Operator Manual LH514
Operator Manual LH514
Operator Manual LH514
497 10 en 2011-09-22
1. INTRODUCTION ............................................................................................................................ 7
1.1. Preface ................................................................................................................................................................. 8
1.2. Type plate ........................................................................................................................................................... 9
1.3. Intended use ...................................................................................................................................................... 10
1.4. Warning and information symbols used in this manual ........................................................................ 10
1.4.1. Safety Symbols Pertaining to the Machine ................................................................................................ 11
2. SAFETY ......................................................................................................................................... 17
2.1. Main safety risks of equipment operation or maintenance work ........................................................ 18
2.2. Safety precautions when servicing a machine ......................................................................................... 20
2.3. General safety instructions when operating the machine .................................................................... 22
2.4. Safety rails user safety instructions ........................................................................................................... 23
2.4.1. Using locking devices ................................................................................................................................... 24
2.4.2. Getting up on top of the unit and building safety rails up ........................................................................ 25
2.4.3. Lowering safety rails and getting down from the unit ............................................................................... 28
2.5. Consideration for the environment when servicing the EQUIPMENT ............................................... 31
2.6. Consideration for the environment when using the EQUIPMENT ...................................................... 32
2.6.1. Economical operation of the equipment ..................................................................................................... 33
2.6.2. Decommissioning .......................................................................................................................................... 34
2.7. PROPER USE ..................................................................................................................................................... 34
2.8. The conditions where the machine is not allowed to be operated ..................................................... 35
2.9. VENTILATION AND DUST PREVENTION ................................................................................................... 35
2.9.1. Dust prevention .............................................................................................................................................. 36
2.10. Danger areas when operating ....................................................................................................................... 37
2.11. Gradient angles ................................................................................................................................................. 39
2.12. Fire prevention .................................................................................................................................................. 41
2.12.1. Fire extinguisher (option) .............................................................................................................................. 41
2.12.2. Fire suppression system (option) ................................................................................................................ 43
2.13. Emergency stops and stopping devices .................................................................................................... 47
2.14. Locking devices ................................................................................................................................................ 48
2.14.1. Frame locking pin .......................................................................................................................................... 48
2.14.2. Boom locking pins ......................................................................................................................................... 51
2.15. Location of main switch ................................................................................................................................. 54
2.16. Escape procedures .......................................................................................................................................... 55
2.17. Refuelling ............................................................................................................................................................ 56
2.18. Cooling system ................................................................................................................................................. 57
2.19. Oils, greases, and fuels .................................................................................................................................. 58
2.20. Hydraulics maintenance ................................................................................................................................. 59
2.21. Pressure accumulators ................................................................................................................................... 61
2.22. Electric system maintenance ........................................................................................................................ 62
2.23. Battery maintenance ........................................................................................................................................ 63
2.24. Welding ............................................................................................................................................................... 65
2.25. Tire maintenance .............................................................................................................................................. 66
1. INTRODUCTION
1. INTRODUCTION
1.1. Preface
Thank you for choosing a product manufactured by Sandvik Mining and Construction.
This manual describes the use of the product. Only people with the proper training are allowed to
operate this product. In addition, the operator must read and understand the contents of the operation
and maintenance manuals and the safety instructions.
The manual gives you information on the structure and operation of the product that is necessary for
correct use and maintenance. It also instructs you in shift-specific service work. Regular maintenance
procedures are explained in the maintenance instructions.
For more complicated maintenance and repair work, we recommend that you contact the nearest
authorized service shop. Our maintenance staff have the skill and special tools needed for more
demanding work.
Through correct use and by following the maintenance instructions, you can expect a high degree of
utilization and a long service life for your product.
Always obey the local legislation in force where accident prevention and environmental protection
are concerned. Generally accepted technical guidelines for safe and professional operation must also
be observed.
Storage
Keep the manual clean and readily accessible by operator and maintenance personnel whenever
needed.
Manual must be replaced immediately if lost, damaged or unreadable. New manuals can be ordered
from Sandvik Mining and Construction by publication number found at the bottom of the manual page.
The information in this manual corresponds to the model and appearance of the product at the time
of delivery. Sandvik Mining and Construction reserves the right to change the technical data and
equipment without prior notice. All information included in the manual is valid at the time of publication.
Manuals are valid only if no modifications are made to the product.
Copyright
This document must not be copied, presented, or delivered to a third party without our permission,
nor used for purposes other than those allowed by us. We reserve the right to change the products
settings and equipment as well as the maintenance and repair instructions without separate notice.
Sandvik Mining and Construction
Manual contents
This SANDVIK loader is intended to load, haul and dump rock material exclusively in underground
mines. Any other use different from this is not considered as intended. The intended use also includes
following the instruction manual and to observe inspection and maintenance rules.
The manufacturer or supplier will not be liable for any damage resulting from the product misuse.
When we refer to the front of the unit, this is the end of the unit where the bucket is attached to. The
right and left sides of the unit are designed in reference to the operators position, looking toward the
front of the unit.
This machine is designed and constructed according to state of the art technology and the recognized
safety rules. Nevertheless, unintended and careless use may cause damage to health of the user or
third persons, or prejudice the machine and other properties.
This loader shall be used only
• for its intended use
• in underground mines only
• when it is in proper mechanical and operational condition
• conscious of safety and possible danger
• in strict notice and use of the instruction manual
The warnings in this manual have been divided into the following three categories.
The term "NOTICE" Indicates a situation which, if not avoided, could result
in damage to property.
• Keep safety instructions and safety labels clean and visible at all times.
• Replace any illegible or missing safety instructions and safety labels before operating the machine.
Hazard
The black symbol inside a yellow triangle with a black border describes the
hazard.
Prohibition
The black symbol inside a red ring with a diagonal red bar describes the
action that should not be taken.
Mandatory action
The white symbol inside a blue circle describes the action that must be taken
to avoid a hazardous situation.
Hazard symbols
The hazard symbols related to each hazardous situation are presented below.
Skin injection hazard High pressure injection hazard Hanging load hazard
Noise hazard
Lifting hazard
General hazard
These symbols are used in warnings and notifications to indicate a the action that should not be taken.
The prohibition symbols are presented in the following table.
Do not remove safety guard Do not modify General symbol for prohibited
action
These symbols are used in warnings and notifications to indicate the action that must be taken to
avoid a hazardous situation.
The mandatory action symbols are presented in the following table.
Wear safety harness Wear ear protection Wear steel toed safety boots
Wear close fitting overalls Wear high visibility vest Wear respirator
Disconnect from power source Switch off and lockout equip- Read the manual or instructions
ment
Use cardboard for locating leaks Use lap belt General symbol for mandatory
in hoses action
2. SAFETY
2. SAFETY
DANGER
Operating or maintaining the machine in a dangerous or
incorrect manner may cause serious injury or death (or other
health risk) if sufficient safety procedures are not followed.
DANGER
Overrun hazard. Can cause severe injury or death. MAKE SURE
THAT THERE ARE NO UNAUTHORIZED PERSONS IN THE
DANGER AREA WHEN THE MACHINE IS BEING OPERATED.
Be seated and have your seat belt fastened when operating the
machine.
It is recommended to keep a record of the use of maintenance and wear parts. This way, the need
for preventive maintenance can be predicted more easily, resulting in the rig’s improved usability,
service life, efficiency and safety.
Failure to take necessary precautions increases the safety risk for the service personnel. All
maintenance personnel working with the rig must be fully aware of possible hazards and must apply
safe working methods. Before any maintenance or repair work, the manufacturer’s instructions must
be read carefully, and they must be followed exactly.
The person responsible for maintenance and repair work must be clearly specified.
Pay attention to the following:
• Never attempt to carry out tasks for which you have not received the relevant training or
authorisation.
• Inform the rig operator about the start of maintenance and repair work.
• Before starting the work, ensure that all unnecessary items are cleared from the vicinity of the site
and that the area is safe to work in.
• If maintenance or repair work is to be carried out on the rig, always ensure that the rig cannot be
accidentally started:
- Turn the main switch off.
- Remove the ignition key.
• Place a DANGER - DO NOT START warning sign on the main switch. The sign may only be
removed by a person who is fully aware of the current status of the work.
• Clean and wash the rig regularly, and always before starting maintenance or repair work.
• Before washing the rig with water, a high-pressure cleaner, a steam cleaner, or any other method,
protect any components that are susceptible to damage from the cleaning method or due to
exposure to water. Pay special attention to the protection of electric motors, boxes, and cabinets.
• If necessary, equip the work site with appropriate steps or working platforms.
• Never use the components of the rig as steps. If the work is carried out at height, or in an otherwise
dangerous position, use proper working platforms to prevent falling. Never climb on the rig's covers.
• Keep all stairs, rails, anti-slip devices, steps, etc. clean of oil, grease, snow, ice, unnecessary items,
and dirt to prevent accidents caused by slipping.
• Use only undamaged, high-quality tools that are appropriate for the work in question.
• Before starting the work, ensure that the rig is on a level surface and the park brake is engaged
and that all tracks/wheels are wedged or that the jacks are lowered to prevent movement.
• Observe the operation and condition of the exhaust pipe and exhaust cleaner in particular, and
ensure sufficient ventilation.
• Diesel engine overheating indicates a fault. Stop the engine and address the cause of the
overheating in order to prevent damage to the engine. Ensure that air can flow freely through the
engine's radiator. If necessary, clean the radiator and remove any obstructions.
• Stop the engine and allow it and the coolant to cool down before checking the coolant level. If this
is not possible, use protective gloves and other protective clothing when opening the radiator cap,
in order to prevent burns and related injuries. Stand as far to the side as possible, turn your face
away, and carefully open the cap slightly. Before opening the cap fully and removing it, wait until
the pressure or coolant stops discharging from the cooling system.
• Use appropriate hoists and lifting methods when moving heavy parts and equipment. Follow the
hoist manufacturer's instructions.
DANGER
Crushing hazard. Can cause severe injury or death. Install frame
locking device when servicing a machine
DANGER
Hazardous boom movement. Can cause severe injury or death.
Ensure that the boom is supported before releasing pressure
from the hydraulic system.
These general instructions describe the safe way procedure using the safety rails. Safety rail layouts
varies lightly from unit to unit but the basic principle using them is the same.
The safety rails are designed to prevent a person from accidentally falling from the machine during
servicing the unit. The safety rails are hinged to the frame structure of the machine and are manually
operated. When not in use, the rails are clamped to the service hatches and before the maintenance
work are to be build up.
WARNING
Always wear required personal protection, such as safety
helmet, safety gloves, safety boots, etc. when handling the
safety rails.
WARNING
Slipping, tripping, or falling hazard. Can cause severe injury or
death. Keep ladders, steps, handrails, handles, and working
platforms clean of oil, dirt, and ice.
Check the safety rails and locking devices regularly. Keep them
in good condition and lubricate the latches and the hinges.
WARNING
Always wear required personal protection, such as safety
helmet, safety gloves, safety boots, etc. when handling the
safety rails.
WARNING
Slipping, tripping, or falling hazard. Can cause severe injury or
death. Keep ladders, steps, handrails, handles, and working
platforms clean of oil, dirt, and ice.
If possible, find out beforehand the right building up sequence for the safety rails.
1. With both hands, take a good grip from the
lower handles and carefully with the steps
provided start climbing up onto the unit.
Always while working on top of the unit, lock the last gate so
that the top of the unit is totally enclosed and secured. Ensure
all the safety rails and gates are properly locked.
2.4.3. Lowering safety rails and getting down from the unit
WARNING
Always wear required personal protection, such as safety
helmet, safety gloves, safety boots, etc. when handling the
safety rails.
WARNING
Slipping, tripping, or falling hazard. Can cause severe injury or
death. Keep ladders, steps, handrails, handles, and working
platforms clean of oil, dirt, and ice.
In order to get the safety rails clamped back to the resting position, lowering the rails must be done
the other way around than the building up procedure.
1. Unlock the gate(s) from the first rail's counter
rail. Lock the gate(s) in resting position. With
sure footing, grip the rail from the middle above
with your both hands, lift a little bit and lower
the rail carefully down.
Before operating with the machine, ensure that the safety rails
are in resting position and properly locked.
When servicing the equipment, you handle many substances that are regarded as hazardous waste.
When dealing with these, be very careful and follow the applicable local regulations. The following
instructions should provide useful guidance - for more location-specific instructions, contact the local
garbage disposal company or the appropriate authority.
Service area
The facilities used for servicing must be designed for this purpose. The floor material must be oil-
resistant-preferably cast concrete. For washing the equipment and to prevent damage from oil, the
sewage system must be equipped with an oil trap.
According to regulations, those in possession of hazardous waste must know the amount, quality,
and origin of the waste; i.e., companies must keep a record of this information. Always follow the
regulations for storage of hazardous waste. It is a good idea for the company to appoint a person
who is responsible for the storage and further processing of hazardous waste.
Any oil that is spilled onto the ground, including biodegradable oil, must be collected as carefully as
possible. Oil waste must not be disposed of by burning, and under no circumstances must oil be
poured down the drain or into water systems. One liter of oil is enough to pollute a million liters of
ground water intended for household consumption.
Used lubrication oil is hazardous waste that must always be processed by an authorized waste
treatment plant. During its use, metal particles and other impurities have entered the oil. These
increase the risks to the user's health.
If the company produces a larger amount of oil waste, it is worth separating. For treatment, oil waste
is divided into three categories:
• Clear oils, which include hydraulic and transmission oils.
• Black oils, which are motor oils. Synthetic and mineral oils are collected in the same container.
• Vegetable oils, which are collected in a separate container.
Greases, fuels, solvents, and other substances must not be mixed with oil waste.
Oil filters, oil rags, fuel filters, and oil absorbents must be collected in a separate container.
Used radiator, brake, and clutch fluids contain traces of heavy metals, zinc, and copper, for which
reason they must not be poured down the drain or mixed with oil waste. They are to be collected in
a separate, labeled container and delivered to the same plants as the oil waste.
Solvents and sludge that has collected on the surface of the oil traps are collected in the same
container. The surface layer in the oil traps must be removed regularly, and the entire trap must be
drained at least once a year, including the sludge at the bottom. Do not mix the oil trap sludge with
oil waste.
Fuel oil
Fuel oil is hazardous waste that must in all cases be processed by an authorized waste treatment
plant.
The best containers for collecting oil waste are the original containers for the oils. Naturally, new
containers become available whenever new oil is purchased. They already have the necessary
warning labels, are easy to close, and can be moved around fairly easily. Always strike out the product
name on the label and clearly label the container oil waste". This ensures that everyone knows the
container contains oil waste. Store the waste in an appropriate manner. A suitable storage room for
hazardous waste has a roof, a leak-proof floor, and preferably a lockable door. When storing
flammable fluids, always ensure that the room has a separate ventilation system or is otherwise well
ventilated. The path to the storage room must be free of obstacles.
Empty oil containers must not be dumped in landfills without having been cleaned. Cleaned plastic
containers can be disposed of as regular waste. Most countries have arranged a recycling system
for metal barrels.
Sandvik actively considers environmental concerns when designing and manufacturing its products.
The equipment are designed to burden the environment as little as possible; i.e., the vibration, noise,
exhaust, and lubrication/additive emissions of the machine have been minimized. The manufacturing
process for the equipment has been designed so that recycled materials are used as much as
possible, and the process quality and emissions are considered carefully in selection of the
subcontractors. There is an ongoing aim of continually lowering the emissions from the machining of
metal, and from painting and assembling the equipment, and these processes fulfill the very strict
requirements of the Finnish environmental legislation.
The costs incurred by using the equipment go hand in hand with the amount and type of emissions
it lets into the environment. Through systematic training of the operator and service personnel, one
can reduce the operating costs of the equipment significantly, and at the same time reduce the
environmental burden caused by the equipment. See the graph below.
An economical driving method and correct operation are another key factor in reducing operating
costs and the effect on the environment:
• Avoid idling. Warm up the machine by performing light tasks, not by idling.
• When you are working, try to keep the engine speed close to the maximum torque or just above it,
as this will ensure optimal engine fuel economy and keep the noise and exhaust emissions low.
There are still some power reserves in the engine for momentary load peaks.
• Avoid unnecessary carrying and use of auxiliary devices (e.g., air–conditioning unit or extra
electrical and other work equipment) that will not be needed for the work at hand.
• Avoid overloading.
E A B
A Other factors
B Storage
C Application and equipment used
D Driving method used
E Level of service and maintenance
2.6.2. Decommissioning
The end user of the equipment is responsible for its decommissioning. If the end user does not have
the ability or the resources to disassemble the equipment, the work must be performed by someone
who does possess the necessary knowledge and skills.
In disposing of the waste material from disassembly of the equipment, the following matters should
be considered:
- The equipment body, all the steel constructions, and the copper and aluminum in the electrical
wiring are recyclable. The metals can be melted and used as raw material for new products, except
for parts that have been in contact with substances that are regarded as hazardous waste. The
contaminated parts can usually be simply cleaned or rinsed, after which they can be recycled.
- Most plastic parts are recyclable, similarly to the metals. Each plastic part carries information on
the material used and a manufacturing date, which can be used for determining whether the part
can be recycled.
- Rubber parts are not regarded as hazardous, and they can be disposed of according to normal
procedures. Tubes (hydraulics etc.) must be cleaned before they are disposed of. Worn--out tires
can be returned to the dealer from whom they were originally bought.
- Windshields and other cabin windows are not accepted for conventional glass recycling, but they
can be disposed of via normal waste disposal methods.
- Electrical components that are classified as hazardous waste (accumulators, batteries, circuit
boards) and other hazardous waste must be delivered to a licensed waste treatment location or be
disposed of according to local regulations.
- Air conditioning units, which contain CFC and HCFC compounds, must always be delivered for
treatment to a licensed waste disposal facility.
- For disposal instructions for fluids and lubricants, refer to the service manual.
These instructions are not binding, but they offer suggestions for appropriate waste disposal
procedures. Local authorities always have more detailed instructions and recommendations on the
disposal of different materials.
When decommissioning the rig, always follow the local
authorities' regulations on waste disposal that are in force at the
time and location of the disassembly.
The use of the equipment for other purposes than what it is designed for, or exceeding the specified
performance ratings is not considered proper use. The manufacturer / supplier is not liable for damage
caused by such use. Proper use also includes observing the information in the user and service
instructions and following the control and service regulations.
Acquaint yourself with the user and service manuals issued by the manufacturer, and keep them
always with the equipment.
DANGER
• Operator does not have sufficient training
• Unauthorized persons are present in the working area
• Safety systems are deficient or out of order
• The area where you are operating has being charged with
explosives
• The environment where you are operating has being contaminated
with explosive gases or explosive dust
• Transportation of persons
• Insufficient ventilation and too high water level in working area
NOTICE
• Risk of loose boulders falling on the machine
• Icy or otherwise slippery operating site
• Insufficient lightning
• The environment where you are operating has being contaminated
with explosive gases or explosive dust
Mining regulations and safety requirements demand careful ventilation plans and air quality
monitoring. If the engine has to be started in an enclosed space, make sure that ventilation is
sufficient, because inhaling exhaust fumes can be lethal.
One of the purposes of ventilation is prevention of dust accumulation.
Method Examples
Prevention Correctly applied working methods, correct equipment
Extraction Cleaning, filtrating
Binding Water spray or vapour, foam, water flushing, chemical treatment of settled dust
Isolation Enclosing, local extraction ducts
Attenuation Local auxiliary ventilation, general ventilation
WARNING
Dust hazard. Breathing or inhaling dust particles will cause
death or severe injury. Always wear proper respirator when
working in a dusty environment.
DANGER
Dangerous machine movement can cause severe injury or
death.
The machine operator should always ensure during work, that there are no unauthorised persons in
the danger area.
Operating / driving in the mine you must strictly follow the site traffic regulations. Pedestrians must
always give the way the vehicle and machinery. If you must bypass the machine, always bypass from
the operator side so that the operator could see you better. Wear approved high visibility clothing.
When operating with machine, always remember that visibility is limited. Ensure that unauthorized
persons are not present in the working area.
Visible area
Blind area
Eye point position according to the standard SFS-EN ISO 3411 "medium operator".
Be careful and drive slowly when approaching emptying station with bucket in lifted position!
Avoid sudden up-and-down boom motion in lifted position, especially when machine is articulated!
It is extremely important to avoid fire in mining conditions. Fire causes flames, heat, hazardous
vapors, explosions, or other hazards.
Check the machine for any possible leaks in fuel and hydraulic circuits. Leaks can cause fire.
All personnel working at production area must be trained to recognize the fire safety risks. The
personnel must be trained to perform correct emergency procedures in case of fire.
Always obey local laws and safety regulations in case of fire.
In general, the following recommendations will help prevent the likelihood of a fire on the machine:
• Keep the machine clean. Clean any and all fuel or oil spills as quickly as possible.
• Repair all electrical wiring and electrical component malfunctions immediately.
• Ensure the engine air intake, fuel, and exhaust systems are maintained properly.
• Inspect the machine regularly for hydraulic oil leaks and make the necessary repairs immediately.
In case of fire:
ANSUL:
Do not re-start the loader again until the cause of the fire has
been established and the fault repaired.
Ensure that all local, site and mine regulations are adhered to
following a machine fire.
The twin pressure switch is wired into engine shutdown panel triggering audio-visual alarm and
starting engine shutdown delay timer sequence on drop of pressure. Timers are factory set to an
automatic 6 seconds, with a 20 second manual timer reset. If there is no operator intervention,
automatic engine shutdown will take place 6 seconds after fire suppression system activation.
If the button 4 is pressed during the 6 second countdown, it resets the timer to an extended 20 second
delay, allowing the operator to have both hands free to drive the vehicle for another 20 seconds before
the engine shuts down automatically.
The panel is fitted with a manual override function (6) to allow the equipment to be moved if necessary.
However, to reduce the risk of the equipment being operated with the fire suppression system
discharged, the override button must be held depressed (spring return button) to maintain override.
As soon as the button is released, the unit will return to the shutdown mode.
Do not re-start the machine again until the cause of the fire has
been established and the fault repaired.
Ensure that all local, site and mine regulations are adhered to
following a machine fire.
If the emergency stop button(s), located in the cabin and at the rear end of the unit (optional) as shown
in attached pictures, is pressed the brakes will engage and engine will stop. The engine cannot be
started until the emergency stop button has been released.
DANGER
Dangerous machine movement can cause severe injury or
death.
4. Repeat the steps 2 and 3 on the other side of the boom. Do not walk under the boom under any
circumstances.
5. Climb up to the cabin and start the engine. Lower the boom slowly against the stops and roll back
the bucket to the ground.
Never turn the main switch off when the engine is running. This
may damage the alternator or the voltage regulator and machine
electronic equipment.
The right hand side window of the operator cabin can be used as emergency exit.
1. Pull the exit sign/ring.
2. Move the sign round the window so that the
rope comes out of the window seal
2.17. Refuelling
DANGER
Smoking, open flames and sparks are dangerous when the fuel
tank is being filled.
Splashing hazard. Can cause severe injury. Never open the filler
cap when the coolant is hot. Allow the machine to cool down
before service.
WARNING
Only carry out work on the cooling system at coolant
temperatures below 50 °C. Wear approved protective gloves,
protective clothing and safety goggles when handling coolant.
NOTICE
Expansion tank is equipped with a locking pressure release cap.
When removing the cap, first lift the lever to unlock the cap and
wait for complete pressure evacuation before removing the cap.
Never open the filler cap when hot.
- Always use only the type of lubricants recommended by the manufacturer. Neglecting these
recommendations can lead to breakage or malfunction of the equipment, which can cause serious
personal or material damage.
- Check regularly that fuel, lubricant, coolant, and hydraulic fluid levels are correct.
- Do not mix different types of fluids and oils.
- When changing or adding fluids and oils, only use new and clean fluids and oils meeting
manufacturer’s requirements.
- Remember that all bearings are not alike. Each bearing has its specific properties and lubricant
requirements. Follow the manufacturer's instructions.
- Starter fluid and other flammable materials must not be stored in the cabin.
- Flammable materials must be protected against heat, sparks, and open flames.
- Storage containers of flammable materials must not be punctured or destroyed by burning, they
may cause risk of explosion.
- Smoking is strictly forbidden when filling up the fuel tank.
• 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 pressurized.
• Always shut down the machine 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.
• 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 Mining and Construction 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 authorization from the manufacturer.
Pressure tests
General
• Make sure that the hydraulic oil is at operating temperature!
• Connect and disconnect the pressure gauge(s) only when the circuit is non pressurized. For more
information refer to Service and repair manual.
• 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.
• Attach all measuring point protection caps after the checking procedure.
DANGER
Danger of explosion. Can cause severe injury or death. Under
no circumstances may any machining, welding or soldering
work be done on the accumulator shell. Work on systems
incorporating accumulators (repairs, connection of pressure
gauges, etc.) may be carried out only after the fluid pressure
has been released.
DANGER
Danger of explosion. Can cause severe injury or death. Only use
Oxygen Free Nitrogen (N2) in pre-charging the accumulator.
The use of oxygen or air can cause an explosion. It is
recommended that a regulating valve be fitted in the gas line
when charging accumulators with rating of less than gas supply
pressure.
New or reconditioned accumulators are delivered with a nitrogen charge of 10 bar (145 psi) to prevent
damage during transit. Before being put into operation they must be charged with nitrogen to the pre-
charge pressure p0. See correct pre-charge pressure form machine hydraulic schematic. Under no
circumstances should oxygen or air be used.
Having connected the hydraulic line, it should be bled of all air by means of bleeder screw on the
accumulator. Use only original spare parts to replace damaged gas valve elements.
• 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.
• Use 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.
• 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 Mining and Construction’s
electric engineering department must be consulted and a written authorization received to
ensure the operation of the device does not change.
DANGER
Electrical shock hazard. Ensure use of personal protective
equipment such as safety glasses, high voltage gloves and arc
flash shield and suit where necessary. Observe special caution
to the hazard of live work.
• If the component been tested must be live, a fellow worker 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 and test equipment rated for the voltage and application.
• Observe special caution.
DANGER
Explosion hazard. Can cause serious injury or death. Battery
charging emits hydrogen gas. Smoking and open flames are
strictly forbidden when servicing a battery.
DANGER
Chemical burn hazard. Can cause serious injury. Always wear
eye protection, protective overalls, and protective gloves when
servicing a battery.
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 clean water. Flush the eyes
with plenty of clean water, and call a doctor.
• 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.
• 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.
• Do not carry battery by terminals. Do not drop battery, puncture or attempt to open battery case.
Do not subject product to open flame or fire and avoid situations that could cause arcing between
terminals.
• Sealed lead acid battery electrolyte is a clear to cloudy liquid with slight acidic odor. Acid saturated
lead oxide is a dark reddish-brown to gray solid with slight acidic odor.
• Lead and Lead Dioxide are not soluble. Battery Electrolyte (acid) is 100% soluble in water.
WARNING
Welding, drilling, cutting or any addition of attachments voids
certification.
Tire removal
• The person responsible for maintenance and repairs should be clearly defined.
• Deflate the air from the tire so that it just has enough air pressure (70kPa) to hold the rim parts firmly
in place before loosening the wheel nuts / bolts.
• Inflate the tire so that it just has enough air pressure (70kPa) to hold the rim parts firmly in place
before tightening the wheel nuts / bolts.
• After the tire and rim assembly have been fastened with proper torque applied to all the wheel nuts/
bolts, should the tire be inflated to the correct operating pressure.
• After preventive maintenance and repairs, always tighten fasteners which have been unscrewed.
Reassemble all dismantled safety appliances immediately after the work is done.
To ensure safe operation this loader has several built-in safety features. The available safety
equipment is listed below.
• Fire extinguisher (optional)
• Fire Suppression System (optional)
• Emergency stop button in the cabin
• Two emergency stop buttons at the rear end of the unit
• Safety interlocks for machine movements
• Emergency steering (optional)
• Frame locking pin
• Boom locking pins
• Reverse alarm
• Rotating beacon (optional)
• R.O.P.S./F.O.P.S. certified safety cabin with A/C
• Lockable main switch
• Safety belt
• Anti-slip strips
• Emergency exit
• Warning signs
Operational conditions
The sound pressure level at the operator’s position was determined in stationary conditions on high
idle (2190 rpm).
Test results
Measured A-weighted emission sound pressure level at operator’s position, LpA [dB re 20
74
μPa]
Uncertainty, KpA [dB] 3
Value determined applying test codes given in ISO 6393 and ISO 6394.
NOTE – The sum of a measured noise emission value and its associated uncertainty represents an
upper boundary of the range of values which is likely to occur in measurements.
WARNING
Exposure to high noise levels may cause loss of hearing. Use
always necessary ear protection when operating under high
noise levels.
Operational conditions
Test result
Rear frame - left side - cooler Rear frame - left side - mask frame
108 19 109
108 109 19
00003850
26 27 117
Optional Optional
Rear frame - right side Rear frame - right side - wiggins fillings
108 19 18
Optional
00003850
121 17 117
Optional
15 13
Optional
Optional
1/2 12 18 20
00003850
12 13
Optional Optional
1/2 112 18
Optional
56004224
108 20 10
16 20 102
108 10 16
Optional
Optional
56004224
111
18 111
Optional
3
116
112 25 24 23 9
9 23
24 25 112
107 11 102 14
122 122
122 122
56037927
11 14
3. MACHINE DESCRIPTION
3. MACHINE DESCRIPTION
Because the loader normally operates in mine conditions, its engine, transmission and hydraulic
systems are filled with oils suitable for typical conditions. However, in cold conditions oils may thicken.
This makes starting difficult and the torque converter and hydraulic pumps may be damaged. For this
reason, avoid any temporary parking in frosty weather. If the machine is to work in very cold or very
hot conditions, see the Maintenance Manual and Engine manufacturer’s Instruction Manual for the
correct oils and the proper fuel selection.
2
1
3
2
Pressing the button and holding it down opens the door. Release the button, when the door is fully
open.
Push the button to override the door hydraulic system and use the door manually.
Pushing the button and holding it down closes the door. Release the button, when the door is fully
closed.
The hydraulic door opening system is operating only when the
machine is in the operational mode.
1 2 3 4
These indicator lights indicate the state of the machine and will give at a glance the same information
as the traditional gauges. Warning and alarm lights are there to inform if any of the signals or
measuring operations are in warning or alarm conditions or if any kind of action is necessary.
Whenever a red or yellow indicator light is lit or whenever an alarm window appears on the display,
an abnormal functioning of the machine or control system will ensue. There is one exception: alarm
light test can be run by turning the ignition key to I-position which makes the indicator lights switch
on for three seconds, both lights must then go out.
The warning and alarm pop-up windows use big signs to indicate the reason for the alarm, the alarm
limit and the measured reading. Alarms from the engine control unit also are shown with the pop-up
windows on the display.
A pop-up window will appear on the display when a warning or an alarm condition is active and it will
remain on the display until the operator removes it. After setting off the pop up window the indicator
light will stay on for as long as the warning or the alarm is active. If the warning or the alarm stops
before the pop up window is set off, the pop up window will disappear from the display automatically
in a few seconds. It is only possible to view a reset warning or alarm by first turning the main power
off and then back on.
An active warning is indicated by a blinking triangle in the main window and yellow warning light. An
active alarm is indicated by an exclamation mark inside a blinking triangle and red alarm light.
Active alarms and warnings are indicated with the following symbols on the gauge windows (the
symbols appear on the left hand side of the symbol for the sensor that the alarm or warning applies
to):
Symbol Explanation
Above or below the alarm limits
All warnings and alarms that have taken place will be marked in the alarm log.
When going over from an alarm condition to a warning condition, the warning window will not be
shown in the display.
3. Charging light
Signal light is on if alternator is not charging. When ignition is on, charging light must be on. Once
engine running, charging light must go out.
Indicates abnormality (to high pressure) in A/C system operation. If this is the case, switch A/C off
and call a service person.
1. Steering lever
By pushing the lever forward turns the machine
to right and pulling the lever turns the machine to 2 3
left (Std, standard).
The four forward and reverse gears (speeds) of
the Power-Shift transmission are selected with
buttons on the steering lever.
2. DeClutch
When the machine is tramming in forward or re-
verse, and the operator press DeClutch button,
the transmission is shifted to neutral as long as
this button remains pressed. Engine rpm can be
used for hydraulics without drive. Available gear 6
5
range is set by a system parameter, usually first
and second gear. Releasing the button returns
the transmission to the previously selected gear.
It is possible to downshift gears or change driving
direction while in DeClutch.
DeClutch mode can be set on or off. If mode is 4
on, the way of action can be chosen from the dis-
play: brake pedal, push button, both or none.
3. Not in use (optional) 1
4. Rocker switch for driving direction STD
• Forward (F)
• Neutral (N)
• Reverse (R)
5. Higher gear
6. Lower gear
5. Higher gear
6. Lower gear
Select with gear mode switch (if automatic mode (optional) is not available, dashboard switch does
not exist).
Driving direction is selected with the rocker switch 4. Forward (F) direction is selected by pushing the
lower end of the rocker switch down. Reverse (R) direction is selected by pushing the upper end of
the rocker switch down. Gear is in neutral when either Forward or Reverse is not selected (middle
position).
When driving direction is selected, higher gears are selected by pushing the button 5 and lower gears
by pushing the button 6. Each time you push the button the gear will increase or decrease by one,
depending on which button (5 or 6) you are pushing.
The selected gear, driving direction and the highest gear available are shown on the display in front
of the operator. Manual text under the displays gear indication bar is darkened
System selects automatically the most suitable gear for the driving conditions. Operator selects the
direction with the rocker switch 4 and if needed, can also limit a particular gear to be the highest
available. The highest gear limitation is activated by pushing the button 5 when current gear is set to
the highest available, in both driving directions. The selected gear, driving direction and the highest
gear limitation are shown on the display in front of the operator. The highest gear limitation is
deactivated by pushing the button 6. Direction can be changed with rocker switch 4, change will occur
when machine speed is reduced under safe speed (set by parameter).Automatic text under the
displays gear indication bar is darkened.
Under normal conditions, always bring the machine to a
complete stop before changing driving direction.
The bucket and boom control lever is on the right side of the operator. The control lever is used to
raise and lower the boom and to dump and roll back the bucket.
The functions of the bucket and boom control lever may be reoriented.
The control lever does not work if:
• the door is open
• the brakes are not released
3. Not in use
• (A) Ejector plate out (optional).
• (B) Side tipping bucket rolling back (optional).
Swedish movements
3. Not in use
• (A) Ejector plate out (optional).
• (B) Side tipping bucket rolling back (optional).
3. Not in use
• (A) Ejector plate out (optional).
• (B) Side tipping bucket rolling back (optional).
The functions of the buttons vary depending on the display window. The symbols at the bottom of the
display window show which function is activated by pressing a button. For example, pressing the
buttons on the main window shown in the picture above opens the following display windows (the
main window opens when the system's operating voltage is switched on).
When the button is pressed, the information window for the main
4 window opens.
When the button is pressed, gauge window 1 opens.
5
To make using the user interface easier, the same symbols with the same functions are used in
various display windows.
Symbol Function
Moving to a previous display window level. For example, returning from the
gauge windows to the main window.
Moving to the next window on the same display window level. For example,
moving from gauge window 1 to gauge window 2.
Moving to the previous window on the same display window level. For ex-
ample, moving from gauge window 4 to gauge window 3.
Scrolling down.
Scrolling up.
Symbol Function
Moving to the next item on the menu.
NOTICE
It is very important, that the service password is not given to
any unauthorized persons. Any unauthorized use of the service
menus may result in serious malfunctions. The service
password may only be given to a service person sufficiently
trained by Sandvik Mining and Construction.
Symbol Function
Moving to the next item on the menu / increasing the setting value.
Moving to the previous item on the menu / decreasing the setting value.
Main window
In normal use, after the main power is switched on, the main window appears on the display.
3 4
12
10 11
2 2
5 6 7 8 9
Manual mode
There are status symbols in the main display which indicate the status of various functions.
The symbol to the upper left on the main window warns of malfunctions of the automatic central
lubrication. The symbol tells that the grease reservoir is empty (the picture of the grease gun becomes
red) or that there are malfunctions in pressurizing (The arrows above and below the symbol of the
grease gun become red).
The symbol to the left on the main window tells the status of the automatic torque converter lock
functions. The symbol is grey when converter lock function is off, and becomes green when you
activate lock function. The converter lock is on only when all its operational conditions are fulfilled
• If the vertical symbol bars are open, converter is not locked.
• If the vertical symbol bars are closed, converter is locked.
The symbol to the left on the main window tells the status of boom float function. The symbol is grey
when float is not activated. When you press the float button, the symbol becomes green to indicate
activated float function.
The symbol to the left on the main window tells the status of ride control. The symbol is grey when
ride control is off. When you press the ride control button, the symbol becomes green. Ride control
system is now on and will activate when operational parameters are fulfilled.
Blinkers (optional)
The symbol on the lower left corner of the main window shows whether the blinker is on or off. The
symbol flashes from grey to green when the blinker is on.
DeClutch (optional)
The symbol to the upper right on the main window shows the status of the DeClutch. The symbol is
grey when DeClutch is not activated, and becomes green when you activate DeClutch.
The symbol to the right on the main window shows the status of the emergency steering. The symbol
is grey when emergency steering is not activated, and becomes red when emergency steering
automatically activates.
The symbol to the right on the main window tells the status of the parking brake (wheel brakes). The
symbol is grey when the parking brake is released, and becomes red when the parking brake is
engaged.
The symbol to the right on the main window tells the status of the brake accumulator pressure. The
symbol is grey when the accumulator pressure is ok, and becomes red when the accumulator
pressure is too low.
The symbol at the lower right corner of the main window shows whether the high beam lights are on
or off. The symbol is grey when the high beam lights are off, and becomes blue when the high beam
lights are on.
Date setting:
• Date setting is done in the same way as time
setting as described above.
6. Display option
8. Information window
The information window is entered by pressing the “question mark” button in the main or some other
menu. For example, the information windows for the following gauge displays are showing you the
alarm and warning upper and lower limits for pressures, temperatures and voltage.
Enter the gauge window by pressing next window“>>” button on the Main window.
There are four gauge windows and they can be seen by using next window “>>” and previous window
“<<” buttons.
▲ Moves back to Main window.
4 5 6
For every measurement it can be set low/high values for alarm and warning. Levels for these values
can vary depending on loader model.
Active alarms and warnings are shown with the following symbols on the gauge window (the symbol
appears on the left hand side of the symbol for the sensor that the alarm or warning applies to):
Warning appears in the display with a blinking yellow warning triangle, an exclamation mark inside.
Alarm appears in the display with a blinking red warning triangle, an exclamation mark inside.
If any warning or alarm appears in the display, do not operate
with the loader until the cause has been determined and
possible fault has been repaired. Call a service person.
10. Tachometer
19 1 20 21 24 25 26 23
27 8 9 10 11 12 13
2 3 4 5 6 7 22 14 15 16 17 18
19 1 22 8 9 10 20 21 23
2 3 4 5 6 7 14 15 16 17 27
Switch functions
19 1 20 21 24 25 26 23
27 8 9 10 11 12 13
2 3 4 5 6 7 22 14 15 16 17 18
1. Ignition key
2. Front lights
3. Rear lights
There is a separate button in the cabin for switching on the high beam lights towards the driving
direction in addition to the low beam lights. You can switch off the high beam lights by pressing the
button again. If the gear is on neutral or forward gears, the high beam lights shine towards the bucket.
In reverse gears high beam lights shine on machine grill end. The high beam lights cannot be switched
on, if the low beam lights are off.
If you press and hold the high beam light button down for 1 second, both the front and the rear high
beam lights illuminate. The next press (without holding) switches off the high beam lights.
The symbol (see display section, function status) at the lower right corner of the main window shows
whether the high beam lights are on or off. The symbol is grey when the high beam lights are off, and
becomes darker when the high beam lights are on.
5. Blinkers (optional)
When you are turning to the right, press the upper end of the switch and the lower end of the switch,
if your intention is to turn to the left . The symbol flashes, when the blinker is on.
6. Gear mode
The transmission mode can be selected from the gear mode switch. The selected mode is shown on
the display in front of the operator. Each time the mode switch is pressed, transmission mode swaps
between MANUAL and AUTO.
MANUAL mode: (if automatic mode (optional) is not available, the dashboard switch does not exist).
• The selected gear, driving direction and the highest gear available are shown on the display in front
of the operator.
• Manual text under the display's gear indication bar is dark.
Allows the operator to turn on the automatic converter lock function with a push button. The symbol
to the left on the main window tells the status of the torque converter lock. The symbol is grey, when
the converter lock is not activated, and becomes darker, when you activate lock. In manual gear
mode, the operator selects the function on/off. In auto gear mode, the converter lock function on is
selected as a default. The lock can be turned off with a push button. Each time the switch is pressed,
the function cycles on/off. The converter lock is on only when all its operational conditions are fulfilled.
The following conditions affect the physical lock-up of the converter:
- The difference between engine rpm and converter output revolutions
- Engine revolutions
- Bucket must be in hauling position
- DeClutch must not be activated
When the converter lock is activated, it is released before changing the gear. After changing the gear,
the lock can reactivate, if the above mentioned conditions are met. In an engine overdrive situation,
the converter lock is released and a pop-up alarm appears on the display.
Pressing the brake pedal releases the converter lock, if an option parameter is used.
The bucket counter is on the upper left corner of the display's main window (the bucket symbol and
a number).
The bucket counter value increases by one every time you press the bucket counter button on the
dasboard. The bucket counter can be reset by pressing the button more than two seconds.
If machine is equipped with VCM-integrated scale (optional), pressing the button shortly opens the
scale main window on the VCM display.
The purpose of this function is to let the bucket smoothly follow the ground, for example when you
want to clear fallen stones off a road.
You can turn on the boom float function by pressing the float button on the dashboard. The boom
must be in full down position. The boom float is deactivated by pressing the float button again.
Controlling the boom also deactivates the float. If the bucket is used during the boom float, the float
will be deactive only as long as the bucket is not used.
The symbol (see display section, function status) to the left on the display's main window tells the
status of the boom float. The symbol is grey when float is not activated and becomes darker when
float is in use.
The purpose of ride control is to improve the machine's drive an operator comfort by suspending the
boom, bucket and load by hydraulics during the tram.
Automatic ride control system is turned on by pressing the control button on the dashboard.
Ride control automatically turns on when certain parameters are met:
• Boom is down
• Gear high enough (usually 2nd gear)
• Speed high enough (usually 5 km/h)
Once activated, control system monitors condition of the bucket - empty or loaded. Activating the
appropriate system and ensuring accumulator charge is exactly equal to individual bucket weights.
Lowering the boom to dig or raising to dump, deactivates ride control. System reactivates once tram
is recommenced.
Pressing the control button a second time, turns of auto ride control system.
The symbol (see display section, function status) to the left on the displays main window tells the
status of ride control. The symbol is grey when ride control is off and becomes darker when ride
control is on.
In an emergency situation after the engine self shutdown (e.g. the unit is in danger area or it has to
be moved for another compulsory reason), the engine can be started momentarily by turning the
ignition key to “0” position and starting the engine again.
If the engine shuts down unexpectedly or the torque converter driven pump breaks down, the pressure
needed for releasing the brakes can be produced with a special brake release pump. After that the
unit can be towed to a safe location. Refer to the Towing section.
Start the brake release pump by pushing the button (16) and holding it down. Pull the brake control
button (19) fully out and release it to middle position. The pump switches on/off to maintain the brake
release pressure, until you release the button (16) or the maximum pressure 140 bar (14,0 MPa) has
been reached. The brakes will be released now. When the brake release pump is used, the engine
must be stopped, the ignition switch must be in "POWER ON" position and the emergency stop must
not be activated.
The operation of the emergency steering pump can be tested by pressing the button. The pump
should start and the status symbol in the main display appears. The test's duration is limited to ten
seconds maximum. Test the pump with the ignition switch in "POWER ON" position, engine not
running.
18. Wiper intermittent potentiometer (only with the unit with cabin)
The interval of the potentiometer can be set with a parameter. The minimum interval is 2 seconds and the
maximum interval is 12 seconds. It affects only the front and the rear wiper, when controlled by the dashboard
button 11.
Pushing the button down engages the wheel/parking brakes. Brakes engage automatically, if
• Electric current is cut off
• Emergency stop is activated
• Engine stops
• Door is open
• Hydraulic oil level too low (optional)
• Brake oil level too low (optional)
• Accumulator pressure for brakes too low
• Transmission oil pressure too low
• Steering control valve fault is activated
• Gear in neutral with 3 seconds delay (Neutral brake, optional)
The brakes are released by pulling the three position button fully up and releasing them to centre
position.
In case of fire, lift the shield and press the button to release the main circuit breakers. If the main
circuit breaker release button has been pushed down, you must open the rear frame fuse box X356
and reset the main circuit breakers to get power back to the loader.
Pressing the main circuit breaker release button may cut power
to the communication radio (optional).
Pushing the button engages the brakes and shuts down the engine. The button must be pulled out
before starting the engine. The emergency stop state appears also on the display.
Read the Remote-Control System Operators Manual carefully before operating with the RC-system.
Check the functioning of the remote control system according to the remote control system
instructions before operation. The RC-switch must be turned off (to position 1) before starting/
operating the machine from the cabin. Position 2 is for remote operation.
24. Fan speed potentiometer (only with the unit with cabin)
Controls the air conditioning unit fan speed stepless from 0-100%.
25. Air Conditioning switch (only with the unit with cabin)
Controls the cabin's temperature. See also the manual for Air Conditioner.
ACS By-pass switch is applicable for automated machines only. Pressing the button by-passes the
ACS (Access Control System) for testing and teaching purposes.
General instructions
Verification of seat effective amplitude transmissibility (SEAT) value of the seat with pneumatic
suspension is:
• 0,6
Verification of seat effective amplitude transmissibility (SEAT) value of the seat with mechanical
suspension is:
• 0,8
10
11
12
4 3 1,2
Weight adjustment
Height adjustment
Fore/aft adjustment
The locking lever must latch into the desired position. It should
not be possible to move the driver seat into another position
when it is locked.
Armrests adjusting
Backrest adjustment
Make sure that the locking lever latch into the desired position.
It should not be possible to move the backrest into another
position when it is locked.
The absorber setting of the seat can be varied to suit the on and off-road driving conditions. The
cushioning effect can be individually adjusted for this purpose.
1. Turn the lever to the desired position and
release.
• Position 1 = soft
• Position 2 = hard
Lateral isolator
Seat heater
Upholstery cleaning
Take care with the backrest frame - it may jerk forward and
cause injury.
F3064 F3035
F3061
F3021
F3046
F3047
F3060
F3002
F3008
F3023
F3059
F3062
F3067
F3050
All circuit breakers are automatic fuses, except the fuses F2100 - F2107 are common automotive
fuses.
* Optional
Circuit breaker blown alarms
Any tripped circuit breaker, except the main circuit breakers F3035 and F3064, gives a separate alarm
on the display.
4. OPERATION INSTRUCTIONS
4. OPERATION INSTRUCTIONS
Check
- For defect tags or warnings
- Frame locking pin not mounted
- Bucket and components condition
- Boom and components condition
- Front and rear frame hydraulic components
- Central lubrication barrel. Fill up if empty (optional).
- Climbing steps and handles
- Cabin and door lock condition
1. Check condition.
2. Visually check tire wear and air pressure.
3. Visually check for loose or missing wheel
bolts / nuts.
WARNING
Only carry out work on the cooling system at coolant
temperatures below 50 °C. Wear approved protective gloves,
protective clothing and safety goggles when handling coolant.
4.1.16. Check the drive selection switch position (with automation unit only)
Do not grab any control devices when climbing into the cabin.
Use only grab handles and foot steps as climbing assistance.
1. Make sure that there is no clutter on the floor when entering into the cabin.
2. Use grab handles and steps provided to maintain 3 points of body contact with the machine while
entering the cabin.
Alarm light test for yellow warning light (1) and red alarm light
(2) last for three seconds. After that both lights must go off.
If active alarms appear, make sure that the cause of the alarm
is determined and the faults are repaired properly.
When using the brake release pump, the engine must not be
running, the emergency stop must not be activated.
DANGER
Releasing the brakes may cause the machine to move
(especially on an inclined surface). Be sure that this does not
cause danger to other people or equipment.
1 2 3
Ensure that the following conditions are met before checking the transmission oil level:
- Machine on level ground
- Brakes engaged
- The engine at low idle
- The gear in neutral position
- Transmission oil in operating temperature
If anything looks anomalous or is in apparent need of repair, inform the service personnel.
Do not start the engine, if you are uncertain of the condition of
the machine. Inform the service personnel immediately, if you
detect a leak or any other kind of malfunction or difference in
normal use.
WARNING
Crushing hazard. Can cause serious injury, damage to
equipment, and the possibility of death. A faulty door interlock
switch may allow the machine to turn unexpected although the
canopy door is opened.
1. Make sure the engine is not running and the parking brake is applied before you start checking
the switch.
2. Carefully check the mechanical condition and
cleanliness of the switch.
• Pay a special attention to the free movement
of the switch arm.
• If any damages (jammed or bent switch arm
etc.) are found replace the switch.
Do not operate the unit before the faulty interlock has been
repaired and tested.
1. Check all emergency stop buttons for damage. There are three emergency stop buttons, one
inside the cabin and two on the rear of the machine, one on either side.
2. Check that none of the emergency stop buttons are pushed.
3. Start the engine.
4. First check the Emergency Stop button in the cabin. Push button in and engine should stop
instantly.
5. Pull the Emergency Stop Button out to release the emergency stop circuit.
6. Restart the engine.
Wait 30 Seconds before restarting - allows starting system to
cool.
7. Push the Emergency Stop button on the left rear side of the machine, the engine should stop
instantly.
8. Pull the Emergency Stop Button out to release the emergency stop circuit.
9. Restart the engine.
Wait 30 Seconds before restarting - allows starting system to
cool.
10. Push in the remaining Emergency Stop button on the right hand rear side of machine, and the
engine should stop instantly.
11. If engine does not shut down, locate the fault and repair the fault according to the wiring diagrams.
Use the brake test button to test the condition of the parking and service brake system. Testing
procedure is as follows:
1. Press the brake test button located on the
dashboard.
The adjacent message appears.
2. Press the “Yes" button to perform the test.
If you press the “No" button, the test is not
performed and the display main window
opens.
When the required conditions are met, the test proceeds automatically from the parking brake test to
the service brake pedal test.
Parking brake test must be successfully completed before performing the service brake test.
DANGER
Releasing the brakes may cause the machine to move
(especially on an inclined surface). Be sure that this does not
cause danger to other people or equipment.
When operating with machine, always remember that visibility is limited. Ensure that unauthorized
persons are not present in the working area.
WARNING
IMPACT HAZARD
Machine rolling over, tilting or stopping suddenly could cause
death or severe impact injuries
Fasten your seat belt and keep it fastened when operating the
machine.
2
3
1
STD
5 6
1
STD
If the machine is operated with remote control (optional) check that the remote control system is
functioning according to the remote control system instructions before every shift. Note also that with
remote control only first gear forward and reverse are in use.
4.4.3. Braking
3. Brakes can also be activated automatically if one of the following conditions is met:
• engine oil pressure drops too low
• emergency stop mode is active
• electric current is cut off
• cabin door is open
• hydraulic oil level too low
• brake oil level too low
• brake accumulator pressure too low
• transmission oil pressure too low
• steering control valve fault is activated
• gear in neutral with 3 seconds delay (Neutral brake, optional)
• Lower the boom to the lowest position and turn the cutting edge of the bucket against the ground.
• Put the transmission into neutral and release the brakes. If the machine does not move you are
parked safely.
• Apply the parking brake (indicator lights come on).
Never turn the main switch off when the engine is running. This
may damage the alternator or the voltage regulator and the
machine electronic equipment.
• Always obey national mandatory rules relating to accident prevention and environmental protection.
The generally recognized technical rules for safe and professional operation must also be observed.
• Complete the instruction manual with obligatory reports and controls according to company rules.
Keep all the safety and the danger signs on the machine in
legible condition, observe and follow them.
Do not start lifting full loads until the engine and the converter
are warmed up to the operating temperature.
The effort spent in levelling the machine's small operating area can pay dividends by increasing its
productivity. When loading, work the area on as wide a front as possible. Work the outer sides of the
muck pile first and then the center.
If you follow correct loading procedures, you and the machine will be a more efficient team.
1. Approach the muck pile with the boom down. Before penetrating the muck pile, put the bucket lip
plate against or very close to the ground.
2. Drive ahead in first gear. Straighten the machine before penetrating the muck pile. Once you have
penetrated the muck pile keep the accelerator pedal in fully down position to keep up an even
speed.
6. Avoid lifting up the rear axle because it leads to unnecessary stress on the front axle.
4.7. Hauling
1. Keep the bucket and the boom in the transport position during hauling process regardless if the
bucket is half empty or full.
2. Activate the converter lock function (optional)
by pushing the button on the instrument panel.
a. Ensure the selected gear allows the unit to
be operated within an engine rev range
where the machine will achieve and
maintain automatic converter lock-up.
• Above 1700 RPM to achieve lock-up
• Above 1350 RPM to maintain lock-up
3. Select such a gear, which provides the conditions where the unit is in total control and it can be
operated in a safe and responsible manner.
• If the auto lock system can not achieve lock-up, it is indicating the selected gear is one gear too
high.
4. Pay attention to the converter temperature. Converter temperature during hauling MUST NOT
exceed 100 °C.
5. Monitor the VCM-system display and the instrument panel to ensure that the normal machine
operating conditions exist.
• If any abnormal reading or alarm occurs, react immediately by shutting down the machine as
soon as possible to allow for urgent maintenance.
WARNING
Excessive use of the brakes in downhill driving could result in
overheating of the brakes. Overheated brakes are a big safety
risk due to significant reduction in the brake force.
1. Keep the bucket and the boom in the transport position during hauling process regardless if the
bucket is half empty or full.
2. Activate the converter lock function (optional)
by pushing the button on the instrument panel.
3. Keep the service brakes on and the transmission in neutral when dumping.
4. Tilt the bucket down. Shake the bucket to ensure that it is empty.
WARNING
Be careful if dumping at decline and using brake pedal to
control the DeClutch function (Optional). After brake releasing
machine may move 1...1,5 meters forward before reverse drive
is engaged.
Once activated, control system monitors condition of the bucket - empty or loaded. Activating the
appropriate system and ensuring accumulator charge is exactly equal to individual bucket weights.
Lowering the boom to dig or raising to dump, deactivates ride control. System reactivates once tram
is recommenced.
Pressing the control button a second time, turns of auto ride control system.
The neutral brake prevents driving the machine downhill on neutral gear.
The neutral brake engages the parking brake when the gear has been on neutral for a time period
defined with a parameter (the default value is 3 seconds). When the operator releases the parking
brake, he has to switch a gear on within a time period.
A window appears on the display that informs that the neutral brake is activated.
The neutral brake is not activated when the brake pedal is pressed (the brake lights are lit).
The DeClutch function can be use for a time period (the default value is 10 seconds). When the
DeClutch function is released, the timer is reset.
The neutral brake will be engaged if the operator does not perform one of the following actions within
a time period set with a parameter:
- Switch on a gear.
- Press the brake pedal.
- Press the DeClutch button.
The neutral brake will be released in the same way as the parking brake.
DANGER
Dangerous machine movement can cause severe injury or
death.
Do not leave the loader main power on in the Remote Mode when
not in use.
Before operating the machine with Remote Control: Check the remote control system functioning
according to Remote Control System Instructions.
