D9R Track-Type Tractor-Machine Safety

SAFETY.CAT.COM

D9R TRACK-TYPETRACTORSMachine Safety

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

© 2007 CaterpillarAll Rights Reserved

i01658146

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

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis 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 specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

6 SEBU7924-02Safety SectionSafety Messages

Safety Sectioni02787346

Safety MessagesSMCS Code: 7000; 7405

g01392978Illustration 2

SEBU7924-02 7Safety Section

Safety Messages


There are several specific safety messages on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all warningsigns.

Make sure that all of the warning signs are legible.Clean the warning signs or replace the warning signsif you cannot read the words. Replace the illustrationsif the illustrations are not legible. When you clean thewarning signs, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the safety signs. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures thewarning sign. Loose adhesive will allow the warningsign 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. AnyCaterpillar dealer can provide new safety signs.

Do Not Operate (1)This safety message is located on the LH verticalwall next to the transmission control.

g01370904

Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

8 SEBU7924-02Safety SectionSafety Messages

ROPS/FOPS STRUCTURE (2)This safety message is on the front RH corner of theROPS assembly.

g01212098

Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture’s protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. This will void the certification. Consulta Caterpillar dealer to determine this structure’slimitations without voiding its certification.

Seat Belt (3)This safety message is located on the LH verticalwall next to the transmission control.

g01370908

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

Shock Hazard (4)This safety message is located on the fuse coverbehind the LH vertical plate in the cab.

g01372247

WARNING! Shock/Electrocution Hazard! Read andunderstand the instructions and warnings in theOperation and Maintenance Manual. Failure to fol-low the instructions or heed the warnings couldcause serious injury or death.

Pressurized System (5)This safety message is located by the filler cap forthe radiator.

g01371640

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.


Safety Messages

Improper Connections for JumpStart Cables (6)This safety message is located on the bottom side ofthe battery compartment cover.

g01370909

Explosion Hazard! Improper jumper cable connec-tions can cause an explosion resulting in seriousinjury or death. Batteries may be located in sep-arate compartments. Refer to the Operation andMaintenance Manual for the correct jump startingprocedure.

High Pressure Cylinder (7)This safety message is on the dipstick that is attachedto the cover for each recoil spring compartment.

g01371642

High Pressure Cylinder. Do not remove any partsuntil all pressure has been relieved to avoid pos-sible personal injury. Relieve pressure by openingrelief valve one turn maximum. See the Operationand Maintenance Manual for correct procedure.

Compressed Recoil Spring (8)This safety message is located inside both trackroller frames.

g01393039

Personal injury or death can result from a com-pressed recoil spring being released suddenly us-ing incorrect disassembly procedures.

A recoil spring that is still held in compressioncan result in the recoil spring being released un-expectedly with extreme force which could causeserious injury or death.

Make sure that the correct disassembly procedureis used, if a front track roller frame that has a crackin the parent metal or weld connection (or a tubu-lar section that has separated from the front ofthe frame assembly) when the recoil spring is stillheld in compression.

Refer to Special Instruction, SMHS8273 whichcontains the disassembly procedure that must beused to decrease the possibility of injury whileperforming service on the track roller frame.

10 SEBU7924-02Safety SectionAdditional Messages

Compressed Recoil Spring (9)This safety message is located inside both trackroller frames.

g01065909

Personal injury or death can result from a com-pressed recoil spring being released suddenly us-ing incorrect disassembly procedures.

A recoil spring that is still held in compressioncan result in the recoil spring being released un-expectedly with extreme force which could causeserious injury or death.

Make sure that the correct disassembly procedureis used, if a front track roller frame that has a crackin the parent metal or weld connection (or a tubu-lar section that has separated from the front ofthe frame assembly) when the recoil spring is stillheld in compression.

Refer to Special Instruction, SMHS8273 whichcontains the disassembly procedure that must beused to decrease the possibility of injury whileperforming service on the track roller frame.

