mecalac AS 50 User manual

AS 50
MECALAC Baumaschinen GmbH Am Friedrichsbrunnen 2 D-24782 Büdelsdorf
Telefon (+49) (0)4331/351-325 Internet: www.mecalac.de
Telefax (+49)(0)4331/351-404 E-Mail: [email protected]
OPERATING INSTRUCTIONS
SWING SHOVEL LOADER
GB

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S050/S051/Z050 I
Table of contents
Introduction
Preface
MECALAC’s swivel shovel loader, articulated loader and loader excavator with backhoe are machines included
in MECALAC’s vast product range covering a wide variety of working tasks.
Decades of experience in the construction of earthmoving machines, the wide range of attachments available as
well as modern production facilities, careful testing and highest quality demand guarantee the highest degree of
reliability of your MECALAC machine.
The extent of documentation delivered by the manufacturer includes the following:
-Equipment operating instructions
-Engine operating instructions
-Equipment spare parts list
-Equipment spare parts list
-EC conformity declaration
Operation instructions
The operation instruction contains all the information which the user requires for operation and maintenance.
In the “Maintenance” section, all maintenance work and operation tests are described which can be carried out
by trained personnel. Repairs on a larger scale which may only be carried out by specialized personnel or by
personnel authorized and trained by the manufacturer, in particular those units subject to the Motor Vehicle
Construction and Use Regulations and the Regulations for the Prevention of Accidents, are not described.
Due to the construction modifications reserved by the manufacturer, there may be differences in the figures;
however, this has no influence on the technical contents.
How to handle this manual
Explanations
-The designation “left” and “right” is to be seen from the driver’s seat in driving direction.
-Optional equipment means: not fitted in series.
Information about illustrations
-(3-35)
means: chapter 3, fig. 35
-(3-35/1)
means: chapter 3, fig. 35, item 1
-(3-35/arrow)
means: chapter 3, fig. 35,

S050/S051/Z050II
Table of contents
Abbreviations used:
UVV =Unfallverhütungsvorschrift (Accident Prevention Regulations)
StVZO =Straßenverkehrzulassungsordnung (German Traffic Regulations)
Edition: 01.2012

S050/S051/Z050 III
Table of contents
Table of contents
1Fundamental safety instructions
1.1 Warnings and symbols ............................................................................................................ 1-2
1.2 Use of the loader as authorized ............................................................................................... 1-2
1.3 Organizational measures ......................................................................................................... 1-2
1.4 Selection of personnel and necessary qualifications ................................................................ 1-3
1.5 Safety information for certain operating phases ....................................................................... 1-4
1.5.1 Normal operation ..................................................................................................................... 1-4
1.5.2 Special work within the exploitation of the machine
and elimination of defects during process of work; disposal ..................................................... 1-7
1.6 Instructions regarding special categories of danger ................................................................. 1-9
1.6.1 Electrical energy ...................................................................................................................... 1-9
1.6.2 Hydraulic systems ................................................................................................................... 1-10
1.6.3 Noise ....................................................................................................................................... 1-10
1.6.4 Oil, grease and other chemical substances ............................................................................. 1-11
1.6.5 Gas, dust, steam, smoke ........................................................................................................ 1-11
1.7 Transport and towing; restart .................................................................................................. 1-11
1.8 Safety information for the contractor or the contractor’s authorized personnel ......................... 1-12
1.8.1 Organizational measures ......................................................................................................... 1-12
1.8.2 Selection of personnel and necessary qualification; additional duties ...................................... 1-12
2Signs
3Protection against theft
3.1 Identifying features on the loader ............................................................................................. 3-2
3.2 Parking the loader.................................................................................................................... 3-2
3.3 Transponder for drive-away interlock ........................................................................................ 3-3
4Description
4.1 Overview ................................................................................................................................... 4-2
4.2 Loader ...................................................................................................................................... 4-3
4.3 Changing a wheel ................................................................................................................... 4-6
4.4 Controls ................................................................................................................................... 4-8
4.5 Instrument panel ...................................................................................................................... 4-9
5Operation
5.1 Pre-use check ......................................................................................................................... 5-2
5.2 Starting up ............................................................................................................................... 5-2
5.2.1 Starting the diesel engine ........................................................................................................ 5-2
5.2.2 Winter operation ...................................................................................................................... 5-3
5.2.2.1 Fuel ......................................................................................................................................... 5-3
5.2.2.2 Changing the engine oil............................................................................................................ 5-4
5.2.2.3 Changing the oil in the hydraulic system ................................................................................. 5-4
5.2.2.4 Anti-freezing agent for the windshield washer system .............................................................. 5-4
5.2.3 Driving the loader on public roads ............................................................................................ 5-4
5.2.4 Working with the loader ........................................................................................................... 5-5
5.2.5 Heating and ventilation system ................................................................................................ 5-7
5.2.5.1 Adjusting the amount of air ...................................................................................................... 5-7
5.2.5.2 Switching on the heater ........................................................................................................... 5-7
5.3 Stopping loader operation ....................................................................................................... 5-8
5.3.1 Parking the loader.................................................................................................................... 5-8
5.3.2 Switching off the diesel engine................................................................................................. 5-8
5.3.3 Switching off the heating and ventilation system ...................................................................... 5-8
5.3.4 Leaving the loader .................................................................................................................... 5-8
5.4 Adjusting the operator’s seat ................................................................................................... 5-9
5.5 Switching the steering ............................................................................................................. 5-9

