Volvo BHL Operating and installation instructions

Service Information
Document Title: Function Group: Information Type: Date:
Safety concerns everybody! 191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Safety concerns everybody!
Always follow the instructions in the machine's operator's manual.
The operator's manual should always be kept in the cab for easy reference.
We have spent many hours engineering and producing a machine with a high level of safety and efficiency. All this time may
be wasted if an individual who is about to perform service on any of our machines does not read through the safety
instructions or does not follow them: for example, does not replace guards, climbs on slippery machine parts instead of
using a ladder, grabs on to hoses instead of the provided handles or uses the wrong tools for the job.
Always use genuine (intended and adapted) spare parts to maintain safe and efficient machine function.
Machines seldom cause accidents. Instead, people do.
A safety-conscious person and a well-maintained machine constitute a safe, efficient and profitable combination.
Any person who does not follow the safety instructions and who ignores the warnings in this manual must make
sure that their work method is safe. Otherwise, there is a great risk of serious accidents and injuries, perhaps even
fatalities.
WARNING
WARNING SYMBOL
This symbol is shown at various points throughout the manual. The appearance of it means "Warning, stay alert! Your safety
is involved!"
Get to know the capacities and limitations of your machine!

Service Information
Document Title: Function Group: Information Type: Date:
CE marking and declaration
of conformity
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
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CE marking and declaration of conformity
(Only applies to machines marketed within the EU/EEA.)
This machine is CE-marked. This means that, when delivered, the machine meets the applicable "Essential Health and Safety
Requirements", which are given in the EU Machine Safety Directive. If changes are made that affect the safety of the
machine, the person making the changes is responsible for the same.
As proof that the requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by Volvo
Construction Equipment for each individual machine. This EU declaration also covers attachments manufactured by Volvo
Construction Equipment. The documentation is a valuable document, which should be kept safe and retained for at least 10
years. The document should always accompany the machine when it is sold.
If the machine is used for other purposes or with other attachments than described in this manual, safety must be
maintained at all times and in each individual case. The person carrying out such action is also responsible for the action
which, in some cases, may require a new CE marking and the issue of a new EU Declaration of Conformity.
EU EMC Directive
The electronic equipment of the machine may in some cases cause interference with other electronic equipment, or the
equipment may be adversely affected by external electromagnetic interference, which may constitute safety risks.
The EU EMC directive on "Electromagnetic conformity" provides a general description of what demands can be made on the
machine from a safety perspective, where permitted limits have been determined and given according to international
standards.
A machine or device which meets the requirements should be CE-marked. Our machines have been specifically tested for
electromagnetic interference. The CE marking of the machine and the declaration of conformity also cover the EMC directive.
If other electronic equipment is fitted to this machine, the equipment must be CE-marked and tested on the machine with
regard to electromagnetic interference.
Unauthorized modifications of the Roll Over Protective Structure (ROPS)
Never make any unauthorized modifications to the ROPS, such as lowering the height of the roof, drilling, welding on fire
extinguisher brackets, radio aerial brackets or other equipment.
Such unauthorized modifications will affect the structural strength of the ROPS cab and will void the certification.
The Roll Over Protective Structure (ROPS) has been approved following testing and meets standards according to ISO 3471:
1994 and SAE 1040 MAY 94.
The cab has also been tested and approved according to FOPS standard as defined by ISO 3449: 1997 and ISO 6055: 1997.
All planned modifications must be reviewed in advance by our Engineering Department in order to determine whether the
alteration can be made without affecting the certification.
It is important that all persons in your organisation, including management, are made fully aware of these rules involving
ROPS.
If anyone in your company discovers that a certain machine was modified in a non-approved manner, your company
must notify the customer and manufacturer if writing regarding which machine it was and how it was modified.
NOTE!
Modifications or removal of material which affects sound, i.e. noise-insulating material, noise-damping or noise-absorbing
material may not be performed. Further, making new holes/openings in the cab or engine compartment is not allowed as
this may increase the sound level in the cab.