Do Not Operate (10) (Winch)This safety message is located on the RH verticalwall of the winch frame.

g01370904

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManual. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

i02789087

Additional MessagesSMCS Code: 7000; 7405

There are several specific warning signs on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all warningsigns.

Make sure that all of the warning signs are legible.Clean the warning signs or replace the warning signsif you cannot read the words. Replace the illustrationsif the illustrations are not legible. When you clean thewarning signs, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the safety signs. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures thewarning sign. Loose adhesive will allow the warningsign 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. AnyCaterpillar dealer can provide new safety signs.


Additional Messages


ESPAR Heating System (1) (If Equipped)


During periods of low idle or low load operation inbelow freezing temperatures, turn on the jacket waterheater that is fired by diesel fuel. This will maintainthe engine coolant temperature at approximately70 °C (160 °F).

Air Conditioning System (2) (If Equipped)

This message is located on the lower left side of thedash panel.


This message for the air conditioner has theappropriate information for the following services: theair conditioner lubricant, the refrigerant charge, andthe refrigerant capacity. Also, this safety messageinstructs 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 maintenancerecommendations.

12 SEBU7924-02Safety SectionCrushing Prevention and Cutting Prevention

i01359664

Crushing Prevention andCutting PreventionSMCS Code: 7000

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

Do not work beneath the cab of the machine unlessthe cab is properly supported.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or whilethe engine is running.

Never jump across the starter solenoid terminalsin order to start the engine. Unexpected machinemovement could result.

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

Stay clear of all rotating and moving parts.

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

Keep objects away from moving fan blades. The fanblade 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 retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes, wear protective glasses when you strikea retainer pin.

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

i01329099

Burn PreventionSMCS Code: 7000

Do not touch any part of an operating engine.Allow the engine to cool before any maintenance isperformed on the engine. Relieve all pressure in theair system, in the oil system, in the lubrication system,in the fuel system, or in the cooling system beforeany lines, fittings or related items are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level only after the engine hasbeen stopped.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot components can cause personalinjury. Do not allow hot oil to contact the skin. Also,do not allow hot components to contact the skin.

Remove the hydraulic tank filler cap only after theengine has been stopped. The filler cap must becool enough to touch with a bare hand. Follow thestandard procedure in this manual in order to removethe hydraulic tank filler cap.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.


Fire Prevention and Explosion Prevention

i01359795

Fire Prevention and ExplosionPreventionSMCS Code: 7000


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

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

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

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

Do not operate the machine near any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil spray or fuel spray in case ofa break in a line, in a hose, or in a seal. Exhaustshields must be installed correctly.

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

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

Dust that is generated from repairing nonmetallichoods or nonmetallic fenders can be flammableand/or explosive. Repair such components in a wellventilated area away from open flames or sparks.

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


Use caution when you are refueling a machine. Donot smoke while you are refueling a machine. Donot refuel a machine near open flames or sparks.Always stop the engine before refueling. Fill the fueltank outdoors.


14 SEBU7924-02Safety SectionFire Extinguisher Location

Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

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

EtherEther is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49 °C (120 °F). Keep ether cylinders awayfrom open flames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the machine isequipped with a thermal starting aid for cold weatherstarting.

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

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

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

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

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

i01834364

Fire Extinguisher LocationSMCS Code: 7419

Make sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher. Obey the recommendations on theinstruction plate.

Mount the fire extinguisher in the accepted locationper local regulations.

Do not weld the ROPS structure in order to install thefire extinguisher. Also, do not drill holes in the ROPSstructure in order to mount the fire extinguisher onthe ROPS.

Strap the mounting plate to a leg of the ROPS inorder to mount the fire extinguisher, as needed. Ifthe weight of the fire extinguisher exceeds 4.5 kg(10 lb), mount the fire extinguisher near the bottom ofthe ROPS. Do not mount the fire extinguisher at theupper one-third area of the ROPS.

Consult your Caterpillar dealer for the properprocedure for mounting the fire extinguisher.

i01329108

Track InformationSMCS Code: 4170; 7000

Track adjusting systems use either grease or oilunder high pressure to keep the track under tension.


