ADE003056

REV01

Operation &
Maintenance
Manual
Supplement
Dozer Access System
Caterpillar Track-Type Tractors
D9T / D10R / D10T / D11N / D11R / D11T

Access System Models:

ADE001001, ADE001002, ADE005629
ADE005630, ADE014070

Ph: +61 7 3863 5800 www.ade.net.au

 7 LITERATURE REFERENCE MATERIALS .......17
1 OVERVIEW..........................................................1
7.1 REFERENCE MATERIAL ................................17
2 SAFETY ...............................................................2

2.1 IMPORTANT SAFETY INFORMATION..................2

2.2 SAFETY SIGNS & LABELS ...............................3

3 PRODUCT IDENTIFICATION INFORMATION ...5

3.1 ACCESS SYSTEM – ID PLATE .........................5

4 OPERATION SECTION.......................................6

4.1 GENERAL DESCRIPTION .................................6

4.2 CONTROLS ....................................................7
4.3 PARK BRAKE .................................................9

5 MOUNTING & DISMOUNTING .........................10

5.1 GENERAL INFORMATION ...............................10

5.2 SYSTEM PREREQUISITES..............................10
5.3 MOUNTING PROCEDURE...............................10
5.4 DISMOUNTING PROCEDURE ..........................10
5.5 EMERGENCY DISMOUNTING PROCEDURE ......11
5.6 DISMOUNTING PROCEDURE – PARTIAL OR
COMPLETE ACCESS SYSTEM FAILURE .......................11

6 MAINTENANCE SECTION................................12

6.1 GENERAL HAZARD INFORMATION ..................12

6.1.1 Crushing & Cutting Prevention..............12
6.2 WHEN REQUIRED.........................................12
6.2.1 Circuit Breaker - Reset..........................12
6.3 BEFORE USE ...............................................13
6.3.1 Walk-Around Inspection........................13
6.4 EVERY 1000 SERVICE HOURS OR 6 MONTHS 13
6.4.1 Bolts and Mounting Hardware...............13
6.4.2 Hydraulic System – Inspect ..................13
6.4.3 Pivot Points – Lubricate ........................14
6.5 EVERY 2000 SERVICE HOURS OR YEARLY ....15
6.5.1 Rubber Bump Stop – Inspect................15
6.6 EVERY 4000 SERVICE HOURS OR 2 YEARS ...16
6.6.1 Hydraulic Oil Compartment...................16

Dozer Access System – CAT D9/D10/D11 i

1 Overview

This manual provides all the necessary information to

operate and maintain the access system fitted to the
Caterpillar D9/D10/D11 track type tractor. Use this
information in-conjunction with Caterpillar information
where specified.

The access system consists of a ladder and platform

fitted to the side of the tractor for improved access to
the operator cab. The ladder and platform are stowed
in the vertical position for tractor operation.

When required, the platform, handrails and ladder can

be unfolded using controls located inside the cab and
on the ripper.

This system is powered by a stand alone hydraulic

power pack with audible and visual alarms for
operation and monitoring of the access system.

The operation and maintenance manual should be

permanently stored in the dozer cab.

Refer to the Parts Manual for replacement parts

information for the dozer access system.

Whenever a question arises regarding the information

contained within this manual please consult Australian
Diversified Engineering Pty Ltd for the latest available
information. Selected manuals may be found at
www.ade.net.au containing the most up to date
information for the product.

Overview
Dozer Access System – CAT D9/D10/D11 1
 or Warning) are to indicate that an instruction must be
2 Safety carried out. The label will contain black text on a white
2.1 Important Safety Information
background. Read and obey the information contained
Safety precautions and warnings may be listed in this
on these labels.
manual and applied to the product (supplied by
Australian Diversified Engineering) in the form of safety
The NOTICE heading may be contained within this
signs and labels.
manual and is used to highlight or alert to certain
aspects of the product. Commonly the NOTICE
Safety signs and labels may be positioned on specific
heading is used to highlight the weight of an object or
parts of the product to draw attention to objects and
some other form of specific information applicable to
situations affecting health and safety. If these hazard
the task to be performed.
warnings are not heeded, bodily injury or death may
occur to you or other persons.
Australian Diversified Engineering cannot anticipate all
possible hazards. For instance, some hazards may be
The severity of the consequences of the hazard may
specific to your workplace or the equipment or tool you
be easily identified by the alert symbol at the top of the
employ to complete the task.
label.

Plan the job before proceeding. Planning before

The DANGER alert symbol is used to warn of a
commencement of the job will help identify possible
hazardous situation that is likely to be life threatening.
hazards in the job procedure which can be eliminated
Ensure you are aware of situations and locations on
or controlled.
the product displaying this alert symbol.

