CAT Lawn Mower 627G User Manual

SEBU7858-03  
July 2009  
Operation and  
Maintenance  
Manual  
627G Wheel Tractor-Scraper  
DBD1-Up (Machine)  
DBZ1-Up (Scraper)  
SAFETY.CAT.COM  
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6
SEBU7858-03  
Safety Section  
Safety Messages  
Safety Section  
i03640971  
Safety Messages  
SMCS Code: 7000; 7405  
There are several specic 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.  
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SEBU7858-03  
7
Safety Section  
Safety Messages  
g01953867  
Illustration 2  
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8
SEBU7858-03  
Safety Section  
Safety Messages  
g01954945  
Illustration 3  
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SEBU7858-03  
9
Safety Section  
Safety Messages  
Do Not Operate (1)  
Crushing Hazard (2)  
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.  
This safety message is positioned on each side of  
the hitch link.  
g01379133  
g01370904  
Hitch and steering movement can reduce clear-  
ances suddenly and cause personal injury...  
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.  
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.  
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10  
SEBU7858-03  
Safety Section  
Safety Messages  
Do Not Weld On The ROPS/FOPS  
Structure (4)  
Do Not Weld On The ROPS/FOPS  
Structure (5)  
This safety message is positioned outside of the cab  
to the left of the rear window.  
This safety message is positioned on the right side of  
the ROPS.  
g01118646  
g01132602  
Structural damage, an overturn, modication, al-  
teration, or improper repair can impair this struc-  
ture's protection capability thereby voiding this  
certication. Do not weld on or drill holes in the  
structure. Consult a Caterpillar dealer to deter-  
mine this structure's limitations without voiding  
its certication.  
Structural damage, an overturn, modication, al-  
teration, or improper repair can impair this struc-  
ture's protection capability thereby voiding this  
certication. Do not weld on or drill holes in the  
structure. Consult a Caterpillar dealer to deter-  
mine this structure's limitations without voiding  
its certication.  
This machine has been certied to the standards  
that are listed on the certication lm. The maximum  
mass of the machine, which includes the operator  
and the attachments without a payload, should not  
exceed the mass on the certication lm.  
Refer to Operation and Maintenance Manual,  
“Guards (Operator Protection)” for more information.  
Refer to Operation and Maintenance Manual,  
“Guards (Operator Protection)” for more information.  
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SEBU7858-03  
11  
Safety Section  
Safety Messages  
Seat Belt (6)  
Improper Connections For Jump  
Start Cables (8)  
This safety message is positioned on the right side of  
the ROPS.  
This safety message is positioned inside the battery  
compartment of the tractor.  
g01370908  
g01370909  
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.  
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.  
High Compressed Spring (7)  
This safety message is positioned on each brake  
actuator.  
Refer to Operation and Maintenance Manual, “Engine  
Starting with Jump Start Cables” for more information.  
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.  
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12  
SEBU7858-03  
Safety Section  
Safety Messages  
Engine Coolant (9)  
Engage The Apron Locking Pin (10)  
This safety message is positioned on the top of the  
radiator tank.  
This safety message is positioned on the right side  
of the bowl.  
g01371640  
g01132609  
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.  
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,  
“Cooling System Coolant Level - Check” for more  
information.  
Refer to Operation and Maintenance Manual,  
“Blocking the Bowl and Apron” for more information.  
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SEBU7858-03  
13  
Safety Section  
Safety Messages  
Engine Coolant (11)  
Engage The Apron Locking Pin (12)  
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.  
This safety message is positioned on the left side  
of the bowl.  
g01633733  
g01371640  
Apron movement could cause serious injury or  
death. Read the Operation and Maintenance Man-  
ual for the proper procedure to engage the apron  
pin.  
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,  
“Blocking the Bowl and Apron” for more information.  
Refer to Operation and Maintenance Manual,  
“Cooling System Coolant Level - Check” for more  
information.  
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14  
SEBU7858-03  
Safety Section  
Safety Messages  
Product Link (13) (If Equipped)  
Crushing Hazard (14)  
This safety message is positioned in the cab.  
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.  
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,  
“Restricted Visibility” for more information.  
Refer to Operation and Maintenance Manual,  
“Product Link” for more information.  