During remote-control driving you should control the loader from a refuge bay or safety platform,
where you are safe from any danger. You should also be aware of the escape route in advance.
Make sure all personnel are at safe distance from the machine, and the machine is in fullview of the
operator. Always obey the site specific requirements.
RC
Always keep within safe distance from the loader when operating with Remote Control.
The emergency radio system (optional) is designed to release the brakes in an emergency situation.
Please do not use it for a normal towing procedure.
The system and its components must be inspected and always
maintained. You must always make sure all components are
undamaged and functioning properly because malfunction of
the system might cause the brakes to release without warning
hereby causing death or serious personal injury.
This part of the manual tells you the main things of using the scale. The workshop manual includes
more detailed information on how to use the scale, refer to chapter appendices.
The info line gives the user instructions and error messages.
1. Symbol field
1 2 3
2. Info line
3. Power switch
You can mark the start of the working shift. The scale resets the sum info of the working information.
1. Press the keys 0 + 1 to start the working shift.
4.13.5. Weighing
Weighing.
Weighing is ready.
In case of problems:
- Lower the boom down
- Press “WEIGH”button or press power
“OFF” and then back to “ON” position.
4.13.6. After the working shift save the data to memory card
At the end of the day you can move the weighing data from the scale to a PC with a memory card.
Save the weighing data to the memory card with the key functions0 + 9 and move the data to the PC.
1. Insert a memory card to the memory card
reader.
1.
4. Press F2 [Cont.].
The integrated scale is an optional equipment for the machine. The weighing system is integrated
into the VCM-system. The VCM display is the user interface. Scale main window opens by pushing
shortly the switch S0022 on the instrument panel.
The weighing is based on the hydraulic pressure needed to lift the load. Pressure is measured within
certain boom movement range. The range is defined by two limit switches.
Maximum accuracy is achieved at full engine and boom speed.
User interface
10 14
11 15
16
12
17
13
1 2 3 4 5 6 7 8 9
Zeroing function
Cancel function
Pressing button 3 "Cancel" the latest bucket is removed from weighing log and from the display.
Pause function
Diagnostic window shows the status of scale-related limit switches and sensors.
Load monitoring
Load monitoring menu includes production information of loads during a shift and a lifetime.
See separate section for further information.
Help
Pressing the "Help" button system gives detailed information about the scale functions.
Bucket limit
Limit is active when the bucket is in back position and weighing is possible.
Pop-ups
The scale will indicate any abnormalities or problems with weighing via pop-ups and error messages.
See separate section for further information.
To maintain the scale accuracy system needs to be zeroed every shift. Perform zeroing at normal
operating temperature as follows:
1. Select scale main window by pushing scale switch on the instrument panel.
2. Press button 2 "Zeroing".
4.14.4. Pop-ups
The scale will indicate any abnormalities or problems with weighing via pop-ups and error messages.
In the event of an error try to proceed to the next operation:
1. Lower a boom to the down position.
2. Try a new weigh.
3. If the error message persists, contact your service representative.
Zeroing reminder
5. ADDITIONAL INSTRUCTIONS
5. ADDITIONAL INSTRUCTIONS
5.1. Towing
5. Release the steering hydraulics by disconnecting the hoses to steering cylinders at the main
steering valve.
• See Service and Repair manual for further information.
• Cover and plug all open hydraulic lines and hoses.
13. When mounting the drive shafts, note that the yokes on both ends must be aligned.
For more information refer to the Service and repair manual.
DANGER
RUN OVER HAZARD. Being run over by the machine will cause
death or severe injury.
The electrohydraulic retrieval hook is an optional equipment for the machine. The purpose of the
system is to release the machine’s brakes for towing, used only in emergency cases to pull the
machine out, e.g. if the machine is stuck in a stope during remote operation or breaks down in other
dangerous situation.
Never use the electrohydraulic retrieval hook for towing another machine. Use appropriate
towing ears or bucket installed towing wire rope kit instead.
Never use the electrohydraulic retrieval hook for attaching the machine for transportation.
Activating the hook valve causes the brakes to be released and thus unexpected machine
movement.
If you are retrieving a machine that is stuck in a stope, reserve a remote controlled towing unit for
safety reasons.
The towing unit must be as heavy or heavier than the disabled loader. Use only one machine to tow
the disabled loader. Towing machine must have enough power and braking capacity to move, stop
and hold both of the machines.
In emergency cases the disabled machine can be towed the axles cardan shafts connected so long
as the towing speed is maximum 5 km/h and distance is maximum 250 meters.
The towing must be performed with the engine shut down. The retrieval hook valve must not be
activated before the engine is shut down, so that the safety feature is not activated.
Towing wire rope kit pn. 56049193
When using the bucket installed towing wire rope kit, ensure that the kit can be fitted to the bucket:
• Bucket side plates must have 50...55 mm holes near the side cutting plates (attaching bolt thread
size M48).
• If possible, use the original manufacturing holes.
• Enlarge the hole diameter if needed.
9. As soon as possible, test the disabled machine’s brakes for normal operation (perform a brake
test).
• See the section “Test service and parking brake function”.
10. Test the retrieval hook functioning after each time it has been operated.
• See the Maintenance Manual section “Checking the electrohydraulic retrieval hook function”.
• Suitable access ramps must be used when driving the loader onto and off transport wagon. Driving
must always be done on level ground.
• When driving over the ramps, use bucket movements to balance the loader.
• Always use low speed and observe special caution when coming from the ramps to the platform.
• Before transporting, lower the bucket down and install the frame locking pin.
• Turn the main switch off.
• Fasten the loader to the platform from the bucket and both ends of the machine with strong straps
and chains so that the loader cannot shift during transporting.
• Lower the safety rails and lock them into down position.
Always respect the law and all the local safety regulations in
lifting work.
1. Lower the safety rails (optional) and lock them in the down position.
2. Install the frame locking pin.
3. Shut down the engine. Turn the main switch off.
4. The lifting points (four) are marked with hook symbols.
• Rear frame lifting lugs must be lifted up before hooking.
10. The lifting routes must be planned so that the load is not moved over persons or such places
where persons may be present.
11. Lift the loader only a few centimeters at first to make sure that it is properly fastened and in balance.
Do not continue lifting until you are sure of proper fastening and balance.
12. If control lines must be used, ensure they are long and strong enough
Environment:
• Storage temperature should be +0...+35°C, and the machine should be protected from direct
sunlight and from rain.
• The humidity of the air should be below 90%.
_C F
30 86
20 68
10 50
0 32
max 90%
Preparations:
• Wash the loader thoroughly if it comes directly from use, or if it has been transported by sea (use
high pressure washer or steam).
• Lubricate all greasing points.
• Empty the pressure accumulators and place warning signs on the machine: 'Pressure accumulators
must be filled before using the loader'.
• Apply protective grease to the piston rods of the cylinders.
• Change all lubricants and fluids
• Check engine air filter and service if necessary.
• Protect electric devices with corrosion inhibitor to prevent contact failures.
• Disconnect batteries
If the temperature is below 0 °C, clear off ice from all steps and handles on the rig.
Because the machine normally operates in mine conditions, its engine, transmission and hydraulic
systems are filled with oils suitable for these conditions. However, in cold conditions they may thicken.
This makes starting difficult and may damage the torque converter and hydraulic pumps. For this
reason, avoid any temporary parking in frosty weather. If the machine will work in very cold or very
hot conditions, see the Maintenance Instructions booklet for the correct oils and the engine
manufacture's instruction manual for the proper fuel.
Starting aids such as preheating engine and hydraulic oil are recommended in temperatures below
-10 °C.
Be aware that starting the engine in cold conditions may require multiple attempts.
6. TROUBLESHOOTING
6. TROUBLESHOOTING
If the machine's main current does not connect, make the following checks.
1. Check that the main switch is in 'ON' position.
If machine steering / bucket control does not work, make following checks.
1. Check all emergency stops (one in the cabin
and one emergency stop button on the both
side of the machine).
• Emergency stops must not be activated.
7. TECHNICAL SPECIFICATIONS
7. TECHNICAL SPECIFICATIONS
Continuing research and development at SANDVIK loader’s may have caused changes to your
machine which are not included in this specification.