SAFETY.CAT.

COM

D9R TRACK-TYPE TRACTORS

Machine Safety

Excerpted from Operation & Maintenance Manual (SEBU7924-02-01)

2007 Caterpillar All Rights Reserved

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Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identied by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identied by NOTICE labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

6 Safety Section Safety Messages

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Safety Section
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Safety Messages
SMCS Code: 7000; 7405

Illustration 2

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7 Safety Section Safety Messages

Do Not Operate (1)

This safety message is located on the LH vertical wall next to the transmission control.

Illustration 3

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There are several specic safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Any Caterpillar dealer can provide new safety signs.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

8 Safety Section Safety Messages

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ROPS/FOPS STRUCTURE (2)

This safety message is on the front RH corner of the ROPS assembly.

Shock Hazard (4)

This safety message is located on the fuse cover behind the LH vertical plate in the cab.

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Structural damage, an overturn, modication, alteration, or improper repair can impair this structures protection capability thereby voiding this certication. Do not weld on or drill holes in the structure. This will void the certication. Consult a Caterpillar dealer to determine this structures limitations without voiding its certication.

WARNING! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death.

Pressurized System (5)

This safety message is located by the ller cap for the radiator.

Seat Belt (3)

This safety message is located on the LH vertical wall next to the transmission control.

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A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.

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9 Safety Section Safety Messages

Improper Connections for Jump Start Cables (6)

This safety message is located on the bottom side of the battery compartment cover.

Compressed Recoil Spring (8)

This safety message is located inside both track roller frames.

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Explosion Hazard! Improper jumper cable connections can cause an explosion resulting in serious injury or death. Batteries may be located in separate compartments. Refer to the Operation and Maintenance Manual for the correct jump starting procedure.

Personal injury or death can result from a compressed recoil spring being released suddenly using incorrect disassembly procedures. A recoil spring that is still held in compression can result in the recoil spring being released unexpectedly with extreme force which could cause serious injury or death. Make sure that the correct disassembly procedure is used, if a front track roller frame that has a crack in the parent metal or weld connection (or a tubular section that has separated from the front of the frame assembly) when the recoil spring is still held in compression. Refer to Special Instruction, SMHS8273 which contains the disassembly procedure that must be used to decrease the possibility of injury while performing service on the track roller frame.

High Pressure Cylinder (7)

This safety message is on the dipstick that is attached to the cover for each recoil spring compartment.

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High Pressure Cylinder. Do not remove any parts until all pressure has been relieved to avoid possible personal injury. Relieve pressure by opening relief valve one turn maximum. See the Operation and Maintenance Manual for correct procedure.

10 Safety Section Additional Messages

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Compressed Recoil Spring (9)

This safety message is located inside both track roller frames.

Do Not Operate (10) (Winch)

This safety message is located on the RH vertical wall of the winch frame.

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Personal injury or death can result from a compressed recoil spring being released suddenly using incorrect disassembly procedures. A recoil spring that is still held in compression can result in the recoil spring being released unexpectedly with extreme force which could cause serious injury or death. Make sure that the correct disassembly procedure is used, if a front track roller frame that has a crack in the parent metal or weld connection (or a tubular section that has separated from the front of the frame assembly) when the recoil spring is still held in compression. Refer to Special Instruction, SMHS8273 which contains the disassembly procedure that must be used to decrease the possibility of injury while performing service on the track roller frame.

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Additional Messages
SMCS Code: 7000; 7405 There are several specic warning signs on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Any Caterpillar dealer can provide new safety signs.

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11 Safety Section Additional Messages

Illustration 4

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ESPAR Heating System (1) (If Equipped)

Illustration 6 Illustration 5
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During periods of low idle or low load operation in below freezing temperatures, turn on the jacket water heater that is red by diesel fuel. This will maintain the engine coolant temperature at approximately 70 C (160 F). Air Conditioning System (2) (If Equipped) This message is located on the lower left side of the dash panel.

This message for the air conditioner has the appropriate information for the following services: the air conditioner lubricant, the refrigerant charge, and the refrigerant capacity. Also, this safety message instructs the usage of the proper safety information. Follow instruction in order to avoid engine damage. Reference: See Operation and Maintenance Manual, Maintenance Interval Schedule for all maintenance recommendations.