Be aware of unintended movement when assembling

and disassembling components and ensure machines
are isolated in accordance with workplace and supplier

The WARNING alert symbol is used to warn of a instructions when performing maintenance.

hazardous situation that is not likely to be life

threatening. Ensure you are aware of situations and Ensure items are installed properly and are not

locations on the product displaying this alert symbol. damaged during the installation procedure or during
operation of the machine. If damaged or installed
incorrectly the product may not operate and perform as
intended and may be made unsafe as a result. Ensure
all items are repaired or replaced and care is taken
The wording given underneath the DANGER or
when installing items on the machine.
WARNING alert symbol will warn of the hazard, the
consequences of the hazard followed by information on
Operate and maintain the machine in accordance with
how to prevent the hazardous situation from occurring.
procedures specified by the original equipment
manufacturer and information contained within this
Some signs placed on the product or machine (which
manual.
do not contain a safety alert or symbol such as Danger

Safety Section
Dozer Access System – CAT D9/D10/D11 2
2.2 Safety Signs & Labels

There are several specific safety signs specific to the

access system. Their exact location and description of
the hazard are reviewed in this section. Make sure that
you can read all safety signs. You must replace a label
if it is damaged, missing or cannot be read. If a label is
on a part that is replaced, make sure a new label is
installed on the replaced part. Contact Australian
Diversified Engineering for replacement labels.

This sign is located inside the cab

This sign is located adjacent to the in-cab and ground

level controls for the access system

Safety Section
Dozer Access System – CAT D9/D10/D11 3
 These signs are located on the side of the access
system

Safety Section
Dozer Access System – CAT D9/D10/D11 4
3 Product Identification
Information

3.1 Access System – ID Plate

An ID plate has been fitted to the access system which

indicates information such as the model number, date
of manufacture and the serial number. Refer to the
plate fitted to each machine for specific details.

ID plate for the access system

Product Identification Information

Dozer Access System – CAT D10/D11 5
4 Operation Section
4.1 General Description

The access system is a three stage electric-over-

hydraulic folding system fitted to the side of the dozer.
The access system utilises a 24V DC hydraulic power
pack coupled with a manifold of hydraulic sequence
valves and pilot operated check valves to drive and
control the hydraulic cylinders that raise and lower the
access system.

Electrical power is provided to the access system

ground level raise & lower controls and the in-cab raise
control if:
 Battery disconnect switch for the electrical system
is in the connected position. Refer to the machine
specific Operation and Maintenance Manual for
Access system in the lowered position for mounting
location and use of the battery disconnect switch.
and dismounting the machine

Electrical power is provided to the access system in-

cab lower control if the:
 Dozer ignition is ON.
 Battery disconnect is connected &
 Park brake is applied.

Access system in the raised or stowed position for

machine operation

Operation Section
Dozer Access System – CAT D9/D10/D11 6
4.2 Controls

Controls for raising and lowering the access system

are located inside the cab and at ground level. Audible
and visual indicators for the status of the access
system are included on the cab control panel. Refer to
your machine for specific location of the cab and
ground level controllers.

The controls for the access system include:

(1) Raise Control
(2) Lower Control
Controls for the access system are located inside the
(3) “STOWED” - Green Visual Indicator
cab and at ground level on the left ripper lift cylinder
(4) “UNSTOWED” - Red Visual Indicator
(5) Access Light
(6) Access Light Switch
(7) Cab Mounted Audible Alarm
(8) Hydraulics Cabinet Mounted Audible Alarm
1

6 6

2
1
3 Ground level control panel

2
4

In-cab control panel

Operation Section
Dozer Access System – CAT D9/D10/D11 7
 5

Machine with hydraulics cabinet mounted to the ROPS

Access light (5) on the deck handrail

Machine with hydraulics cabinet mounted on the cab

deck

(1) & (2) Raise and Lower Controls

External audible alarm (8) mounted to the access Depress the required button to either raise or lower the
system hydraulics cabinet access system.

The hydraulics cabinet may be located on the ROPS or The access controls utilised on this machine are of the
on the cab deck. momentary push button type. This requires the
operator to press the button for the duration of raising
or lowering. If the button is released at any point in the

Operation Section
Dozer Access System – CAT D9/D10/D11 8
system operation then power will be cut immediately Refer to Section 4.3 Park Brake for additional
and the access system will cease to move (commonly information on the cab control panel warnings.
known as ‘dead-man’ controls).
4.3 Park Brake
(3) Green Visual Indicator – “STOWED”
When the park brake is released and the access

Constant illumination when the access system is the system is not in the raised position the cab audible

stowed position. The access system must be in the alarm (7) will sound and the visual alarm (4) will

stowed position for machine operation and activate. Do not continue to operate the machine as

transportation. damage to the access system may occur.