Service Information
Document Title: Function Group: Information Type: Date:
Safety when handling the
machine
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Safety when handling the machine
Volvo Construction Equipment is only responsible if:
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the machine has been used in a correct way and been maintained in accordance with instructions in Service
Manuals and the Operator's Manual for the machine.
prescribed service and prescribed inspections have been carried out at the stated points in time.
the recommended lubricants according to the manual have been used.
no security seals have been broken by other than authorised persons.
all alterations and repairs have been carried out in the way prescribed by Volvo.
only Volvo's genuine spare parts/accessories, or attachments, which meet Volvo's requirements, have been used.
WARNING
Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before
operating the machine.
It is important that the operator reads and follows the instructions in the machine's Operator's Manual.
An untrained operator may cause serious injuries and fatalities.
Never operate a machine for which there is no Operator's Manual available.
Learn to understand the warning plates, symbols and operating instructions for the machine before you start
operating.
A few simple safety rules
General
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Remedy faults or defects which affect the safety as soon as possible.
Always wear a hard hat, safety glasses, gloves, protective shoes and other protective articles when required.
Do not remain in front of or behind the machine while the engine is running.
To avoid unnecessary climbing on the machine use either a long-handled rubber scraper or brush for cleaning the
outsides of the windows.
When servicing the machine and for instance when changing bulbs, a ladder may be necessary.
Make sure that stepping surfaces, service areas, handles and anti-slip surfaces are free from oil, diesel fuel, dirt and
ice and that they are changed if they are damaged or missing.
Check at regular intervals that all anti-slip items are securely fitted. If this is not the case, they should be secured or
replaced.

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Figure 1
Entering or leaving the machine
When you are entering or leaving the machine, always face the machine and use the steps and hand holds. Always
use both hands and one foot or both feet and one hand. Do not jump!
Before operating
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Read the Operator's Manual, before you operate the machine. Follow the operating instructions in the Operator's
Manual and carry out the measures which are detailed in the manual before operating.
A few important rules are given below:
Make a control lamp test before starting the engine by turning the ignition key to position "1", see the Operator's
Manual.
Carry out all safety checks prescribed in the Operator's Manual.
WARNING
Never operate the machine if you are tired or under the influence of alcohol, medicine or other drugs.
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Before starting the engine indoors, make sure that the extraction capacity of the ventilation system is sufficient. The
machine is provided with a diesel engine and the exhaust gases may be dangerous to your health. Make sure the
ventilation is sufficiently good and avoid running the engine for a longer time than necessary particularly when the
ventilation is unsatisfactory.
Read all plates and instructions which are fitted on the machine and given in the Operator's Manual before you
begin to operate or service the machine. Each of the instructions contain important information about safety,
handling and service of the machine.

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Figure 2
Read the Operator's Manual, plates and instructions before you start operating the machine.
Use the lap type seat belt during all operation.
Always sit in the seat facing the front of the machine when starting the engine.
The machine must be operational before putting it to work, that is, all faults which may cause an accident must be
remedied.
Do not operate the machine for long periods without ventilation or with a fully closed cab without having the fan
running (there is risk of lack of oxygen).
Only step on slip-protected surfaces and hold onto the available hand holds and railings.
Lap type seat belt
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If the seat belt needs to be washed: Use a mild soap solution when washing and allow the belt to dry while it is fully
pulled out, before rolling it up. Make sure the belt is fitted in a correct way.
Change the belt immediately if it is worn, damaged or if the machine has been involved in an accident where the
belt had to take some strain.
Changes to the belt or its mountings must never be made.
The seat belt is intended for one adult person only.
Keep the belt rolled-up when not in use.
When the engine is running
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Respect the warning lamps. The red lamps require immediate action or consideration, see instructions in the
Operator's Manual under the instrument panels section.
Apply the parking brake and make sure that the attachment / attachment bracket is resting on the ground before
you leave the machine. Unless you are putting the machine in a service position.
Place gearshift lever and control levers in neutral positions before you leave the machine.
Empty and place the attachment in transporting position before transport operating on a public road.
Stop the engine before you leave the machine unattended.
When there is risk of overturning
The cab constitutes the protection for the operator and it meets the requirements for Roll Over Protective Structure (ROPS)
according to the testing standard for this. See further under “CE-marking”.
A condition for the protection is that the operator is wearing the seat belt and that he or she remains in the cab, if the
machine should roll over.
Falling objects
The cab is dimensioned to meet the standards required against objects falling onto the cab roof in accordance with stated
testing methods, (FOPS). See further under “CE-marking”.
Emergency exits from cab
The cab has seven emergency exits: the two doors, the two side windows, the rear window and the two door windows.

