SAFETY

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7185-12
February 2012

Operation and
Maintenance
Manual
D11R Track-Type Tractor
AAF1-Up (Carrydozer)
7PZ1-Up (Standard)

SAFETY.CAT.COM
6 SEBU7185-12
Safety Section
Safety Messages

Safety Section
i02427650

Safety Messages
SMCS Code: 7000; 7405

g01213283
Illustration 2

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.
SEBU7185-12 7
Safety Section
Safety Messages

Make sure that all of the safety messages are legible. Do Not Weld or Drill the ROPS (2)
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the This message is located on the ROPS.
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.

Do Not Operate (1) g01213285

This message is located on the left side of the cab.

Structural damage, an overturn, modification, al-

teration, or improper repair, can impair this struc-
ture's protective capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.

Do Not Weld or Drill the FOPS (3)

This message is located on the outside of the right
side of the cab.
g01213284

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.

g01213286

Structural damage, an overturn, modification, al-

teration, or improper repair, can impair this struc-
ture's protective capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.
8 SEBU7185-12
Safety Section
Safety Messages

Hot Coolant Under Pressure (4) Improper Connections for Jump

This message is located on the underside of the
Start Cables (6)
access cover for the radiator cap.
This message is located on the underside of each
battery compartment cover.

g00782457

g01213289

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
Improper jumper cable connections can cause ex-
stop the engine and wait until the cooling system
plosion resulting in personal injury.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
If equipped, use the auxiliary starting receptacle to
sure.
insure proper cable connection. Follow procedure
in the Operation and Maintenance Manual.
Unit Injectors (5) Batteries may be located in separate compart-
ments. When using jumper cables, always con-
This message is located on the engine.
nect positive (+) cable to positive (+) terminal of
battery connected to starter solenoid, then, neg-
ative (-) terminal (if machine not equipped with
starter negative terminal, connect to engine block
or a designated ground stud). Follow procedure
in the Operation and Maintenance Manual.

g01213287

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.
SEBU7185-12 9
Safety Section
Safety Messages

Compressed Recoil Spring (7) High Pressure Cylinder (8)

This message is located on the end of the tube of the This message is located on the track roller frame.
front track roller frames.

g01213292
g00934226

Personal injury or death can result from grease

Recoil spring force, if not relieved, can result in under pressure.
personal injury or death. Relieve spring force be-
fore removing the threaded retainer, performing Grease coming out of the relief valve under pres-
repairs on the recoil spring housing, or removing sure can penetrate the body causing injury or
the recoil spring. Consult a Caterpillar dealer for death.
disassembly instructions.
Do not watch the relief valve to see if grease is es-
caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened.

Loosen the relief valve one turn only.

If track does not loosen, close the relief valve and

contact your Caterpillar dealer.
10 SEBU7185-12
Safety Section
Additional Messages

Compressed Recoil Spring (9)

This message is located on the underside of the
cover for the guides on the track roller frames.

g01213293

Stop disassembly if evidence of a crack exists in

the tube or slot beneath this guide. A cracked tube
can break suddenly expelling pieces with great
force that could result in serious injury or death.
Contact a Caterpillar dealer for special disassem-
bly instructions.

i04004234

Additional Messages
SMCS Code: 7000; 7405

There are several specific messages on this

machine. The exact location of the messages and
the description of the information are reviewed in this
section. Please become familiar with all messages.

Make sure that all of the messages are legible.

Clean the messages or replace the messages if you
cannot read the words. Replace the illustrations if
the illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.
SEBU7185-12 11
Safety Section
Additional Messages

g02178881
Illustration 3
Machine with access ladder (if equipped)

Replace any message that is damaged, or missing. The film (1) for the access ladder is located next to
If a message is attached to a part that is replaced, the switch on the ladder control box.
install a message on the replacement part. Any
Caterpillar dealer can provide new messages.
Battery Disconnect Switch (2)
Access Ladder (1) (If Equipped)

g02181295
Illustration 5
Location of battery disconnect switch
g01181995
Illustration 4
12 SEBU7185-12
Safety Section
General Hazard Information

i01175219

General Hazard Information

SMCS Code: 7000

g02180395
Illustration 6
Film for battery disconnect switch

This film (2) is located on the battery disconnect

switch inside the small compartment on the left side g00037887
Illustration 8
of the machine.

