c ts 185 cat

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SAFETYOperation and Maintenance Manual Excerpt

SEBU8438-02August 2009

Operation andMaintenanceManualTS180, TS185, TS220 and TS225Towed ScrapersE1J1-Up (Scraper)E1K1-Up (Scraper)E1L1-Up (Scraper)E1N1-Up (Scraper)E1R1-Up (Scraper)E1S1-Up (Scraper)E1T1-Up (Scraper)E1W1-Up (Scraper)

SAFETY.CAT.COM

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labelson 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 mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe 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 thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications 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 ordeath.

6 SEBU8438-02Safety SectionSafety Messages

Safety Sectioni03410761

Safety MessagesSMCS Code: 7000; 7405

There are several specific safety messages on thismachine. The exact location of the safety messagesand the description of the safety messages arereviewed in this section. Please become familiarizedwith all safety messages.

Make sure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if you cannot read the words. Replace thesafety messages if the illustrations are not legible.When you clean the safety messages, use a cloth,water and soap. Do not use solvent, gasoline, orother harsh chemicals to clean the safety messages.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety message. Looseadhesive will allow the safety message to fall.

Replace any safety message that is damaged, ormissing. If a safety message is attached to a partthat is replaced, install a safety message on thereplacement part. Any Caterpillar dealer can providenew safety messages.

SEBU8438-02 7Safety Section

Safety Messages

g01767453Illustration 2


8 SEBU8438-02Safety SectionSafety Messages

Do Not Operate (1)This safety message is positioned on the left sideof the hitch.

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Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions or heedthe 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 located on the rear of thehitch on each side of the machine.

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Bowl or hitch movement can reduce clearancesin the rear hitch area and cause severe injury ordeath.

Keep hands away from this area when bowl orhitch movement is possible.

Crushing Hazard (3)This safety message is located on the left side of themachine near the apron lock.

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Apron movement can cause serious injury ordeath.

To prevent movement, block the apron when per-forming maintenance in the bowl area.


Additional Messages

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Additional MessagesSMCS Code: 7000; 7405


10 SEBU8438-02Safety SectionAdditional Messages


Capacity (1)This message is located on the left side of the bowl.


This message lists the rated payload mass for thetowed scraper.

Rotary Needle Valve (2)This message is located behind the hydraulicvalve bank. Refer to Operation and MaintenanceManual, “Attaching and Detaching Scraper” for moreinformation.


Transport Lock (3)This message is located near the rear axle on theleft side of the towed scraper and this message islocated near the rear axle on the right side of thetowed scraper.


This message indicates that the transport lockmust be removed before normal operation. Referto Operation and Maintenance Manual, “TransportLock” for more information.


General Hazard Information

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General Hazard InformationSMCS Code: 7000


Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment. These warning tags (SpecialInstruction, SEHS7332) are available from yourCaterpillar dealer.

Know the width of your equipment in order to maintainproper clearance when you operate the equipmentnear fences or near boundary obstacles.

Be aware of high voltage power lines and powercables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the equipment.

Make sure that all protective guards and all coversare secured in place on the equipment.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, 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 andthe personnel that are authorized to give the handsignals. 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 thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditionerrefrigerant through a lighted cigarette can causebodily harm or death.

Never put maintenance fluids into glass containers.Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and Maintenance Manualfor the procedure for placing the equipment in theservicing position.

When you perform maintenance above ground leveluse appropriate devices such as ladders or man liftmachines. If equipped, use the machine anchoragepoints and use approved fall arrest harnesses andlanyards.

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when thenozzle is deadheaded and the nozzle is used withan effective chip deflector and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

12 SEBU8438-02Safety SectionGeneral Hazard Information

Trapped PressurePressure can be trapped in a hydraulic system.Releasing trapped pressure can cause suddenmachine movement or attachment movement. Usecaution if you disconnect hydraulic lines or fittings.High pressure oil that is released can cause a hose towhip. High pressure oil that is released can cause oilto spray. Fluid penetration can cause serious injuryand possible death.

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theequipment. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for the following items:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.