Electrical Storm Injury Prevention

Grease or oil under high pressure coming out of therelief valve can penetrate the body causing injury ordeath. Do not watch the relief valve to see if greaseor oil is escaping. Watch the track or track adjustmentcylinder to see if the track is being loosened.

The pins and bushings in a dry track pin jointcan become very hot. It is possible to burn thefingers if there is more than brief contact with thesecomponents.

i01122596

Electrical Storm InjuryPreventionSMCS Code: 7000

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

• Mount the machine.

• Dismount the machine.

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

i01896223

Before Starting EngineSMCS Code: 1000; 7000

Start the engine only from the operator’scompartment. Do not short across the batteryterminals and do not short across the batteries.Bypassing the engine neutral start system candamage the electrical system.

Inspect the condition of the seat belt and mountinghardware. Replace any damaged parts or worn parts.Regardless of appearance, replace the seat belt afterthree years of use. Do not use an extension for aseat belt on a retractable seat belt.

Adjust the seat so that full pedal travel can beachieved. Make sure that the operator’s back isagainst the back of the seat.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Make sure that all lights are working properly. Beforeyou 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 closeto the machine. Make sure that the area is free ofpersonnel.

i01943212

Engine StartingSMCS Code: 1000; 7000

Diesel engine exhaust contains products of com-bustion which may be harmful to your health.

Always start and operate the engine in a well ven-tilated area and, if in an enclosed area, vent theexhaust to the outside.

Note: If a warning tag is attached to the engine startswitch or to the controls, do not start the engine anddo not move any controls.

1. Move all hydraulic controls to the HOLD positionbefore you start the engine.

2. Move the transmission control to the NEUTRALposition.

3. Engage the parking brake.

NOTICEDo not crank the engine for more than 30 seconds.Allow the starting motor to cool for two minutes beforecranking again.

Turbocharger (if equipped) damage can result, if theengine rpm is not kept low until the engine oil light/gauge verifies the oil pressure is sufficient.

4. Turn the engine start switch in order to start theengine. Release the engine start switch when theengine starts.

i01943255

Before OperationSMCS Code: 7000

Make sure that there are no personnel on themachine or in the area around the machine.

16 SEBU7924-02Safety SectionVisibility Information

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 thedoors and the windows in the open position or in theshut position.

Adjust the rear view mirrors (if equipped) for the bestvision 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.

i02773460

Visibility InformationSMCS Code: 7000

Before you start the machine, the operator shallperform a walk-around inspection in order to ensurethat there are no hazards around the machine.

While the machine is in operation, the operator shouldconstantly survey the area around the machine. Theoperator needs to identify potential hazards as ahazard becomes visible around the machine.

Your machine may be equipped with mirrors or othervisual aids. An example of a visual aid is ClosedCircuit Television (CCTV). The operator shouldensure that the visual aids are in proper workingcondition and that the visual aids are clean. Adjustthe visual aids for the best visibility of all areasaround the machine.

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

• Safety instructions

• Controlled patterns of machine movement

• Controlled patterns of vehicle movement

• Restricted areas

• Operator training

• Warning symbols or warning signs on machinesor on vehicles

• A system of communication

• Communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration that resultin a restriction of visibility shall be verified accordingto “ISO 5006”.

i01390839

OperationSMCS Code: 7000

Only operate the machine while you are in a seat.The seat belt must be fastened while you operatethe machine. Only operate the controls while theengine is running. On machines that are disabled, thecontrols may be used when the engine is not running.

Check for proper operation of all controls andprotective devices while you operate the machineslowly in an open area.

Before moving the machine, the operator mustensure that no one will be endangered.

Do not allow riders on the machine unless themachine has the following equipment:

• additional seat

• additional seat belt

• Rollover Protective Structure (ROPS)

Report any repairs that are needed and noted duringoperation.