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SEBU7858-03  
15  
Safety Section  
Additional Messages  
i03200484  
Additional Messages  
SMCS Code: 7000; 7405  
g01633794  
Illustration 4  
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16  
SEBU7858-03  
Safety Section  
Additional Messages  
g01633796  
g01633797  
g01633799  
g01633801  
Illustration 5  
Illustration 6  
Illustration 7  
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)  
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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)  
g01132926  
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  
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.  
g01119007  
Illustration 12  
Data Privacy (4)  
This message is located in the cab.  
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.  
g01418953  
Illustration 13  
Hood Brace (5)  
This message is located on the right side of the  
engine hood.  
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18  
SEBU7858-03  
Safety Section  
General Hazard Information  
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.  
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.  
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.  
g01132923  
Illustration 17  
Keep the equipment free from foreign material.  
Remove debris, oil, tools, and other items from the  
deck, from walkways, and from steps.  
i03559343  
General Hazard Information  
Secure all loose items such as lunch boxes, tools,  
and other items that are not a part of the equipment.  
SMCS Code: 7000  
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 ame 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 uids into glass containers.  
Drain all liquids into a suitable container.  
g00104545  
Illustration 18  
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SEBU7858-03  
19  
Safety Section  
General Hazard Information  
Obey all local regulations for the disposal of liquids.  
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.  
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  
g00687600  
Illustration 20  
Pressurized air and/or water can cause debris  
and/or hot water to be blown out. This could result in  
personal injury.  
Always use a board or cardboard when you check  
for a leak. Leaking uid 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 uid is injected into your skin,  
you must get treatment immediately. Seek treatment  
from a doctor that is familiar with this type of 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 deector and personal protective  
equipment. The maximum water pressure for  
cleaning purposes must be below 275 kPa (40 psi).  
Containing Fluid Spillage  
Care must be taken in order to ensure that uids  
are contained during performance of inspection,  
maintenance, testing, adjusting and repair of the  
equipment. Prepare to collect the uid with suitable  
containers before opening any compartment or  
disassembling any component that contains uids.  
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 ttings.  
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.  
Refer to Special Publication, NENG2500, “Caterpillar  
Dealer Service Tool Catalog” for the following items:  
Tools that are suitable for collecting uids and  
equipment that is suitable for collecting uids  
Tools that are suitable for containing uids and  
equipment that is suitable for containing uids  
Fluid Penetration  
Obey all local regulations for the disposal of liquids.  
Pressure can be trapped in the hydraulic circuit long  
after the engine has been stopped. The pressure can  
cause hydraulic uid or items such as pipe plugs to  
escape rapidly if the pressure is not relieved correctly.  
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20  
SEBU7858-03  
Safety Section  
Crushing Prevention and Cutting Prevention  
Asbestos Information  
Comply with app  
licable 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  
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 bers. Inhaling this dust can be hazardous  
to your health. The components that may contain  
asbestos bers are brake pads, brake bands, lining  
material, clutch plates, and some gaskets. The  
asbestos that is used in these components is usually  
bound in a resin or sealed in some way. Normal  
handling is not hazardous unless airborne dust that  
contains asbestos is generated.  
g00706404  
Illustration 22  
Improperly disposing of waste can threaten the  
environment. Potentially harmful uids should be  
disposed of according to local regulations.  
Always use leakproof containers when you drain  
uids. Do not pour waste onto the ground, down a  
drain, or into any source of water.  
If dust that may contain asbestos is present, there  
are several guidelines that should be followed:  
Never use compressed air for cleaning.  
i01359664  
Avoid brushing materials that contain asbestos.  
Crushing Prevention and  
Cutting Prevention  
Avoid grinding materials that contain asbestos.  
SMCS Code: 7000  
Use a wet method in order to clean up asbestos  
materials.  
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.  
A vacuum cleaner that is equipped with a high  
efciency particulate air lter (HEPA) can also be  
used.  
Use exhaust ventilation on permanent machining  
jobs.  
Do not work beneath the cab of the machine unless  
the cab is properly supported.  
Wear an approved respirator if there is no other  
way to control the dust.  
Unless you are instructed otherwise, never attempt  
adjustments while the machine is moving or while  
the engine is running.  
