RosRoca Olympus Mini User manual

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Olympus Mini
Service Manual

This Service Manual provides all the relevant service information and data necessary to carry out
designated scheduled maintenance inspections and procedures on systems and components fitted
to Ros Roca S.A. Olympus Mini Refuse Collection Bodies.
The information in this Service Manual must be used in conjunction with the Service Manuals for the
chassis‑cab and any ancillary equipment fitted to the refuse collection vehicle.
This Service Manual is primarily designed to assist skilled technicians in the efficient servicing and
repair of the systems and components described in the manual, but can also be used as a reference
workbook for training purposes.
Ros Roca S.A. Olympus Mini Refuse Collection Vehicle
Caution:
IMPORTANT: It is assumed that technicians carrying out service procedures described in
this Service Manual appreciate, understand and carry out all workshop safety and repair
procedures generally accepted by the motor vehicle repair industry.
It is most important, however, that all technicians read and understand and observe
all the instructions stated in Chapter 2 ‘Health and safety’ of this Manual whenever
undertaking any procedures described in this Manual.
FOREWORD
Olympus Mini Service Manual
F
i
OM1R-SM-GB01R
1 Foreword

Ros Roca S.A. (The Company) reserves the right to
change the specification, design, material, procedure,
and dimensions of the equipment described herein
without prior notice at any time in the future, in
accordance with the Company’s constant product
improvement policy.
Ros Roca S.A. has made every reasonable effort to
ensure the accuracy of the Company publications,
but nothing shown, described or referred to in the
publications should be regarded as an infallible guide
to the procedures, materials, specification, design
of availability of any particular vehicle, nor does this
publication constitute an offer for sale of any particular
vehicle. No liability can be accepted by the company
for any mechanical or electrical malfunction, damage,
loss injury or death caused by the use of incorrect
or misrepresented information, omissions or errors
that may have arisen during the preparation of this
publication.
© 2015 Ros Roca S.A.
ALL RIGHTS RESERVED.
Compiled and Published by:
ROS ROCA S.A.
Avda. Cervera
Tàrrega
España
Teléfono: +(34) 973 50 81 00
www.rosroca.com
No part of this publication may be reproduced, stored
in a retrieval system or transmitted in any form without
the prior permission of the Company.
Publication Record
Edition Publication reference Publication date Comments
This edition OM1R-SM-GB01R June 2015 First edition.
Original instructions.
Description
The Olympus Mini refuse collection bodywork is a rear
loaded, fixed refuse collection bodywork manufactured
to EN 1501‑1.
Intended use
The Olympus Mini refuse collection bodywork shall
be mounted on chassis‑cabs specified for refuse
collection application and shall be used to collect and
transport domestic and industrial waste and recyclable
materials.
The Olympus Mini refuse collection bodywork is not
designed for:
• operation in severe conditions, e.g. extreme
environmental conditions such as:
• below – 25 °C and above + 40 °C temperatures;
• operation in a tropical environment;
• operation in wind velocity in excess of 75 km/h;
• operation in a contaminating environment;
• operation in a corrosive environment;
• operation in potentially explosive atmospheres;
• handling of loads the nature of which could lead
to dangerous situations (e.g. hot wastes, acids and
bases, radioactive materials, contaminated waste,
especially fragile loads, explosives);
• operation on ships.
Manufacturer’s name and address
ROS ROCA S.A.
Avda. Cervera
Tàrrega
España
FOREWORD
ii OM1R-SM-GB01R

CONTENTS
Olympus Mini Service Manual
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iii
OM1R-SM-GB01R
2 Contents
CONTENTS PAGE
1 Introduction ..........................................................................................................................1-1
2 Health and safety..................................................................................................................2-1
3 Daily checks...........................................................................................................................3-1
4 Hydraulic system oil level....................................................................................................4-1
5 Cleaning .................................................................................................................................5-1
6 Scheduled maintenance ......................................................................................................6-1
7 Operational maintenance ....................................................................................................7-1
8 General specification data ..................................................................................................8-1
9 Supplementary information ................................................................................................9-1
I index .......................................................................................................................................I-1

CONTENTS
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CONTENTS PAGE
1 Introduction...........................................................................................................................1-3
1.1 Safety precautions................................................................................................................................... 1‑3
1.2 Immobilising the vehicle prior to service procedures................................................................ 1‑3
INTRODUCTION
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1 Introduction
This manual identifies all the recommended
preventative maintenance service procedures and
inspections to be carried out on Olympus Mini refuse
collection bodies.