(4) Red Visual Indicator – “UNSTOWED” Releasing of the park brake will not automatically raise
the access system. Ladder raise and lower is via the

Red visual indicator flashes depending on the following controls on the cab and ground level control panels

situation: only.

a) Flashing when the system is any position other

than the stowed position.
b) Light flashes in conjunction with sounding of
the in-cab mounted audible alarm (7) if the
park brake is released and the access system
is not in the stowed position.

(5) & (6) Access System Light & Switching

Switching for the access system light is located on the

ground level and in-cab control panels. The light
automatically switches off after a pre-set period of time.

(7) & (8) Audible Alarms

Audible alarms are mounted on the cab control panel

and on the hydraulics cabinet.

When the access system is being raised or lowered the

hydraulics cabinet mounted alarm will sound. When the
park brake is released and the access system is not
stowed the in-cab audible alarm will sound. Releasing
of the park brake will not automatically raise the access
system. Ladder raise and lower is via the controls on
the in-cab and ground level control panels only.

Operation Section
Dozer Access System – CAT D9/D10/D11 9
 To mount the machine using the access ladder:
5 Mounting & Dismounting 1. With the access system in the lowered position
5.1 General Information mount the access system facing the ladder.
Maintain three points of contact whilst on the
 Do not operate access when personnel are access system. If the access system is not lowered
mounting or dismounting the system. operate the ground level switch to completely lower
 Inspect, and when necessary, clean and have the system.
repairs made to steps and handholds before 2. Ensure that the battery disconnect switch is in the
mounting and dismounting. connected position. Refer to the machine specific
 Face the ladder when mounting and dismounting Operation and Maintenance Manual for location
the access system ladder. and operation of the battery disconnect switch.
 Maintain a three-point contact (two feet and one 3. Enter the cab and ensuring that the access system
hand or one foot and two hands) with the steps is free from personnel, use the in-cab controls to
and handrails. raise the ladder to the stowed position. Once
 Never jump off the access system. stowed correctly the green visual indicator on the
 Ensure adequate lighting for mounting and in-cab control panel will be illuminated.
dismounting of the machine in low light conditions. 4. Start and operate the machine in accordance with
 Ensure that the access system is fully lowered procedures outlined in the Caterpillar Operation
before use. and Maintenance Manual as well as applicable
mine site instructions.

5.2 System Prerequisites 5.4 Dismounting Procedure

To allow use of the access system and all operations To dismount the machine via the access system:
via the in-cab and ground level control panels: 1. Stop the machine in accordance with procedures
1. The dozer park brake is applied. outlined in the machine specific Caterpillar
2. The ignition switch is ON. Operation and Maintenance Manual as well as
3. The battery disconnect switch is connected. applicable mine site instructions.
4. The ladder is fully lowered with the handrails raised 2. Ensuring that the ground area is free from
before boarding. personnel use the lower button on the in-cab
control panel to completely lower the access

5.3 Mounting Procedure system.

3. Exit the cab.
Do not attempt to access the machine whilst moving or 4. Visually inspect to ensure the access system has
whilst another operator is in the machine and the lowered and the handrails have raised to the
engine running. Refer to applicable mine site upright position.
regulations for approaching machines. If not governed 5. Face the front of the machine and board the
by mine site regulation ensure two-way radio contact access ladder.
has been made with the operator prior to approaching 6. Dismount the machine maintaining three point
the machine. contact at all times.
7. If required raise the access system to the stowed

Operation Section
Dozer Access System – CAT D9/D10/D11 10
 position using the ground level controls.

5.5 Emergency Dismounting Procedure

Safely dismount the machine in an emergency situation

via the left or right side tracks of the machine. Refer to
further information on alternate exits (if available) in the
machine specific Operation & Maintenance Manual.

5.6 Dismounting Procedure – Partial or

Complete Access System Failure

To dismount the machine (without the use of the

access system) in the event of partial or complete
access system failure:
1. Stop the machine in accordance with procedures
outlined in the Caterpillar Operation and
Maintenance Manual as well as applicable mine
site instructions.
2. Dismount the machine via the left or right side
tracks maintaining three point contact at all times.
3. Ensure the ladder failure is investigated and fault/s
repaired.

Operation Section
Dozer Access System – CAT D9/D10/D11 11
 Perform all maintenance unless otherwise specified as
6 Maintenance Section follows:
 The machine parked on level ground.
 The park brake engaged.
 The engine stopped.
Unintended machine movement may result in
personal injury or death. Before performing  The start switch key off and the key removed.
maintenance on this machine ensure it has
 All disconnect switches locked out and a Do
been isolated in accordance with mine site
and manufacturer procedures and a Do Not Not Start Tag applied.
Start Tag has been applied in the appropriate
 All other external energy sources disconnected
location on the machine.
from the machine.

