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Dumper
1001/1501/2001
Edition: 01 / 2007
Spare part No.: 1000103795
Language: English
Contents
Introduction ............................................................................................................................................................. 10
1 Warranty ....................................................................................................................................................... 10
2 Safety ........................................................................................................................................................... 12
2.2Use ......................................................................................................................................................... 16
3 Description................................................................................................................................................... 20
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Steering .................................................................................................................................................. 26
Hydrauliktank .......................................................................................................................................... 27
Tires ........................................................................................................................................................ 27
Vibrations ................................................................................................................................................ 27
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Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S from serial number AB.... ......... 39
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S up to serial number AB.... ........ 39
4.2 Drivers seat + rollover bar + overhead guard Dumper 2001 ..................................................................... 40
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Refuelling ................................................................................................................................................ 61
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Battery .................................................................................................................................................... 62
Change Hydraulic OiI Filter (Combination Filter) 2001 / 2001 SLE ......................................................... 63
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23 Malfunctions ................................................................................................................................................. 75
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Introduction
This manual and the written supplementary sheets must be kept in the vehicle within easy
reach at the place provided!
This manual contains detailed instructions on the proper operation and use, care and maintenance
and the security regulations necessary for the operation of the vehicle.
- Before first using the vehicle, obtain instructions from trained expert personnel and read the
operating instructions carefully.
- Road safety, reliability and working life primarily depend on fault-free operation and
maintenance.
- LIFTON assumes no liability within the meaning of the Product Liability Act for damage or
consequential losses resulting from the improper use and handling of the products supplied by us.
- Please note that claims cannot be derived from the contents of these operating instructions,
the illustrations and details contained therein in particular such of a design nature nor shall such
give occasion for complaint.
- LIFTON reserves the right to implement technical changes and/or introduce improvements
without being obliged to install or fit the same to vehicles already manufactured.
- Since we are continuously applying our efforts to improve our products, it is possible that your
vehicle contains improvements that could not be taken into account when these operating
instructions were printed.
- The vehicle described in this manual corresponds with the technical level and security
provisions applicable at the time of printing.
If you have any further questions, please dont hesitate to contact your LIFTON distributor.
1 Warranty
The warranty and handling of warranty claims are subject to the general guidelines
of the Professional Association of the Austrian Mechanical Engineering Industry in
the version applicable at the time of printing of this manual.
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2 Safety
All the security regulations set out here and otherwise applicable must
be complied with.
CAUTION.
WARNING.
NOTICE.
The safety regulations must be kept in such a way that they are clearly
visible and available for consultation by the operating personnel at any
time.
All the adhesive labels concerning safety (notices and warnings) must
be clearly legible. Remove dirt.
They must be replaced by new adhesive labels once they are no longer
legible!
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The drivers safety and that of the persons within his field of work
are dependent on the drivers skills. For this reason, he must know
the functions of the operating elements.
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Before starting work, ensure that the operating area, the steps and the
handles are free of oil, dirt, ice and loose objects.
Risk of injuries from slipping and the like.
Use the handles provided for climbing on and off.
Before and during work in the dark, check that the lighting equipment is
operating correctly.
Before starting the dumper, ensure that no children are in the area of
danger.
Handle the dumper carefully and cautiously until you are fully familiar with
it.
Before starting the dumper, check that the cowling is closed and locked.
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When travelling downhill with a full hopper, travel slowly and reduce the engine
speed by slowly releasing the accelerator pedal. When the diesel engine is at
tick-over speed, the dumper is braked hydraulically. The centre of gravity of the
pay load moves forwards as a result of the incline. In the event of doubt, travel
downhill in reverse gear.
When parking, activate the hand-brake. If possible, do not park the dumper on
an incline. If this should be necessary, use a wheel chock or something similar.
When leaving the dumper, check that the hopper is in lowered position.
Keep the floor plates of the dump body clean to ensure that the bulk material
slips easily out of the dump body. Load only flowing material.
Lift sticking or frozen material only towards the front and with the dumper being
aligned straight in driving direction on even ground. Make sure that the material
is really coming off during dumping before the dump body is fully upright,
ohterwise the dumper may tilt.
Never drive too close to a pit since there is the risk that the edge of the pit will
collapse as a result of the wheel pressure. If the edge is sufficiently secured and
a barrier prevents the edge collapsing, the dumper may be driven closer to the
edge.
Never tip material into a pit in which people are present. If the driver cannot see
into the pit, he must be assisted by a person who can see into the pit.
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The sign OUT OF ORDER must be attached clearly visibly and legibly
on a vehicle during repairs or on adjustments.
Inform yourself about first aid measures and the location of the
- First-aid box
-Fire extinguisher
When changing engine oil, use a large collection tank. This prevents oil
escaping and damaging the environment.
Maintenance work should only be carried out when the motor is switched
off. Remove the ignition key. In the event of a risk of rolling, the wheels
should be secured with chocks. In the case of water-cooled engines, the
filler stopper for the radiator should only be half opened when the engine
is warm; this allows the steam pressure to escape. Only then may the
stopper be completely opened.
Before starting up the machine, check the steering and brakes for defects
and proper operation.
The compact dumper is suitable and designed for the transport of the
usual bulk goods arising on building sites and for concrete.
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EG-Konformittserklrung
EC-Declaration of Conformity
Dclaration de conformit
Tredegar,
........................................................ .........................................................