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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.  
Ensure that the ller cap is cool before removing the  
ller cap. The ller cap must be cool enough to touch  
with a bare hand. Remove the ller cap slowly in  
order to relieve pressure.  
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.  
Cooling system conditioner contains alkali. Alkali can  
cause personal injury. Do not allow alkali to contact  
the skin, the eyes, or the mouth.  
Oils  
Stay clear of all rotating and moving parts.  
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.  
If it is necessary to remove guards in order to perform  
maintenance, always install the guards after the  
maintenance is performed.  
Remove the hydraulic tank ller cap only after the  
engine has been stopped. The ller 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 ller cap.  
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.  
Batteries  
When you strike a retainer pin with force, the retainer  
pin can y out. The loose retainer pin can injure  
personnel. Make sure that the area is clear of people  
when you strike a retainer pin. To avoid injury to  
your eyes, wear protective glasses when you strike  
a retainer pin.  
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.  
Chips or other debris can y off an object when you  
strike the object. Make sure that no one can be  
injured by ying debris before striking any object.  
i03605020  
Fire Prevention and Explosion  
Prevention  
i01329099  
SMCS Code: 7000  
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, ttings 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.  
g00704000  
Illustration 23  
General  
Any contact with hot coolant or with steam can cause  
severe burns. Allow cooling system components to  
cool before the cooling system is drained.  
All fuels, most lubricants, and some coolant mixtures  
are ammable.  
Check the coolant level only after the engine has  
been stopped.  
To minimize the risk of re or explosion, Caterpillar  
recommends the following actions.  
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22  
SEBU7858-03  
Safety Section  
Fire Prevention and Explosion Prevention  
Always perform a Walk-Around Inspection, which  
may help you identify a re hazard. Do not operate  
a machine when a re 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 uid leak. Repair  
leaks and clean up uids before resuming machine  
operation. Fluids that are leaking or spilled onto hot  
surfaces or onto electrical components can cause a  
re. A re may cause personal injury or death.  
Remove ammable 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  
condition in order to permit the use of re suppression  
equipment, in case a re should occur.  
g00704059  
Illustration 24  
Use caution when you are fueling a machine. Do not  
smoke while you are fueling a machine. Do not fuel  
a machine near open ames or sparks. Always stop  
the engine before fueling. Fill the fuel tank outdoors.  
Properly clean areas of spillage.  
Clean all accumulations of ammable materials such  
as fuel, oil and debris from the machine.  
Do not operate the machine near any ame.  
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 ammable uids in the  
operator compartment of the machine.  
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 ame cut on tanks or lines that contain  
ammable uids or ammable material. Empty and  
purge the lines and tanks. Then clean the lines and  
tanks with a nonammable solvent prior to welding  
or ame cutting. Ensure that the components are  
properly grounded in order to avoid unwanted arcs.  
Battery and Battery Cables  
Dust that is generated from repairing nonmetallic  
hoods or fenders may be ammable and/or explosive.  
Repair such components in a well ventilated area  
away from open ames 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 res.  
Store fuels and lubricants in properly marked  
containers away from unauthorized personnel. Store  
oily rags and ammable materials in protective  
containers. Do not smoke in areas that are used for  
storing ammable materials.  
g00704135  
Illustration 25  
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SEBU7858-03  
23  
Safety Section  
Fire Prevention and Explosion Prevention  
Caterpillar recommends the following in order to  
minimize the risk of re or an explosion related to  
the battery.  
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.  
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 specic instructions.  
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  
res. Replace cables and related parts that show  
signs of wear or damage. Contact your Caterpillar  
dealer.  
Do not charge a frozen battery. This may cause an  
explosion.  
Gases from a battery can explode. Keep any open  
ames or sparks away from the top of a battery. Do  
not smoke in battery charging areas.  
Wiring  
Check electrical wires daily. If any of the following  
conditions exist, replace parts before you operate  
the machine.  
Never check the battery charge by placing a metal  
object across the terminal posts. Use a voltmeter or  
a hydrometer.  
Fraying  
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:  
Signs of abrasion or wear  
Cracking  
Discoloration  
Fraying  
Cuts on insulation  
Other damage  
Abrasion  
Cracking  
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.  
