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CHAPTER01-GENERAL FOREWORD
This TechnicalHandbook(THB) hasbeenwrittenwith theservicingmechanic inmindand containsimportantinformationrequiredtocarry outrepairandservicingprocedures.
Readthroughthe TechnicalHandbook,butalso the OperatingInstructions forthe WheelLoader beforecommencinganyservicingorrepair work.The TechnicalHandbook,aswellasthe OperatingInstructions and SparePartsList shouldbeusedasasourceofreferenceand assistance-evenwhentheuseriswellacquaintedwiththerangeoftheWheelLoaders.
UsingtheTechnicalHandbookallowstheexperiencedmechanictocarryoutrepairworkina correctmanner.
UsingtheTechnicalHandbook
TheTechnicalHandbookisdividedintomainand sub-groupsthatdealwiththemachineasactually delivered.Anyauxiliaryattachmentsoroptional upgradingintroducedlaterarenotdescribed. Themaintableofcontentsallowstofindthe requiredinformationquickly.
Forthesakeofclarity,theillustrationshavebeen simplifiedandcanthereforedifferslightlyfromthe actualappearanceofthemachine.
Servicingandrepair
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Servicingandrepairworkshouldbecarriedout assoonaspossible.Thiskeepsoverallservicing &repaircoststoaminimumandincreasesthe availabililyoftheWheelLoader.
Duringservicingandrepairwork,alwaysfollow theinstructionscontainedintheTechnicalHandbookandOperatinginstructions.
The AfterSalesService isalwaysavailablefor assistanceandadvice.
Warningsandsymbols
Thefollowingsignsareusedinthemanualto designateinstructionsofparticularimportance:
Precautionaryrulesandmeasures designedtoprotectthemachine operatorandotherpersonsfrom life-threateningdangerorinjuries andtopreventextensivedamage.
Informationandprecautionarymeasuresdesignedtopreventdamage tothemachineorotherproperty.
Dangerintheeventofnonobservanceofthesafetyinstructions
Thiswheelloaderhasbeenbuiltin accordancewithstate-of-the-art standardsandtherecognizedsafetyrules.
However,operatingthemachineif afaultissuspectedorhasoccurred,orcarryingoutrepairworkinexpertlymay
-endangerthelivesofpersonsin contactwithit
-damagethemachineandother property.
Thewheelloadermustbestopped immediatelyonanydamagebeing suspectedoroccurringtoensure thatthesafetyoftheoperator,of otherpersonsattheplaceofuse orofothermaterialpropertyisnot compromised.
Allcomponentsarecarefullyco-ordinated.Trouble-freeoperationand alongservicelifecanonlybe achievedwithoriginalspareparts.
Organizationalmeasures
Theoperatinginstructionsmustalwaysbeat handattheplaceofuseofthemachine,e.g.by stowingtheminthetoolcompartmentortool-box providedforsuchpurpose.
Inadditiontotheoperatinginstructions,observe andinstructtheuserinallothergenerallyapplicablelegalandothermandatoryregulationsrelevanttoaccidentpreventionandenvironmental protection.
Thesecompulsoryregulationsmayalsodealwith thehandlingofhazardoussubstances,issuing and/orwearingofpersonalprotectiveequipment ortrafficregulations.
Theoperatinginstructionsmustbesupplemented byinstructionscoveringthedutiesinvolvedin supervisingandnotifyingspecialorganizational features,suchasjoborganization,workingsequencesorthepersonnelentrustedwiththe work.
Personnelentrustedwithworkonthemachine musthavereadtheoperatinginstructionsandin particularthechapteronsafetybeforebeginning work.Readingtheinstructionsafterworkhasbegunistoolate.Thisappliesespeciallytopersons workingonlyoccasionallyonthemachine,e.g. duringsettingupormaintenance.
Check-atleastfromtimetotime-whetherthe personneliscarryingouttheworkincompliance withtheoperatinginstructionsandpayingattentiontorisksandsafetyfactors.
