rev1 02.

06 MY
General General safety instructions 1

Only people who have been given specialised operation and service
training are allowed to perform operation, service, and adjustment
procedures. Read the Operating and Maintenance Instructions before
using or servicing the equipment.

To avoid potential damage and injuries, carefully plan your work

beforehand. The operator must have full command of all the functions
of the machine before starting to use it.

The operator must always use the required safety equipment, such as
safety helmets, protective overalls, protective footwear, hearing
protectors, eye protectors, and other required protective equipment.

Only perform maintenance work when the machine is parked. Use the
appropriate tools for the task. Replace or repair faulty tools and
equipment. When performing maintenance and repair work, make
sure there are no unauthorised persons in the working area.

Sandvik Mining and Construction

rev1 02.06 MY
General General safety instructions 2

If the machine is damaged, stop the machine immediately as

instructed in the manual. Ensure that the machine cannot be started,
and determine the cause for the malfunction.

If you must weld the machine, remove the alternator wires and open
the main switch before welding. Take into consideration the fire and
explosion hazard created by welding. Make sure that themachine and
its surroundings are clean and fireproof.

Always keep a fire extinguisher to hand, and know how to use it.
Inspect and service the extinguisher at regular intervals and
according to local regulations.

Sandvik Mining and Construction

rev1 02.06 MY
General safety precautions General safety instructions 3

during operations

We recommend that records be kept on repairs and wearing part replacements. Regular
maintenance at correct intervals increases the productivity, reliability, economy, and
safety of the equipment.

Maintenance and repair work can be dangerous unless caution is observed. Everybody
involved in maintenance work should understand the possible hazards, and use safe
working methods. Before starting any maintenance or repair work, read the
manufacturer’s instructions and follow them.

The personnel must not wear long loose hair, nor loose clothing nor jewellery including
rings, because of danger of injury.

Use personal protection suits and other protective equipment as necessary or when
mandatory.

Do not do any modifications, extensions or rebuilding to the machine, which would affect
safety. Consult the supplier or manufacturer. This also includes the addition and
adjustment of safety devices and valves, as well as the welding of frame structures.
Spare parts must correspond to the manufacturer’s technical specifications. Conformity
is guaranteed only with genuine parts.

Sandvik Mining and Construction

rev1 02.06 MY
Fire extinquisher General safety instructions 4

Notify the location and use of fire extinguishers!

It is absolutely necessary to have suitable specialised workshop equipment for high

maintenance performance.

Any maintenance or repair work on the TORO must be performed by trained or instructed
personnel only. Work performed on electric appliances must be done by electricians and
on work on hydraulic appliances by mechanical technicians with specific knowledge and
experience.

Clean and wash the equipment regularly, and always before and after maintenance and
repair work. Before cleaning the machine with water or by steam jet or other cleansers,
cover the alternator, connection boxes and major connections. Remove the covers after
cleaning!

Never attempt to clean, adjust, repair or lubricate the dump truck/ loader while it is in
motion or the engine is running.

Sandvik Mining and Construction

rev1 02.06 MY
General repair instructions General safety instructions 5

The person responsible for maintenance and repairs should be clearly defined.
- Do not do any work that you are not authorised to do.

- Secure extensively the area of maintenance works as needed.

- Inform the users of the equipment of the start of special and maintenance work.

- If the equipment or a part of it has been stopped for maintenance or repair, make sure that it
cannot be started accidentally.

• Turn the main switch off

• Remove the ignition key

• Put a DANGER DO NOT START or corresponding warning sign on the main switch. The sign
must only be removed by a person who is fully aware of the situation.

- If required, ensure that suitable and safe ladders or working platforms are available for repair
and maintenance work.

- Do not use parts of the equipment as steps. If maintenance work must be done high up, or in an
otherwise dangerous place or position, use necessary safety devices to prevent falling.

Sandvik Mining and Construction

rev1 02.06 MY
General repair instructions General safety instructions 6

- All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean of oil, dirt,
snow, and ice to prevent accidents.

- Always use the correct tools for the maintenance task.

- Before commencing maintenance or repair work, ensure that the vehicle is on level ground, and
that it can’t move.

- Pay special attention to the exhaust piping and the exhaust gas cleaning system.
Ensure sufficient ventilation.

- Use a lift jack only on level, hard and firm ground. Before using a jack, make sure the
wheels on the other side of the vehicle are blocked. To avoid possible slipping of the jack,
secure the vehicle with adequate supports and blocks underneath the vehicle.

- Exhaust all the air from the tire before loosening the wheel nuts/bolts. Should you forget to do
this, a broken rim part under pressure can fly apart and cause serious injury.

- Do not try to repair wheel parts by brazing, welding or reworking. Be sure to replace with new
parts of the same size, type and make.

Sandvik Mining and Construction

rev1 02.06 MY
General repair instructions General safety instructions 7

- Never transport a fully inflated spare tire mounted on demountable rims. They should
have just enough air pressure to hold the rim parts firmly in place. Only after the tire
and rim assembly have been fastened with all the wheel nuts/bolts properly torqued
should the tire be inflated to the correct operating pressure.

- When inflating, mounting or dismounting tires, a safety rack, cage or some other
protection must be used

- During tire inflation, do not stand in front of the assembly. Use an extension hose, so
that you can stand to one side.

- When replacing heavy parts, use correct lifting apparatus and techniques.

- After preventive maintenance and repairs, always tighten unscrewed fasteners.

Reassemble all dismantled safety appliances immediately after the work is done.
Insure that all safety systems are tested before the unit is returned to work.

- Ensure safe and environmentally protective disposal of process materials and

exchange parts.

Sandvik Mining and Construction

rev1 02.06 MY
Hydraulics maintenance General safety instructions 8

Maintenance, repair, and installation of hydraulic equipment must only be carried out by
experienced hydraulics experts.

• Do not attempt any such repairs that you do not fully understand.

• Never do any repair work on the hydraulic circuit if the system is pressurised.

• Always stop the engine before tightening or repairing a leaking hose connection.

• Do not try to locate a leak from a hose or a connection by feeling with your hand.
The high-pressure oil spray from the leak can penetrate the skin and cause a
serious injury. A high-pressure oil spray can also start a fire.

• Avoid direct skin contact with oil. Prevent oil from getting into your eyes; use eye
protection.

• Do not work under a device or component that is held up only by the hydraulics.
Use separate supports in conjunction with maintenance and repair.

Sandvik Mining and Construction

rev1 02.06 MY
Hydraulics maintenance General safety instructions 9

• Do not remove cylinders or their valves unless the components held by them are properly
supported and system non--pressurised.

• Pipe connections, hose lengths, and hose types must correspond with the specifications.
When replacing or repairing hoses, use original SANDVIK TAMROCK spare parts or
hoses and fittings recommended by the manufacturer. Ensure that the pressure ratings
of the hoses and connecting fittings correspond with the working pressures.

Any alterations require a written authorisation from the manufacturer.

Pressure tests

General
• The hydraulic oil temperature should be 60...80 _C

• Connect and disconnect the pressure gauge(s) only when the circuit is non pressurised.

• Use only special couplings for pressure testing

• Do not overtighten couplings. When special couplings are used, finger tight is adequate.
Overtightening causes harmful leakage.

• Use hose(s) long enough to read the gauge(s) while sitting in the cabin

Sandvik Mining and Construction

rev1 02.06 MY
Electric system maintenance General safety instructions 10

• Work on electric equipment or materials is only to be carried out by qualified electricians or

other professionals, or assistants under their supervision and control, observing
electrotechnical regulations.
• The local electrotechnical and electric safety regulations must always be observed.
• Only original electric components.
• If disturbances in electric supply occur, stop the vehicle at once.
• Voltage must be cut off from the parts of the equipment or device that are to be checked,
serviced, or repaired, if the regulations so require. Check that the disconnected parts are dead,
and then lock the main switch or arrange a work earthing if necessary.
• Do not touch battery terminals, alternator terminals, or wiring cables while the engine is
operating. Severe electrical shock,which may lead to personal injury, can result from improper
shielding of electrical components.
• Check the electric devices of the equipment regularly. Faults, such as loose wires and damaged
insulation, must be repaired at once.

Sandvik Mining and Construction

rev1 02.06 MY
Electric system maintenance General safety instructions 11

When handling high-voltage components, remember that capacitors may have an electric
charge, even if the voltage is cut off. Short the capacitors with an earthing rod.
• Before making any changes to the electric devices, SANDVIK TAMROCK’s
electric engineering department must be consulted and a written authorisation received
to ensure the operation of the device does not change.

Working on energized components

• If the component must be energized, a fellowworker must be standing by to cut off voltage
with the emergency or main switch in an emergency situation. Follow the electric
safety regulations.

• Use a red-and-white safety chain and warning signs to encircle the working area.

• Use only insulated tools.

• Observe special caution.

Sandvik Mining and Construction

rev1 02.06 MY
Battery maintenance General safety instructions 12

Always wear eye protection, protective overalls, and protective gloves when
servicing batteries.

• Always disconnect the negative (-) pole first, and then the positive (+) pole. Always
reconnect the positive pole (+) first, and then the negative (-) pole.

• Reversing battery polarity can result in personal injury caused by a sudden

discharge of electrolyte from the battery vents and/or the sudden rupture of the
battery case caused by an explosion of internal hydrogen gas.

• To prevent sparking when connecting a battery charger, pull the charger supply
cord or switch the charger off before connecting the charging wires to the battery
terminals. Open the battery cell caps slightly during charging to allow the
generating gases to escape.

• The acid in the battery burns skin, eats holes in clothing, and can cause blindness
if it gets in the eyes. If you get battery acid on your skin, flush the spot at once with
water. If acid gets in the eyes, flush the eyes with plenty of water and call a doctor.

Sandvik Mining and Construction

rev1 02.06 MY
Battery maintenance General safety instructions 13

• When servicing batteries, remember that lead-acid batteries generate (during charging and
discharging) oxygen and hydrogen which form a highly explosive mixture. A spark or an open
flame can cause an explosion. If necessary, ventilate the battery compartment properly before
disconnecting or connecting the cables.

• To prevent explosion, the electrolyte level must be maintained and checked regularly. Add
distilled water, if required, before starting, never immediately after use. With a high enough
electrolyte level, the cells have less space for gases.

• Use a flashlight when checking electrolyte levels, never an open flame.

• The battery terminals should never be shorted as sparks can cause the battery to explode.

• Do not test electric devices by making contact with the battery terminal.

•Always connect the battery charger directly to the batteries. Never connect battery charger to
machine unless isolator is locked open, must remain open for complet charge time.

Sandvik Mining and Construction

rev1 02.06 MY
Welding General safety instructions 14

Before starting to weld, determine thematerial to be welded, and the welding method and fillers.
Contact SANDVIK Mining & Construction Service, if necessary.

• Do not repair steering equipment by welding.

• Welding must be left to qualified personnel.

• Before electric welding, the main switch must be disconnected.

• If welding must be done close to any of the control modules, disconnect the module wiring
before welding.

• The ground cable of the welding machine must be connected as close to the weld as possible.
The ground cable must not be connected so that the current can flow through a
bearing, joint coupling, sealing surface, lever, or control cable.

• Use a protective mask when welding.

• Arrange adequate ventilation.

• Arrange protection against fire.

Sandvik Mining and Construction