Disconnection of hoses and removal of 6.1.1 Crushing & Cutting Prevention

supporting pins and bolts of the access
system may result in unintended machine
movement and/or release of stored energy.
Personal injury or death may result. Before
disassembly of any components of the Disconnection of hoses and removal of
access system ensure that stored energy has supporting pins and bolts of the access
been relieved and components are system may result in unintended machine
chocked/blocked to prevent unintended movement and/or release of stored energy.
movement. Personal injury or death may result. Before
disassembly of any components of the
NOTICE
access system ensure that stored energy has
been relieved and components are
You must read and understand the warnings chocked/blocked to prevent unintended
and instructions contained in the Safety movement.
Section of this manual, before performing any
maintenance procedures.  Support equipment and attachments properly when
working beneath them. Never attempt adjustments
while the machine is moving or the engine is
6.1 General Hazard Information
running unless otherwise specified.
 Hot oil and components can cause personal injury.  Stay clear of all rotating and moving parts.
Do not allow hot oil or components to contact the
skin. 6.2 When Required
 At operating temperature, the hydraulic tank may
6.2.1 Circuit Breaker - Reset
be hot and under pressure.
 Relieve all pressure in hydraulic oil system before
The electrical system for the access system contains
any lines, fittings or related items are disconnected
two circuit breakers located inside the hydraulics
or removed.
cabinet. Reset the circuit breakers when required. If a
circuit breaker continually trips have the circuit
checked.

Maintenance Section
Dozer Access System – CAT D9/D10/D11 12
 6.4 Every 1000 Service Hours or 6 Months

6.4.1 Bolts and Mounting Hardware

Check the tightness of all bolts fitted to the access

system. This includes checking the handrails, access
platforms and their mountings.

6.4.2 Hydraulic System – Inspect

1

2 Inspect all lines, hoses fittings, hose clamps and

cylinders for damage and deterioration. If there are any
damaged, missing or leaking parts ensure that they are
(1) Main Circuit Breaker – 120 Amp
replaced. Check to ensure the mountings for the
(2) Switching Circuit Breaker – 10 Amp
hydraulic cabinet are secure.

6.3 Before Use

6.3.1 Walk-Around Inspection

Perform a walk-around inspection on the machine prior

to operation.
 Clean the access steps from any rubbish build-up
or debris.
 Visually inspect components for damage and wear
and tear. Have any damaged or missing
components repaired or replaced.
 Check to ensure that the audible alarms located
adjacent to the hydraulic oil compartment and on
the in-cab control panel sound whenever the
Machine with hydraulics cabinet mounted on the cab
access system controls are activated.
deck
 Visually inspect all hydraulic lines, hoses, fittings
and hose clamps for security, damage,
deterioration and leaks.
 Visually inspect all switches of the system. Ensure
all visual indicators are operational.
 Check the level of the hydraulic oil compartment.
Top-up if required referring to section Hydraulic
Oil Compartment section in the Maintenance
Section of this manual.

Maintenance Section
Dozer Access System – CAT D9/D10/D11 13
 6.4.3 Pivot Points – Lubricate

Lubricate the main pivot points of the system via the

grease fittings with good quality molybdenum based
grease. There are four grease fittings for the access
system.

Machine with hydraulics cabinet mounted to the ROPS

Two grease fittings at the pivots for the ladder

Two grease fittings at the pivots for the main frame

Hydraulic hoses from ROPS mounted hydraulics
cabinet to the bulkhead on the access system

Open the hydraulics cabinet lid and inspect all hoses

and fittings for leaks. Replace any items as required.
Hydraulic systems and components should be serviced
only in consultation with Australian Diversified
Engineering.

Maintenance Section
Dozer Access System – CAT D9/D10/D11 14
 Grease fitting on the forward main frame pivot

Grease fitting on the rearward main frame pivot

6.5 Every 2000 Service Hours or Yearly Rubber bump stops

6.5.1 Rubber Bump Stop – Inspect

Inspect the condition of the rubber bump stops

mounted to the access system. Replace as required.

Maintenance Section
Dozer Access System – CAT D9/D10/D11 15
6.6 Every 4000 Service Hours or 2 Years

6.6.1 Hydraulic Oil Compartment

Replace the hydraulic oil every 24 months / 2 years in

consultation with Australian Diversified Engineering.
Use only Castrol Hyspin AWH-M ISO Viscosity grade
68 oil or an equivalent specification oil in the hydraulic
system.

Fill point cap for the hydraulic oil compartment

Maintenance Section
Dozer Access System – CAT D9/D10/D11 16
7 Literature Reference
Materials

7.1 Reference Material

Machine specific Caterpillar Operation and

Maintenance Manual.

Reference Information
Dozer Access System – CAT D9/D10/D11 17