Crushing Prevention and Cutting Prevention

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

• Stay away from areas that might have asbestosparticles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

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Crushing Prevention andCutting PreventionSMCS Code: 7000

Support the equipment properly before you performany work or maintenance beneath that equipment.Do not depend on the hydraulic cylinders to holdup the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or while theengine of the towing machine is running.

Whenever there are equipment control linkages theclearance in the linkage area will change with themovement of the equipment or the machine. Stayclear of areas that may have a sudden change inclearance with machine movement or equipmentmovement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to performmaintenance, always install the guards after themaintenance is performed.

When you strike a retainer pin with force, the retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes, wear protective glasses when you strikea retainer pin.

Chips or other debris can fly off an object when youstrike the object. Make sure that no one can beinjured by flying debris before striking any object.

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Burn PreventionSMCS Code: 7000

Allow the machine to cool before any maintenance isperformed. Relieve all pressure in the oil system andrelieve all pressure in the lubrication system beforeany lines, fittings or related items are disconnected.

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Fire Prevention and ExplosionPreventionSMCS Code: 7000


All fuels, most lubricants, and some coolant mixturesare flammable.

14 SEBU8438-02Safety SectionTire Information

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

Remove all flammable materials such as fuel, oil, anddebris from the machine. Do not allow any flammablematerials to accumulate on the machine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not operate the machine near any flame.

Do not weld on lines or on tanks that containflammable fluids. Do not flame cut lines or tanksthat contain flammable fluid. Clean any such lines ortanks thoroughly with a nonflammable solvent priorto welding or flame cutting.

Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate themachine. Clean all electrical connections and tightenall electrical connections.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and the hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.


Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During machine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

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Tire InformationSMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.

A tire explosion is much more violent than ablowout. The explosion can propel the tire, the rimcomponents, and the axle components as far as500 m (1500 ft) or more from the machine. Both theforce of the explosion and the flying debris can causeproperty damage, personal injury, or death.


Electrical Storm Injury Prevention

g00337832Illustration 16(A) At least 15 m (50 ft)(B) At least 500 m (1500 ft)

Do not approach a warm tire. Maintain a minimumdistance, as shown. Stay outside the shaded area inIllustration 16.

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, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

Nitrogen inflated tires reduce the potential ofa tire explosion because nitrogen does not aidcombustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration of rubber, and corrosion ofrim components.

To avoid overinflation, proper nitrogen inflationequipment and training in the usage of the equipmentare necessary. A tire blowout or a rim failure canresult from improper equipment or from misusedequipment.

When you inflate a tire, stand behind the tread anduse a self-attaching chuck.

Servicing tires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tiresand rims, the assemblies could burst with explosiveforce. This explosive force can cause seriouspersonal injury or death. Carefully obey the specificinstructions from your tire dealer.

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Electrical Storm InjuryPreventionSMCS Code: 7000

When lightning is striking in the vicinity of themachine, the operator should never attempt thefollowing procedures:

• Mount the machine.

• Dismount the machine.

If you are in the operator's station during an electricalstorm, stay in the operator's station. If you are on theground during an electrical storm, stay away fromthe vicinity of the machine.

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Before OperationSMCS Code: 7000

Clear all personnel from the machine and from thearea.

Clear all obstacles from the path of the machine.Beware of hazards such as wires, ditches, etc.

Refer to the “Operation and Maintenance Manual” ofthe towing machine for further information.

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Visibility InformationSMCS Code: 7000

Your machine may be equipped with visual aids.Some examples of visual aids are Closed CircuitTelevision (CCTV) and mirrors. Before operating themachine, ensure that the visual aids are in properworking condition and that the visual aids are clean.Adjust the visual aids to minimize blind spots aroundthe towing machine and the towed scraper.

Before you start the towing machine, perform awalk-around inspection in order to ensure that thereare no hazards around the towing machine or thetowed scraper. If there is a blind spot between thetowed scrapers, a person should be used to directmachine movement when the towing machine isbeing reversed.

16 SEBU8438-02Safety SectionOperation

While the towing machine is in operation, constantlysurvey the area around the towing machine in orderto identify potential hazards as hazards becomevisible around the towing machine and the towedscraper.