Service Information
Document Title: Function Group: Information Type: Date:
Safety rules when servicing 191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Safety rules when servicing
This section covers general safety rules when checking and servicing.
Other rules, information and warning texts are given in this manual and also in the Operator's Manual.
CE–marking
This machine is CE marked. This means that when delivered to customer the machine meets the applicable "Essential Health
and Safety Requirements", which are given in the EU Machinery Safety Directive. If changes are made that affect the safety of
the machine, the person carrying out the changes is responsible for the same.
This, for example, means that:
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When installing a two-way radio, a mobile telephone and similar equipment, the installation should be carried out
according to the instructions of the manufacturer in order to eliminate interference to the electronic system and
components intended for the function of the machine. See further under “CE-marking”.
When retro-fitting equipment in or on the cab; do not drill, weld or cut on or into the cab, as such actions reduce
the protection for the operator if the machine should roll over. See further under “CE-marking”.
Before you begin any service work on the machine:
Service work which is not carried out in the correct way is dangerous.
Make sure you have sufficient knowledge, correct information, tools and equipment to carry out the service in a correct way.
Repair or change broken tools and equipment.
Position the machine on level ground and prepare it for service by placing it in one of the service positions, see
.
173 Service positions
NOTE!
No work must be carried out on the machine until you have acquired the appropriate knowledge to do so.
General
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A machine which is used within a contaminated area (polluted environment and/or insanitary area) should be
equipped in a special way. In addition to this, special local safety regulations apply when servicing such a machine.
See also "Check list after fire or heat exposure".
If someone is to take over a job you have started, you must make sure that this person is told how much of the job
has been carried out and how much remains.
WARNING
Only walk or step on the machine's prepared stepping surfaces, see operator's manual.
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Never wear loose-fitting clothing, e.g. a scarf or jewelry, which can get caught and cause injury, when working on
the machine. Long hair should be tied back in a hair net.
Always wear a hard hat, safety glasses, gloves, protective shoes and other protective articles when required.

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Figure 1
Protective equipment
Always stop the engine to service the machine, unless otherwise instructed on plates or in this manual.
Stop the engine before opening engine hood, radiator casings etc. Make sure that no tools or other objects, which
can cause damage, are forgotten and left in the machine.
Environment
Our global environment is today exposed to harm because of the increasing industrialisation of the world. Nature, animals
and humans all over the world are daily exposed to great risks in connection with various ways of handling chemicals.
Yet there are for example no oils or coolants on the market which are not harmful to the environment. Therefore, all, who
handle, service or repair earth moving machines, must use the aids and methods which are necessary in order to carry out
their work in an environmentally correct way.
If you also follow the simple rules listed below, you will contribute to the care of our environment:
Reclamation
Contribute to a careful utilisation of natural resources by handing in discarded material to companies which
specialise in recycling or incineration.
Batteries etc.
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Components such as batteries, plastic objects and others which may constitute an environmental danger, must not
be discarded anywhere or anyhow. Such waste must be taken care of in an environmentally correct way.
Discarded batteries contain substances dangerous to the environment and they should therefore be handled in an
environmentally safe way according to national regulations.
Oils/liquids
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Oil released or spilled onto the ground will harm the environment and could also cause a fire. When emptying/
draining oil or fuel, steps should therefore be taken to avoid unnecessary spillage.
Waste oil and other liquids should always be taken care of by an authorised company.
Be alert to leakage of oil and other liquids! Rectify the leakage immediately.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the greenhouse effect and may therefore never
intentionally be released into the open air. Special training is required for all service work on the air conditioning. In
many countries certification for such work is also required by an authority. See also “Air conditioning”.
Working in contaminated environment
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Used cab and engine air filters from machines which operate in environments containing asbestos or other
dangerous dust must be placed in the tight-fitting bag which is supplied with the new filter, before they are
deposited in a designated place.
The machine must be equipped for working within contaminated area (polluted environment and/or insanitary
area) before any work is carried out. In addition to this, special local regulations apply for such work and when
servicing such a machine.

