the original sources. Other parts of these

documents are based on information from the United

Kingdom Health and Safety Executive.

Refer to Operation and Maintenance Manual,

SEBU8257, “The European Union Physical

Agents (Vibration) Directive 2002/44/EC” for more

information about vibration.

Consult your local Caterpillar dealer for more

information about machine features that minimize

vibration levels. Consult your local Caterpillar dealer

about safe machine operation.

Use the following web site in order to find your local

dealer:

Caterpillar, Inc.

www.cat.com

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 project into the operator space or into

the space for the companion seat (if equipped).

The addition of a radio, fire extinguisher, and other

equipment must be installed so that the defined

operator space and the space for the companion seat

(if equipped) is maintained. Any item that is brought

into the cab should not project into the defined

operator space or the space for the companion seat

(if equipped). A lunch box or other loose items must

be secured. Objects must not pose an impact hazard

in rough terrain or in the event of a rollover.

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 (FOPS) 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:

34 SEBU7858-03

Safety Section

Guards

•Demolition applications

•Rock quarries

•Forestry products

Additional guards may be required for specific

applications or work tools. The Operation and

Maintenance Manual for your machine or your

work tool will provide specific requirements for the

guards. Consult your Caterpillar dealer for additional

information.