Ort, Datum / Place, date / Lieu, date Lee Morris / Managing Director
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EG-Konformittserklrung
EC-Declaration of Conformity
Dclaration de conformit
Tredegar,
........................................................ .........................................................
Ort, Datum / Place, date / Lieu, date Lee Morris / Managing Director
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EG-Konformittserklrung
EC-Declaration of Conformity
Dclaration de conformit
Tredegar,
........................................................ .........................................................
Ort, Datum / Place, date / Lieu, date Lee Morris / Managing Director
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3 Description
Dimensions 1001
Dimensions 1501
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Dimensions 1501 S
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Dimensions 2001
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Engine 1001
Engine Dumper 1001
up to serial number AB.... from serial number AB....
Model YANMAR 3TNE74-NSR YANMAR 3TNV76-XNSV
Typ water cooled water cooled
3-cyl. diesel engine 3-cyl. diesel engine
Stroke 1006 cm 1116 cm
Power to DIN 12,1 kW (16,5 HP) 17 kW (23,1 HP)
Engine speed 2200 U/min 3000 U/min
Battery 12V / 50 Ah 12V / 50 Ah
Diesel tank 15 l 15 l
Engine oil 2,25 l 2,25 l
Cooling water 4l 4l
Engine 1501/1501 S
Engine Dumper 1501/1501 S
up to serial number AB.... from serial number AB....
Model YANMAR 3TNE74-NSR YANMAR 3TNV76-XNSV
Typ water cooled water cooled
3-cyl. diesel engine 3-cyl. diesel engine
Stroke 1006 cm 1006 cm
Power to DIN 14 kW (19,04 HP) 17 kW (23,1 HP)
Engine speed 2500 U/min 3000 U/min
Battery 12V / 50 Ah 12V / 50 Ah
Diesel tank 15 l 15 l
Engine oil 2,25 l 2,25 l
Cooling water 4l 4l
Engine 2001/2001SLE
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Drive gear
Hydrostatic drive gear with automatic control via a self-regulating
axial piston pump and four hydraulic wheel engines.
Twin-Lock traction system, electrical direction switch, permanent
4-wheel
Drive Gear drive.
Steering
Hydrostatic articulated frame steering with emergency steering
characteristics
Working hydraulics
Working hydraulics
1001 1501/1501 S 2001
Gear pumping capacity 25 l/min 25 l/min 25 l/min
Operating pressure 170 bar 170 bar 175 bar
1001/1501/1501 S:
Double-lever control valve, dump body tilting by double-action
cylinder, dump body lifting with parallel guiding system via two
double-action cylinders.
2001:
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Hydrauliktank
Hydraulic tank
Tires
Tires
Noise emission
Noise emission
Vibrations
Fire extinguisher
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Adhesive labels
Label position
1x dump body centre Dumper: 1001/1501/1501 S
at Dumper 1501 an 1501 S, useful load 1500 kg
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1x engine bonnet
2x rear chassis
1x diesel tank
1x hydraulic tank
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1x engine bonnet
2x wing
2x dump body
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Baugruppenbezeichnung 1001/1501
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Baugruppenbezeichnung 1501 S
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Baugruppenbezeichnung 2001
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6 7 8 9 10 11 12 13
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15 11
13 12
13 13
17
3
6 16
5
4
7
1
20 2
19
18
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6 7 8 9 14 15 16 17 10 11 12 13
Betriebseinrichtungen 2001
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S up to serial number AB....
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S up to serial number AB.....
No. Capacity Function
(A)
1 30 stop solenoid, relay timer stop solenoid
2 7,5 horn
3 7,5 controller 5
4 7,5 pump solenoid valve
5 7,5 light switch
6 empty
7 empty
8 7,5 control lamps
9 empty
10 empty
11 empty
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S from serial number AB....
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S from serial number AB.....
F10 F9 F8 F7 F6 F5 F4 F3 No. Capacity Function
(A)
1 50 main fuse
2 40 main fuse
3 10 stop solenoid, relay timer stop solenoid
4 15 pump solenoid valve
5 10 horn, parking break, break light
F1 6 15 indicators
7 15 high beam light
F2 8 10 low beam light
9 10 side marker lamp
10 10 warning signal flasher
Arrangement of the fuses in the fuse box Dumper 2001
Arrangement of the fuses in the fuse box Dumper 2001
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Weight adjustments
The weight is adjusted by turning the hand screw on the rear of
the seat back. An indicator on the rear serves as check, and
should point to zero when the seat is under load.
The seat belt must not be used without the overroll bar.
Overhead guard FOPS
stop eye
stop eye
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Tie the dumper tightly to the loading surface. There are two rings located
on the front frame of the dumper and a bolt on the rear frame for this
purpose.
7 Towing device
The dumper is equipped with a towing device but is not a tractor machine
and cannot be used as such on difficult terrain.
If the dumper is used for towing on the building site, the bucket must
contain a ballast amounting to 25% of the working load. However, the
device towed plus the ballast in the bucket must not exceed the
dumpers working load. The towing bolt of the towing device must be
secured using a locking key.
WARNING: Load material only with the skip and the dumper in a straight
position! Damage may result if the loader unit hits the skip!
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8 Loader unit (2001 SLE)
The loader unit has been designed for raising loose material up to
300 kg.
The 2001 SLE is not suitable for excavating or pushing heavy material.
Bear in mind the following when using the 2001 SLE:
Skip must be lowered when loading.
Always lower the loader unit before dumping out or rotating
the skip.
Do not use the loader unit on slopes.