Discoloration  
Cuts on the insulation of the cable  
Fouling  
Attaching electrical wiring to hoses and tubes that  
contain ammable uids or combustible uids should  
be avoided.  
Corroded terminals, damaged terminals, and loose  
terminals  
Consult your Caterpillar dealer for repair or for  
replacement parts.  
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.  
Keep wiring and electrical connections free of debris.  
Lines, Tubes and Hoses  
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 re hazard.  
Do not bend high pressure lines. Do not strike high  
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.  
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24  
SEBU7858-03  
Safety Section  
Fire Extinguisher Location  
Ether  
Ether (if equipped) is commonly used in cold weather  
applications. Ether is ammable 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.  
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 uid 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 uid is injected  
into your skin, you must get treatment immediately.  
Seek treatment from a doctor that is familiar with this  
type of injury.  
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 ames or sparks.  
Dispose of used ether cylinders properly. Do not  
puncture an ether cylinder. Keep ether cylinders  
away from unauthorized personnel.  
Fire Extinguisher  
Replace the affected parts if any of the following  
conditions are present:  
As an additional safety measure, keep a re  
extinguisher on the machine.  
End ttings are damaged or leaking.  
Be familiar with the operation of the re extinguisher.  
Inspect the re extinguisher and service the re  
extinguisher regularly. Follow the recommendations  
on the instruction plate.  
Outer coverings are chafed or cut.  
Wires are exposed.  
Outer coverings are swelling or ballooning.  
Consider installation of an aftermarket Fire  
Suppression System, if the application and working  
conditions warrant the installation.  
Flexible parts of the hoses are kinked.  
Outer covers have exposed embedded armoring.  
i02370502  
End ttings are displaced.  
Fire Extinguisher Location  
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.  
SMCS Code: 7000  
Make sure that a re extinguisher is available. Be  
familiar with the operation of the re extinguisher.  
Inspect the re extinguisher and service the re  
extinguisher regularly. Obey the recommendations  
on the instruction plate.  
Do not operate a machine when a re hazard  
exists. Repair any lines that are corroded, loose  
or damaged. Leaks may provide fuel for res.  
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.  
The re 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  
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SEBU7858-03  
25  
Safety Section  
Tire Information  
walkways  
To avoid overination, proper nitrogen ination  
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.  
front side door of engine hood  
Do not weld a bracket on the Rollover Protective  
Structure (ROPS) in order to install the re  
extinguisher. Also, do not drill holes in the ROPS in  
order to mount the re extinguisher on the ROPS.  
When you inate 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 specic  
instructions from your tire dealer.  
i01557411  
Tire Information  
SMCS Code: 7000  
Explosions of air inated 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  
re, or by excessive use of brakes.  
i01122596  
Electrical Storm Injury  
Prevention  
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 ying debris can cause  
property damage, personal injury, or death.  
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  
g00337832  
Illustration 27  
SMCS Code: 1000; 7000  
(A) At least 15 m (50 ft)  
(B) At least 500 m (1500 ft)  
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.  
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 ination of tires.  
If the tires were originally inated with air, nitrogen  
is still preferred for adjusting the pressure. Nitrogen  
mixes properly with air.  
Nitrogen inated 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.  
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26  
SEBU7858-03  
Safety Section  
Engine Starting  
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.  
g00927804  
Illustration 28  
Engage the parking brake control.  
Depress the machine horn (1) in order to make sure  
that the machine horn works properly.  
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.  
Briey sound the horn before you start the engine.  
i01349075  
Before Operation  
SMCS Code: 7000  
Clear all personnel from the machine and from the  
area.  
g01120628  
Illustration 29  
Typical example  
Clear all obstacles from the path of the machine.  
Beware of hazards such as wires, ditches, etc.  
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.  
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.  
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.  
For the best vision of the area that is close to the  
machine, adjust the rear view mirrors (if equipped).  
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 horn, the backup alarm  
(if equipped) and all other warning devices are  
working properly.  
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.  
Fasten the seat belt securely.  
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.  
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SEBU7858-03  
27  
Safety Section  
Visibility Information  
i03162317  
i03641204  
Visibility Information  
Restricted Visibility  
SMCS Code: 7000  
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.  