Carry attachments close to the ground, approximately40 cm (15 inches) above ground level. Do not goclose to the edge of a cliff, an excavation, or anoverhang.

If the machine begins to sideslip, perform thefollowing procedure:

• Discard the load.

• Turn the machine downhill.

Be careful to avoid any condition which could leadto tipping. Tipping can occur when you work onhills, banks and slopes. Also, tipping can occurwhen you cross ditches, ridges or other unexpectedobstructions.

Whenever it is possible, operate the machine up theslopes and down the slopes. Avoid operating themachine across the slope, when possible.


Engine Stopping

Keep the machine under control. Do not overload themachine beyond capacity.

Towing devices and eyes that are not part of machinemust be adequate.

Connect trailing equipment to a drawbar or to a hitchonly.

Never straddle a wire cable or allow other personnelto straddle a wire cable.

When you maneuver to connect the equipment, makesure that no personnel are between the machineand trailing equipment. Block the hitch of the trailingequipment in order to align the equipment with thedrawbar.

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure(ROPS) installed during machine operation.

i02624835

Engine StoppingSMCS Code: 1000; 7000

Do not stop the engine immediately after themachine has been operated under load. This cancause overheating and accelerated wear of enginecomponents.

After the machine is parked and the parking brakeis engaged, allow the engine to run for two minutesbefore shutdown. This allows hot areas of the engineto cool gradually.

i01390843

ParkingSMCS 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 NEUTRALposition and move the speed control to LOW IDLEposition. Engage the parking brake.

Lower all attachments to the ground.

Stop the engine.

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

Turn the key for the battery disconnect switch to theOFF position. Remove the key when you exit themachine for an extended period of time.

Turning the battery disconnect switch to the OFFposition will provide the following benefits:

• Prevent battery discharge that is caused by abattery short circuit.

• Prevent battery discharge that is caused by someof the electrical components.

• Prevent battery discharge that is caused byvandalism.

i02780235

Slope OperationSMCS Code: 7000

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

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

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

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

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

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

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

18 SEBU7924-02Safety SectionEquipment Lowering with Engine Stopped

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

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

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

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

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

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

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

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

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

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

i01329161

Equipment Lowering withEngine StoppedSMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment ofall personnel. The procedure to use will vary withthe type of equipment to be lowered. Keep in mindmost systems use a high pressure fluid or air toraise or lower equipment. The procedure will causehigh pressure air, hydraulic, or some other mediato be released in order to lower the equipment.Wear appropriate personal protective equipment andfollow the established procedure in the Operationand Maintenance Manual, “Equipment Lowering withEngine Stopped” in the Operation Section of themanual.

i02652040

Sound Information andVibration InformationSMCS Code: 7000

Sound Level InformationThe 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 cabwas properly installed and maintained. The test wasconducted with the cab doors and the cab windowsclosed.

Hearing protection may be needed when themachine is operated with an open operator station forextended periods or in a noisy environment. Hearingprotection may be needed when the machine isoperated with a cab that is not properly maintained orwhen the doors and windows are open for extendedperiods or in a noisy environment.

The average exterior sound pressure level is 85dB(A) when the “SAE J88Jun86 - Constant SpeedMoving Test” procedure is used to measure the valuefor the standard machine. The measurement wasconducted under the following conditions: distance of15 m (49.2 ft) and “the machine moving forward in anintermediate gear ratio”.


Sound Information and Vibration Information

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the “EU Directives”The dynamic operator sound pressure level is 85dB(A) when “SAE J919Jun 86” is used to measurethe value for an enclosed cab. The cab was properlyinstalled and maintained. The test was conductedwith the cab doors and the cab windows closed.

“The European Union PhysicalAgents (Vibration) Directive2002/44/EC”

Vibration Data for Track-Type Tractors

Information Concerning Hand/Arm VibrationLevel

When the machine is operated according to theintended use, the hand/arm vibration of this machineis below 2.5 meter per second squared.

Information Concerning Whole Body VibrationLevel

This section provides vibration data and a method forestimating the vibration level for track-type tractors.

Note: Vibration levels are influenced by manydifferent 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 thesuspension system, attachments, and condition ofthe equipment

It is not possible to get precise vibration levels forthis machine. The expected vibration levels can beestimated with the information in Table 1 in orderto calculate the daily vibration exposure. A simpleevaluation of the machine application can be used.

Estimate the vibration levels for the three vibrationdirections. For typical operating conditions, use theaverage vibration levels as the estimated level. Withan experienced operator and smooth terrain, subtractthe Scenario Factors from the average vibration levelin order to obtain the estimated vibration level. Foraggressive operations and severe terrain, add theScenario Factors to the average vibration level inorder to obtain the estimated vibration level.

Note: All vibration levels are in meter per secondsquared.

20 SEBU7924-02Safety SectionSound Information and Vibration Information

Table 1

“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Vibration Levels Scenario FactorsMachineType

Typical OperatingActivity 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

ripping 1,25 1,19 1,02 0,40 0,41 0,28Track-TypeTractors

transfer 0,87 0,80 0,97 0,43 0,40 0,34

Note: Refer to “ISO/TR 25398 Mechanical Vibration -Guideline for the assessment of exposure to wholebody vibration of ride on operated earthmovingmachines” for more information about vibration.This publication uses data that is measuredby international institutes, organizations andmanufacturers. This document provides informationabout the whole body exposure of operators ofearthmoving equipment. Refer to Operation andMaintenance Manual, SEBU8257, “The EuropeanUnion Physical Agents (Vibration) Directive2002/44/EC” for more information about machinevibration levels.

The Caterpillar suspension seat meets the criteria of“ISO 7096”. This represents vertical vibration levelunder severe operating conditions. This seat is testedwith the input “spectral class EM6”. The seat has atransmissibility factor of “SEAT<0.7”.

The whole body vibration level of the machine varies.There is a range of values. The low value is 0.5meter per second squared. The machine meets theshort term level for the design of the seat in “ISO7096”. The value is 1.61 meter per second squaredfor this machine.

Guidelines for Reducing Vibration Levels onEarthmoving Equipment

Properly adjust machines. Properly maintainmachines. Operate machines smoothly. Maintain theconditions of the terrain. The following guidelines canhelp reduce the whole body vibration level:

1. Use the right type and size of machine, equipment,and attachments.

2. Maintain machines according to themanufacturer’s 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 orderto maintain the conditions of the terrain.

4. Use a seat that meets “ISO 7096”. Keep the seatmaintained and adjusted.

a. Adjust the seat and suspension for the weightand the size of the operator.

b. Inspect and maintain the seat suspension andadjustment 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 orderto minimize the vibration level.

a. Drive around obstacles and rough terrain.

b. Slow down when it is necessary to go overrough terrain.

8. Minimize vibrations for a long work cycle or a longtravel distance.

a. Use machines that are equipped withsuspension systems.

b. Use the ride control system on Track-TypeTractors.

c. If no ride control system is available, reducespeed in order to prevent bounce.

d. Haul the machines between workplaces.


Operator Station

9. Less operator comfort may be caused by other riskfactors. The following guidelines can be effectivein order to provide better operator comfort:

a. Adjust the seat and adjust the controls in orderto achieve good posture.

b. Adjust the mirrors in order to minimize twistedposture.

c. Provide breaks in order to reduce long periodsof sitting.

d. Avoid jumping from the cab.

e. Minimize repeated handling of loads and liftingof loads.

f. Minimize any shocks and impacts during sportsand leisure activities.

SourcesThe vibration information and calculation procedureis based on “ISO/TR 25398 Mechanical Vibration- Guideline for the assessment of exposureto whole body vibration of ride on operatedearthmoving machines”. Harmonized data ismeasured by international institutes, organizationsand manufacturers.

This literature provides information about assessingthe whole body vibration exposure of operators ofearthmoving equipment. The method is based onmeasured vibration emission under real workingconditions for all machines.