Forreasonsofsecurity,longhairmustbetied backorotherwisesecured,garmentsmustbe close-fittingandnojewellery,suchasrings,may beworn.Injurymayresultfrombeingcaughtup inthemachineryorfromringscatchingonmovingparts.
Useprotectiveequipmentwhereverrequiredby thecircumstancesorbylaw.
Observeallsafetyinstructionsandwarningsattachedtothemachine.
Seetoitthatsafetyinstructionsandwarnings attachedtothemachinearealwayscompleteand perfectlylegible.
Intheeventofsafety-relevantmodificationsor changesinthebehaviourofthemachineduring operation,stopthemachineimmediatelyandreportthemalfunctiontothecompetentauthority/person.
Nevermakeanymodifications,additionsorconversionswhichmightaffectsafetywithoutthe supplier’sapproval.Thisalsoappliestotheinstallationandadjustmentofsafetydevicesandvalvesaswellastoweldingworkonload-bearing elements.
Sparepartsmustcomplywiththetechnicalrequirementsspecifiedbythemanufacturer.Spare partsfromoriginalequipmentmanufacturerscan bereliedtodoso.
Replacehydraulichoseswithinstipulatedandappropriateintervals,evenifnosafety-relevantdefectshavebeendetected.
Adheretoprescribedintervalsorthosespecified intheoperatinginstructionsforroutinechecks andinspections.
Fortheexecutionofmaintenancework,toolsand workshopequipmentadaptedtothetaskonhand areabsolutelyindispensable.
Thepersonnelmustbefamiliarwiththelocation andoperationoffireextinguishers.
Observeallfire-warningandfire-fightingprocedures.
Selectionandqualificationofpersonnel
Anyworkonandwiththemachinemustbeexecutedbyreliablepersonnelonly.Statutory minimumagelimitsmustbeobserved.
Employonlytrainedorinstructedstaffandsetout clearlytheindividualresponsibilitiesofthepersonnelforoperation,set-up,maintenanceandrepair.
Makesurethatonlyauthorizedpersonnelworks onorwiththemachine.
Definethemachineoperator’sresponsibilitiesalsowithregardtoobservingtrafficregulationsgivingtheoperatortheauthoritytorefuseinstructionsbythirdpartiesthatarecontrarytosafety.
Donotallowpersonstobetrainedorinstructed orpersonstakingpartinageneraltrainingcoursetoworkonorwiththemachinewithoutbeing permanentlysupervisedbyanexperiencedperson.
Workontheelectricalsystemandequipmentof themachinemustbecarriedoutonlybyaskilled electricianorbyinstructedpersonsunderthesupervisionandguidanceofaskilledelectricianand inaccordancewithelectricalengineeringrules andregulations.
Workonchassis,brakeandsteeringsystems mustbeperformedbyskilledpersonnelonly, whichhasbeenspeciallytrainedforsuchwork.
Workonthehydraulicsystemmustbecarriedout onlybypersonnelwithspecialknowledgeand experienceofhydraulicequipment.
OPERATING,SAFETY INSTRUCTIONS Standardoperation
Avoidanyoperationalmodethatmightbeprejudicialtosafety.
Beforebeginningwork,familiarizeyourselfwith thesurroundingsandcircumstancesofthesite, suchasobstaclesintheworkingandtravelling area,thesoilbearingcapacityandanybarriers separatingtheconstructionsitefrompublicroads.
Takethenecessaryprecautionstoensurethat themachineisusedonlywheninasafeand reliablestate.
Operatethemachineonlyifallprotectiveand safety-orienteddevices,suchasremovablesafety devices,emergencyshut-offequipment,soundproofingelementsandexhausters,areinplace andfullyfunctional.
Checkthemachineatleastonceperworking shiftforobviousdamageanddefects.Reportany changes(incl.changesinthemachine’sworking behaviour)tothecompetentorganization/person immediately.Ifnecessary,stopthemachineimmediatelyandlockit.
Intheeventofmalfunctions,stopthemachine immediatelyandlockit.Haveanydefectsrectifiedimmediately.
Startthemachinefromthedriver’sseatonly.
Duringstart-upandshut-downproceduresalways watchtheindicatorsinaccordancewiththeoperatinginstructions.
Beforesettingthemachineinmotion,makesure thatnobodyisatrisk.
Beforestartingworkortravellingwiththemachine,checkthatthebraking,steering,signalling andlightingsystemsarefullyfunctional.
Beforesettingthemachineinmotionalways checkthattheaccessorieshavebeensafelystowedaway.
Whentravellingonpublicroads,waysandplaces alwaysobservethevalidtrafficregulationsand,if necessary,makesurebeforehandthatthemachineisinaconditioncompatiblewiththeseregulations.
Inconditionsofpoorvisibilityandafterdarkalwaysswitchonthelightingsystem.
Personsaccompanyingthedrivermustbeseated onthepassengerseatsprovidedforthispurpose.
Whencrossingunderpasses,bridgesandtunnels orwhenpassingunderoverheadlinesalways makesurethatthereisissufficientclearance.
Alwayskeepatadistancefromtheedgesof buildingpitsandslopes.
Avoidanyoperationthatmightbearisktomachinestability.
Nevertravelacrossslopes;alwayskeeptheworkingequipmentandtheloadclosetotheground, especiallywhentravellingdownhill.
Onslopingterrainalwaysadaptyourtravelling speedtotheprevailinggroundconditions.Never changetoalowergearonaslopebutalways beforereachingit.
Beforeleavingthedriver’sseatalwayssecurethe machineagainstinadvertentmovementandunauthorizeduse.
MAINTENANCE,SAFETY INSTRUCTIONS
Observetheadjusting,maintenanceandinspectionactivitiesandintervalssetoutintheoperatinginstructions,includinginformationonthereplacementofpartsandequipment.These activitiesmaybeexecutedbyskilledpersonnel only.
Briefoperatingpersonnelbeforebeginningspecialoperationsandmaintenancework,andappoint apersontosupervisetheactivities.
Inanyworkconcerningtheoperation,conversion oradjustmentofthemachineanditssafetyorienteddevicesoranyworkrelatedtomaintenance,inspectionandrepair,alwaysobservethe start-upandshut-downproceduressetoutinthe operatinginstructionsandtheinformationon maintenancework.
Ensurethatthemaintenanceareaisadequately secured.
Ifthemachineiscompletelyshutdownformaintenanceandrepairwork,itmustbesecured againstinadvertentstartingby:
-removingtheignitionkeyand -attachingawarningsign.
Carryoutmaintenanceandrepairworkonlyifthe machineispositionedonstableandlevelground andhasbeensecuredagainstinadvertentmovementandbuckling.
Toavoidtheriskofaccidents,individualparts andlargeassembliesbeingmovedforreplacementpurposesshouldbecarefullyattachedto liftingtackleandsecured.Useonlysuitableand technicallyperfectliftinggearandsuspensionsystemswithadequateliftingcapacity.Neverwork orstandundersuspendedloads.
Thefasteningofloadsandtheinstructingofcraneoperatorsshouldbeentrustedtoexperienced personsonly.Themarshallergivingtheinstructionsmustbewithinsightorsoundoftheoperator.
Forcarryingoutoverheadassemblyworkalways usespeciallydesignedorotherwisesafety-orientedladdersandworkingplatforms.Neverusemachinepartsasaclimbingaid.
Wearasafetyharnesswhencarryingoutmaintenanceworkatgreaterheights.
Keepallhandles,steps,handrails,platforms, landingsandladdersfreefromdirt,snowandice.
Cleanthemachine,especiallyconnectionsand threadedunions,ofanytracesofoil,fuelor preservativesbeforecarryingoutmaintenance/repair.Neveruseaggressivedetergents.Uselintfreecleaningrags.
Beforecleaningthemachinewithwater,steamjet (high-pressurecleaning)ordetergents,coveror tapeupallopeningswhich-forsafetyand functionalreasons-mustbeprotectedagainst water,steamordetergentpenetration.Special caremustbetakenwithelectricmotorsand switchgearcabinets.
Ensureduringcleaningofthemachinethatthe temperaturesensorsofthefire-warningandfirefightingsystemsdonotcomeintocontactwith hotcleaningagentsasthismightactivatethe fire-fightingsystem.
Aftercleaning,removeallcoversandtapesappliedforthatpurpose.
Aftercleaning,examineallfuel,lubricant,and hydraulicfluidlinesforleaks,looseconnections, chafemarksanddamage.Anydefectsfound mustberectifiedwithoutdelay.
Alwaystightenanyscrewedconnectionsthat havebeenloosenedduringmaintenanceandrepair.
Anysafetydevicesremovedforset-up,maintenanceorrepairpurposesmustberefittedand checkedimmediatelyuponcompletionofthe maintenanceandrepairwork.
Ensurethatallconsumablesandreplacedparts aredisposedofsafelyandwithminimumenvironmentalimpact.
WARNINGOFSPECIAL DANGERS
Electricenergy
Useonlyoriginalfuseswiththespecifiedcurrent rating.Switchoffthemachineimmediatelyif troubleoccursintheelectricalsystem.
Whenworkingwiththemachine,maintainasafe distancefromoverheadelectriclines.Ifworkisto becarriedoutclosetooverheadlines,theworkingequipmentmustbekeptwellawayfrom them.Caution,danger!Checkouttheprescribed safetydistances.
Ifyourmachinecomesintocontactwithalive wire
-donotleavethemachine
-drivethemachineoutofthehazardzone
-warnothersagainstapproachingandtouching themachine
-havethelivewirede-energized
-donotleavethemachineuntilthedamaged linehasbeensafelyde-energized.
Theelectricalequipmentofmachinesistobe inspectedandcheckedatregularintervals.Defectssuchaslooseconnectionsorscorched cablesmustberectifiedimmediately.
Gas,dust,steamandsmoke
Operateinternalcombustionenginesandfueloperatedheatingsystemsonlyonadequately ventilatedpremises.Beforestartingthemachine onenclosedpremises,makesurethatthereis sufficientventilation.
Observetheregulationsinforceattherespective site.
Carryoutwelding,flame-cuttingandgrinding workonthemachineonlyifthishasbeenexpresslyauthorized,astheremaybeariskof explosionandfire.
Beforecarryingoutwelding,flame-cuttingand grindingoperations,cleanthemachineandits surroundingsfromdustandotherinflammable substancesandmakesurethatthepremisesare adequatelyventilated.RISKOFEXPLOSION.
Hydraulicandpneumaticequipment
Checkalllines,hosesandscrewedconnections regularlyforleaksandobviousdamage.Repair damageimmediately.Splashedoilmaycauseinjuryandfire.
Depressurizeallsystemsectionsandpressure pipes(hydraulicsystem,compressed-airsystem) toberemovedinaccordancewiththespecific instructionsfortheunitconcernedbeforecarrying outanyrepairwork.
Hydraulicandcompressed-airlinesmustbelaid andfittedproperly.Ensurethatnoconnections areinterchanged.Thefittings,lengthsandquality ofthehosesmustcomplywiththetechnicalrequirements.
Noise
Duringoperation,allsoundbafflesofthemachine mustbeclosed.
Alwaysweartheprescribedearprotectors.
Oil,greaseandotherchemical substances
Whenhandlingoil,greaseandotherchemical substances,observetheproduct-relatedsafety regulations.
Becarefulwhenhandlinghotconsumables(risk ofburningorscalding).
TRANSPORTINGANDTOWINGRECOMMISSIONING
Themachinemustbetowed,loadedandtransportedonlyinaccordancewiththeoperatinginstructions.
Fortowingthemachineobservetheprescribed transportposition,admissiblespeedanditinerary. Useonlyappropriatemeansoftransportandliftinggearofadequatecapacity.
Therecommissioningproceduremustbestrictly inaccordancewiththeoperatinginstructions.