Other persons must stay clear of the dumper when working
Bucket must be in a horizontal position when pushing or
picking up material (see mark on bucket ram).
Dumper must be in a straight position when pushing or
picking up material (no steering).
Never use the loader unit as a crane.
Lower the bucket onto the skip when driving the dumper.
Warning: Load material only with the skip and the dumper
in a straight position!
Damage may result if the loader unit hits the
skip!
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The loader unit bucket is no earthmoving tool! Load only bulk material.
The loader unit has not been designed for higher forces.
Always engage 1st speed and do not steer the wheels when driving
against a pile of material. Always move the bucket flat on the ground
before picking up material.
When penetrating into a pile with the bucket, fully dump in the bucket
(lever to the left). Avoid spinning the wheels: this can cause damage to
the drive, or the wheels to dig into the ground on loose ground.
Raise the bucket out of the material (lever to the rear). If there is too much
material in the bucket, reverse a little to remove a little material from the
bucket.
Raise the bucket until you can see it over the front edge of the skip.
Avoid losing material by carefully dumping out the bucket (lever to the
right) and by raising the whole loader unit at the same time (lever
diagonally to the rear right).
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2 At the left side of the pump below the floor plate there is one
1
high-pressure control valve each at the top and at the bottom.
Procedure:
* Loosen castellated nut width across 14 (item 2) and turn
it out to the end of the screw.
* Turn in bolt by means of a 4 mm Allen key (item 1) until
you feel a noticeable resistance. Then make another
half turn.
4 * Take off the plastic plug (4) in the centre of the wheel
motor face.
1 2 3
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1 At the (left side of) the pump below the floor plate there is one
high-pressure control valve each at the top and at the bottom.
2
Procedure:
Loosen lock nut width across 14 part 2 and turn it
out till the end of the screw.
Turn in screw with hexagon socket head width across
4 part 1 until it is flush with the nut
* Retighten castellated nut width across 14 (item 2).
Now the device can be towed slowly (2 km/h at max.) over a short
distance (1 km at max.). Then the valves have to be activated again. To
this end proceed in reverse order (turn out screw to stop).
Place the withdrawal device with the front end on the wheel engine and
fix using screw M12x55.
1 3
2
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Check:
Pressure hoses, hose connections and hydraulic cylinder seals
for oil leaks. Radiator for water leaks Engine for water and oil leaks
Tightness of battery terminals
The oil level is to be checked using the Dipstick when the machine
is standing horizontally and the engine switched off.
If necessary, top up with engine oil. For this purpose, open the oil
cap and fill in engine oil from a clean container.
Check the level of the hydraulic oil at the inspection window on the
left side when the engine cowling is open.
(at Dumper 1001/1501/1501 S lower the first boom)
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CAUTION: Only check the coolant level when the engine is cold.
If necessary, top up with coolant. For this purpose, turn the radiator cap
anti-clockwise and remove.
10.5 Refuelling
WARNING: Never run the fuel tank empty, since otherwise the fuel
system must be bled.
When climbing onto the machine, always use both handles and the
non-slip tread. Keep the tread and pedals free of mud, oil, ice and other
residues.
Carry out the necessary checks every day before starting work (see Sec.
15 Daily maintenance)
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The driver must be sitting in the drivers seat and the seat adjusted
to his body (springs, position, back see Sec. 4.2 Drivers seat).
Starting procedure:
Stage 1: Ignition on
NOTICE: The control lamps for oil pressure and charging must
come on lamp test
Stage 3: Start
Do not turn the start engine longer than 10 seconds during each
starting attempt.
If the engine does not start, wait 30 seconds before a new attempt
to start, to allow the battery to recover.
During operation, leave the ignition key at the on position. If the key
is returned to the 0 position, the motor switches off.
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WARNING: The only safe method to bridge an empty battery is to have the
following procedure carried out by 2 persons. This is necessary
in order to remove the start aid cable without the driver having
to leave the drivers cabin while the engine is running.
CAUTION: Do not attempt to connect the charging battery with a start aid
cable if it is frozen. This can cause a fracture or an explosion.
Comply with these instructions in the given sequence and
completely as set out, in order to avoid personal injuries.
Check before connecting that the start aid battery is also a 12 V battery.
Check the start aid cable and terminals for damage, rust, etc.
1. Set the ignition keys of both vehicles to off and ensure that the operating
levers of both vehicles are in the neutral position, and that the vehicles are
not in contact with each other.
2. Unscrew the filler stoppers of the battery and check that the acid solution
is at the right level. In addition, place a clean cloth over the open filler
openings to prevent the acid solution boiling over.
CAUTION: If acid splashes onto your skin, eyes or clothes, rinse them
immediately with plenty of water.
3. Connect the two positive terminals (+) of the two batteries using one start
aid cable. Check that the cable and the terminal are firmly fixed.
CAUTION: Never try to connect the start aid cable directly to the starter
motor ignition switch, and instead always connect it to the
positive terminal (+) of the dumper battery.
The connection between the negative poles (-) using the start
aid cable should always be made last.
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4. Connect the start aid cable to the negative terminal (-) of the
battery of the dumper to be started.
5. Finally connect the start aid cable to the negative terminal (-) of
the battery of the vehicle providing assistance.
Check that the cable and terminals are firmly fixed.
Rotate the terminals of the start aid cable several times around the
battery terminals to establish a good electrical contact.