This switch controls the machine electrical system. Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before servicing or before repairing the machine.
Air Conditioner (3) These warning tags are Special Instruction,
SEHS7332. These warning tags are available from
your Caterpillar dealer.

Know the width of your equipment in order to maintain

proper clearance near fences, boundary obstacles,
etc.

Wear a hard hat, protective glasses and other

protective equipment in order to accommodate job
conditions.

Do not wear loose clothing or jewelry that can catch

on controls or on other parts of the machine.

Ensure that all protective guards and all covers are

g01118600
Illustration 7 secured in place on the machine.

This film (3) is located on the left side of the dash Keep the machine free from foreign material. Remove
panel near the bottom of the dash. debris, oil, tools and other items from the deck, from
walkways and from steps.

Secure all loose items that are not a part of the

machine. Secure lunch boxes, tools and other items.

Know the appropriate work site hand signals. Also,

know the personnel that are authorized to give the
hand signals. Accept 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 emitted from a flame that
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause
bodily harm or death.
SEBU7185-12 13
Safety Section
General Hazard Information

Never put maintenance fluids into glass containers. Refer to Special Publication, NENG2500, “Tools and
Drain all liquids into a suitable container. Shop Products Guide” for the following items:

When you discard a liquid, abide by local regulations. • Tools that are suitable for collecting fluids and for
containing fluids
Use all cleaning solutions with care. Report all
necessary repairs. • Equipment that is suitable for collecting fluids and
for containing fluids
Do not allow unauthorized personnel on the machine.
Obey all local regulations for the disposal of liquids.
Unless you are instructed otherwise, perform the
maintenance with the following conditions:
Asbestos Information
• The machine is parked on level ground. Caterpillar equipment and replacement parts that
are shipped from Caterpillar are asbestos free.
• The attachments are lowered to the ground. Caterpillar recommends the use of only genuine
Caterpillar replacement parts. If any replacement
• The attachment controls are in the HOLD position. parts that contain asbestos are used, the following
guidelines should be used in handling these parts
• The transmission control is in the NEUTRAL and asbestos debris.
position.
Use caution. Avoid inhaling dust that might be
• The parking brake switch is engaged. generated when you handle components that contain
asbestos fibers. If this dust is inhaled, it can be
• The engine is stopped. hazardous to your health. The components that may
contain asbestos fibers are brake pads, brake bands,
• The engine start switch key is turned off and the lining material, clutch plates, and some gaskets. The
key is removed. asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
• The disconnect switch is in the OFF position and handling is not hazardous, unless airborne dust that
the key is removed. contains asbestos is generated.

Pressure Air If dust which can contain asbestos is present, there

are several guidelines that should be followed.
Pressure air can cause personal injury. When
pressure air is used for cleaning, wear a protective Never use compressed air for cleaning. Avoid
face shield, protective clothing and protective shoes. brushing of materials or grinding of materials that
contain asbestos. Use a wet method in order to clean
The maximum air pressure must be below 205 kPa up asbestos materials. A vacuum that is equipped
(30 psi) for cleaning purposes. with a high efficiency particulate air filter (HEPA) can
also be used.
Fluid Penetration Use exhaust ventilation on permanent machining
jobs.
Always use a board or cardboard when you check for
a leak. Leaking fluid under pressure can penetrate
Wear an approved respirator if there is no other way
body tissue. Fluid penetration can cause serious
to control the dust.
injury and possible death. A pin hole leak can cause
severe injury. If fluid is injected into your skin, you
Comply with applicable rules and regulations for the
must obtain treatment immediately. Seek treatment
work place. In the USA, use Occupational Safety and
from a doctor that is familiar with this type of injury.
Health Administration requirements. These OSHA
requirements can be found in “29 CFR 1910.1001”.
Containing Fluid Spillage
Obey environmental rules and environmental
Care must be taken in order to ensure that fluids regulations for disposal of asbestos.
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the Stay away from areas that might have asbestos
machine. Be prepared to collect the fluid with suitable particles in the air.
containers before opening any compartment or
disassembling any component containing fluids.
14 SEBU7185-12
Safety Section
Crushing Prevention and Cutting Prevention

