SEBU7858-03 July 2009 Operation and Maintenance Manual 627G Wheel Tractor-Scraper DBD1-Up (Machine) DBZ1-Up (Scraper) SAFETY.CAT.
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.
6 Safety Section Safety Messages SEBU7858-03 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.
SEBU7858-03 Illustration 2 7 Safety Section Safety Messages g01953867
8 Safety Section Safety Messages Illustration 3 SEBU7858-03 g01954945
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 clearances suddenly and cause personal injury...
10 Safety Section Safety Messages SEBU7858-03 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, modification, alteration, or improper repair can impair this structure's protection capability thereby voiding this certification.
SEBU7858-03 11 Safety Section Safety Messages Seat Belt (6) This safety message is positioned on the right side of the ROPS. Improper Connections For Jump Start Cables (8) This safety message is positioned inside the battery compartment of the tractor. g01370908 g01370909 A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn.
12 Safety Section Safety Messages SEBU7858-03 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 pressure. Do not touch the hot surfaces. Refer to the Operation and Maintenance Manual for the procedure to follow when you check the radiator. Apron movement could cause serious injury or death.
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 The coolant is hot and the coolant is under pressure. Do not touch the hot surfaces. Refer to the Operation and Maintenance Manual for the procedure to follow when you check the radiator.
14 Safety Section Safety Messages SEBU7858-03 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 g01381177 This machine is equipped with a Caterpillar Product Link communication device. When electric/electronic detonators are used, this communication device should be deactivated within 12 m (40 ft) of a blast site, or within the distance mandated under applicable legal requirements.
SEBU7858-03 15 Safety Section Additional Messages i03200484 Additional Messages SMCS Code: 7000; 7405 Illustration 4 g01633794
16 Safety Section Additional Messages SEBU7858-03 Illustration 5 g01633796 Illustration 8 g01633801 Illustration 6 g01633797 Illustration 9 g01633802 Alternate Exit (1) This message is located on the ROPS support assembly behind the operator and to the right of the operator. Illustration 7 g01633799 Illustration 10 g00907967 If the primary exit is blocked, use the hammer to break the window. Exit the machine through the window.
SEBU7858-03 17 Safety Section Additional Messages This message is located on the discharge line of the air conditioner compressor. Illustration 11 g00924082 Air Tank (3) This message is located at the bottom of the left side access door on the tractor. This message is also located at the right rear of the scraper. Illustration 14 g01132926 Release the hood brace before attempting to lower the engine hood.
18 Safety Section General Hazard Information SEBU7858-03 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.
SEBU7858-03 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. 19 Safety Section General Hazard Information 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.
20 Safety Section Crushing Prevention and Cutting Prevention SEBU7858-03 Asbestos Information • 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.
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.
22 Safety Section Fire Prevention and Explosion Prevention SEBU7858-03 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.
SEBU7858-03 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.
24 Safety Section Fire Extinguisher Location SEBU7858-03 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. Illustration 26 g00687600 Check lines, tubes and hoses carefully.
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.
26 Safety Section Engine Starting SEBU7858-03 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. Illustration 28 g00927804 Depress the machine horn (1) in order to make sure that the machine horn works properly.
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 configuration 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.
28 Safety Section Operation SEBU7858-03 Note: The shaded areas indicate the approximate location of areas with significant restricted visibility. There is restricted visibility to the area directly behind the machine. Failure to make sure the area is clear could result in injury or death. Use a second person on the ground to make sure that the area is clear before you operate the machine in the REVERSE position. Refer to the Operation and Maintenance Manual, “Operation Information” for more information.
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 A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability.
30 Safety Section Equipment Lowering with Engine Stopped SEBU7858-03 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. Hearing protection may be needed when the machine is operated with an open operator station for extended periods or in a noisy environment.
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.
32 Safety Section Sound Information and Vibration Information SEBU7858-03 c. Provide machines and schedule time in order to maintain the conditions of the terrain. e. Minimize repeated handling of loads and lifting of loads. 4. Use a seat that meets “ISO 7096”. Keep the seat maintained and adjusted. f. Minimize any shocks and impacts during sports and leisure activities. a. Adjust the seat and suspension for the weight and the size of the operator. b.
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.
34 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.