12 Safety Section Crushing Prevention and Cutting Prevention

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Crushing Prevention and Cutting Prevention

SMCS Code: 7000 Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks. Do not work beneath the cab of the machine unless the cab is properly supported. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running. Never jump across the starter solenoid terminals in order to start the engine. Unexpected machine movement could result. Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine. Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement. Stay clear of all rotating and moving parts. If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is performed. Keep objects away from moving fan blades. The fan blade will throw objects or cut objects. Do not use a kinked wire cable or a frayed wire cable. Wear gloves when you handle wire cable. When you strike a retainer pin with force, the retainer pin can 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. 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.

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. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level only after the engine has been stopped. Ensure that the 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. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils
Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin. Remove the hydraulic tank 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.

Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

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13 Safety Section Fire Prevention and Explosion Prevention

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Fire Prevention and Explosion Prevention

SMCS Code: 7000

Dust that is generated from repairing nonmetallic hoods or nonmetallic fenders can be ammable and/or explosive. Repair such components in a well ventilated area away from open ames or sparks. Inspect all lines and hoses for wear or for deterioration. The hoses must be properly routed. The lines and the hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause res.

Illustration 7

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All fuels, most lubricants, and some coolant mixtures are ammable. Flammable uids that are leaking or spilled onto hot surfaces or onto electrical components can cause a re. Fire may cause personal injury and property damage. Remove all ammable materials such as fuel, oil, and debris from the machine. Do not allow any ammable materials to accumulate on the machine. Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily rags and any ammable materials in protective containers. Do not smoke in areas that are used for storing ammable materials. Do not operate the machine near any ame. 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 on lines or on tanks that contain ammable uids. Do not ame cut lines or tanks that contain ammable uid. Clean any such lines or tanks thoroughly with a nonammable solvent prior to welding or ame cutting. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the machine. Clean all electrical connections and tighten all electrical connections.
Illustration 9
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Illustration 8

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Use caution when you are refueling a machine. Do not smoke while you are refueling a machine. Do not refuel a machine near open ames or sparks. Always stop the engine before refueling. Fill the fuel tank outdoors.

14 Safety Section Fire Extinguisher Location

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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. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer. Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specic instructions. Do not charge a frozen battery. This may cause an explosion.

Replace the parts if any of the following conditions are present:

End ttings 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 ttings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat.
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Fire Extinguisher
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.

Ether
Ether is ammable and poisonous. Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray. Do not store ether cylinders in living areas or in the operator compartment of a machine. Do not store ether cylinders in direct sunlight or in temperatures above 49 C (120 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. Do not spray ether into an engine if the machine is equipped with a thermal starting aid for cold weather starting.

Fire Extinguisher Location

SMCS Code: 7419 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. Obey the recommendations on the instruction plate. Mount the re extinguisher in the accepted location per local regulations. Do not weld the ROPS structure in order to install the re extinguisher. Also, do not drill holes in the ROPS structure in order to mount the re extinguisher on the ROPS. Strap the mounting plate to a leg of the ROPS in order to mount the re extinguisher, as needed. If the weight of the re extinguisher exceeds 4.5 kg (10 lb), mount the re extinguisher near the bottom of the ROPS. Do not mount the re extinguisher at the upper one-third area of the ROPS. Consult your Caterpillar dealer for the proper procedure for mounting the re extinguisher.
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Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Repair any lines that are loose or damaged. Leaks can cause res. Consult your Caterpillar dealer for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.

Track Information
SMCS Code: 4170; 7000 Track adjusting systems use either grease or oil under high pressure to keep the track under tension.

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15 Safety Section Electrical Storm Injury Prevention

Grease or oil under high pressure coming out of the relief valve can penetrate the body causing injury or death. Do not watch the relief valve to see if grease or oil is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. The pins and bushings in a dry track pin joint can become very hot. It is possible to burn the ngers if there is more than brief contact with these components.
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Make sure that the machine is equipped with a lighting system that is adequate for the job conditions. Make sure that all lights are working properly. Before you start the engine or before you move the machine, make sure that no one is working on the machine, working underneath the machine or working close to the machine. Make sure that the area is free of personnel.
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Engine Starting
SMCS Code: 1000; 7000

Electrical Storm Injury Prevention

SMCS Code: 7000 When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:

Diesel engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside. Note: If a warning tag is attached to the engine start switch or to the controls, do not start the engine and do not move any controls. 1. Move all hydraulic controls to the HOLD position before you start the engine. 2. Move the transmission control to the NEUTRAL position. 3. Engage the parking brake. NOTICE Do not crank the engine for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking again. Turbocharger (if equipped) damage can result, if the engine rpm is not kept low until the engine oil light/ gauge veries the oil pressure is sufcient. 4. Turn the engine start switch in order to start the engine. Release the engine start switch when the engine starts.
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Mount the machine. Dismount the machine.