i01359664 i00998454

Crushing Prevention and Burn Prevention

Cutting Prevention SMCS Code: 7000
SMCS Code: 7000
Coolant
Support the equipment properly before you perform
any work or maintenance beneath that equipment. At operating temperature, the engine coolant is
Do not depend on the hydraulic cylinders to hold hot and the engine coolant is under pressure. The
up the equipment. Equipment can fall if a control is radiator and all lines to heaters or to the engine
moved, or if a hydraulic line breaks. contain hot coolant or steam. Any contact can cause
severe burns.
Do not work beneath the cab of the machine unless
the cab is properly supported. Steam can cause personal injury.

Unless you are instructed otherwise, never attempt Only check the coolant level after the engine has
adjustments while the machine is moving or while been stopped. Make sure that the radiator filler cap
the engine is running. is cool. In order to remove the radiator cap with the
bare hand, the radiator cap must be cool. In order to
Never jump across the starter solenoid terminals relieve pressure, remove the radiator filler cap slowly.
in order to start the engine. Unexpected machine
movement could result. Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
Whenever there are equipment control linkages the the skin, the eyes and the mouth.
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay Allow cooling system components to cool before
clear of areas that may have a sudden change in draining.
clearance with machine movement or equipment
movement. Oils
Stay clear of all rotating and moving parts. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
If it is necessary to remove guards in order to perform contact the skin.
maintenance, always install the guards after the
maintenance is performed. At operating temperature, the hydraulic tank is hot
and the hydraulic tank can be under pressure.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects. Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be cool
Do not use a kinked wire cable or a frayed wire cable. enough to touch.
Wear gloves when you handle wire cable.
Remove the hydraulic tank filler cap slowly in order
When you strike a retainer pin with force, the retainer to relieve pressure.
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people Relieve all the pressure in any system (air systems,
when you strike a retainer pin. To avoid injury to oil systems, fuel systems, or cooling systems) before
your eyes, wear protective glasses when you strike any system components are disconnected.
a retainer pin.

Chips or other debris can fly off an object when you Batteries
strike the object. Make sure that no one can be
injured by flying debris before striking any object. Batteries give off flammable fumes which can
explode.

Do not smoke when observing the battery electrolyte

levels.

Electrolyte is an acid. Electrolyte can cause personal

injury. Do not allow electrolyte to contact the skin or
the eyes.
SEBU7185-12 15
Safety Section
Fire Prevention and Explosion Prevention

Always wear protective glasses when you work with Do not expose the machine to flames, burning brush,
batteries. etc.

Shields, which protect hot exhaust components from

i01105712
oil or from fuel spray in the event of a line failure, tube
Fire Prevention and Explosion or seal failure, must be installed correctly.

Prevention Fire Extinguisher

SMCS Code: 7000
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
All fuels, most lubricants and some coolant mixtures
are flammable. If fuel leaks onto hot surfaces or onto Inspect the fire extinguisher and service the fire
extinguisher. Obey the recommendations on the
electrical components, fire can result. If fuel spills
instruction plate.
onto hot surfaces or onto electrical components, fire
can result. Do not smoke while you refuel. Do not
Mount the fire extinguisher in one of the following
smoke when you are in a refueling area.
locations:
Do not smoke in battery charging areas. Also, do not
smoke in areas that store material that is flammable. • Right, outside leg of the ROPS