6. Now start the dumper. If it does not start immediately, start the
engine of the vehicle providing assistance in order to avoid an
excessive load on the start aid battery.
- release the start aid cable from the battery of the vehicle providing
starting assistance, first from the negative terminal (-) and then from
the positive terminal (+).
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The bucket may only be emptied lateral with flowing load material.
Observe if the material is sliding uniformly before fully raiseing the
bucket (see adhesive label on the dashboard).
Lift and empty the dump body on a plain surface only when the
dumper is aligned straight in travelling direction (see label at the
right dump body edge)
When the lifted and filled dump body shall be lowered, the control
lever may be operated only carefully to ensure slow lowering of
the dump body.
WARNING: Lowering the bucket too quickly and causing it to hit
against the frame can damage the dumper and cause
it to tip over!
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- Turn the ignition key to the 0 position, stopping the engine. Remove
the key when leaving the dumper.
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15.1 General
The working condition and the working life of machinery is influenced to a considerable extent by care
and maintenance.
Cleaning: in the first 3 months, wash only with cold water (no high pressure or steam-jet washing), after the
first 3 months ensure a minimum distance of 30 cm between the spray jets and the vehicle, do not use
water of a temperature exceeding 60 C or any aggressive detergents.
For this reason, compliance with the prescribed maintenance work is in the interest of any machine owner.
The maintenance activity is imposed as an obligation by the manufacturer. Failure to comply may lead to
restrictions of the warranty.
Maintenance work concerning the engine is set out in the engine operating instruction.
If lubricants are used that do not correspond with the manufacturers recommendations, all warranty claims
shall expire.
Before carrying out maintenance or repair work on your machine, determine the precise details of the
damage incurred.
Before starting maintenance or repair works, lower the working equipment to the ground. Insert locking
and safety levers.
- Release the residual pressure in the hydraulic system
- Allow the engine to cool (hot radiator water)
If work is to be carried out when the machine is raised, secure it appropriately (supports).
If maintenance or repairs are carried out in an enclosed space, ensure sufficient ventilation.
Dispose of oil filters, oil, etc. in accordance with the environment protection laws.
When working on or underneath the dumper, place a warning notice on the seat or easily visible and
legible in the crawler excavator.
Remove the ignition key.
Never work on the electrical equipment at humid places or with damp hands (gloves).
When working on the electrical equipment, disconnect the negative terminal (-) from the battery.
Always replace sealing elements that have been removed (O-rings, flange seals, etc.) with new ones.
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After all maintenance or repair work, clean the vehicle of all dirt and oil
residues. Danger of slipping!
The hours specified for the maintenance interval correspond with the
hours on the operating hour meter.
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Maintenance activity every 10 h every 50 h every 250 h every 500 h every 1000 h
Structural component (daily) (weekly) (6 months) (12 months) (18 months)
ENGINE
Leakage O
Visual inspection O
Fixing screws, tight fit O
Engine speed O
Exhaust system O
Tappet clearance O
Oil level O
Fuel level O
Preliminary filter with water separator O
Fuel tank X
Fuel filter O <>
V-belt: condition and tension O
Dynamo, starter O
Electrical connections O
Preheating system O
Battery fluid O
Cooling agent O
Radiator fins X
Water pump O
Cooling system and hoses O
- check - replace
X - clean (1) - replace first
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Maintenance activity every 10 h every 50 h every 250 h every 500 h every 1000 h
Structural component (daily) (w eekly) (6 months) (12 months) (18 months)
HYDRAULIC UNIT
Fixing screws, Hydraulic pumps O
Leakage (lines, pumps, cylinders) O
ELECTRICAL SYSTEM
Pilot lamps O
Function of system O
Fixing O
TRAVELLING GEAR
Wheels after work O
Wheel nuts O
Wheel bearings O
- check - replace
X - clean (1) - replace first
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Maintenance activity every 10 h every 50 h every 250 h every 500 h every 1000 h
GENERAL
Hydraulic fittings and hoses O
Bolts O
Lighting equipment O
Fixing of lines O
- check - replace
X - clean (1) - replace first
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16 Daily maintenance
16.2 Engine
The oil level must be checked using a measuring rod when the machine
is standing horizontally and the engine is switched off.
Also check the quality of the oil; if the oil is particularly dirty, change the
oil before expiry of the interval.
NOTICE: The notches of the oil measuring rod show the minimum and
maximum oil levels.
If necessary, top up with engine oil. For this purpose, open the oil cap
and fill in engine oil from a clean container.
WARNING: The quality of the engine oil is shown on the list of lubricants.
Only use engine oil of the same quality.
CAUTION: Only check the coolant level when the engine is cold.
If necessary, top up with coolant. For this purpose, turn the radiator cap
anti-clockwise and remove.
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WARNING: If the control lamp on the dashboard lights up, the air
filter must be cleaned immediately.
Important when working with high concentrations of
dust.
Refuelling
WARNING: Never run the fuel tank empty, since otherwise the
fuel system must be bled.
16.3 Hydraulics
Check the level of the hydraulic oil at the inspection window on the
left side when the engine cowling is open.
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17.1 Engine
V-belt tension
The first filling of engine oil and oil filter must be replaced especially after
the first 50 hours.
The further oil change intervals are contained in the engine operating
instructions.
Battery
When replacing the battery, dispose of the old battery in accordance with
the environment protection laws.
NOTICE: The battery acid level must be between the minimum and
the maximum marks. Only top up battery acid with distilled
water.