Service Information
Document Title: Function Group: Information Type: Date:
Safety when handling oils
and fuel
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Safety when handling oils and fuel
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When changing oil in the engine, hydraulic system or transmission: Remember that the oil may be hot and can
cause burns.
Engine, hydraulic and transmission oils as well as diesel fuel have a corrosive effect on mucous membranes, for
example, in eyes and throat and on skin. Therefore, take special care to keep such oils away from these sensitive
body parts.
When emptying/draining oils or fuel, steps must be taken to avoid unnecessary spills. In places where a container
for collecting the liquid cannot be used, use a pump or connect a hose to ensure safe handling. Oil released or
spilled on the ground will harm the environment and could also cause a fire.
Waste oil/fluids must always be taken care of by a company authorized for such work.
Remember the fire hazard!

Service Information
Document Title: Function Group: Information Type: Date:
Safety when lifting and
supporting the machine
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Safety when lifting and supporting the machine
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When lifting or supporting machine parts, use equipment with a lifting capacity that equals at least the weight of
the part in question.
All lifting devices, such as straps, slings, ratchet blocks, must comply with governing national regulations for lifting
devices. We will not accept any responsibility if any lifting devices, tools or work methods are used other than those
described in this publication.
If a jack is to be used, make sure that the ground or floor is even and is sufficiently firm or strong to support the
expected load.
Prevent the machine from rolling by applying the parking brake and placing suitable wedges on both sides of the
wheels which are not to be raised off the ground.
Always use a jack with sufficient lifting capacity and position the jack according to instructions for the work that is
to be done.
Make sure that the jack is correctly positioned and is at the correct angle to the lifting point on the machine.
Take care to position supports under the machine in a safe way.

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Working under raised
loader arm
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Working under raised loader arm
Always secure the loader arm with safety strut before beginning any work.
Figure 1
Securing loader arm
1.
2.
Spring cotter
Pin
1.
2.
3.
4.
Raise the loader arm to the upper position.
Disconnect the spring cotter.
Remove the pin and lower the safety strut in position over cylinder rod.
Fit the pin and connect the spring cotter.
Lower the loader arm until it rests on the safety strut.
Figure 2
Securing loader arm
WARNING
Check that the safety strut is positioned correctly on the loader arm.

Service Information
Document Title: Function Group: Information Type: Date:
Safety when working with
batteries
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
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Safety when working with batteries
Figure 1
Battery charging
Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. In addition, batteries
give off hydrogen gas when they are loaded (supplying electricity) or being charged.
Together with the oxygen in the air, hydrogen gas forms a very explosive mixture.
This combination, corrosive acid and explosive gas, means a high risk of accidents during all work with batteries used in
vehicles.
Therefore, it is very important that you take great care and follow the rules below when you are working with batteries.
Follow these instructions when charging batteries:
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Batteries give off explosive gases. Never smoke near batteries.
Figure 2
Do not smoke near batteries!
Begin by disconnecting the ground lead when removing a battery. In order to reduce the risk of sparks that can
cause fire, always connect the ground lead last when fitting a battery.
Never tilt a battery to any great extent in any direction. Battery electrolyte may leak out.
Do not connect a discharged battery in series with a fully charged battery. The current surge can cause the batteries
to explode.
Do not allow metal objects (such as tools, rings, wristwatches) to come in contact with battery terminals. Risk of fire
and personal injury.
Always cover the top of the battery with a rag or other non-conducting material when you work close to the
batteries.

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Always refit the terminal caps on the batteries.
Batteries contain substances dangerous to health and the environment. Discarded batteries must therefore be
disposed of according to local and/or national regulations.
Charging batteries
Explosion hazard
When a battery is being charged, an explosive mixture of oxygen and hydrogen is formed. A short circuit, open flame or
spark near the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the
charging clamps. Ventilate well, especially if the battery is charged in a confined space.
Corrosive sulphuric acid
The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately.
Wash with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately
with plenty of water and seek immediate medical attention.