Batteries can be installed in separate compartments. • Left, outside leg of the ROPS
When you use jump start cables, always connect
Do not weld the ROPS structure in order to install the
the positive (+) jump start cable to the positive (+)
terminal of the battery that is connected to the starter fire extinguisher. Also, do not drill holes in the ROPS
structure in order to mount the fire extinguisher on
solenoid. Connect the negative (−) jump start cable
the ROPS.
from the external source to the negative (−) terminal
of the starter.
Strap the mounting plate to a leg of the ROPS in
order to mount the fire extinguisher. If the weight of
Note: If the starter is not equipped with a negative (−)
terminal, connect the negative (−) jump start cable the fire extinguisher exceeds 4.5 kg (10 lb), mount
the fire extinguisher near the bottom of the ROPS. Do
to the engine block.
not mount the fire extinguisher at the upper one-third
For specific starting instructions, see Operation area of the ROPS.
And Maintenance Manual, “Starting with Jump Start
Cables”. Ether
Clean all electrical connections and tighten all Ether is poisonous and flammable. Inhaling ether
electrical connections. Check the electrical wires vapors can cause personal injury. Repeated contact
daily for loose wires or for frayed wires. Tighten all of ether with skin can cause personal injury. Use
loose wires before you operate the machine. Repair ether only in well ventilated areas. Do not smoke
all frayed electrical wires before you operate the while you replace ether cylinders. Use ether with care
machine. in order to avoid fires. Do not store ether cylinders in
living areas or in the operator's compartment.
Keep all fuels and all lubricants stored in properly
marked containers. Also, store all fuels and all Do not store ether cylinders in direct sunlight or at
lubricants away from any unauthorized persons. temperatures above 49°C (120°F). Discard ether
cylinders in an approved place. Do not puncture ether
Store oily rags and other flammable material in a cylinders. Do not burn ether cylinders. Keep ether
protective container. cylinders out of the reach of unauthorized personnel.

Do not weld on pipes or on tubes that contain

flammable fluids. Do not flame cut on pipes or on
Lines, Tubes and Hoses
tubes that contain flammable fluids. Clean pipes or Do not bend high pressure lines. Do not strike high
tubes thoroughly with nonflammable solvent before
pressure lines. Do not install lines, tubes or hoses
you weld on pipes or on tubes. Also, clean pipes or
that are bent or damaged.
tubes thoroughly with nonflammable solvent before
you flame cut on pipes or on tubes.
Repair lines, tubes and hoses that are loose or
damaged. Leaks can cause fires. See your Caterpillar
Remove all flammable materials such as fuel, oil and dealer for repair parts or for replacement parts.
other debris from the machine. Do not allow any
flammable materials to accumulate on the machine.
16 SEBU7185-12
Safety Section
Fire Extinguisher Location

Carefully check lines, tubes and hoses. Do not Grease or oil under high pressure coming out of the
use your bare hand to check for leaks. Use a relief valve can penetrate the body causing injury or
board or cardboard in order to check for leaks. For death. Do not watch the relief valve to see if grease
details about fluid penetration, see Operation and or oil is escaping. Watch the track or track adjustment
Maintenance Manual, “General Hazard Information” cylinder to see if the track is being loosened.
in the Safety Section. Tighten all connections to the
recommended torque. The pins and bushings in a dry track pin joint
can become very hot. It is possible to burn the
Replace the parts if any of the following conditions fingers if there is more than brief contact with these
are found: components.

• The end fittings are damaged. i00691724

• The end fittings are leaking. Electrical Storm Injury

• The outer covering is chafed or the outer covering Prevention
is cut.
SMCS Code: 7000
• The wire shield is exposed.
Electrical storms may produce lightning. Lightning
• The outer covering is ballooning locally. may strike in the near vicinity of the machine.