You should check the original directive. Thisdocument summarizes part of the content of theapplicable law. This document is not meant tosubstitute the original sources. Other parts of thesedocuments are based on information from the UnitedKingdom Health and Safety Executive.

Refer to Operation and Maintenance Manual,SEBU8257, “The European Union PhysicalAgents (Vibration) Directive 2002/44/EC” for moreinformation about vibration.

Consult your local Caterpillar dealer for moreinformation about machine features that minimizevibration levels. Consult your local Caterpillar dealerabout safe machine operation.

Use the following web site in order to find your localdealer:

Caterpillar, Inc.www.cat.com

i01649970

Operator StationSMCS Code: 7000; 7301

Any modifications to the inside of the operatorstation should not project into the operator space.The addition of a radio, fire extinguisher, and otherequipment must be installed so that the definedoperator space is maintained. Any item that is broughtinto the cab should not project into the definedoperator space. A lunch box or other loose itemsmust be secured. Objects must not pose an impacthazard in rough terrain or in the event of a rollover.

i01992325

Guards(Operator Protection)SMCS Code: 7000; 7150; 7325

There are different types of guards that are used toprotect the operator. The machine and the machineapplication determines the type of guard that shouldbe used.

A daily inspection of the guards is required in order tocheck for structures that are bent, cracked or loose.Never operate a machine with a damaged structure.

The operator becomes exposed to a hazardoussituation if the machine is used improperly or if pooroperating techniques are used. This situation canoccur even though a machine is equipped with anappropriate protective guard. Follow the establishedoperating procedures that are recommended for yourmachine.

22 SEBU7924-02Safety SectionGuards

Rollover Protective Structure(ROPS), Falling Object ProtectiveStructure (FOPS) or Tip OverProtection Structure (TOPS)The ROPS/FOPS Structure (if equipped) on yourmachine is specifically designed, tested and certifiedfor that machine. Excavators are not equippedwith ROPS structures. Any alteration or anymodification to the ROPS/FOPS Structure couldweaken the structure. This places the operatorinto an unprotected environment. Modifications orattachments that cause the machine to exceed theweight that is stamped on the certification plate alsoplace the operator into an unprotected environment.Excessive weight may inhibit the brake performance,the steering performance and the ROPS. Theprotection that is offered by the ROPS/FOPSStructure will be impaired if the ROPS/FOPSStructure has structural damage. Damage to thestructure can be caused by an overturn, a fallingobject, a collision, etc.

Do not mount items (fire extinguishers, first aidkits, work lights, etc) by welding brackets to theROPS/FOPS Structure or by drilling holes in theROPS/FOPS Structure. Welding brackets or drillingholes in the ROPS/FOPS Structures can weakenthe structures. Consult your Caterpillar dealer formounting guidelines.

The Tip Over Protection Structure (TOPS) isanother type of guard that is used on mini hydraulicexcavators. This structure protects the operator inthe event of a tipover. The same guidelines for theinspection, the maintenance and the modification ofthe ROPS/FOPS Structure are required for the TipOver Protection Structure.

Other Guards (If Equipped)Protection from flying objects and/or falling objects isrequired for special applications. Logging applicationsand demolition applications are two examples thatrequire special protection.

A front guard needs to be installed when a worktool that creates flying objects is used. Meshfront guards that are approved by Caterpillar orpolycarbonate front guards that are approved byCaterpillar are available for machines with a cab oran open canopy. On machines that are equipped withcabs, the windshield should also be closed. Safetyglasses are recommended when flying hazards existfor machines with cabs and machines with opencanopies.

If the work material extends above the cab, topguards and front guards should be used. Typicalexamples of this type of application are listed below:

• Demolition applications

• Rock quarries

• Forestry products

Additional guards may be required for specificapplications or work tools. The Operation andMaintenance Manual for your machine or yourwork tool will provide specific requirements for theguards. Consult your Caterpillar dealer for additionalinformation.

Documents

D9R Track-Type Tractor-Machine Safety