The size and the conguration 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 signicant 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).  
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”.  
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”.  
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 trafc to move when it is safe  
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  
Modications of the machine conguration by the  
user that result in a restriction of visibility shall be  
evaluated.  
g01635673  
Illustration 30  
Top view of the machine  
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28  
SEBU7858-03  
Safety Section  
Operation  
Note: The shaded areas indicate the approximate  
location of areas with signicant restricted visibility.  
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.  
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.  
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.  
i03565616  
Operation  
If the machine begins to sideslip downward on a  
grade, immediately remove the load and turn the  
machine downhill.  
SMCS Code: 7000  
Machine Operating Temperature  
Range  
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.  
The standard machine conguration is intended  
for use within an ambient temperature range  
of 40 °C (40 °F) to 50 °C (122 °F). Special  
congurations for different ambient temperatures  
may be available. Consult your Caterpillar dealer for  
additional information on special congurations of  
your machine.  
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.  
Machine Operation  
Never straddle a wire cable. Never allow other  
personnel to straddle a wire cable.  
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.  
Before you maneuver the machine, make sure  
that no personnel are between the machine and  
attachments.  
While you operate the machine slowly in an open  
area, check for proper operation of all controls and all  
protective devices.  
Know the maximum dimensions of your machine.  
Always keep the Rollover Protective Structure  
(ROPS) installed during machine operation.  
Before you move the machine, you must make sure  
that no one will be endangered.  
i02624835  
Do not allow riders on the machine unless the  
machine has the following equipment:  
Engine Stopping  
additional seat  
SMCS Code: 1000; 7000  
additional seat belt  
Do not stop the engine immediately after the  
machine has been operated under load. This can  
cause overheating and accelerated wear of engine  
components.  
Rollover Protective Structure (ROPS)  
Never use the work tool for a work platform.  
Note any needed repairs during machine operation.  
Report any needed repairs.  
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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.  
A well trained operator that follows the instructions  
in the Operation and Maintenance Manual has  
the greatest impact on stability. Operator training  
provides a person with the following abilities:  
observation of working and environmental conditions,  
feel for the machine, identication of potential  
hazards, and operating the machine safely by making  
appropriate decisions.  
i03370980  
Parking  
When you work on side hills and when you work on  
slopes, consider the following important points:  
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:  
Speed of travel At higher speeds, forces of inertia  
tend to make the machine less stable.  
Roughness of terrain or surface The machine  
may be less stable with uneven terrain.  
tire size  
machine weight  
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.  
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.  
Mounted equipment Balance of the machine  
may be impeded by the following components:  
equipment that is mounted on the machine, machine  
conguration, weights, and counterweights.  
Engage the parking brake.  
Lower all equipment to the ground. Activate any  
control locks.  
Nature of surface Ground that has been newly  
lled with earth may collapse from the weight of the  
machine.  
Stop the engine.  
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.  
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.  
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.  
Width of tracks or tires Narrower tracks or  
narrower tires further increase the digging into the  
ground which causes the machine to be less stable.  
i02780235  
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.  
Slope Operation  
SMCS Code: 7000  
Machines that are operating safely in various  
applications depend on these criteria: the machine  
model, conguration, machine maintenance,  
operating speed of the machine, conditions of the  
terrain, uid levels, and tire ination pressures. The  
most important criteria are the skill and judgment of  
the operator.  
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.  
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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.  
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.  
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 specic  
applications are also required. Consult the Operation  
and Maintenance Manual sections for the proper uid  
level requirements and intended machine use.  
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”.  
i01329161  
Equipment Lowering with  
Engine Stopped  
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 specied  
in “ISO 6393:2008”.  
SMCS Code: 7000  
Sound Level Information for  
Machines in European Union  
Countries and in Countries that  
Adopt the “European Union  
Directives”  
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 systems use a high pressure uid 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.  
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”  
i03596373  
Sound Information and  
Vibration Information  
Vibration Data for Wheel Scrapers  
SMCS Code: 7000  
Information Concerning Hand/Arm Vibration  
Level  
S/N: DBD1-Up  
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.  
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.  
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 inuenced by many  
different parameters. Many items are listed below.  