• There is evidence of kinking or of crushing of the Personnel should never attempt to mount the
flexible part of the hose. machine during an electrical storm. Personnel should
never attempt to dismount the machine during an
• The armoring is embedded in the outer cover. electrical storm while lightning is striking in the near
vicinity of the machine.
• The end fittings are displaced.
If you are in the operator's cab during an electrical
Make sure that all clamps, guards and heat shields storm, stay in the cab. If you are on the ground during
are installed correctly in order to prevent vibration, an electrical storm, stay away from the machine.
rubbing, and excessive heat during operation.
The following procedures should never be attempted
while lightning is striking in the near vicinity of the
i01258143 machine:
Fire Extinguisher Location • Mount the machine.
SMCS Code: 7419
• Dismount the machine.
Do not weld a bracket on the Rollover Protective
If you are in the operator's station during an electrical
Structure (ROPS) in order to install the fire
storm, stay in the operator's station. If you are on the
extinguisher. Also, do not drill holes in the ROPS in
ground during an electrical storm, stay away from the
order to mount the fire extinguisher on the ROPS.
vicinity of the machine during an electrical storm.
Strap the mounting plate to a leg of the ROPS
in order to mount the fire extinguisher. If the fire i01896223
extinguisher weighs more than 4.5 kg (10 lb), mount
the fire extinguisher low on one leg of the ROPS. Do Before Starting Engine
not mount the fire extinguisher on the upper one-third
portion of the leg. SMCS Code: 1000; 7000

Start the engine only from the operator's

i01329108 compartment. Do not short across the battery
Track Information terminals and do not short across the batteries.
Bypassing the engine neutral start system can
damage the electrical system.
SMCS Code: 4170; 7000

Track adjusting systems use either grease or oil

under high pressure to keep the track under tension.
SEBU7185-12 17
Safety Section
Engine Starting

Inspect the condition of the seat belt and mounting Adjust the rearview mirrors (if equipped) for best
hardware. Replace any damaged parts or worn parts. vision close to the machine. Make sure that the
Regardless of appearance, replace the seat belt after machine horn, the backup alarm (if equipped) and all
three years of use. Do not use an extension for a other warning devices are working properly.
seat belt on a retractable seat belt.
Reference: Refer to Operation and Maintenance
Adjust the seat so that full pedal travel can be Manual, “Walk-Around Inspection” in this manual.
achieved. Make sure that the operator's back is
against the back of the seat. Fasten the seat belt securely.

Make sure that the machine is equipped with a

i01390839
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,
Operation
make sure that no one is working on the machine, SMCS Code: 7000
working underneath the machine or working close
to the machine. Make sure that the area is free of Only operate the machine while you are in a seat.
personnel. The seat belt must be fastened while you operate
the machine. Only operate the controls while the
i03653839 engine is running. On machines that are disabled, the
controls may be used when the engine is not running.
Engine Starting
Check for proper operation of all controls and
SMCS Code: 1000; 7000 protective devices while you operate the machine
slowly in an open area.
If a warning tag is attached to the engine start switch
or to the controls, do not start the engine. Also, do Before moving the machine, the operator must
not move any controls. ensure that no one will be endangered.

Move all hydraulic controls to the HOLD position Do not allow riders on the machine unless the
before you start the engine. Move the transmission machine has the following equipment:
control lever to the NEUTRAL position.
• additional seat
Engage the parking brake.
• additional seat belt
Diesel engine exhaust contains products of
combustion which can be harmful to your health. • Rollover Protective Structure (ROPS)
Always run the engine in a well ventilated area. If
you are in an enclosed area, vent the exhaust to the Report any repairs that are needed and noted during
outside. operation.

Briefly sound the horn before starting the engine. 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
i01896559
overhang.
Before Operation If the machine begins to sideslip, perform the
SMCS Code: 7000 following procedure:

Clear all personnel from the machine and from the • Discard the load.
area.
• Turn the machine downhill.
Remove all obstacles from the path of the machine.
Beware of hazards such as wires, ditches, etc. Be careful to avoid any condition which could lead
to tipping. Tipping can occur when you work on
Be sure that all windows are clean. Secure the doors hills, banks and slopes. Also, tipping can occur
and the windows in either the open position or the when you cross ditches, ridges or other unexpected
shut position. obstructions.
18 SEBU7185-12
Safety Section
Parking