1.1 Safety precautions
WARNING:
IT IS THE RESPONSIBILITY OF THE
TECHNICIAN TO COMPLY WITH ALL THE
RELEVANT SAFETY PRECAUTIONS AND
PROCEDURES LISTED IN CHAPTER 2
‘HEALTH AND SAFETY’ OF THIS MANUAL
AS WELL AS ALL PREVAILING SAFE
SYSTEMS OF WORK, HEALTH AND SAFETY
REGULATIONS, WORKSHOP REGULATIONS
AND WORKSHOP CODES OF PRACTICE
WHEN CARRYING OUT THE PROCEDURES
DESCRIBED IN THIS MANUAL.
1.2 Immobilising the vehicle prior
to service procedures
Before commencing any service procedure, the refuse
collection vehicle must be immobilised as follows:
1. Stand the vehicle on clean, level and stable ground.
2. Engage the parking brakes.
3. Select Neutral ‘N’.
4. Stop the engine.
5. Chock the wheels.
6. Check that the tailgate is in the normal lowered
position, locked to the body.
7. Turn the ‘Body main’ switch to ‘off’ position.
Remove and retain the key.
8. Switch ignition ‘off’. Remove and retain the key.
9. Secure a sign reading ‘DO NOT START OR
OPERATE VEHICLE’ to the steering wheel.
10. Lock all cab doors. Remove and retain the keys.
11. If necessary isolate or disconnect the battery.
(Refer to chassis‑cab manufacturer’s service
information for procedures).
INTRODUCTION
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CONTENTS PAGE
2 Health and safety..................................................................................................................2-3
2.1 Introduction................................................................................................................................................ 2‑3
2.2 Safety symbol, warnings, cautions and notes............................................................................... 2‑3
2.3 Trained personnel..................................................................................................................................... 2‑3
2.4 Use of these instructions....................................................................................................................... 2‑3
2.5 Precautions and protection for personnel...................................................................................... 2‑4
2.5.1 Personal hygiene ...................................................................................................................................... 2‑4
2.5.2 Protective clothing .................................................................................................................................. 2‑4
2.6 Working at high level.............................................................................................................................. 2‑5
2.7 First aid and emergency treatment .................................................................................................. 2‑6
2.7.1 Workshop first aid equipment ............................................................................................................ 2‑6
2.7.2 Cuts and wounds...................................................................................................................................... 2‑6
2.7.3 Carbon monoxide poisoning ............................................................................................................... 2‑6
2.7.4 Burns ............................................................................................................................................................. 2‑6
2.7.5 Contact with and/or ingestion of fluids .......................................................................................... 2‑6
2.8 Workshop precautions, procedures and practices ..................................................................... 2‑7
2.8.1 Material safety data sheets...................................................................................................................2‑7
2.8.2 Responsible technician, the Key Holder.......................................................................................... 2‑8
2.8.3 Immobilising the vehicle........................................................................................................................ 2‑8
2.8.4 General workshop precautions........................................................................................................... 2‑8
2.8.5 Work place cleanliness........................................................................................................................... 2‑8
2.8.6 Moving or rotating parts ....................................................................................................................... 2‑9
2.8.7 Hot components....................................................................................................................................... 2‑9
2.8.8 ‘Live’ work ................................................................................................................................................... 2‑9
2.8.9 Fasteners ..................................................................................................................................................... 2‑9
2.8.10 Protecting vehicle components during grinding, drilling and welding............................... 2‑9
2.8.11 Welding on or near the vehicle........................................................................................................... 2‑9
2.8.12 Manual handling and movement of loads....................................................................................... 2‑10
2.8.13 Access and lifting equipment.............................................................................................................. 2‑10
2.8.14 Cleaning of equipment...........................................................................................................................2‑10
2.8.15 Environmental protection precautions............................................................................................ 2‑10
2.8.16 Fuel, oil, lubricants, degreasants and filters .................................................................................. 2‑11
2.8.17 Solvents ....................................................................................................................................................... 2‑11
2.8.18 Contact with plastic material residues after fires........................................................................ 2‑11
2.9 Cleaning a vehicle .................................................................................................................................... 2‑12
2.9.1 Pressure washing...................................................................................................................................... 2‑12
2.10 Vehicle electrical systems ..................................................................................................................... 2‑12
2.10.1 General electrical precautions............................................................................................................. 2‑12
2.10.2 Disconnection and reconnection of electrical components.................................................... 2‑13
2.11 Welding on or near the vehicle........................................................................................................... 2‑13
2.12 Hydraulic and pneumatic systems..................................................................................................... 2‑14
2.12.1 Returning the vehicle to service......................................................................................................... 2‑14
HEALTH AND SAFETY
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2 Health and safety
2.1 Introduction
This chapter states the precautions to be observed by
personnel carrying out maintenance operations on an
Olympus Mini refuse collection body.
