MODIFICATIONS TO YOUR ROPS/FOPS WILL VOID CERTIFICATION

Have your protective structure inspected at least every 1000 service hours, or you may be liable in an accident.

When unauthorised changes are made that may modify any of the above, the certification of the structure may be voided. Any modifications to these structures such as welding, cutting or addition of attachments, can change the metallurgy or structural strength. Such changes can reduce the effectiveness of the structures and must be avoided.

Examples of changes that may adversely affect the cab certification are:

• Drilled holes in the ROPS, FOPS seat mounting or seat
• Welding on the ROPS, FOPS seat mounting or seat
• Mounting heavy objects using existing cab bosses
• Use of untested (per the standards) cab mounts
• Use of attachments that exceed the machine certification weight
• Use of a seat or seat belt other than listed as standard or optional for the machine
• Installing monitoring screens etc which invade the operator safe zone or interfere with visibility
• Any dents or deformation of the ROPS, FOPS structure
• Excessive rust of the ROPS, FOPS structure
• Heat discoloration and/or grinding on the ROPS, or FOPS structure

Failure to receive advanced approval from the manufacturer for any or all of these items may result in voided cab certification.

ROPS Australia will visually inspect the structure. You must arrange this to occur at least every 1000 service hours or as recommended in the operation and/or maintenance guide.

ROPS Australia will repair or replace if any of the following are found:

Loose or missing bolts - Replace any bolts with those specified by the manufacturer and tighten to the recommended torque specifications.

Worn or damaged rubber - mounting pads - If the mounting pad cannot be visually inspected for wear, replacement is necessary if the ROPS rattles (makes noise) when the machine is operated on a rough surface. Ensure that mounts are only replaced with those specified by the manufacturer.

Corrosion - Contact the manufacturer for details on reparability limits.

Generally minor damage - Non-structural damage e.g. damage to removable panels, doors, windows and attachments, may be repaired.

Machine Rollover or struck by falling object - If a machine has experienced a rollover, or has been struck, the certification may be voided and an inspection by the manufacturer or a suitably qualified engineer is recommended. If there is any visible permanent damage or if the structures mounting brackets, legs or roof structure members are deformed the structure must be inspected by the manufacturer or a suitably qualified engineering company such as ROPS Australia, or replaced altogether. Replacement of all mounting bolts for ROPS and FOPS structures is necessary.

Cracks in welds or parent metal of the structure - Some cracks in the welds may be repairable. Parent metal cracks that originate from welds may also be repairable. Parent metal cracks not originating from the welds should not be repaired. Contact ROPS Australia for details on reparability limits.

Bent, deformed or broken ROPS legs or mounting brackets - Repairs should not be made and replacement of the ROPS and/or mounting brackets is necessary. If damage to any structural component is detected, it may be repaired by replacing the damaged components in a manner and with parts supplied and approved by the manufacturer. If this cannot be done, the structure should be replaced. Under no circumstances should a damaged structure be straightened. The manufacturer or a suitably qualified engineering company should certify any structural repairs carried out.

Machine Fire - Structures that have experienced a fire can be used again if a visual inspection of the structural members does not show evidence of permanent deformation from the heat of the fire.

Attachment Installation Guidelines - Because many countries require manufacturers to certify these structures, the unauthorised alteration or modification of these structures voids the certification. As a result, government inspectors can and do shut down a machine for such unauthorized use. For example, a customer welded fire extinguisher mounting brackets on ROPS legs in the incorrect position. The ROPS was replaced at the customer’s expense because the welds were in a critical area and these ROPS could not be certified. Similarly, there have been a number of instances where customers have welded bosses, and drilled holes in protective structures for the mounting of vandalism guards. These have resulted in the need for replacement of the protective structure at the owner’s expense.

Do not drill, cut, or apply heat to a structure for either repair or modification without authorisation from the manufacturer. Where a protective device has been damaged or modified to the extent that the effectiveness of the structure and/or the mounting system has been impaired, which could include rust, then the owner/controller of the machine has an obligation to repair it before it is put back into service.

Seatbelts and anchorages must be maintained and kept in an effective condition at all times. A seatbelt warning sign should be prominently displayed in every protective structure cabin. Operator manuals should also explain the increased level of protection provided by wearing these restraint devices in the event of a roll over or other such incident. It needs to be remembered that these structures are fitted to provide protection to the operator, and should not be modified in any way that may reduce this level of protection.

For this reason it is of the utmost importance that you stay in close contact with your ROPS/FOPS manufacturer, such as ROPS Australia.

ROPS Australia design, fabricate and destructively test ROPS and FOPS to suit the majority of makes and models of vehicle in the Australian market. Including the fully authorised inspection and re-certification of existing ROPS and FOPS, whether produced by them or not.

For more information on this process phone 08 9583 3944 or contact us.