Whenever it is possible, operate the machine up the • Prevent battery discharge that is caused by some
slopes and down the slopes. Avoid operating the of the electrical components.
machine across the slope, when possible.
• Prevent battery discharge that is caused by
Keep the machine under control. Do not overload the vandalism.
machine beyond capacity.
i03745198
Towing devices and eyes that are not part of machine
must be adequate. Slope Operation
Connect trailing equipment to a drawbar or to a hitch SMCS Code: 7000
only.
Machines that are operating safely in various
Never straddle a wire cable or allow other personnel applications depend on these criteria: the machine
to straddle a wire cable. model, configuration, machine maintenance,
operating speed of the machine, conditions of the
When you maneuver to connect the equipment, make terrain, fluid levels, and tire inflation pressures. The
sure that no personnel are between the machine most important criteria are the skill and judgment of
and trailing equipment. Block the hitch of the trailing the operator.
equipment in order to align the equipment with the
drawbar. A well trained operator that follows the instructions
in the Operation and Maintenance Manual has
Know the maximum dimensions of your machine. the greatest impact on stability. Operator training
provides a person with the following abilities:
Always keep the Rollover Protective Structure observation of working and environmental conditions,
(ROPS) installed during machine operation. feel for the machine, identification of potential
hazards, and operating the machine safely by making
i02862972 appropriate decisions.

Parking When you work on side hills and when you work on
slopes, consider the following important points:
SMCS Code: 7000
Speed of travel – At higher speeds, forces of inertia
Park on a level surface. If you must park on a grade, tend to make the machine less stable.
use blocks to prevent the machine from rolling.
Roughness of terrain or surface – The machine
Apply the service brake in order to stop the machine. may be less stable with uneven terrain.
Move the transmission control lever to NEUTRAL
position and move the speed control to LOW IDLE Direction of travel – Avoid operating the machine
position. Engage the parking brake. across the slope. When possible, operate the
machine up the slopes and operate the machine
Lower all attachments to the ground. down the slopes. Place the heaviest end of the
machine uphill when you are working on an incline.
Activate the implement shutoff control (hydraulic
lockout). Mounted equipment – Balance of the machine
may be impeded by the following components:
Stop the engine. equipment that is mounted on the machine, machine
configuration, weights, and counterweights.
Turn the engine start switch key to OFF position and
remove the key. Nature of surface – Ground that has been newly
filled with earth may collapse from the weight of the
Turn the key for the battery disconnect switch to the machine.
OFF position. Remove the key when you exit the
machine for an extended period of time. Surface material – Rocks and moisture of the
surface material may drastically affect the machine's
Turning the battery disconnect switch to the OFF traction and machine's stability. Rocky surfaces may
position will provide the following benefits: promote side slipping of the machine.

• Prevent battery discharge that is caused by a Slippage due to excessive loads – This may cause
battery short circuit. downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
SEBU7185-12 19
Safety Section
Engine Stopping

Width of tracks or tires – Narrower tracks or i01329161

narrower tires further increase the digging into the
ground which causes the machine to be less stable. Equipment Lowering with
Implements attached to the drawbar – This may
Engine Stopped
decrease the weight on the uphill tracks. This may SMCS Code: 7000
also decrease the weight on the uphill tires. The
decreased weight will cause the machine to be less Before lowering any equipment with the engine
stable. stopped, clear the area around the equipment of
all personnel. The procedure to use will vary with
Height of the working load of the machine – the type of equipment to be lowered. Keep in mind
When the working loads are in higher positions, the most systems use a high pressure fluid or air to
stability of the machine is reduced. raise or lower equipment. The procedure will cause
high pressure air, hydraulic, or some other media
Operated equipment – Be aware of performance to be released in order to lower the equipment.
features of the equipment in operation and the effects Wear appropriate personal protective equipment and
on machine stability. follow the established procedure in the Operation
and Maintenance Manual, “Equipment Lowering with
Operating techniques – Keep all attachments or Engine Stopped” in the Operation Section of the
pulled loads low to the ground for optimum stability. manual.
Machine systems have limitations on slopes –
Slopes can affect the proper function and operation i02818812
of the various machine systems. These machine
systems are needed for machine control. Sound Information and
Vibration Information
Note: Safe operation on steep slopes may require
special machine maintenance. Excellent skill of SMCS Code: 7000
the operator and proper equipment for specific
applications are also required. Consult the Operation
and Maintenance Manual sections for the proper fluid Sound Level Information
level requirements and intended machine use.
Hearing protection may be needed when the
machine is operated with an open operator station for
i02624835 extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
Engine Stopping operated with a cab that is not properly maintained or
when the doors and windows are open for extended
SMCS Code: 1000; 7000 periods or in a noisy environment.
Do not stop the engine immediately after the
machine has been operated under load. This can Sound Level Information for
cause overheating and accelerated wear of engine Machines in European Union
components.
Countries and in Countries that
After the machine is parked and the parking brake Adopt the “EU Directives”
is engaged, allow the engine to run for two minutes
before shutdown. This allows hot areas of the engine The operator sound pressure level is 84 dB(A).
to cool gradually. The operator sound pressure level was measured
according to the static test procedures and conditions
that are specified in “ISO 6394” or in “86/662/EEC”.
20 SEBU7185-12
Safety Section
Sound Information and Vibration Information

“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 influenced 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.

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.”

Machine Typical Operating Vibration Levels Scenario Factors

Type Activity X axis Y axis Z axis X axis Y axis Z axis
dozing 0,74 0,58 0,70 0,31 0,25 0,31
Track-Type
ripping 1,25 1,19 1,02 0,40 0,41 0,28
Tractors
transfer 0,87 0,80 0,97 0,43 0,40 0,34
SEBU7185-12 21
Safety Section
Sound Information and Vibration Information

Note: Refer to “ISO/TR 25398 Mechanical Vibration - b. Inspect and maintain the seat suspension and
Guideline for the assessment of exposure to whole adjustment mechanisms.
body vibration of ride on operated earthmoving
machines” for more information about vibration. 5. Perform the following operations smoothly.
This publication uses data that is measured
by international institutes, organizations and a. Steer
manufacturers. This document provides information
about the whole body exposure of operators of b. Brake
earthmoving equipment. Refer to Operation and
Maintenance Manual, SEBU8257, “The European c. Accelerate.
Union Physical Agents (Vibration) Directive
2002/44/EC” for more information about machine d. Shift the gears.
vibration levels.
6. Move the attachments smoothly.
The Caterpillar suspension seat meets the criteria of
“ISO 7096”. This represents vertical vibration level 7. Adjust the machine speed and the route in order
under severe operating conditions. This seat is tested to minimize the vibration level.
with the input “spectral class EM6”. The seat has a
transmissibility factor of “SEAT<0.7”. a. Drive around obstacles and rough terrain.

The whole body vibration level of the machine varies. b. Slow down when it is necessary to go over
There is a range of values. The low value is 0.5 rough terrain.
meter per second squared. The machine meets the
short term level for the design of the seat in “ISO 8. Minimize vibrations for a long work cycle or a long
7096”. The value is 1.61 meter per second squared travel distance.
for this machine.
a. Use machines that are equipped with
Guidelines for Reducing Vibration Levels on suspension systems.
Earthmoving Equipment
b. Use the ride control system on Track-Type
Properly adjust machines. Properly maintain Tractors.
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can c. If no ride control system is available, reduce
help reduce the whole body vibration level: speed in order to prevent bounce.

1. Use the right type and size of machine, equipment, d. Haul the machines between workplaces.
and attachments.
9. Less operator comfort may be caused by other risk
2. Maintain machines according to the manufacturer's factors. The following guidelines can be effective
recommendations. in order to provide better operator comfort:

a. Tire pressures a. Adjust the seat and adjust the controls in order
to achieve good posture.
b. Brake and steering systems
b. Adjust the mirrors in order to minimize twisted
c. Controls, hydraulic system and linkages posture.

3. Keep the terrain in good condition. c. Provide breaks in order to reduce long periods
of sitting.
a. Remove any large rocks or obstacles.
d. Avoid jumping from the cab.
b. Fill any ditches and holes.
e. Minimize repeated handling of loads and lifting
c. Provide machines and schedule time in order of loads.
to maintain the conditions of the terrain.
f. Minimize any shocks and impacts during sports
4. Use a seat that meets “ISO 7096”. Keep the seat and leisure activities.
maintained and adjusted.

a. Adjust the seat and suspension for the weight

and the size of the operator.
22 SEBU7185-12
Safety Section
Operator Station

Sources i03656846

The vibration information and calculation procedure Guards

is based on “ISO/TR 25398 Mechanical Vibration (Operator Protection)
- Guideline for the assessment of exposure
to whole body vibration of ride on operated SMCS Code: 7000; 7150; 7325
earthmoving machines”. Harmonized data is
measured by international institutes, organizations There are different types of guards that are used to
and manufacturers. protect the operator. The machine and the machine
application determines the type of guard that should
This literature provides information about assessing be used.
the whole body vibration exposure of operators of
earthmoving equipment. The method is based on A daily inspection of the guards is required in order to
measured vibration emission under real working check for structures that are bent, cracked or loose.
conditions for all machines. Never operate a machine with a damaged structure.
You should check the original directive. This The operator becomes exposed to a hazardous
document summarizes part of the content of the situation if the machine is used improperly or if poor
applicable law. This document is not meant to operating techniques are used. This situation can
substitute the original sources. Other parts of these occur even though a machine is equipped with an
documents are based on information from the United appropriate protective guard. Follow the established
Kingdom Health and Safety Executive. operating procedures that are recommended for your
machine.
Refer to Operation and Maintenance Manual,
SEBU8257, “The European Union Physical
Agents (Vibration) Directive 2002/44/EC” for more Rollover Protective Structure
information about vibration. (ROPS), Falling Object Protective
Consult your local Caterpillar dealer for more Structure (FOPS) or Tip Over
information about machine features that minimize Protection Structure (TOPS)
vibration levels. Consult your local Caterpillar dealer
about safe machine operation. The ROPS/FOPS Structure (if equipped) on your
machine is specifically designed, tested and
Use the following web site in order to find your local certified for that machine. Any alteration or any
dealer: modification to the ROPS/FOPS Structure could
weaken the structure. This places the operator
Caterpillar, Inc. into an unprotected environment. Modifications or
www.cat.com attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
i03634321
Excessive weight may inhibit the brake performance,
Operator Station the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
SMCS Code: 7000; 7301 Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
Any modifications to the inside of the operator station structure can be caused by an overturn, a falling
should not project into the operator space or into object, a collision, etc.
the space for the companion seat (if equipped).
The addition of a radio, fire extinguisher, and other Do not mount items (fire extinguishers, first aid
equipment must be installed so that the defined kits, work lights, etc) by welding brackets to the
operator space and the space for the companion seat ROPS/FOPS Structure or by drilling holes in the
(if equipped) is maintained. Any item that is brought ROPS/FOPS Structure. Welding brackets or drilling
into the cab should not project into the defined holes in the ROPS/FOPS Structures can weaken
operator space or the space for the companion seat the structures. Consult your Caterpillar dealer for
(if equipped). A lunch box or other loose items must mounting guidelines.
be secured. Objects must not pose an impact hazard
in rough terrain or in the event of a rollover.
SEBU7185-12 23
Safety Section
Guards

The Tip Over Protection Structure (TOPS) is

another type of guard that is used on mini hydraulic
excavators. This structure protects the operator in
the event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.

Other Guards (If Equipped)

Protection from flying objects and/or falling objects is
required for special applications. Logging applications
and demolition applications are two examples that
require special protection.

A front guard needs to be installed when a work tool

that creates flying objects is used. Mesh front guards
that are approved by Caterpillar or polycarbonate
front guards that are approved by Caterpillar are
available for machines with a cab or an open canopy.
On machines that are equipped with cabs, the
windows should also be closed. Safety glasses are
recommended when flying hazards exist for machines
with cabs and machines with open canopies.

If the work material extends above the cab, top

guards and front guards should be used. Typical
examples of this type of application are listed below:

• 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.