Precautions to be observed by personnel operating an
Olympus Mini refuse collection body are contained in
the equivalent chapter of the Olympus Mini Operator’s
Handbook.
It is everyone’s responsibility to make sure that they
and their colleagues work safely. The intention of
these guidelines is to draw to the attention of Service
Technicians the importance of safety issues and to
highlight known hazards. Read this chapter very
carefully and use the procedures as a guide to safe
working practice at all times. If necessary, discuss any
points that are not clear with your Safety Officer or
Manager.
The guidelines contained in this Manual are not
definitive and do not override nor replace local
rules and instructions. There may be additional
ways to make sure that operative and maintenance
organisations work safely and you must also follow any
local rules and safe working practices that may apply.
The information in this chapter should be used
in conjunction with the appropriate chapters of
the workshop manuals, operator’s handbooks or
other service information applicable to the vehicle
chassis‑cab and any ancillary equipment fitted to the
vehicle.
Special attention should be paid to safety procedures
and precautions which must be observed with
electronic systems, high pressure fuel systems, urea
injection systems, high temperature catalyst exhaust
systems and air conditioning refrigeration systems
fitted to modern commercial vehicle chassis‑cabs.
2.2 Safety symbol, warnings,
cautions and notes
The following Safety Symbol is used throughout
this Manual to indicate information that is essential
to Health and Safety. The symbol applies to ALL
information contained in this chapter.
All Safety Information MUST be strictly adhered to.
WARNINGS
WARNING:
A WARNING IS PRINTED IN THIS STYLE.
IT REFERS TO ANY PROCEDURE WHICH
MUST BE FOLLOWED PRECISELY TO AVOID
POSSIBILITY OF PERSONAL INJURY OR
DEATH.
Caution:
A Caution is printed in this style. It refers to
any procedure which must be followed to
avoid damage to components or cause them
to malfunction.
Note:
A Note is printed in this style. It refers to essential
information about any operation or event that is not a
WARNING or Caution.
2.3 Trained personnel
The vehicle may be dangerous in the wrong hands,
and only suitably trained and authorised persons using
approved safety equipment where relevant, should
operate, service and repair this vehicle.
Maintenance personnel must have completed an
approved training course including the following:
• Safety precautions to be observed when operating
and carrying out maintenance and repairs to the
refuse collection vehicle.
• Working safely at height.
• Checking of the safety devices.
• Identification of components requiring
maintenance for keeping the refuse collection
vehicle safe and the intervals at which servicing is
required.
• How to use the lifting points of heavy components
or sub‑assemblies that have to be lifted in one
piece.
2.4 Use of these instructions
These instructions are only intended for use by trained
and authorised personnel with the vehicle(s) for which
this Manual is applicable. They should not be used
by any other persons, on any other vehicle or for any
other purpose.
HEALTH AND SAFETY
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2.5 Precautions and protection
for personnel
2.5.1 Personal hygiene
Personal hygiene is important at all times, particularly
for those working in the waste disposal environment
where rats can breed and spread diseases such as
LEPTOSPIROSIS.