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Remove dirt, dust, leaves, etc. from the radiator fins. Clean at
shorter intervals in higher concentrations of dust.
Check and replace if necessary the cooling water hose and
cooling clamps.
17.2 Hydraulics
Hydraulic pump
Remove dirt, dust, leaves, etc. from the radiator fins. Clean at
shorter intervals in higher concentrations of dust.
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Lubrication plan 1001 / 1501
Before starting any maintenance work with the dump body tilted,
fold down the red maintenance support by removing the pin and
tilting up the dump body. The support will retain the dump body
in case it starts dropping.
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Before starting any maintenance work with the dump body tilted,
fold down the red maintenance support by removing the pin and
tilting up the dump body. The support will retain the dump body
in case it starts dropping.
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Before starting any maintenance work with the dump body tilted,
fold down the red maintenance support by removing the pin and
tilting up the dump body. The support will retain the dump body
in case it starts dropping.
Check the tire pressure visually every day. Test the tire pressure
by means of pressure gauge once a week.
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18.1 Engine
18.2. Hydraulics
Check the fixing of the cable harness and battery. Tighten if necessary
and secure against twisting.
* Before the cold weather starts, check the battery acid for frost
protection. Switch to winter diesel if necessary. Check engine coolant for
frost protection.
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19.1 Engine
Open the cap, unscrew the filter cartridge, remove the cartridge
and replace with a new cartridge. Clean the dust separator.
19.2 Hydraulics
Readjust if necessary.
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* Open the intake filter (horizontal) (SW27) and replace the filter cartridge.
* Top up with clean hydraulic oil via filter unit (filtration 16 mm) until the
inspection glass is covered up to the top edge.
* Insert a new return filter cartridge and close the cap properly.
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20.1 Engine
20.2 Tyres
20.3 Brakes
Functional test for efficiency of foot brake, parking brake and
auxiliary brake. If the braking action has become insufficient,
please contact the manufacturer.
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* Disconnect the earth cable from the battery or remove the battery and
store in a protected place
WARNING: When laid-up, the machine should be started and run without
load once a month.
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22 Lubricants table
BP Energol SHF 46
Hydraulic oil
Fina Hydrav TSX 46
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23 Malfunctions
ENGINE
Engine cannot be started No fuel Refuel
INDICATOR LAMPS
Engine oil pressure indicator Oil pressure too low Stop engine immediately, check oil
lamp comes on during level and top up if necessary
operation
If oil level is correct, oil pump is
defective
(service workshop)
Charge monitor lamp comes Generator not charging properly Re-tension V-belt
on during operation
Parking brake pilots lamp lightsOil level in the tank of the main braking Refill oil
up during operation cylinder is too low
Pilot lamp for hydraulic oil filter Oil filter clogged Change oil filter
lights up and audible warning
signal is given when engine is Switch at filter defective Change witch
warm
Fuel reserve pilot lamp lights Too little fuel Refill fuel
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Contents
S E A L I N G S, H O S E S
Oil, fuel spots below the engine Loose hose connections Tighten hose connection
Oil loss in hydraulic system Loose hose fittings Tighten hose fittings, check
hydraulic oil level, top up if
necessary
Dumper doesn`t lift load Primary pressure relief valve Check pressure with pressure
adjusted too low gauge -> setting 170 bar
(franchised workshop)
Cylinders are lowering too fast Sets of seals soiled or defective Franchised workshop
Hydraulic oil foaming out of the tank Air in the system Retighten suction hoses
venting system
Dump body was lowered with Remove oil traces (no dump body
engine at standstill motion with engine at standstill)
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Contents
HYDRAULIK SYSTEM
Dumper cannot lift load Primary pressure valve set too low Check pressure using pressure
.-> set value 175 bar
(authorised workshop)
Hydraulic oil bubbles out of the Air in the system Tighten intake hosesn
tank vent
Bucket was lowered with the Remove traces of oil (do not move
engine switched off bucket when the engine is
switched off)
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Safety instructions
1 Preface
- excavators,
- loaders,
- excavator-loaders,
- bulldozers,
- dump trucks,
- scrapers,
- graders,
- pipe-laying machines,
- trench cutting machines,
- compactors and
- special-purpose earthmoving machines.
When operating and servicing earthmoving machinery, the respective national safety instructions,
e.g. in the Federal Republic of Germany the accident prevention regulations for earthmoving
machinery (VBG 40), vehicles (VBG 12) and the safety regulations for vehicle maintenance (ZH 1/
454), must also be observed.
As a supplement to the operating instructions, the statutory regulations for public road transport
and for accident prevention must be observed. Such regulations may, for example, also relate to
the handling of hazardous substances or the wearing of personal protective gear.
In addition, existing safety requirements must also be observed for special locations (tunnels,
galleries, quarries, pontoons, contaminated areas etc.).
2 Intended use
2.1 Earthmoving machinery must be operated only under the intended operating conditions provided
by the manufacturer in the operating instructions.
2.2 The use is as intended when the earthmoving machine is used with the corresponding operating
devices in accordance with the European or national safety regulations or for other work for which
it is suitable according to the manufacturers instructions.
2.3 Changes to the safety systems of the earthmoving machine by the owner without the prior consent
of the manufacturer are inadmissible.
2.4 Spare parts must comply with the technical requirements specified by the manufacturer.
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Safety instructions
3 General information
3.4 The earthmoving machine must be operated only in a safe, serviceable state.
3.5 The operating instructions issued by the manufacturer must be observed for operation, servicing,
repair, assembling and transport.