If you are in the operators station during an electrical storm, stay in the operators station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.
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Before Starting Engine

SMCS Code: 1000; 7000 Start the engine only from the operators compartment. Do not short across the battery terminals and do not short across the batteries. Bypassing the engine neutral start system can damage the electrical system. Inspect the condition of the seat belt and mounting hardware. Replace any damaged parts or worn parts. Regardless of appearance, replace the seat belt after three years of use. Do not use an extension for a seat belt on a retractable seat belt. Adjust the seat so that full pedal travel can be achieved. Make sure that the operators back is against the back of the seat.

Before Operation
SMCS Code: 7000 Make sure that there are no personnel on the machine or in the area around the machine.

16 Safety Section Visibility Information

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Clear all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc. Make sure that all windows are clean. Secure the doors and the windows in the open position or in the shut position. Adjust the rear view mirrors (if equipped) for the best vision of the area near the machine. Ensure that the horn, the backup alarm (if equipped), and all other warning devices are working properly. Fasten the seat belt securely.
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Communication between workers and operators

prior to approaching the machine Modications of the machine conguration that result in a restriction of visibility shall be veried according to ISO 5006.
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Operation
SMCS Code: 7000 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. On machines that are disabled, the controls may be used when the engine is not running. Check for proper operation of all controls and protective devices while you operate the machine slowly in an open area. Before moving the machine, the operator must ensure that no one will be endangered. Do not allow riders on the machine unless the machine has the following equipment:

Visibility Information
SMCS Code: 7000 Before you start the machine, the operator shall perform a walk-around inspection in order to ensure that there are no hazards around the machine. While the machine is in operation, the operator should constantly survey the area around the machine. The operator needs to identify potential hazards as a hazard becomes visible around the machine. Your machine may be equipped with mirrors or other visual aids. An example of a visual aid is Closed Circuit Television (CCTV). The operator should ensure that the visual aids are in proper working condition and that the visual aids are clean. Adjust the visual aids for the best visibility of all areas around the machine. 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:

additional seat additional seat belt Rollover Protective Structure (ROPS)

Report any repairs that are needed and noted during operation. Carry attachments close to the ground, approximately 40 cm (15 inches) above ground level. Do not go close to the edge of a cliff, an excavation, or an overhang. If the machine begins to sideslip, perform the following procedure:

Safety instructions Controlled patterns of machine movement Controlled patterns of vehicle movement Restricted areas Operator training Warning symbols or warning signs on machines
or on vehicles

Discard the load. Turn the machine downhill.

Be careful to avoid any condition which could lead to tipping. Tipping can occur when you work on hills, banks and slopes. Also, tipping can occur when you cross ditches, ridges or other unexpected obstructions. Whenever it is possible, operate the machine up the slopes and down the slopes. Avoid operating the machine across the slope, when possible.

A system of communication

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17 Safety Section Engine Stopping

Keep the machine under control. Do not overload the machine beyond capacity. Towing devices and eyes that are not part of machine must be adequate. Connect trailing equipment to a drawbar or to a hitch only. Never straddle a wire cable or allow other personnel to straddle a wire cable. When you maneuver to connect the equipment, make sure that no personnel are between the machine and trailing equipment. Block the hitch of the trailing equipment in order to align the equipment with the drawbar. Know the maximum dimensions of your machine. Always keep the Rollover Protective Structure (ROPS) installed during machine operation.
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Turn the key for the battery disconnect switch to the OFF position. Remove the key when you exit the machine for an extended period of time. Turning the battery disconnect switch to the OFF position will provide the following benets:

Prevent battery discharge that is caused by a

battery short circuit.

Prevent battery discharge that is caused by some

of the electrical components. vandalism.