Leptospirosis, or Weil’s disease, is a form of jaundice
with early stages similar to influenza. The infection
sometimes enters the body through breaks in the
skin, so thorough first aid treatment of all wounds is
important.
Leptospirosis is carried in the urine of rats. If you
have the slightest suspicion that you are working in a
contaminated environment follow these rules rigidly:
1. Wear protective clothing at all times.
2. Do not allow the inside of protective clothing to
become soiled.
3. After removing protective clothing wash it
thoroughly and allow to dry.
4. Wash hands and forearms thoroughly after working
and especially before eating and drinking.
5. Wash every scratch, graze or cut of the skin, treat it
with antiseptic, and cover it with a sterile dressing,
e.g. plaster. This applies to ALL wounds; not just
those suffered at work.
6. If the First‑Aid kit requires replenishing, report it to
your supervisor.
7. With any injury that is more than a scratch or slight
cut, consult your doctor and mention the type of
work you do.
8. Do not rub your mouth, nose or eyes when
working.
9. At all visits to your doctor, mention the type of
work you do and the environment you work under.
10. Apply barrier creams before each work period.
Note: Preparations containing lanolin replace the
natural skin oils which can be removed when washing.
11. Do not wash skin with fuels, thinners or solvents.
12. Obtain medical advice if skin disorders develop.
2.5.2 Protective clothing
1. Use and take care of all personal protective
clothing and equipment supplied by your employer
for your safety.
2. While operating or carrying out maintenance on a
refuse collection vehicle, wear protective clothing
complying with health and safety legislation and
standards applicable to the country in which the
vehicle is being used, including:
• A boiler suit, or a two piece protective overall,
not too loosely fitting and of a distinctive
colour.
• Protective boots or shoes with steel toe caps
and in‑soles.
• A hard protective hat.
• Protective gloves.
• Protective spectacles.
• Goggles and particle mask if working in dusty
conditions.
• Suitable eye protection to protect eyes from
welding flash or sparks from grinding.
• Reflective armbands or jacket when working on
the road.
3. Wear impervious gloves where there is a risk of
contact with hydraulic system oil.
4. Wear eye protection (chemical goggles or face
shields) where there is a risk of eye contact.
5. Avoid contaminating clothes and protective
equipment with oil:
6. Do not put oily rags in pockets.
7. Clean overalls regularly.
8. Discard unwashable or oil impregnated clothing.
9. Do not wear loose fitting clothing whilst operating
or carrying out maintenance on the vehicle.
10. Always remove all personal jewellery, e.g. rings,
watches, chains etc., before commencing operation
or work on the vehicle.
11. Tie long hair back from the face.
HEALTH AND SAFETY
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2.6 Working at high level
WARNINGS:
FAILURE TO OBSERVE THE FOLLOWING
PRECAUTIONS MAY RESULT IN INJURY OR
DEATH.
DO NOT UNDER ANY CIRCUMSTANCE
WALK ON OR LOAD THE PLASTIC TAILGATE
ROOF COVERS (SEE FIG. 2-1, 1). THESE ARE
NOT LOAD-BEARING STRUCTURES.
SAFETY HARNESS ATTACHMENT LUGS
(SHAL) SHOULD NOT UNDER ANY
CIRCUMSTANCES BE USED AS LIFTING
POINTS TO RAISE THE BODY.
High level components and equipment mounted on
the roof of the body and tailgate are generally located
in positions accessible from the side or rear of the
vehicle.
Where possible, any maintenance (inspection,
replacement, repairs) of high level components and
equipment mounted on the body or tailgate should
be carried out using suitable access platforms to
either side or rear of the vehicle. Access platforms
should be used in compliance with all prevailing Health
and Safety Regulations, Workshop Regulations and
Workshop Codes of Practice.
Where components cannot be accessed from the side
or rear of the vehicle and it becomes necessary to
work on top of the body roof or tailgate, always wear
an approved safety harness connected to a Safety
Harness Attachment Lug (see Fig. 2‑1, 2) in accordance
with all prevailing safe systems of work, Health and
Safety Regulations, Workshop Regulations and
Workshop Codes of Practice.