Service Information
Document Title: Function Group: Information Type: Date:
Starting with booster
batteries
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Starting with booster batteries
When starting with booster batteries, the following must be observed:
Check that the booster batteries or other power source have the same voltageas the standard batteries.
WARNING
The batteries could explode due to the current surge if a fully charged battery is connected to a completely
discharged battery. Since the batteries contain sulphuric acid, this could result in personal injuries.
Follow these steps:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Move the gear selector to neutral.
Apply the parking brake.
Check that the booster batteries or other power source have the same voltage as the standard batteries.
Do not disconnect the cables to the standard batteries!
Connect (+) on the booster battery to (+) on the battery nearest the starter motor.
Connect the other start cable from (-) on the booster battery to the machine chassis, such as on the frame member
close to the starter motor.
Start the engine with the ignition key in the cab.
Once the engine has started, remove the start cable between the chassis and the booster battery negative terminal
(-). Then remove the start cable between the positive terminals (+).
Refit the terminal caps on the battery terminals.

Service Information
Document Title: Function Group: Information Type: Date:
Fire prevention measures 191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Fire prevention measures
General
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There is always a risk of fire. Find out which type of fire extinguisher to use, where it is located and how to use it.
The fire extinguisher in the machine should be located according to the figure or in an external box that can be
locked.
Fire-fighting equipment installed in or on the machine must be maintained in working order. Such equipment
should be regarded as a complement to the operator's own efforts in case of a fire.
The equipment should not be considered as a replacement of the operator's own fire fighting efforts.
Fire extinguishers mounted on the machine or used when working on the machine must fulfil certain requirements.
See the Operator's Manual.
At the slightest sign of fire, if the situation allows it and keeping in mind your own safety, take the following action:
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drive the machine away from the danger area.
lower attachment(s) to their bottom position so that the attachment rests on the ground.
stop the engine by turning the ignition key to the "0" position.
leave the cab.
turn off the battery disconnect switch.
start fighting the fire and call the fire department if necessary.
Figure 2
Smoking and open flames are absolutely forbidden when filling fuel or any time diesel fuel is in contact with
the open air.
Smoking or open flames are absolutely forbidden close to the machine when filling fuel or at any time the fuel
system is in contact with the open air.
Diesel fuel is flammable and must not be used for cleaning. Use an approved solvent instead.
Remember that certain solvents can cause skin rashes and are usually flammable. Avoid inhaling solvent vapour.
Engine starting aids are flammable. Store such items in cool and adequately ventilated areas.
Remember that such aids must not be used in combination with electric preheating of induction air.
Cleanliness
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Cleanliness is a decisive factor for operational reliability of the machine's systems. Therefore, keep the servicing area
clean. Oil or water make floors and steps slippery and are also dangerous in combination with electrical systems or
tools. Oily clothes or clothes drenched in grease constitute a serious fire hazard.
Check daily that the machine and equipment, such as underbody skid plates, are free from dirt and oil. This reduces
the risk of fire and makes it easier to detect defective components or loose parts.

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NOTICE
If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical
components and insulation of the electrical cabling even at relatively moderate water pressure and
temperature. Protect electrical cabling in a suitable manner.
Keep the machine especially clean when operating in environments with fire hazards, such as saw mills, garbage
dumps, etc. In such environments, suitable equipment to reduce the risk of accumulation of material and
spontaneous combustion should be fitted (for example muffler guard, radiator screen, heavy-duty cyclone pre-
cleaner, etc.).
Electrical system
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Check electrical cables with regard to chafing damage and make sure that they cannot be damaged in such a way.
This applies particularly to unfused electrical cables, which are red.
For example, electrical cables between:
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Batteries
Battery-starter motor
Alternator-starter motor
Cable to engine preheating coil.
When unfused cables have been disconnected, it is important to check that they are re-connected and clamped in
such a way that they cannot be exposed to chafing. Unfused cables must not rest against oil and fuel hoses.
When fitting any optional equipment, make sure that all cables (circuits) are connected across a fuse and routed
and clamped so that there is no risk of chafing.
Fuel, hydraulic and brake systems
Check to make sure that there is no chafing damage to fuel, hydraulic and brake hoses.
Welding and grinding
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Welding and grinding on the machine may only be done in a clean area and not in places that contain combustible
liquids, such as fuel tanks, hydraulic pipes or similar.
Work with extra care when welding and grinding near flammable objects.
NOTICE
A fire extinguisher should be easily accessible during all welding work.
Never weld on a painted surface without first removing the paint. Welding on a painted surface generates, in
addition to health-hazardous vapours, technically inferior welds which may lead to future failures, with subsequent
accidents.
Actions after a fire: see “Checklist after a fire or heat exposure”.

Service Information
Document Title: Function Group: Information Type: Date:
Checklist after a fire or heat
exposure
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Checklist after a fire or heat exposure
If a machine has been damaged by fire or been exposed to intense heat, the following precautionary measures according to
the following check list must under all circumstances be followed:
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As a precaution, seal rings (O-rings or axle/shaft seals) should always be handled as if they were made of fluor
rubber, see also section “Fluor rubber”.
WARNING
Avoid splashing when washing a machine damaged by fire. For this reason, never use high-pressure washing
equipment.
Never touch burned components or parts with your bare hands when there is a risk that you may be exposed to
contact with melted polymers. First, wash thoroughly with plenty of lime water (a solution or a suspension of
calcium hydroxide, i.e. slaked lime).
Use thick, protective gloves made of rubber and wear goggles that are certain to protect your eyes.
Seek medical attention if your skin may have come in contact with burnt fluor rubber. The skin should be treated
with Hydrofluoric Acid Burn Jelly or similar.
Symptoms may not appear until several hours after contact with burnt fluor rubber.
Discard protective gloves, rags and other items that may have come into contact with burnt fluor rubber.

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Document Title: Function Group: Information Type: Date:
Rules when handling tyres 191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Rules when handling tyres
WARNING
Tires installed on a split rim may explode and cause very severe injuries.
Inflating
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Never stand to the side of the tyre while inflating which is fitted on a split rim. Use a self-locking outlet with a hose
long enough to allow you to stand outside of the hazard zone during inflation, see the illustration.
Make sure that the hazard zone is clear when the tyre is inflated.
The machine must be unladen when checking tyre pressure.
Spare tyres should only be filled with enough air to allow the rim parts to be held in place.
Secure a loose wheel with an inflation cage, cable or chains before inflating. Before removing the inflation cage,
check that the tyre is properly fitted to the rim. Adjustments should be made before the wheel is inflated.
Do not attempt to adjust side rings or lock rings when the tyre is inflated.
Tyres used at less than 80% of normal pressure and rims or tyres suspected of being damaged should not be
inflated with the wheel attached to the machine.
Fitting of tyres and rims
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Handling of tyres should be performed by authorised personnel only.
The tyre should be deflated before removal from the machine.
Never install a tyre on a rim that has not been recommended for that tyre.
Never assemble rim parts for different dimensions or use damaged or faulty parts.
Exercise caution if using reconditioned wheel details. Welding errors, faulty heating or soldering may have
weakened the parts and may cause the detail to break.
Make sure the lock ring groove in the rim is cleaned from foreign matter and rust before fitting the lock ring.
Use a lubricant recommended by the tyre manufacturer when fitting onto the rim.
Repairing tyres and rims
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Never cut, weld nor heat the wheel parts in any manner.
Exercise caution when using bead breakers and hydraulic jacks. Remain outside the hazard zone when removing
foreign objects from the tyres. A bead breaker that releases can cause severe personal injury and may result in
death.