3.6 The contractor must supplement safety regulations where necessary with special instructions
adapted to local operating conditions.
3.7 Operating instructions and safety-relevant instructions must be in safekeeping by the operators
seat. In the case of earthmoving machinery without cabs, they may be kept at the application site.
3.8 The operating instructions and the safety instructions must be present in full and in a legible state.
3.9 Safety devices on earthmoving machinery must not be disabled during machine operation.
3.10 Protective working gear must be worn during machine operation. Rings, scarves and open jackets
must be avoided. Goggles, safety footwear, safety helmets, protective gloves, reflective
waistcoats, ear plugs etc. may be needed for specific operations.
3.11 Prior to beginning work, information on first aid and on emergency services (ambulance, fire
service, helicopter) is essential.
It must be checked that a first-aid kit complying with the regulations is present.
3.12 The location and operation of fire extinguishers on the earthmoving machine and the local fire-
alarm and fire-fighting facilities must be known.
3.13 Loose parts, e.g. tools or other accessories, must be secured on the earthmoving machine.
3.14 Doors, windows, covers, flaps etc. must be secured against inadvertent closing when in opened
state.
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Safety instructions
4 Hazard zone
4.1 All persons must keep out of the hazard zone of earthmoving machinery.
The hazard zone is the surrounding area of the earthmoving machine in which persons may be
reached by operation-induced movements of the earthmoving machine, its operating devices and
its attachments or by swinging-out loads, by falling material or by falling operating devices.
4.2 The machine operator may work with the earthmoving machine only if no person is within the
hazard zone.
4.3 The machine operator must give a warning signal if persons are exposed to danger.
4.4 The machine operator must stop working with the earthmoving machine if persons fail to leave the
hazard zone despite a warning.
4.5 No person may have access to the pivot range of earthmoving machinery with centre pivot
steering when the engine is running.
4.6 An adequate safety clearance (min. 500 mm) must be kept from fixed components, e.g. structures,
quarry faces, scaffolding or other machines, to prevent the risk of crushing.
4.7 If the safety clearance cannot be observed, the area between fixed components and the operating
range of the earthmoving machine must be closed off.
4.8 If the machine operator has a restricted view of his driving and operating area due to deployment-
induced influences, he must be assisted by a marshaller or the driving and operating area must
be secured by a fixed barrier.
5 Stability
5.1 Earthmoving machinery must be used, driven and operated in such a way that its stability or its
security against overturning is guaranteed.
5.2 The machine operator must adapt the travelling speed to local conditions and keep the operating
device as close as possible to the ground when driving over sloping or uneven terrain.
5.3 In the case of earthmoving machinery fitted with additional stabilising devices to increase stability,
the manufacturers operating instructions must be observed.
5.4 Earthmoving machinery must be kept sufficiently far away from the edge of quarries, trenches,
stockpiles and slopes to prevent any risk of overturning.
5.5 Earthmoving machinery must be secured against inadvertent movement or slippage when working
close to the edges of excavations, shafts, ditches, trenches and slopes.
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Safety instructions
6 Operation
6.1 General
6.1.1 Machine operators must be appointed by the contractor to operate or service the earthmoving
machine.
6.1.2 Operating devices (adjusting components) may be activated only by the operator or from the
operators console.
6.1.3 The steps and areas provided must be used for access to the machine. They must be kept in a
non-slip state.
6.1.4 For earthmoving machinery fitted with quick-change devices for mounting and discharging the
operating device, of which locking mechanism is not clearly visible from the operators workplace
(design, soiling), the following additional safety measures are essential:
- The firm fit of the operating device at the connection of the quick-change device must be
controlled directly by the operator or another person.
- If this is not feasible, the operating device must be lifted only to such an extent that the firm fit
can be checked by rearward tilting and dumping.
All persons must keep out of the hazard zone during this test run.
6.2.1 Apart from the machine operator, no persons may be transported on earthmoving machinery
unless special places have been provided for this purpose by the manufacturer.
These special places must be equipped with fixed seats and securing devices to prevent
persons from falling from the earthmoving machine.
6.2.2 No one may mount or alight from earthmoving machinery except with the prior consent of the
machine operator and when the machine is stationary.
6.3 Driving
6.3.1 Prior to starting up the earthmoving machine, the operators seat, the mirror and the adjustable
parts must be set in such a way as to ensure operational safety.
6.3.2 The safety belt must be applied when earthmoving machinery is fitted with a ROPS system or a
TOP protective structure.
6.3.3 The windows must be clean, and free from condensation and ice.
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Safety instructions
6.3.4 Cold-start aids (ether) must not be used near sources of heat or open flames or on poorly
ventilated premises.
6.3.5 The roadways must be designed so as to ensure smooth, safe operation, i.e. they must be
adequately wide with the lowest possible gradient and laid on a base with a good bearing
capacity.
6.3.6 The bearing capacity of bridges, basement ceilings, vaulting etc. must be checked before driving
over them.
6.3.7 The clearance dimensions of underpasses, tunnels etc. must be checked prior to driving into
them.
6.3.8 On high gradients and slopes, the load must be kept towards the incline if possible to increase
stability.
6.3.9 The engine must not be out of gear when driving downhill. Prior to driving down the slope, the
gear suited to the terrain must be selected and no gear change made while driving downhill.
6.3.10 Slopes on driveways must be designed to ensure that earthmoving machinery can be safely
braked.