Safety Harness Attachment Lugs (SHAL) are primarily
designed for the use of Ros Roca manufacturing,
production and service personnel when working at
height on vehicle roofs in line with risk assessments
and safe systems of work conducted at Ros Roca.
Customers may use the Safety Harness Attachment
Lugs only if they have conducted necessary risk
assessments and prescribed subsequent safe systems
of work based on their own activities.
If in doubt, contact your local Health and Safety
Officer.
If access to components under the covers is required,
remove them first as described in the appropriate
sections of the Olympus Mini Workshop Manual.
4639-OM1-R-GB-G1
1
2
Fig. 2-1 Olympus Mini roof
1. Tailgate roof covers.
2. Safety Harness Attachment Lug (SHAL).
HEALTH AND SAFETY
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2.7 First aid and emergency treatment
2.7.1 Workshop first aid equipment
1. The workshop must be equipped with First Aid
equipment complying with local legislation.
2. Familiarise yourself with the equipment,
procedures and practices.
3. If the first‑aid kit requires replenishing report it to
your supervisor.
2.7.2 Cuts and wounds
1. Treat open cuts and wounds immediately.
2. Wash every scratch, graze or cut of the skin, treat it
with antiseptic, and cover it with a sterile dressing,
e.g. plaster. This applies to ALL wounds; not just
those suffered at work.
2.7.3 Carbon monoxide poisoning
If Carbon Monoxide poisoning is suspected:
1. Move the patient into fresh air immediately,
keeping the patient at rest and warm.
2. Administer artificial respiration if the patient has
stopped breathing.
3. Summon an ambulance and send the patient to
hospital. If an ambulance is not available, make
sure the patient is accompanied by a proficient
First aid person.
2.7.4 Burns
In the event of a skin burn, immediately administer the
following emergency treatment:
1. Run cold, clean water over the affected area.
2. Cover the burned area, including any clothing, with
a dry, clean, sterile dressing.
3. Consult a medical centre or doctor as soon as
possible.
4. Do not:
• Remove any clothing over the burn.
• Burst any blisters.
• Apply any cream or oily preparation to the
burned area.
2.7.5 Contact with and/or ingestion of fluids
For First aid instructions covering ingestion, inhalation,
skin or eye contact with fluids used in systems and
components fitted to vehicles for which this Manual is
applicable, consult the appropriate Safety Data Sheet
contained in this chapter.
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2.8 Workshop precautions,
procedures and practices
2.8.1 Material safety data sheets
The European Commission’s Chemical Agents Directive
(CAD) (98/24/EC) establishes minimum health and
safety conditions for the protection of the health and
safety of workers from the risks related to chemical
agents at work.
This Directive is implemented In Great Britain by
the Control of Substances Hazardous to Health
Regulations 2002 (COSHH), which requires employers
to control exposure to hazardous substances to
prevent ill health.
Further information about COSHH, refer to:
http://www.hse.gov.uk/coshh/
Similar legislation may exist in other countries.
In compliance with this legislation, manufacturer’s
of chemical agents, including diesel fuel, lubricating
oils, antifreeze, screen‑wash and etc., are required
to produce Safety Data Sheets detailing specific
information about the hazards of the product.
Hazardous substances include:
• Substances used directly in work activities (e.g.
adhesives, paints, cleaning agents).
• Substances generated during work activities (e.g.
fumes from soldering and welding).
• Naturally occurring substances (e.g. grain dust).
• Biological agents such as bacteria and other
microorganisms.
COSHH requires employers to:
• Assess the risks to health from hazardous
substances used in or created by workplace
activities.
• Not carry out work which could expose employees
to hazardous substances without first considering
the risks and the necessary precautions, and what
else is required to comply with COSHH.
• Prevent or control employees’ exposure to
hazardous substances.
• Ensure that control measures are used and
maintained properly and that safety procedures
are followed.
• Monitor the exposure of employees to hazardous
substances, where necessary.
• Carry out appropriate health surveillance where
necessary or COSHH sets specific requirements.
• Prepare plans and procedures to deal with
accidents, incidents and emergencies involving
hazardous substances, where necessary.
• Provide employees with suitable and sufficient
information, instruction and training.