Operator training, behavior, mode, and stress  
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SEBU7858-03  
31  
Safety Section  
Sound Information and Vibration Information  
Job site organization, preparation, environment,  
weather, and material  
Machine type, quality of the seat, quality of the  
suspension system, attachments, and condition of  
the equipment  
It is not possible to get precise vibration levels for  
this machine. The expected vibration levels can be  
estimated with the information in Table 1 in order  
to calculate the daily vibration exposure. A simple  
evaluation of the machine application can be used.  
Estimate the vibration levels for the three vibration  
directions. For typical operating conditions, use the  
average vibration levels as the estimated level. With  
an experienced operator and smooth terrain, subtract  
the Scenario Factors from the average vibration level  
in order to obtain the estimated vibration level. For  
aggressive operations and severe terrain, add the  
Scenario Factors to the average vibration level in  
order to obtain the estimated vibration level.  
Note: All vibration levels are in meter per second  
squared.  
Table 1  
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”  
Vibration Levels  
Scenario Factors  
Typical Operating  
Activity  
Machine Family  
Machine Type  
X
Y
Z
X
Y
Z
axis  
axis  
axis  
axis  
axis  
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.  
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.  
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”.  
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.  
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.  
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32  
SEBU7858-03  
Safety Section  
Sound Information and Vibration Information  
c. Provide machines and schedule time in order  
e. Minimize repeated handling of loads and lifting  
to maintain the conditions of the terrain.  
of loads.  
4. Use a seat that meets “ISO 7096”. Keep the seat  
f. Minimize any shocks and impacts during sports  
maintained and adjusted.  
and leisure activities.  
a. Adjust the seat and suspension for the weight  
Sources  
and the size of the operator.  
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.  
b. Inspect and maintain the seat suspension and  
adjustment mechanisms.  
5. Perform the following operations smoothly.  
a. Steer  
b. Brake  
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.  
c. Accelerate.  
d. Shift the gears.  
6. Move the attachments smoothly.  
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.  
7. Adjust the machine speed and the route in order  
to minimize the vibration level.  
a. Drive around obstacles and rough terrain.  
b. Slow down when it is necessary to go over  
Refer to Operation and Maintenance Manual,  
SEBU8257, “The European Union Physical  
Agents (Vibration) Directive 2002/44/EC” for more  
information about vibration.  
rough terrain.  
8. Minimize vibrations for a long work cycle or a long  
travel distance.  
Consult your local Caterpillar dealer for more  
information about machine features that minimize  
vibration levels. Consult your local Caterpillar dealer  
about safe machine operation.  
a. Use machines that are equipped with  
suspension systems.  
b. Use the ride control system on wheel scrapers.  
Use the following web site in order to nd your local  
dealer:  
c. If no ride control system is available, reduce  
speed in order to prevent bounce.  
Caterpillar, Inc.  
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.  
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SEBU7858-03  
33  
Safety Section  
Operator Station  
i03634321  
Rollover Protective Structure  
(ROPS), Falling Object Protective  
Structure (FOPS) or Tip Over  
Protection Structure (TOPS)  
Operator Station  
SMCS Code: 7000  
S/N: DBD1-Up  
The ROPS/FOPS Structure (if equipped) on your  
machine is specically designed, tested and certied  
for that machine. Excavators are not equipped  
with ROPS structures. Any alteration or any  
modication to the ROPS/FOPS Structure could  
weaken the structure. This places the operator  
into an unprotected environment. Modications or  
attachments that cause the machine to exceed the  
weight that is stamped on the certication 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.  
Any modications 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, re extinguisher, and other  
equipment must be installed so that the dened  
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 dened  
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)  
Do not mount items (re extinguishers, rst 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.  
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.  
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 modication of  
the ROPS/FOPS Structure are required for the Tip  
Over Protection Structure.  
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.  
Other Guards (If Equipped)  
Protection from ying 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 ying 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 ying 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:  
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34  
SEBU7858-03  
Safety Section  
Guards  
Demolition applications  
Rock quarries  
Forestry products  
Additional guards may be required for specic  
applications or work tools. The Operation and  
Maintenance Manual for your machine or your  
work tool will provide specic requirements for the  
guards. Consult your Caterpillar dealer for additional  
information.  
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