Prevent battery discharge that is caused by

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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. 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. When you work on side hills and when you work on slopes, consider the following important points: Speed of travel At higher speeds, forces of inertia tend to make the machine less stable. Roughness of terrain or surface The machine may be less stable with uneven terrain. Direction of travel Avoid operating the machine across the slope. When possible, operate the machine up the slopes and operate the machine down the slopes. Place the heaviest end of the machine uphill when you are working on an incline. Mounted equipment Balance of the machine may be impeded by the following components: equipment that is mounted on the machine, machine conguration, weights, and counterweights.

Engine Stopping
SMCS Code: 1000; 7000 Do not stop the engine immediately after the machine has been operated under load. This can cause overheating and accelerated wear of engine components. 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.
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Parking
SMCS Code: 7000 Park on a level surface. If you must park on a grade, use blocks to prevent the machine from rolling. Apply the service brake in order to stop the machine. Move the transmission control lever to NEUTRAL position and move the speed control to LOW IDLE position. Engage the parking brake. Lower all attachments to the ground. Stop the engine. Turn the engine start switch key to OFF position and remove the key.

18 Safety Section Equipment Lowering with Engine Stopped

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Nature of surface Ground that has been newly lled with earth may collapse from the weight of the machine. Surface material Rocks and moisture of the surface material may drastically affect the machines traction and machines stability. Rocky surfaces may promote side slipping of the machine. Slippage due to excessive loads This may cause downhill tracks or downhill tires to dig into the ground, which will increase the angle of the machine. 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. Implements attached to the drawbar This may decrease the weight on the uphill tracks. This may also decrease the weight on the uphill tires. The decreased weight will cause the machine to be less stable. Height of the working load of the machine When the working loads are in higher positions, the stability of the machine is reduced. Operated equipment Be aware of performance features of the equipment in operation and the effects on machine stability. Operating techniques Keep all attachments or pulled loads low to the ground for optimum stability. Machine systems have limitations on slopes Slopes can affect the proper function and operation of the various machine systems. These machine systems are needed for machine control on slopes. Note: Safe operation on steep slopes may require special machine maintenance. Excellent skill of the operator and proper equipment for specic applications are also required. Consult the Operation and Maintenance Manual sections for the proper uid level requirements and intended machine use.

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Equipment Lowering with Engine Stopped

SMCS Code: 7000 Before lowering any equipment with the engine stopped, clear the area around the equipment of all personnel. The procedure to use will vary with the type of equipment to be lowered. Keep in mind most 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.
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Sound Information and Vibration Information

SMCS Code: 7000

Sound Level Information

The operator Equivalent Sound Pressure Level (Leq) is 84 dB(A) when ANSI/SAE J1166 MAY 90 is used to measure the value for an enclosed cab. This is a work cycle sound exposure level. The cab was properly installed and maintained. The test was conducted with the cab doors and the cab windows closed. Hearing protection may be needed when the machine is operated with an open operator station for extended periods or in a noisy environment. Hearing protection may be needed when the machine is operated with a cab that is not properly maintained or when the doors and windows are open for extended periods or in a noisy environment. The average exterior sound pressure level is 85 dB(A) when the SAE J88Jun86 - 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.

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19 Safety Section Sound Information and Vibration Information

Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives
The dynamic operator sound pressure level is 85 dB(A) when SAE J919Jun 86 is used to measure the value for an enclosed cab. The cab was properly installed and maintained. The test was conducted with the cab doors and the cab windows closed.

Note: All vibration levels are in meter per second squared.

The European Union Physical Agents (Vibration) Directive 2002/44/EC

Vibration Data for Track-Type Tractors
Information Concerning Hand/Arm Vibration Level When the machine is operated according to the intended use, the hand/arm vibration of this machine is below 2.5 meter per second squared. Information Concerning Whole Body Vibration Level This section provides vibration data and a method for estimating the vibration level for track-type tractors. Note: Vibration levels are inuenced by many different parameters. Many items are listed below.

Operator training, behavior, mode, and stress 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.