• Manufacturers of Substances Hazardous to Health
are required by law to provide Safety Data Sheets
for each product.
It is the responsibility of all personnel who may come
into contact with such substances to familiarise
themselves with the hazard and to take the necessary
steps as advised by the data sheet(s).
Customers are recommended to store copies of Safety
Data Sheets and other safety information pertinent
to systems and components fitted to vehicles for
which this Manual is applicable at the end of this
chapter. There may be additional ways to make sure
that operative and maintenance organisations work
safely and you must also follow any local rules and safe
working practices that may apply.
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2.8.2 Responsible technician, the Key Holder
1. One person, the Key Holder, must be responsible
for the safety of all personnel involved when a
vehicle is undergoing any form of maintenance
work. Normally the Key Holder will be the person
who is working on the vehicle.
2. The Key Holder is responsible for immobilising the
vehicle.
3. Any other person who needs access to the vehicle
for whatever reason must inform the Key Holder of
their intentions.
4. On completion of work all personnel must inform
the key holder that they are leaving the vehicle.
5. If the Key Holder leaves the vehicle for any reason,
he must nominate a new Key Holder and make sure
that all affected personnel know who the new Key
Holder is.
6. The Key Holder must make sure that when
the engine is run, all personnel are clear of the
bodywork until the engine is stopped and the
ignition key is removed with the cab door locked.
2.8.3 Immobilising the vehicle
To immobilise the vehicle the Key Holder must:
1. Turn the ‘Body main’ key operated switch to ‘off’
and remove the key and any spare keys (see
Refuse Collection Vehicle Operator’s Handbook).
2. Turn the ignition switch to ‘off’ and remove the key
and any spare keys.
3. Secure a sign reading ‘DO NOT START OR
OPERATE VEHICLE’ to the steering wheel.
4. Lock all the cab doors and remove the key and any
spare keys.
5. Retain all the keys while work is in progress.
6. If required, turn the vehicle’s battery isolation
switch, if fitted, to off or disconnect the vehicle’s
battery.
2.8.4 General workshop precautions
1. Chock the vehicle wheels at all times when
maintenance work is in progress (Refer to
chassis‑cab manufacturer’s Workshop Manual for
information and instructions).
2. Personnel must not enter the body or tailgate
hopper unless the engine is stopped, the cab door
is locked and the Key Holder has been advised of
work in progress.
3. If it is necessary to work on the roof of the vehicle,
an approved safety harness MUST be worn and
attached to the vehicle Tailgate Safety Harness
Attachment Lug (SHAL).
4. Use exhaust gas extraction hoses and equipment
when running engines within an enclosed working
area.
5. Where practicable, degrease components prior to
handling.
6. Do not work under the vehicle when supported
only by a jack; always use safety stands.
7. Only use the correct tools for the task, do not
improvise.
8. Follow all precautions relating to the use of power
tools.
9. Do not stare directly into the beams of high
brightness LEDs, such as LED lamps and warning
lamps; doing so may cause permanent damage to
your eyes.
2.8.5 Work place cleanliness
A clean and tidy work place is a safe work place.
1. Put rubbish in bins and do not allow it to
accumulate.
2. Mop up oil or coolant spillages immediately using
an approved method.
3. Do not leave tools or equipment lying around.
4. Do not allow hoses or cables to cross the
workplace.
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2.8.6 Moving or rotating parts
There are risks of serious injury due to entanglement
or collision with rotating parts such as fans, engine
components or propeller shafts.
All personnel must be aware of the risks and take
precautions to distance themselves from moving or
rotating parts at all times.
All guards are to be fastened in position when the
vehicle is operational.
2.8.7 Hot components
Many vehicle components, i.e. the engine, gearbox,
brakes etc. operate at temperatures high enough to
cause skin burns to personnel coming into contact
with a recently operated engine unit.
Exhaust systems, turbochargers, catalytic converters
and their components can reach extremely high
temperatures.
To avoid the risk of skin burns, allow the vehicle
component to cool before carrying out any work.
Take care to avoid contact with hot components,
particularly exhaust system components, and fluids,
such as hydraulic system oil, on a vehicle when
carrying out tests with the engine running.
