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®© 2010 CaterpillarAll Rights Reserved

SAFETYOperation and MaintenanceManual Excerpt

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SEBU7247-01May 2001

Operation andMaintenance

ManualD8R Series II Track-Type Tractor

AKA1-Up (Machine)6YZ1-Up (Machine)

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i01097883

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

Improper operation, lubrication, maintenance or repair of this product can be dangerous 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 hazardwarnings are 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 orpictorially presented.

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. Thewarnings 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 Caterpillar is used,you must satisfy yourself that it is safe for you and for others. You should also ensure that theproduct 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 beforeyou start any job. Caterpillar dealers have the most current information available. For a list of the mostcurrent publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

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.

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6Safety SectionSafety Signs and Labels

Safety Section

i01506904

Safety Signs and Labels

SMCS 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 warningsigns if you cannot read the words. Replace theillustrations if the illustrations are not visible. Whenyou clean the warning signs, use a cloth, water, and

soap. Do not use solvent, gasoline, or other harshchemicals to clean the warning signs. Solvents,gasoline, or harsh chemicals could loosen theadhesive that secures the warning sign. Looseadhesive will allow the warning sign to fall.

Replace any warning sign that is damaged ormissing. If a warning sign is attached to a part ofthe machine that is replaced, install a warning signon the replacement part. Any Caterpillar dealer canprovide new warning signs.

Do Not Operate

g00680037Illustration 2

This warning sign is positioned in the cab beneaththe left window.


DO NOT OPERATE OR WORK ON THIS MACHINE

UNLESS YOU HAVE READ AND UNDERSTANDTHE INSTRUCTIONS AND WARNINGS IN THEOPERATION AND MAINTENANCE MANUALS.FAILURE TO FOLLOW THE INSTRUCTIONS ORHEED THE WARNINGS COULD RESULT IN IN-JURY OR DEATH. CONTACT ANY CATERPILLARDEALER FOR REPLACEMENT MANUALS. PROP-ER CARE IS YOUR RESPONSIBILITY.

Improper Connections for JumpStart Cables


This warning sign is in the battery compartment.

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7Safety Section



Improper jumper cable connections can cause anexplosion resulting in personal injury. Batteriescan be located in separate compartments. Whenusing jumper cable always connect positive (+) ca-ble to positive (+) terminal of battery connected tostarter solenoid and negative (−) cable from exter-nal source to starter negative (−) terminal. (If notequipped with starter negative terminal, connectto engine block.)

Do Not Weld On ROPS


This warning sign is on the ROPS.

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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. Consult a Caterpillar dealer to deter-mine this structure’s limitations without voidingits certification.

Do Not Weld on FOPS


This warning sign is located on the FOPS.

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9Safety Section



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. Consult a Caterpillar dealer to deter-mine this structure’s limitations without voidingits certification.

High Pressure Cylinder


This warning sign is on the dipstick that is attachedto the cover for each recoil spring compartment.


Personal injury or death can result from greaseunder pressure.

Grease coming out of the relief valve under pres-sure can penetrate the body causing injury ordeath.

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 andcontact your Caterpillar dealer.

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Compressed Recoil Spring


This warning sign is located inside both track rollerframes.



This warning sign is located inside both track rollerframes.


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 of theframe assembly) when the recoil spring is still heldin 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.

Unit Injectors


The warning sign for the electronic unit injector istypically located on the valve cover base.

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11Safety Section



Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.

This engine uses high voltage to the unit injectors.Disconnect the unit injector enable circuit connectorin order to prevent personal injury. Do not come intocontact with the unit injector terminals while theengine is operating.

Hydraulic System Accumulator


This warning sign is located on the front of the

console that is to the right of the operator’s seat.


This warning sign is located on top of the consolethat is to the right of the operator’s seat.

g00773721

Illustration 20

Accumulator and lines under high pressure. Dis-connecting or disassembly while pressurized canresult in personal injury or death. Refer to the ser-vice manual for instructions.


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12Safety SectionGeneral Hazard Information

This warning sign is located on the accumulator.The accumulator is in the console that is located tothe right of the operator’s seat. The accumulator ismounted to the right, rear ROPS post.


High pressure cylinder. Rapid discharging fromdisconnecting or disassembly can result in per-sonal injury or death. See your Caterpillar dealer

for tools and instructions for relieving pressure orcharging. Precharge only with nitrogen gas.

i01426767

General Hazard Information

SMCS Code: 7000


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

Know the width of your equipment in order tomaintain proper clearance when you operate theequipment near fences or near boundary obstacles.

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


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

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

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

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools,and other items that are not a part of the equipment.

Know the appropriate work site hand signals and

the personnel that are authorized to give the handsignals. Accept hand signals from one person only.

Do not smoke when you service an air conditioner.Also, do not smoke if refrigerant gas may bepresent. Inhaling the fumes that are released from aflame that contacts air conditioner refrigerant cancause bodily harm or death. Inhaling gas from airconditioner refrigerant through a lighted cigarettecan cause bodily harm or death.

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

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and MaintenanceManual for the procedure for placing the equipmentin the servicing position.

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13Safety Section

General Hazard Information

Pressure Air and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could resultin personal injury.

When pressure air and/or pressure water is usedfor cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must bebelow 275 kPa (40 psi).

Trapped Pressure

Pressure can be trapped in a hydraulic system.Releasing trapped pressure can cause suddenmachine movement or attachment movement. Usecaution if you disconnect hydraulic lines or fittings.High pressure oil that is released can cause a hoseto whip. High pressure oil that is released cancause oil to spray. Fluid penetration can causeserious injury and possible death.

Fluid Penetration

Pressure can be trapped in the hydraulic circuitlong after the engine has been stopped. Thepressure can cause hydraulic fluid or items suchas pipe plugs to escape rapidly if the pressure is

not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has beenrelieved or personal injury may occur. Refer to theService Manual for any procedures that are requiredto relieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leakcan cause severe injury. If fluid is injected into yourskin, you must get treatment immediately. Seek

treatment from a doctor that is familiar with this typeof injury.

Containing Fluid Spillage

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

Refer to Special Publication, NENG2500, “Tools andShop Products Guide” for the following items:

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

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

Obey all local regulations for the disposal of liquids.

Asbestos Information


Caterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCaterpillar replacement parts. Use the followingguidelines when you handle any replacement partsthat contain asbestos or when you handle asbestosdebris.

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14Safety SectionCrushing Prevention and Cutting Prevention

Use caution. Avoid inhaling dust that might begenerated when you handle components thatcontain asbestos fibers. Inhaling this dust canbe hazardous to your health. The componentsthat may contain asbestos fibers are brake pads,brake bands, lining material, clutch plates, and

some gaskets. The asbestos that is used in thesecomponents is usually bound in a resin or sealed insome way. Normal handling is not hazardous unlessairborne dust that contains asbestos is generated.

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

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

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

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

• Use exhaust ventilation on permanent machiningjobs.

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

• Comply with applicable rules and regulations

for the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

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

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should be

disposed of according to local regulations.

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

i01359664

Crushing Prevention andCutting Prevention

SMCS 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 terminals

in 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.

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15Safety Section

Burn Prevention

If it is necessary to remove guards in order toperform maintenance, always install the guardsafter the maintenance is performed.

Keep objects away from moving fan blades. Thefan blade will throw objects or cut objects.

Do not use a kinked wire cable or a frayed wirecable. Wear gloves when you handle wire cable.

When you strike a retainer pin with force, theretainer pin can fly out. The loose retainer pin caninjure personnel. Make sure that the area is clearof people when you strike a retainer pin. To avoidinjury to your eyes, wear protective glasses whenyou strike a retainer pin.

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

i01329099

Burn Prevention

SMCS 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 inthe air system, in the oil system, in the lubricationsystem, in the fuel system, or in the cooling systembefore any lines, fittings or related items aredisconnected.

Coolant

When 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 steamcan cause severe burns. Allow cooling systemcomponents to cool before the cooling system isdrained.

Check the coolant level only after the engine hasbeen stopped.

Ensure that the filler cap is cool before removingthe filler cap. The filler cap must be cool enoughto touch with a bare hand. Remove the filler capslowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkalican cause personal injury. Do not allow alkali tocontact the skin, the eyes, or the mouth.

Oils

Hot 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. Followthe standard procedure in this manual in order toremove the hydraulic tank filler cap.

Batteries

Electrolyte is an acid. Electrolyte can causepersonal injury. Do not allow electrolyte to contactthe skin or the eyes. Always wear protective glassesfor servicing batteries. Wash hands after touchingthe batteries and connectors. Use of gloves isrecommended.

i01359795

Fire Prevention and ExplosionPrevention

SMCS 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,and debris from the machine. Do not allow anyflammable materials to accumulate on the machine.

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16Safety SectionFire Prevention and Explosion Prevention

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 linesor tanks thoroughly with a nonflammable solventprior to welding or flame cutting.

Check all electrical wires daily. Repair any wires that

are loose or frayed before you operate the machine.Clean all electrical connections and tighten allelectrical 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 adequatesupport and secure clamps. Tighten all connectionsto the recommended 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.


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 or

a 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 causean explosion.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Ether

Ether is flammable and poisonous.

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

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17Safety Section

Track Information

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 machineis equipped with a thermal starting aid for coldweather starting.

Lines, Tubes and Hoses

Do 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 notuse your bare hand to check for leaks. Use aboard or cardboard to check for leaks. Tighten allconnections to 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,this will help to prevent vibration, rubbing againstother parts, and excessive heat.

i01329108

Track Information

SMCS Code: 4170; 7000

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

Grease or oil under high pressure coming out ofthe relief valve can penetrate the body causinginjury or death. Do not watch the relief valve tosee if grease or oil is escaping. Watch the trackor track adjustment cylinder to see if the track isbeing 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 InjuryPrevention

SMCS 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 anelectrical storm, stay in the operator’s station. If youare on the ground during an electrical storm, stayaway from the vicinity of the machine.

i01411864

Mounting and Dismounting

SMCS Code: 7000


Mount the machine and dismount the machineonly at locations that have steps and/or handholds.Before you mount the machine, clean the steps andthe handholds. Inspect the steps and handholds.Make any necessary repairs.

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18Safety SectionBefore Starting Engine

Face the machine whenever you mount the machineand whenever you dismount the machine.

Maintain a three-point contact with the steps andwith the handholds.

Note: Three-point contact can be two feet and onehand. Three-point contact can also be one foot andtwo hands.

Never mount a moving machine. Never dismount amoving machine. Never jump off the machine.

Do not carry tools or supplies when you mount themachine or when you dismount the machine. Use ahand line to raise and lower tools or supplies.

Do not use any controls as handholds when youenter the operator compartment or when you exitthe operator compartment.

Alternate Exit

Machines that are equipped with cabs may havealternate exits. For additional information onmachines that are equipped with alternate exits,see Operation and Maintenance Manual, “AlternateExit”.

i00037733

Before Starting Engine

SMCS 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 wornparts. Regardless of appearance, replace theseat belt after three years of use. Do not use anextension for a seat 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 witha lighting system that is adequate for the jobconditions. Make sure that all lights are workingproperly. Before you start the engine or beforeyou move the machine, make sure that no one isworking on the machine, working underneath themachine or working close to the machine. Makesure that the area is free of personnel.

i01492207

Engine Starting

SMCS Code: 1000; 7000

If a warning tag is attached to the start switch orattached to the controls, do not start the engine.Also, do not move any controls.

Move all hydraulic controls to the HOLD positionbefore starting the engine. Move the transmissioncontrol to NEUTRAL position.

Engage the parking brake switch.

Diesel engine exhaust contains products ofcombustion. These products can be harmful to yourhealth. Always start the engine and always operatethe engine in a well ventilated area. If you are in an

enclosed area, vent the exhaust to the outside.

i01370348

Before Operation

SMCS Code: 7000

Clear all personnel from the machine and from thearea.

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

Be sure that all windows are clean. Secure thedoors and the windows in either the open positionor the shut position.

Adjust the rearview mirrors (if equipped) for bestvision close to the machine. Make sure that themachine horn, the backup alarm (if equipped) andall other warning devices are working properly.

Reference: Refer to Operation and MaintenanceManual, “Walk-Around Inspection” in this manual.

Fasten the seat belt securely.

i01390839

Operation

SMCS 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,the controls may be used when the engine is notrunning.

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20Safety SectionSound Information and Vibration Information

i01273543

Sound Information andVibration Information

SMCS Code: 7000

The operator sound exposure Leq (equivalentsound pressure level) measured according to thework cycle procedures specified in “ANSI/SAEJ1166May90” is 83 dB(A), for the cab offered byCaterpillar, when properly installed and maintainedand tested with the doors and windows closed.

The operator sound pressure level measuredaccording to the procedures specified in “SAEJ919Jun86” is 83 dB(A), for the cab offered byCaterpillar, when properly installed and maintainedand tested with the doors and windows closed andwith the machine in middle gear range and moving.

The exterior sound pressure level for the standardmachine measured at a distance of 15 m (49.2 ft)according to the test procedures specified in “SAEJ88Jun86”, with the machine in middle gear rangeand moving, is 83 dB(A).

Sound Performance for MachinesOffered in European UnionCountries and in Countries thatAdopt the EU Directives

The operator sound pressure level is 81 dB(A)measured according to dynamic test proceduresand conditions specified in “ISO 6396” or“95/27/EC”.

As manufactured by Caterpillar, this machine’sexterior sound power level meets the criteriaspecified in the European Directives noted on thecertificate of conformance and the accompanyinglabels.

Vibration Level

The hands and arms are exposed to a weighted rootmean square acceleration that is less than 2.5 m/s2.

The whole body is exposed to a weighted rootmean square acceleration that is less than 0.5 m/s2.

Measurements are obtained on a representativemachine using the procedures in the followingstandards:

• “ISO 2631/1”

• “ISO 5349”

• “SAE J1166”

i01491726

Guards

(Operator Protection)SMCS Code: 7150

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 orderto check for structures that are bent, cracked orloose. Never operate a machine with a damagedstructure.

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 described in theOperation and Maintenance Manual, “OperatingTechniques” information.

Rollover Protective Structure(ROPS), Falling Object ProtectiveStructure (FOPS) or Tip Over

Protection Structure (TOPS)The ROPS/FOPS Structure on your machine isspecifically designed, tested and certified for thatmachine. Any alteration or any modification to theROPS/FOPS Structure could weaken the structure.This places the operator into an unprotectedenvironment. Modifications or attachments thatcause the machine to exceed the weight that isstamped on the certification plate also place theoperator into an unprotected environment. Excessiveweight may inhibit the brake performance, thesteering performance and the ROPS. The protectionthat is offered by the ROPS/FOPS Structure will be

impaired if the ROPS/FOPS Structure has structuraldamage. Damage to the structure can be causedby an overturn, a falling object, 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.

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21Safety Section

Operator Station

The Tip Over Protection Structure (TOPS) isanother type of guard that is used on some smallermachines. 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 Tip

Over Protection Structure.

Flying Object or Falling ObjectGuard (If Equipped)

Logging, demolition and other specific applicationsrequire special flying or falling operator protection.It is recommended that safety glasses be worn inaddition to using the flying object or falling objectguard.

A flying object guard needs to be installed whena work tool that creates flying objects is used.

Mesh front guards that are approved by Caterpillarare available for machines with a cab or an opencanopy. On machines that are equipped with cabs,the windshield should also be closed.

When you perform demolition applications that areabove the top of the cab or you perform loggingapplications, Caterpillar recommends the installationof a falling object guard structure. The falling objectguard structure protects the front of the structureand the top of the structure.

Additional guards may be required for specificapplications or work tools. An example of the

additional guards is a polycarbonate windowthat may have a front screen cover or a guard.The Operation and Maintenance Manual for yourmachine or your work tool will provide specificrequirements for the guards. Consult your Caterpillardealer for additional information.

i01334657

Operator Station

SMCS Code: 7000; 7301

This Caterpillar machine is equipped with a factory

installed cab that conforms to industry standards.The standards specify the clearance that is requiredin the cab for the operator. This machine complieswith one or more of the following standards:

• “SAE J154”

• “ISO 3411”

• “EN 474-1”

• “EN 23411”

Any modifications to the inside of the cab shouldnot project into this defined space. The addition ofa radio, fire extinguisher, and other equipment mustbe installed so that the defined space is maintained.Any item that is brought into the cab should notproject into this defined space. A lunch box or other

loose items must be secured. Objects must notpose an impact hazard in rough terrain or in theevent of a machine rollover.

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