DRIVING DOWN VIBRATION

The European Union Physical Agents (Vibration)

Directive 2002/44/EC

Pocket Guide
 The European Union Physical Agents (Vibration) Directive 2002/44/EC

WHY YOU NEED TO TAKE ACTION NOW

EU member states have to comply with the European Union Physical
Agents (Vibration) Directive 2002/44/EC, and transpose it no later than
July 6, 2005.

Unlike previous directives on machine sound levels and engine emissions,

you have an important role to play because the effective control of
vibration exposure is not just a function of the manufacturer's machine.

Vibration exposure results primarily from these three factors - the machine,
operator technique and ground conditions - and you have a responsibility
to influence all three.

YOUR RESPONSIBILITIES
The directive places responsibilities on employers to:

 assess the levels of vibration experienced by employees and decide if

they are likely to be exposed to limits laid out in the directive

 where necessary, take steps to reduce employees’ exposure to vibration

 provide employees with information and training on how to operate

machines to reduce the risk of exposure to vibration

 keep a record of your risk assessment and control actions

 review and update your risk assessment regularly

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 VIBRATION TYPES
Exposure to vibration at work happens in two main ways:

 whole-body vibration, or WBV

 hand-arm vibration, or HAV

Hand-arm vibration levels in earth-moving machines with a ride-on

operator are, in general, below the legal thresholds where you need to
take action. Consequently, this pocket guide deals only with the action
you should take to reduce whole-body vibration.

UNDERSTANDING VIBRATION AND

OPERATOR DISCOMFORT
Vibration experienced by employees when operating earth-moving
machines, or any vibratory equipment, may result in operator discomfort.

Caterpillar understands that our machines work in some of the harshest

environments, which can decrease operator comfort. Understanding
how vibration is transmitted and controlled can help you reduce
vibration exposure and improve operator efficiency and productivity.

The level of whole-body vibration is a combination of the severity of the

vibration and the length of time the employee is exposed.

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 The most common causes of high level whole-body vibration
exposure are:

 the machine you are operating is unsuitable for the task

 operators are using poor techniques, such as driving too fast or

operating the machine too aggressively

 your employees are being jolted or continuously shaken

 machine roadways or work areas are potholed, cracked or covered

in rubble

ARE THERE ANY OTHER FACTORS INVOLVED?

Other contributions to operator discomfort include:

 poorly designed controls, making it difficult to operate the machine

easily, or to see properly without twisting or stretching

 incorrect adjustment by the operator of the seat position and hand

and foot controls, so they have to twist, bend, lean and stretch
continually to operate the machine

 sitting for long periods without being able to change position

 poor operator posture

 repeated manual handling and lifting of loads by the operator

 repeatedly climbing into or jumping down from a high cab, or one

which is difficult to access

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  the operator's level of general fitness and choice of sports activity

You should consider all these factors when assessing the risk of
whole-body vibration exposure for your employees.

WHICH INDUSTRIES ARE MOST LIKELY TO EXPOSE

OPERATORS TO WHOLE-BODY VIBRATION?
 construction and quarrying machinery

 tractors and other agricultural and forestry machinery

 industrial trucks, such as lift trucks and straddle carriers

 road haulage machines, rail machines and buses

HOW DO I ASSESS WHOLE-BODY

VIBRATION LEVELS?
Recognise that operators are exposed to some degree of vibration when
operating machines. The first step is to complete a risk assessment by
collecting the basic information you need, observing work tasks and
talking to your managers and employees. If you have a local safety
organisation or trade association, they should be able to provide
additional guidance on how to complete a risk assessment.

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 Exposures may be high where you find one or more of the following:

 the machines you are using are unsuitable for the tasks for which
they are being used

 operators are using poor techniques, such as driving too fast or

operating the machine too aggressively

 your employees are being jolted or continuously shaken

 machine roadways or work areas are potholed, cracked or covered

in rubble

This should produce enough information to allow you to record your

findings and assess which groups of your employees might be most
at risk.

The second step is to conduct a self-assessment using vibration

information provided by international institutes, organisations and
manufacturers. This pocket guide contains three examples of how
you can calculate and assess an employee's exposure to
whole-body vibration.

Most machine activities in normal use will produce daily exposures

below the limit value. But some off-road machinery operated for long
periods in conditions that generate high levels of vibration or jolting
may exceed the exposure limit value.

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 If vibration exposure information is not available, you may
commission a vibration expert to measure the WBV levels and
compare the results with those in the directive.

Once you have the results, you can determine a course of action.
If you have a local safety organisation or trade association, they
should be able to provide additional guidance on how to proceed if
exposure information is not available.