6.3.12 Earthmoving machinery must not be driven on the public highway unless an operating and driving
licence compatible with the national traffic legislation is available.
6.3.13 Outside the public transport area, e.g. on construction sites, traffic regulations should be applied
analogously. This point should also be taken into account there with respect to the driving licence.
6.4.1 The machine operator must not swing the operating devices across occupied driving, operating
and working places of other machines unless they are secured with fall-over protective structures
(FOPS).
6.4.2 If the required protection above the drivers cab is not present, the driver of that vehicle must
leave the drivers stand when swinging across it is necessary.
6.4.3 The vehicles must be loaded in such a way that they are not overloaded and cannot lose any
material while being driven. They must be loaded from the lowest possible height.
6.4.4 The unloading locations must be designed to ensure that extensive reversing is avoided as fast
as possible.
6.4.5 Earthmoving machinery must not be operated at dumping sites unless appropriate measures have
been taken to prevent inadvertent movement or overturning.
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Safety instructions
6.5 Marshallers
6.5.1 Marshallers must be clearly recognisable, e.g. through special clothing. They must be within the
visual range of the machine operator.
6.5.2 During their marshalling activity, marshallers must not be given other tasks which might distract
them from their functions.
6.6.1 When there is a risk of heavy objects falling, earthmoving machines must not be used unless their
operators stand is fitted with a protective roof (FOPS); in the case of excavators a protective
windscreen (FGPS) must also be present.
6.6.2 Close to earth and rock walls, excavators should be set up and operated in such a way that the
operators stand and the steps leading to it are on the side of the earthmoving machine away from
the wall.
6.6.3 Demolition work must not be done with earthmoving machinery unless it is assured that persons
are not at risk.
6.6.4 Prior to carrying out demolition work with excavators, e.g. demolishing with demolition pendulums,
the weight of the pendulum must be coordinated with the load capacity of the machine and the
boom length.
6.6.5 The highest point of the operating device of the earthmoving machine should be above the
component to be demolished.
6.7.1 Prior to carrying out excavation work with earthmoving machinery, a check must be made in the
area to be excavated for underground lines which might present a risk to persons.
6.7.2 If underground lines are present, their location and course must be determined by agreement with
the owner or operator of the line and the necessary safety measures must be stipulated and taken.
6.7.3 The course of lines in the construction site zone must be clearly marked under supervision prior to
earthmoving work being commenced. If the location of lines cannot be determined, exploratory
trenches must be dug, if necessary by hand.
6.7.4 If underground lines or their protective coverings are contacted or damaged inadvertently, the
machine operator must stop work immediately and notify the supervisor.
6.8.1 When working with earthmoving machinery close to overhead electric lines and contact lines, a
safety clearance dependent on the voltage rating of the overhead line must be kept between such
lines and the earthmoving machine and its operating devices to prevent a voltage transfer. This
also applies to the clearance between such lines and attachments or slung loads.
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Safety instructions
6.8.3 All working movements of earthmoving machinery, e.g. the boom positions, the swinging of
cables and the dimensions of slung loads must be taken into account, as must ground
irregularities through which the earthmoving machine is tilted and thus comes closer to overhead
lines.
Wind may make overhead lines and operating devices swing out, reducing the clearance.
6.8.4 If adequate clearance from electrical transmission lines and contact lines cannot be maintained,
the contractor must implement other safety measures against voltage transfer by agreement with
the owner or operator of the lines. This may be done, for example, by
6.8.5 In the event of a voltage transfer, the following rules must be observed:
If earthmoving machinery is used below ground or in enclosed areas, adequate ventilation must
be provided and the valid regulations must be observed.
6.10 Stoppages
6.10.1 Prior to breaks or finishing work, the operator must move the earthmoving machine to level ground
with an adequate bearing capacity and secure it from movement.
The operating devices must be set down or secured in such a way that no inadvertent movement
is possible.
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Safety instructions
6.10.2 The operator must not leave the earthmoving machine unless the operating devices are set down
or secured
6.10.3 Earthmoving machines must be parked only where they present no obstacle, e.g. to public
highway or site traffic. If necessary they must be secured by warning devices such as warning
triangles, warning cords, flashing or warning lamps.
6.10.4 Prior to leaving the operating stand, the operator must set all control devices to neutral and apply
the brakes.
6.10.5 Before leaving the earthmoving machine, the operator must first switch off the driving motors and
secure them against unauthorised starting.
6.11.1 Lifting-gear deployment covers the lifting, transporting and lowering of loads by means of a
slinging aid (cable, chain etc.), with the assistance of persons being required for slinging and
releasing the load.
This means, for example, the lifting and lowering of pipes, shaft rings or containers with
earthmoving machinery.
6.11.2 Earthmoving machinery must not be used in lifting-gear deployment unless the prescribed safety
devices are present and fully functioning.
and in addition for hydraulic excavators with a legal working load of more than 1000 kg or a
overturning moment of more than 40 000 Nm
6.11.3 Loads must be slung in such a way that they cannot slip or fall out.
6.11.4 Persons involved in guiding the load and riggers must remain within the visual field of the machine
operator.
6.11.5 The machine operator must keep loads as close as possible to the ground and prevent their
swinging.
6.11.6 Earthmoving machinery must not be driven with a slung load unless the roadway is as even as
possible.
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Safety instructions
6.11.7 When earthmoving machinery is in lifting-gear deployment, riggers may approach the boom only
with the consent of the machine operator and only from the side. The machine operator must not
give his consent unless the earthmoving machine is stationary and the operating device is not
being moved.