Service Information
Document Title: Function Group: Information Type: Date:
Safety for work on
hydraulic systems
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Safety for work on hydraulic systems
The hydraulic systems in our backhoe loaders work at very high pressures, up to approx. 35 MPa (350 bar) (5075
psi). In order to prevent serious personal injuries, it's important that the systems are maintained correctly and that
all persons who come into contact with the machines are very careful and very alert to any defects.
Those who follow the simple rules below have laid a good foundation for accident prevention.
General
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Never adjust a pressure limiting valve to a higher pressure than that recommended by the manufacturer.
A hydraulic hose that swells, for example, at a connection, indicates that it's about to burst. Replace the hose as
soon as possible! Pay attention to leaks from hydraulic hoses and connections. Repair the leakage before the part
bursts!
Scrapped accumulators must be punctured before they are discarded to prevent explosions. Carefully drill a hole
with a 3 mm (0.12 in) drill bit.
WARNING
If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious
personal injuries.
Pressure release
When the engine has been stopped, there remains an accumulated pressure in the system. The remaining pressure in the
system must be lowered, so-called depressurization (releasing pressure), before hose connections, plugs, etc. are opened in
the hydraulic system or brake system.
1.
2.
3.
Lower attatchment(s) to the ground.
Turn off the engine and remove the ignition key.
Release the system pressure by moving the control levers forward and rearward several times with full strokes.
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
All pressurised vessels must be opened very carefully, so that any residual pressure is released.
Check-tightening of leaking couplings and connections should only be done after all the pressure in the system has
been completely released.
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

All pressurized tanks/vessels shall be opened carefully so that any residual pressure is released.
Check-tightening of leaking couplings and connections may only performed after the system is completely
depressurized.
WARNING
Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on
bare skin.
To check for leaks, use a steel plate or stiff board, never use your hands.

Service Information
Document Title: Function Group: Information Type: Date:
Health hazards with paint,
plastics and rubber
191 Service Information 2014/3/20
Profile:
BHL, BL70 [GB]
Health hazards with paint, plastics and rubber
Work on painted surfaces
No welding or torch-cutting is allowed on painted surfaces. All paint is broken down when heated and forms a wide variety
of substances that may be irritating and very hazardous to health after prolonged or repeated exposure.
The following safety instructions must be followed:


Remove all paint by sand-blasting at least 10 cm (4 in.) around the welding or cutting point (use suitable breathing
protection).
If the work area cannot be sand-blasted, remove the paint in another way, for example, with a paint remover
(solvent).
NOTE!
When using paint removers (solvents), use an air extractor, breathing protection and protective gloves.
High-speed grinding machines and grinding discs also heat the paint and must only be used if there's an air
extractor on the grinding machine. Use breathing protection as well.
Rubber and plastics
WARNING
When heated, rubber and plastics can give off substances that are hazardous to personal health and the
environment.
The following safety instructions must be followed:




Do not weld or cut near polymer materials (rubber and plastics) without first protecting them from the heat.
Never burn polymer materials when scrapping them.
Be careful when handling machines that have been exposed to fire or other intense heat. Also, refer to “Checklist
after a fire or other heat exposure”.
Always use protective gloves, protective glasses/goggles and breathing protection.
Fluor rubber
WARNING
Risk of serious corrosive injuries!
WARNING
When hydrogen fluoride rubber is heated, there is a risk of hydrogen fluoride gas build-up already at approx. 320 °C
(610 °F). When inhaled, the gas is extremely corrosive to respiratory tracts.
Certain seals designed to withstand high operating temperatures (for example, in engines, transmissions, axles, brakes,
hydraulic motors and pumps) may be made of fluor rubber, which will form hydrogen fluoride and hydrofluoric acid when
exposed to intense heat.
This acid is highly acidic and corrosive. It cannot be rinsed or washed off the skin, and causes very severe burn and corrosive
injuries that take a very long time to heal. As a rule, injured tissue must be removed surgically.
The acid may remain on machine parts for a very long time (several years) after a fire.
NOTE!
It may take several hours after contact with the acid before any symptoms become apparent.

If swelling, redness or burning sensations appear and contact with heated fluor rubber is suspected, contact a physician
immediately. If a machine or a component for a machine has been exposed to fire or other intense heat, it shall be handled
by specially trained personnel.
Thick protective neoprene rubber gloves and tight-fitting protective goggles must be used during all handling of machines
after a fire.
WARNING
Burning of painted parts, plastic or rubber parts constitutes a health hazard.
Decontamination
The area around a heated part that is suspected of being made of fluor rubber must be decontaminated by thorough and
ample washing with lime water (a solution or suspension of calcium hydroxide, that is, slaked lime in water). After the work
has been completed, wash the protective gloves in lime water and discard them.
The safety instructions in the following checklist must be followed under all circumstances if a machine has been exposed to
a fire or other intense heat: