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10 SERVICING AND INSPECTION
10.1
Basic safety instructions for servicing and inspection
Operator’s Manual Personnel
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Perform servicing and inspection work only if you have read and understood the Operator’s Manual.
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Observe the basic safety instructions and all the warning signs attached to the loader.
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The Operator’s Manual describes the work to be performed. However, the descriptions of work processes provide the necessary instructions only for experienced specialized technicians.
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Keep the Operator’s Manual with the loader at all times.
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Maintenance and inspection personnel must have specialized knowledge of servicing and inspection work on the loader. The specialized knowledge required can be obtained at training sessions from Wacker Neuson
Service.
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Perform servicing and inspection work only with suitable work clothing and personal protective equipment.
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Wear hearing protection should there be noise exceeding 90 dbA.
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Securing the loader and attachment
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Perform servicing and inspection work only if the loader is secured as described in the chapter »Securing the loader«.
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Crushing hazard. An improperly supported loader lift arm may fall unexpectedly.
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Do not perform maintenance or service tasks under raised loader lift arms until the loader lift arm support device (ISO10533) has been inserted and locked between the hydraulic lift cylinder end and the loader lift arm to prevent any movement of the loader lift arms during maintenance and service.
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Extensive repair information is provided in the separate Repair Manual.
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Position the attachments on the ground so that no movements can occur when mechanical or hydraulic connections are released.
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Do not attempt any service repair requiring the technician to perform the work standing in the articulated steering crush zone. Do not repair the hydraulic steering cylinders or remove the hydraulic lines until the articulated frame lock has been installed to prevent inadvertent steering movement.
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Secure equipment or components that are to be attached or removed, or whose installation position is to be changed, to prevent them from unintentionally moving, slipping or falling, by means of suitable lifting gear, or suspension or support equipment.
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Clean dirt from steps and handles and keep them ready for use.
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Tools
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Use diagnostic and repair tools that are in serviceable condition and have been calibrated regularly to ensure accuracy. Consult the Repair Manual for recommended special tools necessary to safely complete the repair task.
Handling combustible fluids
Fire Hazard.
• Do not smoke when handling combustible fluids and avoid fire or open flames.
• Do not use water to extinguish fires on the load
er or burning fluids. Use suitable extinguishing agents, such as powder, carbon dioxide or foam extinguishers.
• Always call the fire department in the event of a fire.
Cleaning
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Clean the machine before attempting to diagnose or repair the wheel loader.
• Do not use flammable solvents.
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Do not use cleaning agents that create harmful vapors.
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Avoid any contact with electrical or rubber products when using water or steam.
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High pressure washers are not recommended for cleaning the inside of the cab or the operator station.
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Wear appropriate protective clothing such as goggles and gloves to supplement protective clothing for the rest of the body.
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Residual pressure in the hydraulic system
Personal injury hazard.
• Pressurized jets of fluid can penetrate human skin.
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In the event that oil penetrates the skin, seek immediate medical attention to reduce the risk of infection and complications from infection.
• Confirm that the hydraulic system pressure has been relieved before attempting to repair the system or component.
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Even for a loader parked on a horizontal surface with its loader lift arms completely lowered and engine turned off, there can still be considerable residual pressure in parts of the hydraulic system.
• Residual pressure reduces gradually at first. If a hydraulic system is to be opened immediately after being shut down, the system shall be relieved before repairs are attempted. Do not attempt to work on the system if the components are not comfortable to touch. Hot surfaces and liquids can cause severe burns.
• For loaders with load holding control devices on the lifting and/or tipping cylinder, you must open the valves
as described in Section 8, page 140 »Relieving residual pressure in the hydraulic system« in order to lower
the loader lift arms.
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Handling fuel, oil and grease
Burn hazard.
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The operating temperature of the engine and hydraulic system fluids exceeds 93°C (200°F).
Contact with human skin will cause severe burns.
• Do not touch hot fluid.
• In the event of contact with hot fluid seek emer
gency room treatment immediately.
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Avoid skin and eye contact with oils and greases. Wear protective gloves and safety goggles.
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Do not use fuel or solvents to clean your skin.
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Eliminate any oil or fuel leaks immediately.
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Avoid environmental damage. Do not allow oil and oil-containing waste to spill on the ground or get into bodies of water!
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Immediately soak up with binding material any oil or fuel that has leaked, and dispose of it separately from other waste in an ecologically sound manner.
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Even biodegradable »environmentally friendly« oil must be disposed of separately, just like other oil.
Threaded connections, pipes, hydraulic hoses
WARNING
Personal injury hazard.
• Pressurized jets of fluid can penetrate human skin.
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In the event that oil penetrates the skin, seek immediate medical attention to reduce the risk of infection and complications from infection.
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Do not use your hands to look for leaks. To look for leaks, use a piece of cardboard or paper on which you can identify oil which has escaped.
• Eliminate any leaks in the hydraulic fittings, hoses or steel conduits immediately.
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Do not repair damaged pipes and hydraulic hoses; rather, replace them immediately with new ones available from your Wacker Neuson dealer even if only moisture penetration is visible.
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Batteries
Personal injury hazard. Battery acid is corrosive to metallic surfaces and harmful to human skin.
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Wear protective clothing, goggles and gloves when working near batteries.
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If battery acid contacts the skin, wash immediately in clear water.
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Seek the advice of a doctor for treatment of skin burns.
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In the event acid contacts eyes, rinse immediately with clear water and seek immediate medical attention.
Explosion hazard.
A rapidly discharged battery vents explosive gases.
• Do not use open flames or smoke near batter
ies. -Use particular caution to vent the battery storage area well to avoid gas accumulation.
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Follow jump start procedures to reduce the potential for arcing when the cables are connected and disconnected.
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Do not place metallic objects on or near the battery terminals to avoid short circuits from contact with both poles of the battery. This will generate extreme heat and potentially ignite explosive battery gases.
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Always take off jewelry and metal watches before working on the battery or the electrical system.
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Dispose of old batteries in an ecologically sound way, separate from other waste.
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Engine exhaust fumes
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Diesel engine exhaust fumes are harmful. Do not inhale exhaust gas. Do not operate the wheel loader in a closed space.
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For servicing and inspection work performed in a closed space, extract the exhaust fumes using an extraction system and ventilate the space well.
Electrical system
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Always observe the correct order when disconnecting the battery.
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Disconnecting: First the negative pole and then the positive pole.
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Connecting: First the positive pole and then the negative pole.
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Always disconnect the battery before working on the electrical system if tools, spare parts, etc. with electrical components or contacts could touch it.
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Always disconnect the battery before welding.
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After maintenance
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After completing maintenance and inspection work, always reattach all the safety devices.
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Do not start the engine until the loader is no longer being worked on and everyone has left the danger area.
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Only start the engine from the operator’s seat.
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Perform a functional test with the loader after completing servicing and inspection work.
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