20 Safety Section Sound Information and Vibration Information

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Table 1

ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment. Machine Type Track-Type Tractors Typical Operating Activity dozing ripping transfer Vibration Levels X axis 0,74 1,25 0,87 Y axis 0,58 1,19 0,80 Z axis 0,70 1,02 0,97 X axis 0,31 0,40 0,43 Scenario Factors Y axis 0,25 0,41 0,40 Z axis 0,31 0,28 0,34

Note: Refer to ISO/TR 25398 Mechanical Vibration Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines for more information about vibration. This publication uses data that is measured by international institutes, organizations and manufacturers. This document provides information about the whole body exposure of operators of earthmoving equipment. Refer to Operation and Maintenance Manual, SEBU8257, The European Union Physical Agents (Vibration) Directive 2002/44/EC for more information about machine vibration levels. The Caterpillar suspension seat meets the criteria of ISO 7096. This represents vertical vibration level under severe operating conditions. This seat is tested with the input spectral class EM6. The seat has a transmissibility factor of SEAT<0.7. 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 1.61 meter per second squared for this machine. Guidelines for Reducing Vibration Levels on Earthmoving Equipment Properly adjust machines. Properly maintain machines. Operate machines smoothly. Maintain the conditions of the terrain. The following guidelines can help reduce the whole body vibration level: 1. Use the right type and size of machine, equipment, and attachments. 2. Maintain machines according to the manufacturers recommendations. a. Tire pressures b. Brake and steering systems c. Controls, hydraulic system and linkages 3. Keep the terrain in good condition. a. Remove any large rocks or obstacles.

b. Fill any ditches and holes. c. Provide machines and schedule time in order to maintain the conditions of the terrain. 4. Use a seat that meets ISO 7096. Keep the seat maintained and adjusted. a. Adjust the seat and suspension for the weight and the size of the operator. b. Inspect and maintain the seat suspension and adjustment mechanisms. 5. Perform the following operations smoothly. a. Steer b. Brake c. Accelerate. d. Shift the gears. 6. Move the attachments smoothly. 7. Adjust 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 rough terrain. 8. Minimize vibrations for a long work cycle or a long travel distance. a. Use machines that are equipped with suspension systems. b. Use the ride control system on Track-Type Tractors. c. If no ride control system is available, reduce speed in order to prevent bounce. d. Haul the machines between workplaces.

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21 Safety Section Operator Station

9. Less operator comfort may be caused by other risk factors. The following guidelines can be effective in order to provide better operator comfort: a. Adjust the seat and adjust the controls in order to achieve good posture. b. Adjust the mirrors in order to minimize twisted posture. c. Provide breaks in order to reduce long periods of sitting. d. Avoid jumping from the cab. e. Minimize repeated handling of loads and lifting of loads. f. Minimize any shocks and impacts during sports and leisure activities.

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Operator Station
SMCS Code: 7000; 7301 Any modications to the inside of the operator station should not project into the operator space. The addition of a radio, re extinguisher, and other equipment must be installed so that the dened operator space is maintained. Any item that is brought into the cab should not project into the dened operator space. 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.
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Guards (Operator Protection)

SMCS Code: 7000; 7150; 7325 There are different types of guards that are used to protect the operator. The machine and the machine application determines the type of guard that should be used. A daily inspection of the guards is required in order to check for structures that are bent, cracked or loose. Never operate a machine with a damaged structure. The operator becomes exposed to a hazardous situation if the machine is used improperly or if poor operating techniques are used. This situation can occur even though a machine is equipped with an appropriate protective guard. Follow the established operating procedures that are recommended for your machine.

Sources
The vibration information and calculation procedure is based on ISO/TR 25398 Mechanical Vibration - Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines. Harmonized data is measured by international institutes, organizations and manufacturers. This literature provides information about assessing the whole body vibration exposure of operators of earthmoving equipment. The method is based on measured vibration emission under real working conditions for all machines. You should check the original directive. This document summarizes part of the content of the applicable law. This document is not meant to substitute the original sources. Other parts of these documents are based on information from the United Kingdom Health and Safety Executive. Refer to Operation and Maintenance Manual, SEBU8257, The European Union Physical Agents (Vibration) Directive 2002/44/EC for more information about vibration. Consult your local Caterpillar dealer for more information about machine features that minimize vibration levels. Consult your local Caterpillar dealer about safe machine operation. Use the following web site in order to nd your local dealer: Caterpillar, Inc. www.cat.com

22 Safety Section Guards

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Rollover Protective Structure (ROPS), Falling Object Protective Structure (FOPS) or Tip Over Protection Structure (TOPS)
The ROPS/FOPS Structure (if equipped) on your machine is 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. 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. 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.

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.

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: