COM
D9R TRACK-TYPE
TRACTORS
Machine Safety
© 2007 Caterpillar
All Rights Reserved
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Safety Section
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Safety Messages
SMCS Code: 7000; 7405
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Illustration 2
SEBU7924-02 7
Safety Section
Safety Messages
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Illustration 3
Make sure that all of the warning signs are legible. Do not operate or work on this machine unless
Clean the warning signs or replace the warning signs you have read and understand the instructions
if you cannot read the words. Replace the illustrations and warnings in the Operation and Maintenance
if the illustrations are not legible. When you clean the Manuals. Failure to follow the instructions or heed
warning signs, use a cloth, water and soap. Do not the warnings could result in injury or death. Con-
use solvent, gasoline, or other harsh chemicals to tact any Caterpillar dealer for replacement manu-
clean the safety signs. Solvents, gasoline, or harsh als. Proper care is your responsibility.
chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning
sign to fall.
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Structural damage, an overturn, modification, al- WARNING! Shock/Electrocution Hazard! Read and
teration, or improper repair can impair this struc- understand the instructions and warnings in the
ture’s protection capability thereby voiding this Operation and Maintenance Manual. Failure to fol-
certification. Do not weld on or drill holes in the low the instructions or heed the warnings could
structure. This will void the certification. Consult cause serious injury or death.
a Caterpillar dealer to determine this structure’s
limitations without voiding its certification.
Pressurized System (5)
Seat Belt (3) This safety message is located by the filler cap for
the radiator.
This safety message is located on the LH vertical
wall next to the transmission control.
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Personal injury or death can result from a com- Do not operate or work on this equipment unless
pressed recoil spring being released suddenly us- you have read and understand the instructions
ing incorrect disassembly procedures. and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
A recoil spring that is still held in compression the warnings could result in injury or death. Con-
can result in the recoil spring being released un- tact any Caterpillar dealer for replacement manu-
expectedly with extreme force which could cause als. Proper care is your responsibility.
serious injury or death.
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Illustration 4
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Illustration 6
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Illustration 5
This message for the air conditioner has the
During periods of low idle or low load operation in appropriate information for the following services: the
below freezing temperatures, turn on the jacket water air conditioner lubricant, the refrigerant charge, and
heater that is fired by diesel fuel. This will maintain the refrigerant capacity. Also, this safety message
the engine coolant temperature at approximately instructs the usage of the proper safety information.
70 °C (160 °F).
Follow instruction in order to avoid engine damage.
Air Conditioning System (2) (If Equipped)
Reference: See Operation and Maintenance Manual,
This message is located on the lower left side of the “Maintenance Interval Schedule” for all maintenance
dash panel. recommendations.
12 SEBU7924-02
Safety Section
Crushing Prevention and Cutting Prevention
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Never jump across the starter solenoid terminals Any contact with hot coolant or with steam can cause
in order to start the engine. Unexpected machine severe burns. Allow cooling system components to
movement could result. cool before the cooling system is drained.
Whenever there are equipment control linkages the Check the coolant level only after the engine has
clearance in the linkage area will change with the been stopped.
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in Ensure that the filler cap is cool before removing the
clearance with machine movement or equipment filler cap. The filler cap must be cool enough to touch
movement. with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Stay clear of all rotating and moving parts.
Cooling system conditioner contains alkali. Alkali can
If it is necessary to remove guards in order to perform cause personal injury. Do not allow alkali to contact
maintenance, always install the guards after the the skin, the eyes, or the mouth.
maintenance is performed.
SMCS Code: 7000 Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and the hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
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Illustration 7
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Illustration 9
14 SEBU7924-02
Safety Section
Fire Extinguisher Location
Gases from a battery can explode. Keep any open Replace the parts if any of the following conditions
flames or sparks away from the top of a battery. Do are present:
not smoke in battery charging areas.
• End fittings are damaged or leaking.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or • Outer coverings are chafed or cut.
a hydrometer.
• Wires are exposed.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to • Outer coverings are ballooning.
the Operation Section of this manual for specific
instructions. • Flexible part of the hoses are kinked.
Do not charge a frozen battery. This may cause an • Outer covers have embedded armoring.
explosion.
• End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
Make sure that a fire extinguisher is available. Be are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
familiar with the operation of the fire extinguisher.
parts, and excessive heat.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate. i01834364
Do not bend high pressure lines. Do not strike high Consult your Caterpillar dealer for the proper
pressure lines. Do not install any lines that are bent procedure for mounting the fire extinguisher.
or damaged.
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Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Track Information
SMCS Code: 4170; 7000
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or Track adjusting systems use either grease or oil
cardboard to check for leaks. Tighten all connections under high pressure to keep the track under tension.
to the recommended torque.
SEBU7924-02 15
Safety Section
Electrical Storm Injury Prevention
Grease or oil under high pressure coming out of the Make sure that the machine is equipped with a
relief valve can penetrate the body causing injury or lighting system that is adequate for the job conditions.
death. Do not watch the relief valve to see if grease Make sure that all lights are working properly. Before
or oil is escaping. Watch the track or track adjustment you start the engine or before you move the machine,
cylinder to see if the track is being loosened. make sure that no one is working on the machine,
working underneath the machine or working close
The pins and bushings in a dry track pin joint to the machine. Make sure that the area is free of
can become very hot. It is possible to burn the personnel.
fingers if there is more than brief contact with these
components.
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• Dismount the machine. Note: If a warning tag is attached to the engine start
switch or to the controls, do not start the engine and
If you are in the operator’s station during an electrical
do not move any controls.
storm, stay in the operator’s station. If you are on the
ground during an electrical storm, stay away from
1. Move all hydraulic controls to the HOLD position
the vicinity of the machine.
before you start the engine.
Before Operation
SMCS Code: 7000
Clear all obstacles from the path of the machine. • Communication between workers and operators
Beware of hazards such as wires, ditches, etc. prior to approaching the machine
Make sure that all windows are clean. Secure the Modifications of the machine configuration that result
doors and the windows in the open position or in the in a restriction of visibility shall be verified according
shut position. to “ISO 5006”.
Adjust the rear view mirrors (if equipped) for the best
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vision of the area near the machine.
SMCS Code: 7000 Check for proper operation of all controls and
protective devices while you operate the machine
Before you start the machine, the operator shall slowly in an open area.
perform a walk-around inspection in order to ensure
that there are no hazards around the machine. Before moving the machine, the operator must
ensure that no one will be endangered.
While the machine is in operation, the operator should
constantly survey the area around the machine. The Do not allow riders on the machine unless the
operator needs to identify potential hazards as a machine has the following equipment:
hazard becomes visible around the machine.
• additional seat
Your machine may be equipped with mirrors or other
visual aids. An example of a visual aid is Closed • additional seat belt
Circuit Television (CCTV). The operator should
ensure that the visual aids are in proper working • Rollover Protective Structure (ROPS)
condition and that the visual aids are clean. Adjust
the visual aids for the best visibility of all areas Report any repairs that are needed and noted during
around the machine. operation.
It may not be possible to provide direct visibility on Carry attachments close to the ground, approximately
large machines to all areas around the machine. 40 cm (15 inches) above ground level. Do not go
Appropriate job site organization is required in order close to the edge of a cliff, an excavation, or an
to minimize hazards that are caused by restricted overhang.
visibility. Job site organization is a collection of rules
and procedures that coordinates machines and If the machine begins to sideslip, perform the
people that work together in the same area. Examples following procedure:
of job site organization include the following:
• Discard the load.
• Safety instructions
• Turn the machine downhill.
• Controlled patterns of machine movement
Be careful to avoid any condition which could lead
• Controlled patterns of vehicle movement to tipping. Tipping can occur when you work on
hills, banks and slopes. Also, tipping can occur
• Restricted areas when you cross ditches, ridges or other unexpected
obstructions.
• Operator training
Whenever it is possible, operate the machine up the
• Warning symbols or warning signs on machines slopes and down the slopes. Avoid operating the
or on vehicles machine across the slope, when possible.
• A system of communication
SEBU7924-02 17
Safety Section
Engine Stopping
Keep the machine under control. Do not overload the Turn the key for the battery disconnect switch to the
machine beyond capacity. OFF position. Remove the key when you exit the
machine for an extended period of time.
Towing devices and eyes that are not part of machine
must be adequate. Turning the battery disconnect switch to the OFF
position will provide the following benefits:
Connect trailing equipment to a drawbar or to a hitch
only. • Prevent battery discharge that is caused by a
battery short circuit.
Never straddle a wire cable or allow other personnel
to straddle a wire cable. • Prevent battery discharge that is caused by some
of the electrical components.
When you maneuver to connect the equipment, make
sure that no personnel are between the machine • Prevent battery discharge that is caused by
and trailing equipment. Block the hitch of the trailing vandalism.
equipment in order to align the equipment with the
drawbar.
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Park on a level surface. If you must park on a grade, Roughness of terrain or surface – The machine
use blocks to prevent the machine from rolling. may be less stable with uneven terrain.
Apply the service brake in order to stop the machine. Direction of travel – Avoid operating the machine
Move the transmission control lever to NEUTRAL across the slope. When possible, operate the
position and move the speed control to LOW IDLE machine up the slopes and operate the machine
position. Engage the parking brake. down the slopes. Place the heaviest end of the
machine uphill when you are working on an incline.
Lower all attachments to the ground.
Mounted equipment – Balance of the machine
Stop the engine. may be impeded by the following components:
equipment that is mounted on the machine, machine
Turn the engine start switch key to OFF position and configuration, weights, and counterweights.
remove the key.
18 SEBU7924-02
Safety Section
Equipment Lowering with Engine Stopped
Sound Level Information for Note: All vibration levels are in meter per second
squared.
Machines in European Union
Countries and in Countries that
Adopt the “EU Directives”
The dynamic operator sound pressure level is 85
dB(A) when “SAE J919Jun 86” is used to measure
the value for an enclosed cab. The cab was properly
installed and maintained. The test was conducted
with the cab doors and the cab windows closed.
Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Note: Refer to “ISO/TR 25398 Mechanical Vibration - b. Fill any ditches and holes.
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving c. Provide machines and schedule time in order
machines” for more information about vibration. to maintain the conditions of the terrain.
This publication uses data that is measured
by international institutes, organizations and 4. Use a seat that meets “ISO 7096”. Keep the seat
manufacturers. This document provides information maintained and adjusted.
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and a. Adjust the seat and suspension for the weight
Maintenance Manual, SEBU8257, “The European and the size of the operator.
Union Physical Agents (Vibration) Directive
2002/44/EC” for more information about machine b. Inspect and maintain the seat suspension and
vibration levels. adjustment mechanisms.
The Caterpillar suspension seat meets the criteria of 5. Perform the following operations smoothly.
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. This seat is tested a. Steer
with the input “spectral class EM6”. The seat has a
transmissibility factor of “SEAT<0.7”. b. Brake
The vibration information and calculation procedure There are different types of guards that are used to
is based on “ISO/TR 25398 Mechanical Vibration protect the operator. The machine and the machine
- Guideline for the assessment of exposure application determines the type of guard that should
to whole body vibration of ride on operated be used.
earthmoving machines”. Harmonized data is
measured by international institutes, organizations A daily inspection of the guards is required in order to
and manufacturers. check for structures that are bent, cracked or loose.
Never operate a machine with a damaged structure.
This literature provides information about assessing
the whole body vibration exposure of operators of The operator becomes exposed to a hazardous
earthmoving equipment. The method is based on situation if the machine is used improperly or if poor
measured vibration emission under real working operating techniques are used. This situation can
conditions for all machines. occur even though a machine is equipped with an
appropriate protective guard. Follow the established
You should check the original directive. This operating procedures that are recommended for your
document summarizes part of the content of the machine.
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documents are based on information from the United
Kingdom Health and Safety Executive.
Caterpillar, Inc.
www.cat.com
22 SEBU7924-02
Safety Section
Guards
The ROPS/FOPS Structure (if equipped) on your Additional guards may be required for specific
machine is specifically designed, tested and certified applications or work tools. The Operation and
for that machine. Excavators are not equipped Maintenance Manual for your machine or your
with ROPS structures. Any alteration or any work tool will provide specific requirements for the
modification to the ROPS/FOPS Structure could guards. Consult your Caterpillar dealer for additional
weaken the structure. This places the operator information.
into an unprotected environment. Modifications or
attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
structure can be caused by an overturn, a falling
object, a collision, etc.