S050/S051/Z050IV
Table of contents
6Attachments
6.1 Mounting and dismounting attachments without hydraulic connections ................................... 6-2
6.1.1 Standard/lightweight bucket ..................................................................................................... 6-2
6.1.2 Fork-lift attachment .................................................................................................................. 6-3
6.1.3 Lifting hook .............................................................................................................................. 6-4
6.2 Mounting and dismounting attachments with a hydraulic connection ....................................... 6-4
6.2.1 Multi-purpose bucket ............................................................................................................... 6-4
6.3 Using other attachments .......................................................................................................... 6-6
7Rescue, towing, lashing, lifting by crane
7.1 Rescue, towing, lashing ........................................................................................................... 7-2
7.1.1 Rescuing/towing of the loader if the engine or drive has failed .................................................. 7-2
7.1.1.1 Towing the swivel loader when the engine has failed ................................................................ 7-2
7.1.1.2 Towing the swing shovel loader when the drive has failed ........................................................ 7-4
7.2 Lifting by crane ........................................................................................................................ 7-5
8Maintenance
8Maintenance plan .................................................................................................................... 8-1
8.1 Maintenance notes .................................................................................................................. 8-3
8.2 Maintenance work .................................................................................................................... 8-4
8.2.1 Checking the engine oil level ................................................................................................... 8-4
8.2.2 Checking the oil level in the axles ............................................................................................ 8-4
8.2.2.1 Rear axle ................................................................................................................................. 8-4
8.2.2.2 Planetetary gear ...................................................................................................................... 8-4
8.2.2.3 Front axle ................................................................................................................................ 8-4
8.2.3 Changing the oil in the distribution gear ................................................................................... 8-5
8.2.4 Checking the oil level in the hydraulic oil reservoir ................................................................... 8-5
8.2.5 Changing the engine oil............................................................................................................ 8-5
8.2.6 Changing the oil in the axles ................................................................................................... 8-6
8.2.6.1 Rear axle ................................................................................................................................. 8-6
8.2.6.2 Planetary gear ......................................................................................................................... 8-7
8.2.6.3 Front axle ................................................................................................................................ 8-7
8.2.7 Changing the oil in the hydraulic system ................................................................................. 8-8
8.2.8 Changing the backflow suction filter insert/suction strainer ...................................................... 8-9
8.2.9 Maintaining/replacing the air filter............................................................................................. 8-9
8.2.10 Changing the safety cartridge .................................................................................................. 8-10
8.2.11 Replacing the fuel filter ............................................................................................................ 8-11
8.2.12 Exchanging the starter battery................................................................................................. 8-11
8.2.13 Maintaining/replacing the fresh air filter .................................................................................... 8-11
8.2.14 Checking/adjusting the parking brake ...................................................................................... 8-12
8.2.15 Checking/adjusting the service brake ....................................................................................... 8-13
8.3 Lubrication points .................................................................................................................... 8-13
8.3.1 Rear axle pivot bolt .................................................................................................................. 8-13
8.3.2 Rear axle ................................................................................................................................. 8-14
8.3.3 Front axle ................................................................................................................................ 8-14
8.3.4 Bucket motor ........................................................................................................................... 8-14
8.3.5 Ball rotary connection .............................................................................................................. 8-15
8.3.6 Driver cabin door ...................................................................................................................... 8-15
8.3.7 Engine hood ............................................................................................................................ 8-15
8.3.8 Multi-purpose bucket ............................................................................................................... 8-16
9Malfunctions, causes and remedies
10 Diagrams
10.1 Wiring diagram ...................................................................................................................... 10 -1
10.2 Hydraulic circuit diagram ....................................................................................................... 10 -4

S050/S051/Z050 V
Table of contents
11 Technical data (loader)
11.1 Loader .................................................................................................................................... 11 -2
11.2 Engine ................................................................................................................................... 11 -2
11.3 Starter.................................................................................................................................... 11 -2
11.4 Alternator ............................................................................................................................... 11 -2
11.5 Hydrostatic drive unit ............................................................................................................. 11 -2
11.6 Axle loads ............................................................................................................................. 11 -2
11.7 Tires ...................................................................................................................................... 11 -3
11.8 Steering system .................................................................................................................... 11 -3
11.9 Brake system ........................................................................................................................ 11 -3
11.10 Electrical system ................................................................................................................... 11 -3
11.11 Hydraulic system ................................................................................................................... 11 -3
11.11.1 Swivel mechanism 11 -3
11.11.2 Stabilizers ............................................................................................................................. 11 -3
11.12 Fuel supply system ............................................................................................................... 11 -4
11.13 Heating and ventilation system .............................................................................................. 11 -4
11.14 Full flow suction filter ............................................................................................................. 11 -4
11.15 Electrical contamination indicator .......................................................................................... 11 -4
11.16 Oil cooler with thermostat control .......................................................................................... 11 -4
11.17 Noise emission ...................................................................................................................... 11 -4
12 Technical data (Attachments)
12 Attachments .......................................................................................................................... 12 -2
12.1 Buckets ................................................................................................................................. 12 -2
12.2 Fork-lift attachment ................................................................................................................ 12 -4
12.4 Lifting hook ............................................................................................................................ 12 -6
13 Additional options, modifications, notes on inspection for loaders
13.1 Additional options .................................................................................................................. 13 -2
13.2 Modifications .......................................................................................................................... 13 -2

Safety regulations

S45E/S45T/Z45T1-2
1Safety regulations
1Fundamental safety
instructions
1.1 Warnings and symbols
In this operation manual the following designations or
symbols are used for important information.
NOTE
Special information for the economical use of the machine.
CAUTION
Special information for necessities and prohibitions for
avoiding damages.
DANGER
Information or necessities and prohibitions for prevention of
damage to persons or extensive damage to goods.
1.2 Use of the loader as authorized
1.2.1 This machine was designed according to the
state of the art and recognized safety rules. Nevertheless
the use of the machine may cause danger for the user or
third parties or impairments to the machine or other real
values.
1.2.2 The machine and attachments may only be used
in a technical non-objectionable condition, taking all safety
regulations especially with regard to the operating manuals
(machine and engine). In particular defects which could
have a detrimental effect on the safety of the machine
should be eliminated immediately.
1.2.3 The machine is determined exclusively for the
purposes described in this operating manual. Any other
utilization is not permitted. The manufacturer is not liable
for any damage caused in this connection. The user solely
carries the risk.
The authorized use of the machine also requires the
observation of the operating manual (machine and engine)
as well as the observation of the inspection and mainte-
nance conditions.
1.3 Organizational measures
1.3.1 The operating manual (machine and engine) must
be available at all times and at the site where the machine
is in operating condition.

S45E/S45T/Z45T 1-3
Safety regulations 1
1.3.2 In addition to the operating manual (machine and
engine) the general applicable and other binding regula-
tions for the prevention of accidents (especially the safety
regulations of the German Trade Association - VBG 40) as
well as the regulations for environment protection must be
observed and the personnel must be accordingly instructed.
Traffic regulations must also be observed.
1.3.3 The personnel in charge of working with the
machine must read the operating manual (machine and
engine) before start of work, especially the chapter
concerning safety precautions.
This also applies to personnel working occasionally with
the machine, e.g. during maintenance work.
1.3.4 The driver must wear a seat belt during operation.
1.3.5 Personnel working with the machine must not
wear long flowing hair, loose clothing or jewelry including
rings as this could cause injuries by getting caught up or
pulled in by the machine.
1.3.6 All safety and danger plates on the machine must
be observed.
1.3.7 All safety and danger plates must be attached to
the machine and must be kept in legible condition.
1.3.8 In case of modifications to the machine, especially
in case of damages or changes in the operating behavior
of the machine which could influence the safety of the
machine, stop the machine immediately and inform the
competent person in charge about the incident.
1.3.9 Without the manufacturer’s consent, do not make
any modifications or conversions to the machine which
could affect safety. This also applies to the installation and
adjustment of safety devices, valves and welding work to
supporting parts.
1.3.10 Check hydraulic system, especially hydraulic
pipes, at regular intervals for defects. Immediately eliminate
any defects found.
1.3.11 The prescribed inspection periods set down in the
operating manual (machine and engine) and the mainte-
nance plan must be observed.
1.4 Selection of personnel and necessary
qualifications
Fundamental obligations
1.4.1 The machine may only be driven and maintained
by personnel selected by the employer for this purpose.

S45E/S45T/Z45T1-4
1Safety regulations
These persons must:
-have attained the age of 18 years,
-be physically and intellectually suitable,
-have been instructed in the operation or maintenance of
the machine and must have demonstrated their ability to
their employer,
-must be expected to carry out the work conveyed to them
in diligent manner.
1.4.2 Electrical work on the machine may only be
carried out by a qualified electrician or persons supervised
by a qualified electrician according to the electrotechnical
regulations.
1.4.3 Only qualified specialists may carry out work on
the transmission mechanism and to the hydraulic system.
1.4.4 Only personnel with special experience and the
necessary know-how are permitted to carry out work on the
hydraulic system.
1.5 Safety Information for Certain
Operating Phases
1.5.1 Normal Operation
1.5.1.1 Other persons must not be transported!
1.5.1.2 Start and drive the machine from the driver’s seat
only!
1.5.1.3 During starting and switching-off operation ob-
serve the control lamps according to the operation manual
(machine and engine)!
1.5.1.4 Before commencing work/driving check brakes,
steering, signal lights and lights for their functioning!
1.5.1.5 Before moving the machine always check that
the attachments are safely stowed so that no accident
may occur!
1.5.1.6 Before commencing work make yourself familiar
with the working environment. This means observing
obstacles on the working site, quality and resistance of the
soil ground, undertaking the necessary protection precau-
tions between the building site and the public traffic.
1.5.1.7 Before starting the machine make sure that no
person is endangered by the machine!
1.5.1.8 Take measures so that the machine can be
operated in a safe and functional manner. The machine
may only be operated when all safety devices, e. g.
detachable safety devices, sound-absorption, exist and
function.

S45E/S45T/Z45T 1-5
Safety regulations 1
1.5.1.9 Avoid any work operation which appears to be
dangerous!
1.5.1.10 Persons must not be carried in the working
equipment, e.g.in the attachments!
1.5.1.11 The operator may only carry out work with the
machine when no persons are in the danger zone.
The danger zone means that area near the machine where
persons may be injured
-by work-induced movements of the machine,
-by work attachments and devices,
-by loads swiveling out,
-by loads falling down,
-by attachments falling down from the machine.
1.5.1.12 In case of danger to persons the operator must
give appropriate warning signs. It may be necessary to
stop work.
1.5.1.13 In case of functional defects stop machine imme-
diately and safeguard it. Eliminate defects immediately!
1.5.1.14 Check machine at least once every shift for
external visible damage and defects with regard to any
changes and to the operating behavior of the engine.
Report any defects or changes immediately to the person
in charge. If necessary stop the machine immediately and
safeguard it.
1.5.1.15 The driver may only slew the attachments over-
head driving, operating and working areas if these areas are
suitably safeguarded by protective roofing. These protec-
tion roofs must offer appropriate safety against loads and
goods falling down. In case of doubt, it should be assumed
that they are not protective roofs.
1.5.1.16 When driving, the attachment is to be kept as
close to the ground as possible.
1.5.1.17 Please observe the applicable traffic regulations
when driving on public roads, paths or open spaces. The
machine must be brought into roadworthy condition in
beforehand.
1.5.1.18 In general, switch on lights in poor visibility and
during darkness.
1.5.1.19 If lights of the machine are not adequate for the
safe execution of certain work, additional lighting must be
provided on the working site, especially at dumping points.
1.5.1.20 Should the driver’s sight of his driving and working
area be restricted due to work-induced influences, he must
be given guidance or he must safeguard the working area
by a firm barrier.

S45E/S45T/Z45T1-6
1Safety regulations
1.5.1.21 The person giving guidance must be a reliable
person and must be informed about his tasks before
commencement of the work.
1.5.1.22 The driver and guide must agree on signals for
communication. These signals may only be given by the
driver and guide.
1.5.1.23 The guide must be easily recognizable e.g. by
wearing warning clothing and must always be in the driver’s
field of vision.
1.5.1.24 When passing subways, bridges, tunnels, elec-
trical overhead lines make sure that there is adequate
clearance!
1.5.1.25 Keep good clearance when working at the edge
of quarries, pits, rubbish dumps and embankments to
eliminate any danger of the machine plunging down. The
contractor or his deputy must stipulate the distance from
the edge taking the soil bearing capacity into consideration.
1.5.1.26 The machine may only be used at stationary
dumping areas when firmly integrated installation are
provided to prevent the machine from running or sliding
down.
1.5.1.27 Avoid such work which could have detrimental
effect on the stability of the machine.
The stability can be detrimented by:
-overloading,
-too soft ground,
-abrupt acceleration or deceleration of driving movement
or working movement,
-reversing out of high driving speed,
-working on slopes,
-driving too quickly round sharp bends,
-driving the machine on rough terrain with the bucket arm
swung.
1.5.1.28 Do not drive along slopes in traverse direction.
Always carry working equipment and loads near the
ground, especially when driving down slopes. Sudden
cornering is forbidden!
1.5.1.29 On steep inclines and gradients, the load is to be
carried on the uphill side.
1.5.1.30 Before the slope, reduce the speed and always
adapt to the local conditions! Always adapt the speed of
the machine to the environmental conditions when driving
down slopes! Never change into low gear when driving on
slopes but before entering the slope!
1.5.1.31 Reversing over a longer period must be avoided!
1.5.1.32 When leaving the machine always safeguard the
machine to prevent it from unintentionally rolling away or
prevent non-authorized persons from using it!
1.5.1.33 The driver must not leave the machine if the
attachments are not lowered or safeguarded.

S45E/S45T/Z45T 1-7
Safety regulations 1
1.5.1.34 During work-brakes and after work hours the
driver should endeavor to leave the machine on good
bearing soil and if possible on level ground and safeguard
the machine to prevent it from unintentionally rolling away.
1.5.2 Special work within the exploitation
of the machine and elimination of defects
during process or work; disposal
1.5.2.1 The prescribed dates for adjustment work, mainte-
nance work and inspections laid down in the operating
manual (machine and engine) must be strictly observed.
This also applies to details regarding the interchanging of
parts/ part equipment. This work may only be executed by
skilled personnel.
1.5.2.2 For all work concerning the operation, conversion
or adjustment of the machine and its safety devices as well
as inspection, maintenance and repair work please observe
the switching and stopping operation in accordance with
the operating manual (machine and engine) as well as the
related instructions for maintenance work.
1.5.2.3 The engine must be switched off before mainte-
nance or repair work is carried out.
1.5.2.4 The stability of the machine or the attachments
must be guaranteed at all times during maintenance and
repair work.
1.5.2.5 Maintenance and repair work may only be carried
out when the attachment is set down on the ground or
supported or when equivalent measures against un-inten-
tional movement were taken.
During maintenance and repair work under the bucket arm:
-the bucket arm must be mechanically propped up,
e.g. by inserting the bucket arm support (option) (1-1/
arrow).
-the ball block valve for working and additional hydraulic
(1-2/arrow) must be closed.
-the swing mechanism must be blocked. Remove the
blocking wedge out of the mounting (1-3/arrow), switch to
swing blocking (1-4/arrow), and secure with spring pin.
1.5.2.6 If necessary, protect the maintenance area on a
large scale.
1.5.2.7 The machine must be protected from unintentio-
nally starting after it was switched off for maintenance and
repair work:
-remove the ignition key
-attach warning sign at battery main switch.
This applies especially to works to the electrical equipment.
1.5.2.8 Individual pieces and large assemblies must be
carefully secured to hoisting equipment when being substi-
tuted to avoid any damage. Only suitable and technical
sound hoisting equipment may be used as well as crane
equipment with adequate payload. Do not stand or work
underneath suspended loads!
Figure 1-1
Figure 1-3
Figure 1-2