It may not be possible to provide direct visibility onlarge machines to all areas around the machine.Appropriate job site organization is required in orderto minimize hazards that are caused by restrictedvisibility. Job site organization is a collection of rulesand procedures that coordinates machines andpeople that work together in the same area. Examplesof job site organization include the following:

• Safety instructions

• Controlled patterns of machine movement andvehicle movement

• Workers that direct traffic to move when it is safe

• Restricted areas

• Operator training

• Warning symbols or warning signs on machinesor on vehicles

• A system of communication

• Communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration by theuser that result in a restriction of visibility shall beevaluated.

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OperationSMCS Code: 7000

Machine Operating TemperatureRangeThe standard machine configuration is intendedfor use within an ambient temperature rangeof −40 °C (−40 °F) to 50 °C (122 °F). Specialconfigurations for different ambient temperaturesmay be available. Consult your Caterpillar dealer foradditional information on special configurations ofyour machine.

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ParkingSMCS Code: 7000

Park the towing machine and the towed scraper ona level surface. If you must park on a grade, chockthe wheels with suitable chocks. Take into accountthe following:

Apply the service brake in order to stop the towingmachine. Refer to the “Operation and MaintenanceManual” of the towing machine for proper parkingprocedures.

Engage the parking brake of the towing machine.

Lower all equipment to the ground.

Stop the engine of the towing machine.

Turn the engine start switch to the OFF position andremove the engine start switch key.

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Slope OperationSMCS Code: 7000

Machines that are operating safely in variousapplications depend on these criteria: the machinemodel, configuration, machine maintenance,operating speed of the machine, conditions of theterrain, fluid levels, and tire inflation pressures. Themost important criteria are the skill and judgment ofthe operator.

A well trained operator that follows the instructionsin the Operation and Maintenance Manual hasthe greatest impact on stability. Operator trainingprovides a person with the following abilities:observation of working and environmental conditions,feel for the machine, identification of potentialhazards, and operating the machine safely by makingappropriate decisions.

When you work on side hills and when you work onslopes, consider the following important points:

Speed of travel – At higher speeds, forces of inertiatend to make the machine less stable.

Roughness of terrain or surface – The machinemay be less stable with uneven terrain.


Equipment Lowering with Engine Stopped

Direction of travel – Avoid operating the machineacross the slope. When possible, operate themachine up the slopes and operate the machinedown the slopes. Place the heaviest end of themachine uphill when you are working on an incline.

Mounted equipment – Balance of the machinemay be impeded by the following components:equipment that is mounted on the machine, machineconfiguration, weights, and counterweights.

Nature of surface – Ground that has been newlyfilled with earth may collapse from the weight of themachine.

Surface material – Rocks and moisture of thesurface material may drastically affect the machine'straction and machine's stability. Rocky surfaces maypromote side slipping of the machine.

Slippage due to excessive loads – This may causedownhill tracks or downhill tires to dig into the ground,which will increase the angle of the machine.

Width of tracks or tires – Narrower tracks ornarrower tires further increase the digging into theground which causes the machine to be less stable.

Implements attached to the drawbar – This maydecrease the weight on the uphill tracks. This mayalso decrease the weight on the uphill tires. Thedecreased weight will cause the machine to be lessstable.

Height of the working load of the machine –When the working loads are in higher positions, thestability of the machine is reduced.

Operated equipment – Be aware of performancefeatures of the equipment in operation and the effectson machine stability.

Operating techniques – Keep all attachments orpulled loads low to the ground for optimum stability.

Machine systems have limitations on slopes –Slopes can affect the proper function and operationof the various machine systems. These machinesystems are needed for machine control on slopes.

Note: Safe operation on steep slopes may requirespecial machine maintenance. Excellent skill ofthe operator and proper equipment for specificapplications are also required. Consult the Operationand Maintenance Manual sections for the proper fluidlevel requirements and intended machine use.

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Equipment Lowering withEngine StoppedSMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipmentof all personnel. The system uses high pressurefluid to raise the equipment and the system useshigh pressure fluid to lower the equipment. Followthe established procedure in the Operation andMaintenance Manual, “Equipment Lowering withEngine Stopped” in the Operation Section of themanual.

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c ts 185 cat