2.8.8 ‘Live’ work
It is sometimes necessary to perform adjustments to
the vehicle with the engine and vehicle systems ‘live’
(running).
1. Take great care when carrying out any ‘live’
(running) operations and adjustments.
2. Where possible, have an assistant standing by in a
position where they can stop the engine or vehicle
system in an emergency.
3. Locate and check the operation of all ‘Emergency
stop’ push‑buttons before starting any ‘live’ work.
2.8.9 Fasteners
When assembling/refitting components using
fasteners such as torque loaded bolts, nyloc nuts or
split pins etc., always use new fasteners. Do not re‑use
old fasteners except where specifically mentioned in
the text.
2.8.10 Protecting vehicle components during
grinding, drilling and welding
When grinding, drilling and welding or similar, take
appropriate precautions to prevent damage to pipes,
hoses, wiring, glazing, cab paintwork and rubber
suspension parts.
1. Shield vulnerable components from the sparks and
heat generated by grinding and welding.
2. If protection by shielding is not possible, remove
vulnerable components.
Caution:
If drilling holes, be aware of electrical
components behind the place where you
are drilling. Do not allow swarf to fall onto
electrical components, as this can result in
electrical short circuits.
Vehicles may be equipped with an automatic
chassis lubrication system, involving a number of
additional pipes. These pipes are made from plastic,
and are readily damaged. Refer to the chassis‑cab
manufacturer’s manuals for further information.
2.8.11 Welding on or near the vehicle
Exercise extreme care when carrying out welding
operations. Electric arc welding can cause serious
damage to any electronic items fitted to the vehicle.
1. Always stop the engine and disconnect the
batteries and electronic units in the approved
sequence (Refer to chassis‑cab manufacturer’s
workshop manual for information and instructions)
before carrying out any welding repairs.
2. Ensure that the vehicle is not leaking diesel, oil or
hydraulic fluids as these may ignite whilst welding.
3. Always have a serviceable fire extinguisher close at
hand.
4. Wear eye protection to protect eyes from welding
flash.
5. Erect protective screens to protect other personnel
from the dangers of the area.
HEALTH AND SAFETY
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2.8.12 Manual handling and
movement of loads
All persons planning the lifting or movement of loads
or involved in lifting or movement of loads must obey
the requirements of National and Local legislation and
regulations.
Many of the vehicle parts are either extremely heavy
and/or complicated in shape and size. Attempting to
move such components may cause bodily injury.
The approximate weights of major components are
listed in the Technical Data section of applicable
chapters.
To avoid personal injury or damage to equipment when
you work on the vehicle you must obey the following
rules.
1. Use correct methods when lifting or carrying items
by hand.
2. Use suitable lifting equipment and methods when
lifting or moving heavy or large objects.
3. Make sure that lifting equipment has been
inspected and is certified fit for use.
4. Make sure that safety pins, props and stands are
positioned correctly before the start of work.
5. Never land any item of equipment in a walkway or
clear zone.
6. Keep the work area clean and free from
obstruction.
7. Keep any personnel not involved with the
procedure at a safe distance.
2.8.13 Access and lifting equipment
Some maintenance tasks require the erection of access
platforms and/or lifting equipment to provide a safe,
stable platform.
1. Access platforms or lifting equipment must
be erected by qualified personnel. Under no
circumstances must unqualified personnel erect or
alter such equipment.
2. Access platforms and lifting equipment must be
regularly inspected for continued serviceability.
2.8.14 Cleaning of equipment
1. Do not attempt to clear blockages or remove
damaged items whilst the equipment is running.
2. Keep fingers, hair and loose clothing away from
moving parts.
3. Do not attempt to climb or reach over guards.
2.8.15 Environmental protection precautions
1. Contact the Local Government Authority or
Environmental Protection Agency for advice or
disposal facilities.
2. Collect and dispose of used oil carefully.
3. Mop up all spillages.
4. Do not burn used hydraulic oil, rubbers, plastics or
polyurethane foams.
5. Dispose of used oil through authorized waste
disposal contractors.
HEALTH AND SAFETY
2‑10 OM1R-SM-GB01R
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