WHAT CAN I DO TO CONTROL THE RISKS FROM

WHOLE-BODY VIBRATION?
The actions you decide to take should be in proportion to the risk
identified. Where exposures are likely to be high, and where other
factors, such as manual handling, twisting or stretching, may be
significant, you may need to give higher priority to controlling the risk.

On the other hand, where vibration exposure is likely to be low, and no

other risk factors are present, you will probably need to do very little.

When you have decided what actions to take, you should also decide
who will be responsible for taking them and by when. Record these
details in your risk assessment.

There is a range of steps you can take to reduce whole-body vibration

to the levels required by the directive.

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Actions for controlling risks could include the following:

Train and instruct operators

adjust the driver weight setting on their suspension seats,
where it is available, to minimise vibration and to avoid the
seat suspension 'bottoming out' when travelling over
rough ground
adjust the seat position and controls correctly, where
adjustable, to provide good lines of sight, adequate support and
ease of reach for foot and hand controls
adjust the vehicle speed to suit the ground conditions to avoid
excessive bumping and jolting
steer, brake, accelerate, shift gears and operate attached
equipment, such as excavator buckets, smoothly
follow worksite routes to avoid travelling over rough, uneven
or poor surfaces

Choose machinery suitable for the job

Select machines with:

the appropriate size, power and capacity for the work and
the ground conditions
a suspension seat that meets ISO 7096 and gives good support to
the back, buttocks, thighs and feet
sufficient and easy adjustment of the seat for height, backrest
and seat position and which will suit a wide range of driver sizes
controls which do not require high levels of muscular effort,
stretching, leaning or twisting
access to the cab which is not awkward or difficult

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 Maintain machinery and ground surface
make sure that paved surfaces or site roadways are well
maintained - fill in potholes, level ridges and remove rubble
correctly maintain vehicle suspension systems, including cab,
tyre pressures and seat suspension
make sure the controls, hydraulic system and linkages are
well maintained
obtain advice from seat manufacturers, machine manufacturers
or vibration specialists when replacing a vehicle seat. Seats
need to be carefully matched to the vehicle to avoid making
vibration exposure worse

Plan your schedules

introduce work schedules to avoid long periods of exposure in
a single day and allow for breaks, where possible

WHAT CAN I DO IN THE LONGER-TERM?

Having taken action to reduce whole-body vibration levels, you can
take longer-term measures to reduce vibration at source.

Machinery must be designed and constructed so that risks resulting

from vibrations produced by the machinery are minimised, taking
account of technical progress and the availability of means of reducing
vibration, in particular at source.

Manufacturers should be able to provide you with information on

vibration for their machines.

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 Ask manufacturers or suppliers whether they tested the machinery
in the way you will use it.

Ask manufacturers or suppliers to advise you how to use and maintain

the machines to minimise whole-body vibration levels.

WHAT TRAINING SHOULD I GIVE TO OPERATORS?

Arrange training to tell operators about whole-body vibration,
and what they can do to reduce their level of exposure.

In particular, cover the importance of:

 sitting and posture

 how to adjust the seat for good seating position and posture
and, where a suspension seat is fitted, for the operators weight,
especially when different people drive the machine

 correct tyre pressures

 keeping speed low on uneven terrain

 avoiding debris and potholes

 varying work patterns to reduce exposure

 reporting operator discomfort, as early as possible

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 DETERMINING EXPOSURE TO WHOLE-BODY
VIBRATION
If you are planning to determine employee vibration exposure values yourself,
the following pages will help you understand the process.

The goal of the assessment process is to determine the Total Vibration

Exposure Points (PE tot ) for a particular activity. This value will help you decide
what action to take.

The first step is to use Table 1 to look up the vibration levels along
the three axes - x, y and z - for a particular machine and activity.
These three axes are at right angles to each other, as you can
see from the diagram below.

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 APPLYING SCENARIO FACTORS
When you have looked up the vibration levels in Table 1, and before
you go any further, you have to apply 'scenario factors' to these
vibration levels, where appropriate.

You will then go on to use these adjusted values to determine the

Total Vibration Exposure Points (PE tot).

You'll find the scenario factors displayed in the three columns on the
right of Table 1. They are easy to apply.

If the work scenario is light (see Example 1, Page 16)

 subtract the x axis scenario factor from the x axis vibration level reading
 subtract the y axis scenario factor from the y axis vibration level reading
 subtract the z axis scenario factor from the z axis vibration level reading

If the work scenario is average (see Example 2, Page 17)

 do not apply the scenario factors

If the work scenario is heavy (see Example 3, Page 18)

 add the x axis scenario factor to the x axis vibration level reading
 add the y axis scenario factor to the y axis vibration level reading
 add the z axis scenario factor to the z axis vibration level reading

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 Table 1 TYPICAL VIBRATION LEVELS ALONG

MACHINE MACHINE TYPE TYPICAL OPERATING VIBRATION LEVELS SCENARIO FACTORS

FAMILY ACTIVITY X axis Y axis Z axis X axis Y axis Z axis
[m/s2] [m/s2] [m/s2] [m/s2] [m/s2] [m/s2]
Compactor Single Drum Vibratory compaction (boulder) 0.47 0.53 0.41 0.17 0.22 0.12
compaction (silt) 0.29 0.28 0.28 0.08 0.17 0.11
Vibratory Asphalt with vibration 0.33 0.40 0.48 0.11 0.08 0.14
without vibration 0.35 0.43 0.36 0.13 0.20 0.19
Pneumatic-Tire Roller compacting 0.23 0.27 0.39 0.16 0.19 0.56
idling 0.03 0.04 0.04 0.01 0.01 0.01
Landfill work cycle 0.55 0.83 0.34 0.17 0.33 0.15
Excavator Compact Track excavating 0.33 0.21 0.19 0.19 0.12 0.10
Excavator hydraulic breaker app. 0.49 0.28 0.36 0.20 0.13 0.17
transfer movement 0.45 0.39 0.62 0.17 0.18 0.28
Track Excavator excavating 0.44 0.27 0.30 0.24 0.16 0.17
hydraulic breaker app. 0.53 0.31 0.55 0.30 0.18 0.28
mining application 0.65 0.42 0.61 0.21 0.15 0.32
transfer movement 0.48 0.32 0.79 0.19 0.20 0.23
Wheel Excavator excavating 0.52 0.35 0.29 0.26 0.22 0.13
transfer movement 0.41 0.53 0.61 0.12 0.20 0.19
Loader Backhoe Loader excavating 0.28 0.26 0.20 0.09 0.16 0.06
Skid Steer Loader load & carry motion 0.86 0.73 0.93 0.30 0.33 0.35
Multi Terrain Loader v-shape motion 1.21 1.00 0.82 0.30 0.84 0.32
Track Loader load & carry motion 0.89 0.67 0.52 0.12 0.16 0.10
transfer movement 0.58 0.49 0.60 0.18 0.12 0.15
v-shape motion 1.24 0.93 0.63 0.41 0.35 0.18
Compact Wheel Loader load & carry motion 0.94 0.86 0.65 0.27 0.29 0.13
Wheel Loader load & carry motion 0.84 0.81 0.52 0.23 0.20 0.14
mining application 1.27 0.97 0.81 0.47 0.31 0.47
transfer movement 0.76 0.91 0.49 0.33 0.35 0.17
v-shape motion 0.99 0.84 0.54 0.29 0.32 0.14
Motor Grader Motor Grader finish grading 0.41 0.48 0.38 0.22 0.26 0.14
hard grading 0.61 0.64 0.78 0.21 0.21 0.30
transfer movement 0.39 0.36 0.58 0.25 0.25 0.34
Paving Asphalt Paver transfer movement 0.75 0.40 1.08 0.30 0.12 0.37
Equipment work cycle 0.11 0.15 0.34 0.04 0.06 0.17
Pipe Layer Pipe Layer work cycle 0.21 0.23 0.24 0.09 0.11 0.14
Planer Cold Planer / Mill work cycle 0.15 0.14 0.17 0.05 0.08 0.03

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 MACHINE MACHINE TYPE TYPICAL OPERATING VIBRATION LEVELS SCENARIO FACTORS
FAMILY ACTIVITY X axis Y axis Z axis X axis Y axis Z axis
[m/s2] [m/s2] [m/s2] [m/s2] [m/s2] [m/s2]
Road Reclaimers Road Reclaimers cutting 0.15 0.10 0.17 0.06 0.03 0.02
roading 0.21 0.34 0.25 0.03 0.07 0.04
Scraper Wheel Scraper work cycle 1.05 0.18 1.12 0.34 0.40 0.42
Soil Stabilizer Soil Stabilizer cutting 0.15 0.10 0.17 0.06 0.03 0.02
roading 0.21 0.34 0.25 0.03 0.07 0.04
Telehandler Telehandler combination 0.79 0.54 0.68 0.04 0.02 0.10
Track-Type Track-Type Tractor dozing 0.74 0.58 0.70 0.31 0.25 0.31
Tractor ripping 1.25 1.02 0.40
1.19 0.41 0.28
transfer movement 0.87 0.80 0.97 0.43 0.40 0.34
Truck Articulated Truck loading process 0.29 0.41 0.24 0.17 0.23 0.16
travel with load 0.64 0.89 0.67 0.21 0.29 0.21
travel without load 0.82 1.02 0.81 0.26 0.26 0.28
unloading 0.49 0.42 0.30 0.25 0.33 0.18
Off-Highway Truck loading process 0.20 0.22 0.21 0.19 0.17 0.19
travel with load 0.61 0.63 0.82 0.21 0.24 0.34
travel without load 0.73 0.73 0.87 0.20 0.25 0.33
unloading 0.37 0.37 0.33 0.14 0.13 0.08

THREE AXES
Once you have applied the appropriate scenario factor to each vibration
level, take these adjusted values, along with the exposure duration for
each axis, and look up values for PEx, PEy and PEz, on Table 2.

If the vibration level reading (with scenario factor applied) does not
appear in the left hand column in Table 2, go the next highest value
in the column and use that figure to determine the P exposure.

For example: if your vibration level reading (with scenario factor applied)
is 0.67, you need to use the next highest value (0.7) to determine the
P exposure.

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 The highest of the three values - PEx, PEy and PEz - gives you
the Total Vibration Exposure Points (PE tot) for that particular
work scenario.

The value for (PE tot) will help you determine the vibration control
actions you need to take.

Table 2 TOTAL VIBRATION EXPOSURE POINTS (PE tot) VALUES

2.5 31 63 156 313 625 937 1250 1563 1875 2500
2.4 29 58 144 288 576 864 1152 1440 1728 2304
Vibration level (with scenario factor applied) [m/s ]
2

2.3 26 53 132 265 529 794 1058 1323 1587 2116

2.2 24 48 121 242 484 726 968 1210 1452 1936
2.1 22 44 110 221 441 662 882 1103 1323 1764
2.0 20 40 100 200 400 600 800 1000 1200 1600
1.9 18 36 90 181 361 542 722 903 1083 1444
1.8 16 32 81 162 324 486 648 810 972 1296
1.7 14 29 72 145 289 434 578 723 867 1156
1.6 13 26 64 128 256 384 512 640 768 1024
1.5 11 23 56 113 225 338 450 563 675 900
1.4 10 20 49 98 196 294 392 490 588 784
1.3 8 17 42 85 169 254 338 423 507 676
1.2 7 14 36 72 144 216 288 360 432 576 Exposure
Limit
1.1 6 12 30 61 121 182 242 303 363 484 Value 529
1.0 5 10 25 50 100 150 200 250 300 400
0.9 4 8 20 41 81 122 162 203 243 324
0.8 3 6 16 32 64 96 128 160 192 256
0.7 2 5 12 25 49 74 98 123 147 196
0.6 2 4 9 18 36 54 72 90 108 144 Exposure
Action
0.5 1 3 6 13 25 38 50 63 75 100 Value 100
0.4 1 2 4 8 16 24 32 40 48 64
0.3 0 1 2 5 9 14 18 23 27 36
0.2 0 0 1 2 4 6 8 10 12 16
0.1 0.2 0.5 1 2 3 4 5 6 8 hours
6 12 30 60 120 180 240 300 360 480 minutes
Exposure duration

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Grey area (PE tot value 0-100)
If the PE tot value is in the grey area and well away from the yellow
area, no action is needed. If the PE tot value is close to the yellow area,
take reasonable action to reduce vibration exposure to a minimum
and provide employee information and training on vibration reduction.

Yellow area (PE tot value 101- 529)

If the PE tot value is in the yellow area, implement a programme of
measures to reduce exposure to a minimum. Ensure health surveillance
is provided for exposed employees.

Red area (PE tot value over 529)

If the PE tot value is in the red area, take immediate action to bring
exposure below the Exposure Limit Value and implement a suitable
programme of control measures and health surveillance if the exposure
remains above the Exposure Action Value.

The following three examples show how PE tot values are determined
for different machines, operating in different conditions.

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 Example 1 COMPACT WHEEL LOADER
(Scenario: light vibration exposure)

 good working conditions (smooth terrain)

 experienced operator
 typical operating conditions: load & carry motion
 duration: 4 hours

Look up the x, y and z axes vibration levels for the compact wheel
loader in Table 1. As this is a light vibration exposure scenario,
subtract the appropriate scenario factor from each vibration
level value.

Determine the PE values (x, y and z) for the compact wheel loader by
using the exposure duration and adjusted vibration levels in Table 2
on page 14.

machine exposure X axis PEx Y axis PEy Z axis PEz

(working condition) duration vibration vibration vibration
level level level
minus scenario minus scenario minus scenario
factor factor factor
Compact wheel loader 4 hours 0.94 - 0.27 = 0.67 98 0.86 - 0.29 = 0.57 72 0.65 - 0.13 = 0.52 72
(load & carry motion) (use 0.7) (use 0.6) (use 0.6)
Total 98 72 72

The highest PE value (98) represents the Total Vibration Exposure

Points (PE tot). This determines the action you should take.

Action
Since the Total Vibration Exposure Points (PE tot ) do not exceed 100, the
Exposure Action Value is not exceeded. If the results are close to the yellow
area, take reasonable action to reduce vibration exposure to a minimum and
provide employee information and training on vibration reduction.

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 Example 2 WHEEL LOADER AND TRACK EXCAVATOR
(Scenario: average vibration exposure)
 Wheel loader
normal working conditions (smooth terrain)
experienced operator
typical operating conditions
v-shape motion (loading dumpers)
duration: 4 hours

 Track excavator
typical operating conditions
mining application
duration: 3 hours

Look up the x, y and z axes vibration levels for the wheel loader and
crawler excavator in Table 1. As this is an average vibration exposure
scenario, no scenario factors are applied to the vibration level values.

Determine the PE values (x, y and z) for the wheel loader and crawler
excavator by using the exposure duration and vibration levels in Table
2 on page 14.

machine exposure X axis PEx Y axis PEy Z axis PEz

(working condition) duration vibration vibration vibration
level level level

Wheel loader 4 hours 0.99 200 0.84 162 0.54 72

(V-shape motion) (use 1.0) (use 0.9) (use 0.6)
Track excavator 3 hours 0.65 74 0.42 38 0.61 74
(mining application) (use 0.7) (use 0.5) (use 0.7)

Total 274 200 146

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 The highest PE value (274) represents the Total Vibration Exposure
Points (PE tot). This determines the action you should take.

Action
Since the Total Vibration Exposure Points (PE tot) are between 100 and 529,
the Exposure Action Value is exceeded, but not the Exposure Limit Value.
Implement a programme of measures to reduce exposure and risks to a
minimum. Ensure health surveillance is provided for exposed employees.

Example 3 SKID STEER LOADER

(Scenario: heavy vibration exposure)

 hard working conditions (severe terrain)

 operator with limited experience
 typical operating condition: load & carry motion
 duration: 8 hours

Look up the x, y and z axes vibration levels for the skid steer loader
in Table 1. As this is a heavy vibration exposure scenario, add the
appropriate scenario factor to each vibration level value.

Determine the PE values (x, y and z) for the skid steer loader by using
the exposure duration and adjusted vibration levels in Table 2 on
page 14.

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 machine exposure X axis PEx Y axis PEy Z axis PEz
(working condition) duration vibration vibration vibration
level level level
plus scenario plus scenario plus scenario
factor factor factor
Skid steer loader 8 hours 0.86 + 0.30 = 1.16 576 0.73 + 0.33 = 1.06 484 0.93 + 0.35 = 1.28 676
(load & carry motion) (use 1.2) (use 1.1) (use 1.3)
Total 576 484 676

The highest PE value (676) represents the Total Vibration Exposure

Points (PE tot). This determines the action you should take.

Action
Since the Total Vibration Exposure Points (PE tot ) are above 529, the Exposure
Limit Value is exceeded. Take immediate action to bring exposure below the
Exposure Limit Value. Implement a suitable programme of control measures
and health surveillance if the exposure remains above the Exposure
Action Value.

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 Sources

The vibration information and calculation procedure shown in this brochure and pocket guide
is based on ISO/TR 25398 Mechanical vibration - Guideline for the assessment of exposure to
whole-body vibration of ride on operated earth-moving machines - using harmonised data
measured by international institutes, organisations and manufacturers.

This brochure and pocket guide provide information on how to assess the whole-body
vibration exposure of operators of earth-moving machines. The method is based on measured
vibration emission under real working conditions for all manufacturers' machines, not just
Caterpillar machines.

You should check the original directive, as this document only summarises part of the content of the
applicable law, and is not meant to substitute taking reference from original sources. Other parts of
these documents are based on information from the United Kingdom Health and Safety Executive.

Contact your local Caterpillar dealer for more information on how to select machine features to
minimise operator vibration and operate your Caterpillar machines safely.

Visit www.cat.com to find your local dealer

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HEGQ3339 (10/2005) hr

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All Rights Reserved