S45E/S45T/Z45T1-8
1Safety regulations
1.5.2.9 Only experienced personnel should be entrusted
with the securing of loads!
Loads must be secured so that they cannot slip or fall
down.
1.5.2.10 Attached loads may only be moved with the
machine when the road is graded.
1.5.2.11 When working with hoisting equipment/elevators
the slingers may only work with the approval of the driver
and from the side of the boom. The driver may only give his
consent if the machine is standing still and the working
attachment is not being moved.
1.5.2.12 Persons assisting with the guidance of loads and
slingers may only stay in visual or communication reach of
the driver.
1.5.2.13 The operator must move the load as close to the
ground as possible and avoid to swivel the load.
1.5.2.14 The operator may not move the load over the
heads of persons.
1.5.2.15 In the case of erection work having to be carried
out above normal human height, suitable safety ascent
devices and working platforms must be used. Do not use
engine parts as climbing and descending facilities. Use
safety harnesses when working at very great heights.
All handles, steps, railings, podests, platforms, ladders
must be kept free from dirt and ice.
1.5.2.16 Clean the machine, especially connections and
screw connections before commencement of maintenance
work and make sure that the machine is free from oil, fuel
oil or dirt. Do not use aggressive detergents. Use lintless
cleaning rags!
1.5.2.17 Before cleaning the machine with water or steam
jet (high pressure cleaning unit) or with detergent protect
all areas where water/ steam/ detergent may penetrate and
affect the functions or safety of the machine by a suitable
cover or by applying tape. In particular, such parts as
engine components, e.g. injection pump, generator go-
vernor, starter are very delicate.
1.5.2.18 After cleaning completely remove all protection
covering and tape.
1.5.2.19 After cleaning check all pipelines for fuel, engine
oil and hydraulic oil for leakages, loose connections,
abrased parts and damages. Eliminate defects imme-
diately.
1.5.2.20 Always fasten screw connections after comple-
tion of maintenance and repair work.
1.5.2.21 Should it be necessary to dismantle safety de-
vices during mounting, maintenance or repair work, these
safety devices must be re-installed and checked carefully
after completed maintenance and repair work.
Figure 1-4

S45E/S45T/Z45T 1-9
Safety regulations 1
1.5.2.22 Make sure that fuel, accessory material and
interchanged parts are safely disposed of with no danger
to the environment.
1.5.2.23 The machine should be checked by a specialist
before commissioning. In addition, it should be checked
after essential modifications before it returns to service.
1.5.2.24 The machine must be checked by a specialist
once a year. Furthermore, a specialist must check the
machine whenever necessary because of operating condi-
tions.
1.5.2.25 The test results must be recorded and kept in the
archives at least until the following control date.
1.6 Instructions regarding special cate-
gories of danger
1.6.1 Electrical energy
1.6.1.1 Only use original fuses (mandatory current).
Immediately switch off machine in case of breakdown of
electrical supply.
1.6.1.2 When working near overhead lines and overhead
wires, a safety clearance must be kept between the
machine and its working equipment in order to prevent
sparking over. The safety clearance depends on the nominal
voltage of the overhead/wire line. This also applies to the
distance between the lines and to the attachments and
slung loads.
The following safety clearance must be observed, to meet
the above mentioned requirement:
Nominal voltage Safety clearance
(kilovolt) (meter)
up to 1 kV 1,0 m
above 1 kV up to 110 kV 3,0 m
above 110 kV up to 220 kV 4,0 m
above 220 kV up to 380 kV 5,0 m
unknown nominal voltage 5,0 m
When approaching overhead lines all working movements
of the machine must be taken into consideration, e.g. the
position of jibs, the swinging of ropes and the dimensions
of slung loads.
In addition, attention must be paid to any roughness of soil
which could cause an inclined position of the machine thus
getting it closer to the overhead line. The fact that overhead
lines may swing out during windy weather and may reduce
the distance must also be taken into consideration.

S45E/S45T/Z45T1-10
1Safety regulations
1.6.1.3 In the case of sparking over any work or move-
ment must stop. Instructions to be followed:
bring the machine out of the danger area by lifting or
lowering the attachments or by swiveling away or driving
the machine out of the area. If this is not possible then the
following rules must be observed:
-do not leave the driver’s cabin
-warn persons standing near the machine not to approach
or touch the machine
-give immediate instructions to have the power cut off
-leave the machine only when it is sure that the electricity
in the damaged/contacted power line is switched off so
that the line is dead!
1.6.1.4 Work on the electrical system or on the operating
system may only be carried out by a skilled electrician or
by personnel instructed or supervised by such trained
electrician according to electrotechnical regulations.
1.6.1.5 The electrical installation of a machine must be
reviewed/inspected at regular intervals. Any defects, e.g.
loose connections or scorched cabling, must be elimi-
nated immediately.
1.6.1.6 The cable must be disconnected from the nega-
tive pole of the battery before inspection, maintenance or
repair of machine parts and components.
1.6.2 Hydraulic systems
1.6.2.1 Only experts may carry out work on the hydraulic
system.
1.6.2.2 All pipelines, hoses and screw connections must
be checked regularly for leakages and visible damages.
Immediately eliminate such defects. Spurting hydraulic oil
may cause injuries and fire.
1.6.2.3 Those hydraulic system segments which are to
be opened must be made free of pressure before com-
mencement of the repair work according to the assembly
group description.
1.6.2.4 The hydraulic pipelines must be correctly laid and
connected. Do not get the connections mixed up. The
spare parts must be in an accordance with the technical
requirements stipulated by the manufacturer. This is, of
course, guaranteed when original spare parts are ordered.
1.6.3 Noise
Sound protection equipment must be in protective position
during operation of the machine.

S45E/S45T/Z45T 1-11
Safety regulations 1
1.6.4 Oil, grease and other chemical
substances
1.6.4.1 The relevant safety regulations must be observed
when using oil, grease or other chemical substances.
1.6.4.2 Caution when working with hot fuel and other
accessory material (danger of burning and scalding).
1.6.4.3 Caution when working with brake fluid and battery
acid.
TOXIC AND CAUSTIC!
1.6.4.4 Be careful when working with fuel.
FIRE HAZARD!
-Before refuel, switch off engine and remove ignition key.
-Do not refuel in a closed operating area.
-Never refuel near open fire or sparks.
-Do not smoke during refueling.
-Immediately wipe up spilled fuel.
-Keep machine free of fuel, oil and grease.
1.6.5 Gas, dust, steam, smoke
1.6.5.1 The machine may only be started and run in
closed operating areas where there is sufficient ventilation.
The regulations for the respective working site must be
strictly observed.
1.6.5.2 Only carry out welding, burning and grinding work
on the machine when this is explicitly approved. Otherwise
danger of fire and explosion!
1.6.5.3 Before carrying out welding, burning and grinding
work clean the machine and its vicinity from combustibles
and make sure that the room is adequately ventilated.
Explosion hazard!
1.7 Transport and towing, restart
1.7.1 The machine may only be towed if the brakes and
steering function.
1.7.2 Towing may be carried out only by means of an
adequately dimensioned towing bar in connection with
towing devices.
1.7.3 When towing drive slowly. Persons must not
remain near the towing bar.

S45E/S45T/Z45T1-12
1Safety regulations
1.7.4 When the machine is loaded and transported the
necessary auxiliary equipment must be fitted to prevent
any unintended movement. The tires must be kept clean of
mud, snow and ice so that the machine can drive on the
ramp without danger of sliding.
1.7.5 Restart the machine strictly observing the regu-
lations of the operating manual.
1.8 Safety information for the contractor
or the contractor’s authorized personnel
1.8.1 Organizational measures
1.8.1.1 We would like to emphasize that parts and
accessories that are not supplied by us are also not tested
and approved by us. Installation and/or use of such products
can thus negatively affect the constructional qualities of
your loader and thereby reduce the active and passive
driving stability. The manufacturer cannot be held respon-
sible for damage that results from the use of non-original
parts and accessories.
1.8.1.2 Inform about the location/use of fire extinguishers
(1-5/arrow) and first-aid kit (1-6/arrow).
1.8.2 Selection of personnel, qualifications;
additional duties
1.8.2.1 Only reliable persons are allowed to work on/with
the machine. The minimum legal age must be observed.
1.8.2.2 Only employ trained or instructed personnel.
Clearly define the competencies of the personnel regarding
operation, installation, maintenance and repair work.
Ensure that only authorized personnel may work on/ with
the machine.
1.8.2.3 Determine the driver’s responsibility regarding
traffic regulations. Authorize him to refuse instructions
given by third parties when these instructions are detrimental
to the safety of the driver and the machine.
1.8.2.4 Personnel that are being trained are permitted to
operate the loader only if they are under constant super-
vision of an experienced person authorized by the employer!
Figure 1-5
Figure 1-6