6.11.8 No damaged or inadequately dimensioned slinging aids (cables, chains) must be used.
Protective gloves must always be worn when working with slinging aids.
7.1 Earthmoving machinery must not be assembled, converted or dismantled except under the
direction of qualified personnel appointed by the contractor and with the manufacturers operating
instructions being observed.
7.3 Stability must be ensured at all times including during maintenance work.
7.4 The operating devices must be secured from moving by being set down on the ground or with
equivalent measures, e.g. supporting sleeves or jacks. If necessary, the superstructure of
excavators must be secured against swivelling.
7.5 In the case of earthmoving machinery with centre pivot steering, the pivot joint must be positively
locked when work is being done in that area.
7.6 When installing and dismantling counterweights, they must be placed only at the locations
prescribed by the manufacturer.
7.7 For jacking up earthmoving machinery, lifting gear must be used in such a way as to prevent any
slippage. Tilted positions of the lifting gear or their inclined application are inadmissible.
7.8 Lifted earthmoving machinery must be secured by shoring up, e.g. with diagonal stacks of planks
or squared timbers or with jacks.
Earthmoving machinery which is lifted with operating devices, must be supported immediately
after being lifted. No work may be done under raised earthmoving machinery which is held in
place only by the hydraulic system.
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Safety instructions
7.9 Prior to replacing the bucket scrapers of scraper vehicles or scraper-dozers, the scraper buckets
must be set down on a non-tilting, unbreakable base.
7.10 Maintenance and repair work on scraper buckets must be done only when the closing flap is
secured.
7.11 Prior to any maintenance and repair work, the driving motors must be stopped.
Only maintenance or repair work which cannot be carried out with a drive is exempt from these
requirements. It must be ensured that the drive can be stopped immediately in any hazardous
situation prior to beginning such work.
7.12 In the case of earthmoving machinery with a combustion engine, the battery must be disconnected
prior to any work on the electrical system or any arc welding.
7.13 When disconnecting the battery, first the negative and then the positive pole must be
disconnected. Reconnection is done in the reverse sequence.
7.14 The battery must be covered with insulating material if any maintenance work is done in its vicinity.
No tools may be laid down on the battery.
7.15 In the case of electrically driven earthmoving machinery, the electrical systems and where
necessary the mobile connection lines must be switched off and secured against inadvertent or
unauthorised switching on.
7.16 Protective devices of moving machine parts must not be opened or removed unless the drive has
been stopped and secured against unauthorised starting.
Protective devices are, for example, motor compartment flaps, doors, guards, housings.
7.17 On completion of assembly, maintenance or repair work, all protective devices must be correctly
mounted again.
7.18 Welding work on load-bearing parts of earthmoving machinery, e.g. lattice booms, lifting cranks,
must be carried out in accordance with the recognised rules of welding technology.
7.19 No welding or drilling may be carried out on roll-over, tipp-over or fall-over protective structures
(ROPS, TOPS, FOPS).
7.20 Modifications, e.g. welding on the hydraulic or compressed air system, must not be undertaken
except with the authorisation of the manufacturer.
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Safety instructions
7.21 The control pressure, dynamic pressure and internal tank pressure must be reduced before
starting work on the hydraulic system.
7.22 Only those hoses and lines prescribed by the manufacturer may be used.
7.23 Hydraulic hoses and lines must be skilfully laid and installed.
7.24 Smoking and the use of open flames are forbidden during refuelling.
8.1 The recovery and towing of earthmoving machinery must be done with adequately dimensioned
towing devices only.
8.2 The towing points or blocks prescribed by the manufacturer, e.g. lugs, hooks, must be used.
8.3 The towing vehicle must be driven slowly. All persons must keep out of the range of towing
devices.
8.4 During loading and transport, earthmoving machinery and any necessary auxiliary devices must
be secured against inadvertent movement.
8.5 The travelling gear and crawler unit of earthmoving machinery must be cleaned of mud, snow and
ice to such an extent that ramps can be negotiated without a risk of slippage.
8.6 Low-loader access ramps must be fitted with wooden planks before being negotiated by tracked
vehicles.
8.7 Before the actual transport, the route to be covered should be inspected to ensure that the roads
are wide enough, bridge and underpass openings large enough, and roads, tracks and bridges
are strong enough.
9 Supervision
9.2 Before starting his work, the machine operator must also check as specified by the manufacturer
that safety, driving and operating devices, e.g. overload warning system, brakes, steering,
lighting, are fully functioning.
When mounting operating devices on quick-change systems, the firm fit of the operating device
must be checked by moving it in all directions. During this process, all persons must keep out of
the hazard zone.
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Safety instructions
9.3 Hydraulic hoses must be replaced as soon as the following damage is noticeable:
9.4 The coolant level must be checked only when the lid is cool; the lid must be turned carefully to
reduce the pressure.
9.5 The machine operator must report any recorded defects without delay to the supervisor and, in the
event of a change of operator, to the operator replacing him.
9.6 In the event of defects endangering the operational safety of the earthmoving machine, it must be
taken out of operation until the defects have been rectified.
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Safety instructions
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Neuson Limited
Crown Business Park
Tredegar
Gwent South Wales NP22 4EF
Phone (+44) 1495 723083
Fax (+44) 1495 713941
e-Mail: office@liftondumpers.com
www.neusonkramer.com