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Safety Notes
June 2004 - 9507ES/5
General Safety Notes
Fatigue and finite life problems associated with
welded products such as ROLL OVER PROTECTIVE
STRUCTURES (ROPS).
Operational experience of ROPS indicates that equipment
of this type may become structurally inadequate and has
even failed during normal operations because users have
not inspected and maintained this equipment. Although
ROPS seem to be relatively maintenance-free, regular
periodic inspections to ensure ROPS are damage free and
thus capable of functioning in a rollover cannot be over
emphasized. Through periodic inspections, cracks, loose
bolts, damage, and other normal wear and tear related
problems can be eliminated before they become serious.
Proper inspection and maintenance procedures can
ensure that ROPS will perform the lifesaving function they
are designed for and expected to do.
Introduction
There are in-service factors which tend to degrade a ROPS/
FOPS systems energy absorbing or load carrying
capability.
A few of these factors are:
z Structural damage from vibrations and/or loadings
during some operations.
z A corrosive environment
z Continued use of the machine after rollover or accident
involving structural damage
z Unauthorized modification
z Worn or deteriorated isolation mounts
z Bolt replacement with less than the correct grade or
neglect in maintaining proper bolt torque
z Improper installation
Any of these factors can cause an unsafe condition to exist
as well as exposing all concerned parties to liability
damages. The following guidelines will be helpful if
followed.
Attachments and/or Modifications
Generally ROPS/FOPS structures are not intended as
external load carrying members and must not be used to
mount attachments such as pull hooks, winches, side
booms, etc. without the manufacturers approval.
Non external load transmitting attachments such as
mirrors, fans, heaters, lights, etc. should be installed
following the manufactures guidelines. Typically these
attachments are located in non critical areas such as roof
sheets, enclosure sheet metal, or the middle portion of the
ROPS legs.
Modifications to basic design such as increasing canopy
height, or relocating ROPS legs should be avoided as
recertification is required.
Maintenance
Inspection - A scheduled, frequent visual check of mounting
hardware by operation or service personnel is recommended.
As most ROPS are different and function in different service
environments, no specific inspection interval can be
recommended. Inspection in conjunction with regular service
intervals is suggested. The inspection should check for:
z Worn, damaged or missing resilient mounts. Excessive
motion or rattling during operation are indications of a
problem. The mounts should be disassembled and
repaired if required.
z Loose, missing or damaged mounting hardware (bolts, nuts,
washers, etc.). Bolts should be checked for proper torque.
z Cracks in ROPS/FOPS structure and mounting system.
The machine should be cleaned and disassembled as
necessary to allow inspection for cracks in the structure
and mounting system. Cracks are usually associated
with weld details and usually show as a line of rust
before it will be clear as a crack. Rust lines should be
taken as indications of cracks and verified by inspection
following the manufacturers procedures. Only some
cracks will badly affect the ROPS/FOPS function.
Cracks in enclosure sheet metal generally are not
structurally important. The manufacturer can identify
the appropriate measures. If in doubt, consult the
manufacturer.
z Water drainage paths. The check should verify clear
water drainage paths so that entrapped water will not
freeze and crack or deform the structure.
z Corrosion. Extensive paint peeling and rusting should
be noted and corrective action taken.
z Seat Belt. The presence and operability of a seat belt
should be noted. The belt should be clean,free of dirt
and grease and the latch should function smoothly.
z Other inspection. The structure should be inspected
following a rollover, collision or fire.
Repair
z Replace missing or damaged hardware with the
manufactures specified hardware. Re-torque all loose
threaded fasteners to the manufacturers specifications.
z Replace worn or damaged resilient mounts to prevent
further damage to the mounting surfaces and to prevent
more severe vibration problems.
z Determine the repairability of cracks in ROPS/FOPS
structures on the basis of the crack details and effect on the
particular design. The manufacturer must be consulted at
this step. Some general rules which may be helpful are:
z Enclosure sheet metal cracks are repairable.
z Small cracks may be repairable. Consult manufacturer.
z If damaged by rollover, collision or fire consult manufacturer.
z In all cases, when doubt exists; consult manufacturer.
Roll Over Protective Structures - ROPS
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