Operator's Manual: Volvo TAD1662VE

Original instructions
BG00408868 en-US I.001.1 2017-06-07
Operator's Manual
Volvo TAD1662VE
TH551
Operator's Manual TH551
WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product. Keep this publication for future reference.
Copyright © Sandvik
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Table of Contents
1 Introduction ................................................................... 11
1.1 The purpose of these instructions ......................................................12
1.2 Identification of the product ................................................................ 13
1.2.1 Product type and serial number .................................................. 13
1.2.2 Product manufacturer ..................................................................14
1.2.3 Manuals .......................................................................................14
1.2.4 Location of manuals on the product ............................................ 15
1.2.5 How to identify the correct manual for the product ......................15
1.2.6 Validity of the manuals ................................................................ 15
1.3 Copyright notice ................................................................................... 16
1.4 Definitions ............................................................................................. 16
1.5 Terminology and abbreviations ...........................................................17
2 Safety and Environmental Instructions ...................... 19

2.1 Safety labels, safety messages and signals ...................................... 20
2.1.1 Signal words ................................................................................20
2.1.2 General hazard symbol ............................................................... 20
2.1.3 Mandatory action symbols ...........................................................21
2.1.4 Prohibited action symbols ........................................................... 22
2.1.5 Hazard symbols ...........................................................................23
2.1.6 Labels on the product ..................................................................25
2.1.7 Visual and audible signals ...........................................................43
2.2 User obligations ....................................................................................44
2.2.1 Managing work related hazards .................................................. 45
2.2.2 Scheduled safety inspections and preventive maintenance ........45
2.2.3 Personal Protective Equipment ................................................... 46
2.3 Product limitations ............................................................................... 47
2.3.1 Intended use ................................................................................47
2.3.2 Prohibited use ............................................................................. 48
2.3.3 Centre of the gravity .................................................................... 48
2.3.4 Maximum inclination angles ........................................................ 49
2.3.5 Operator visibility .........................................................................52
2.3.6 Modifications ............................................................................... 53
2.4 Hazard zone ...........................................................................................54
2.5 Safeguarding .........................................................................................55
2.5.1 Safety functions ...........................................................................55
2.5.2 Guards .........................................................................................55
2.5.3 Protective devices ....................................................................... 58
2.6 Complementary protective measures .................................................72
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2.6.1 Use of Emergency stop function ................................................. 72

2.6.2 Emergency exit ............................................................................73
2.6.3 Safe access to machine and three-point support ........................ 75
2.6.4 Isolation and energy dissipation .................................................. 76
2.6.5 Location of the isolation switches ................................................81
2.7 Fire risk control measures ...................................................................84
2.7.1 In case of fire ...............................................................................85
2.7.2 Fire prevention ............................................................................ 86
2.7.3 Fire retardant and flammable materials .......................................86
2.7.4 Fire extinguisher(s) (optional) ......................................................86
2.7.5 FS1000 Fire suppression system (optional) ................................88
2.7.6 ANSUL fire suppression system (optional) ..................................91
2.7.7 After a fire ....................................................................................100
2.8 Protection against emission hazards ................................................. 100
2.8.1 Noise ........................................................................................... 100
2.8.2 Vibration ...................................................................................... 101
2.8.3 Dust ............................................................................................. 103
2.8.4 Hazardous gases ........................................................................ 103
2.8.5 Diesel particulate matter ..............................................................104
2.9 Emergency procedures ........................................................................105
2.10 Safety considerations for maintenance ..............................................106
2.10.1 Daily inspections and tasks for operators ....................................107
2.10.2 Tasks which require definite technical skills and maintenance
training .........................................................................................108
2.10.3 Getting on top of the machine ..................................................... 109
2.10.4 Working on top of the machine ....................................................110
2.10.5 Working under the machine ........................................................ 110
2.10.6 Supporting the machine for maintenance procedures .................111
2.10.7 Tire maintenance .........................................................................112
2.11 Environment ..........................................................................................115
2.11.1 Decommissioning ........................................................................ 115
2.11.2 Dismantling ..................................................................................116
2.11.3 Disposal .......................................................................................118
2.12 Potential product related hazards identified by the user ..................119
2.13 Incident reporting ................................................................................. 120
3 Machine Description ..................................................... 121

3.1 Recommended operating conditions ................................................. 122
3.2 Machine specifications ........................................................................ 122
3.3 Main component locations .................................................................. 123
3.4 Machine orientation ..............................................................................124
3.5 Description of controls and functions ................................................125
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3.5.1 Instrument panel ..........................................................................125

3.5.2 Cabin ceiling fixtures ................................................................... 131
3.5.3 Inclination gauges ....................................................................... 132
3.5.4 Monitor: Stonkam SV-MO700125DC .......................................... 133
3.5.5 Box payload indicator lights .........................................................134
3.5.6 HJS ServiceCheck display module for DPF (optional) ................ 135
3.5.7 Control levers and pedals ............................................................138
3.5.8 Vehicle Control and Management System .................................. 145
3.6 Operator's seat ..................................................................................... 175
3.6.1 General instructions .................................................................... 175
3.6.2 Safety instructions ....................................................................... 176
3.6.3 Seat functions and operation .......................................................178
3.7 Trainer's seat .........................................................................................186
3.8 Circuit breakers .................................................................................... 187
3.8.1 Location of circuit breaker boxes .................................................187
3.8.2 Circuit breakers descriptions and values .....................................188
4 Operation Instructions ..................................................193

4.1 Starting procedure ................................................................................194
4.1.1 Turn the main switch to the "ON" position ................................... 194
4.1.2 Close the suspension discharge valve ........................................ 195
4.1.3 Open the fuel lines shut off valve ................................................ 196
4.1.4 Getting into the cabin .................................................................. 197
4.1.5 Activate brakes ............................................................................199
4.1.6 Check fuel level ........................................................................... 200
4.1.7 Starting the engine ...................................................................... 200
4.1.8 Switch the lights on ..................................................................... 201
4.1.9 Check that the controls are functioning correctly ........................ 201
4.1.10 Check that all the controls are functioning correctly (Ejector box)
.................................................................................................... 202
4.2 Using driving controls ..........................................................................203
4.2.1 Setting unit in motion ...................................................................203
4.2.2 Braking ........................................................................................ 207
4.2.3 Parking ........................................................................................ 209
4.2.4 Stopping the engine .................................................................... 211
4.3 Operating the machine .........................................................................215
4.3.1 Hauling ........................................................................................ 215
4.3.2 Dumping procedure .....................................................................219
4.3.3 Dumping the ejector box ............................................................. 220
4.3.4 Suspension adjustment ............................................................... 221
4.3.5 Scale control ................................................................................221
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5 Operator's Maintenance Instructions ..........................231

5.1 Operator's maintenance responsibilities ........................................... 232
5.1.1 Typical work cycle ....................................................................... 232
5.2 Operator's maintenance tasks ............................................................ 233
5.2.1 Walk around inspection ............................................................... 233
5.2.2 Check hand portable fire extinguisher .........................................233
5.2.3 Check engine oil ..........................................................................234
5.2.4 Check window washer fluid level .................................................234
5.2.5 Check engine additional equipment ............................................ 235
5.2.6 Check lights .................................................................................236
5.2.7 Check guards and plates .............................................................236
5.2.8 Check engine coolant level ......................................................... 237
5.2.9 Check fuel system ....................................................................... 238
5.2.10 Fill fuel tank ................................................................................. 239
5.2.11 Fill AdBlue tank ........................................................................... 240
5.2.12 Fill the grease tank ...................................................................... 241
5.2.13 Check upbox and dropbox oil levels ............................................242
5.2.14 Check brake hydraulic oil level ....................................................243
5.2.15 Check tires and wheel nuts ......................................................... 243
5.2.16 Check the jacking cylinders .........................................................244
5.2.17 Check major components for oil, fuel and coolant leaks and
mounting ......................................................................................245
5.2.18 Check the dump box ................................................................... 246
5.2.19 Check and clean camera(s) ........................................................ 246
5.2.20 Check hydraulic oil level ..............................................................246
5.2.21 Check seat belt condition ............................................................ 247
5.2.22 Check the alarm lights .................................................................247
5.2.23 Check VCM system alerts ........................................................... 248
5.2.24 Check emergency stop and shutdown system ............................248
5.2.25 Brake test .................................................................................... 249
5.2.26 Checking the neutral brake function ............................................251
5.2.27 Check door interlock switch function and condition .....................252
5.2.28 Check ANSUL fire suppression system (option) ......................... 253
5.2.29 Check gear box oil level .............................................................. 254
6 Additional Instructions ................................................. 255

6.1 Using the brake releasing pump ......................................................... 256
6.2 Using the emergency steering system (optional) ..............................257
6.3 Towing ................................................................................................... 257
6.3.1 Common safety messages ..........................................................257
6.3.2 Dump truck to be towed .............................................................. 258
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6.3.3 Towing a disabled machine with the TH551 ................................ 261

6.4 Lifting methods and lifting points .......................................................262
6.5 Jack system .......................................................................................... 265
6.5.1 Jack system (lifting) .....................................................................268
6.5.2 Jack system (lowering) ................................................................272
6.6 Operation in cold weather ....................................................................272
6.7 Arctic package (option) ........................................................................273
6.8 Storing instructions ..............................................................................275
6.9 Transporting the dump truck ...............................................................276
7 Troubleshooting ............................................................ 281

7.1 Faults on the instrument panel ........................................................... 282
7.2 Engine will not crank over ................................................................... 282
7.3 Engine will crank over but not start ....................................................282
7.4 Engine stalls during operation ............................................................ 283
7.5 Excessive exhaust smoke ................................................................... 283
7.6 Engine misfiring ....................................................................................283
7.7 Engine knocking ................................................................................... 284
7.8 Engine oil pressure low ....................................................................... 284
7.9 Engine overheats ..................................................................................284
7.10 Hydraulic oil foams ...............................................................................284
7.11 Machine will not move ..........................................................................285
7.12 Machine will not turn ............................................................................ 285
7.13 Little or no dump box action ............................................................... 286
7.14 Defective lighting system .................................................................... 286
8 Technical Specifications .............................................. 287

8.1 Machine specifications ........................................................................ 288
8.2 Machine weights ................................................................................... 289
8.3 Main components weights ...................................................................290
8.4 Brake system ........................................................................................ 292
8.5 Engine ....................................................................................................292
8.6 Default pressure settings .....................................................................293
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1 Introduction
Copyright © Sandvik 11 (298)

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1.1 The purpose of these instructions

The purpose of these instructions is to promote intended safe, proper and
optimal use of Sandvik products and to help the user to identify, avoid and
prevent hazardous situations, and related consequences.
These instructions must be followed along with any instructions given in
local laws and regulations, any orders given by local authorities, and all
protective measures specific for the site.
Read and understand the complete manual carefully and follow given
instructions strictly. If there is anything you do not understand, ask your
employer or your local Sandvik representative to explain it. All sections of
this manual contain information which is vital for your safety. The manual
must be replaced immediately if lost, damaged or unreadable. For
replacement copies, please contact your local Sandvik representative.
When ordering replacement copies you must provide your Sandvik
representative with the following information of the product:
• Product model and serial number
• Manual types
• Number of paper copies or Toolman electronic manuals
• Language version of the manuals
• Delivery address
The instructions set forth in the operator’s and other manuals are to be
used as a part of the training material during orientation. By following these
instructions, safe practices will result, maintenance cost and downtime will
be minimized, and the reliability and lifetime of the equipment will be
optimized.
12 (298) Copyright © Sandvik

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1.2 Identification of the product

1.2.1 Product type and serial number
The model and serial number of the product are shown on the identification
plate.
• European Economic Area (EEA) countries with CE marking (plate
reorder number: 56026777)
• Member states of the Eurasian Customs Union with EAC marking (plate
reorder number BG00870827)
• Other countries (plate reorder number: 56026776)

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Identification plate location
The identification plate is located at the center articulation area at the left
side of the machine.
1.2.2 Product manufacturer

Sandvik Mining and Construction Oy
P.O. Box 434
20360 Turku
Finland
http://www.miningandconstruction.sandvik.com/
1.2.3 Manuals
Product documentation includes the following manuals:
• The operator’s manual includes operating instructions, operator’s safety
considerations, and maintenance tasks for which an operator would be
responsible. It does not include maintenance procedures that should be
performed with less than daily frequency.
• The maintenance manual includes the preventative maintenance
schedule and a description of all scheduled maintenance tasks. It also
includes fluid and lubricant specifications and capacities. It does not
include occasional service, breakdown, or repair procedures.
• The parts manual includes part lists and illustrations for spare parts.
The model and serial number are shown on the identification plate (see the
section, "Product type and serial number"). Make sure that the model
corresponds to the one given on the cover of this manual.

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1.2.4 Location of manuals on the product

The machine is equipped with document box for the machine
documentation. The document box is located in the cabin.
1.2.5 How to identify the correct manual for the product

• Operator’s manual
The model for which the manual is intended for is given on the cover of
the Operator's manual.
• Maintenance manual
The model for which the manual is intended for is given on the cover of
the Maintenance manual.
• Parts manual
The model and serial number for which the manual is intended for are
given on the cover of the Parts manual.
1.2.6 Validity of the manuals
This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include information
on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.

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1.3 Copyright notice

This publication is copyright of Sandvik Mining and Construction Oy - ©
Sandvik Mining and Construction Oy. It must not be copied, reproduced, or
otherwise made available in full or in part to any third party without Sandvik
Mining and Construction Oy´s prior written consent.
All Rights Reserved.
1.4 Definitions
• Product: Machine, machinery, partly completed machinery, component
or tool, including related services
• User: The owner, operator or authorized and trained person involved in
the transportation, installation, operation, maintenance and disposal of
the product
• Information for use: The information in this manual, the safety labels
and signals on the product, and other related information used separately
or in combination to convey information to the user
• Harm: Physical injury or damage to health. This is always in relation to
people, not to equipment or property
• Hazard: Potential source of harm
• Risk: Combination of a probability of occurrence of harm and the severity
of that harm.
• Risk of property damage: Combination of a probability of occurrence of
property damage and the severity of that property damage
• Environmental risk: Combination of a probability of occurrence of
environmental damage and the severity of that environmental damage.
• Hazard zone: Any space within and/or around the product in which a
person is exposed to a hazard.
• Intended use of a product: Use of a product in accordance with the
information provided in the instructions for use.
• Prohibited use: Any use which is not intended use, especially use that is
specifically prohibited in the information for use or use which is plainly
dangerous.
• Safe working procedures: Practices and methods developed for users
by their employer for work to be performed. These detail how specific
risks in the workplace will be managed, taking into account information
for use supplied with the product as well as local acts, laws and
regulations.
• Safeguard: Guard or protective device.
• Guard: Physical barrier, designed as part of the product, to provide
protection.
• Protective device: Safeguard other than a guard, which reduces the risk
either alone or in conjunction with a guard; e.g., interlocking device, hold-
to-run control, limiting device.

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• Emergency stop: Function which is intended to 1) avoid dangerous

situations or to reduce existing hazards to persons and damage to
product or work in progress 2) To be initiated by a single human action
• Emission value: Numerical value quantifying an emission generated by
a product (e.g., noise, vibration, hazardous substances, radiation).
• Exposure value: Quantifies the exposure of persons to emissions when
the product is in use. Exposure values can be estimated using the
emission values.
• Respirator: Approved respiratory protective device
• ROPS: Roll-Over Protective Structure. Structure that has been designed
and constructed to reduce the possibility of a seat-belted operator being
injured should the machine rollover.
• FOPS: Falling Object Protective Structure. Structure that has been
designed and constructed to provide operators with reasonable
protection from falling objects.
1.5 Terminology and abbreviations

This section provides an explanation of some common abbreviations that
may be used throughout this manual:
• AC = Air Conditioning
• CLS = Coolant Level Sensor
• DEF = Diesel Exhaust Fluid
• DPF = Diesel Particulate Filter
• EATS = Exhaust Aftertreatment System
• ECM, ECU = Engine Control Module, Engine Control Unit
• EGR = Exhaust Gas Recirculation
• EMS = Engine Management System
• HVAC = Heating, Ventilation, and Air Conditioning
• LHD = Load Haul Dump
• PDU = Pump Drive Unit
• ROPS/FOPS = Roll Over Protective Structure/Falling Objects Protective
Structure
• SAHR = Spring Applied, Hydraulically Released
• SCA = Supplemental Coolant Additive
• SCR = Selective Catalytic Reduction
• VCM = Vehicle Control and Management system
• VEB = Volvo Engine Brake
• VIH = Vehicle Interface Harness
• Vodia = Volvo Diagnostics

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2 Safety and Environmental Instructions

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2.1 Safety labels, safety messages and signals

This section includes explanations of safety symbols, signs, signals and
labels used on the product and in the information for use.
2.1.1 Signal words
The following signal words and symbols are used to identify safety
messages in these instructions:
DANGER
The signal word, "DANGER", indicates a hazardous situation which, if not
avoided, will result in death or severe injury.
WARNING
The signal word, "WARNING", indicates a hazardous situation which, if not
avoided, could result in death or severe injury.
NOTICE
The signal word, "NOTICE", indicates a situation which, if not avoided,
could result in damage to property or environment.
2.1.2 General hazard symbol
This general hazard symbol identifies important safety messages in this

manual.
When you see this symbol, be alert; your safety is involved. Carefully read
and understand the message that follows, and inform other users.

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2.1.3 Mandatory action symbols

Mandatory action symbols specify actions to be taken to avoid a hazard.
Mandatory actions are indicated by white symbols on a blue background.
All personnel working on or near the machine must understand and comply
with information given in all mandatory action symbols.
Wear protective gloves Wear eye-protector Wear safety helmet
Wear hearing protec-

Wear safety harness Wear safety footwear
tors
Wear high visibility

Wear protective clothing Wear respirator
clothing
Disconnect from power Switch off and lockout Read the manual or
source equipment instructions
Use cardboard for locat-

Use two-point belt Use three-point belt
ing leaks in hoses
General mandatory action

symbol

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2.1.4 Prohibited action symbols

Prohibited action symbols indicate actions which are prohibited in order to
avoid a hazard. Prohibited actions are indicated by a red circle with a red
diagonal line across the circle. The action which is prohibited will always be
in black. All personnel working on or near the machine must understand
and comply with information given in all prohibited action symbols.
No climbing No smoking No open flames
Do not touch Limit or restrict access Do not weld
Do not remove safety General prohibited action

Do not modify
guard symbol

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2.1.5 Hazard symbols

Hazard symbols are used to indicate the type of the hazard and the
potential consequences. Hazard symbols are indicated by a yellow triangle
with black symbols and black frames. All personnel working on or near the
machine must understand and comply with information given in all hazard
symbols.
Mechanical hazard symbols
Falling load hazard Crushing hazard Flying material hazard
Crushing hazard - feet Crushing hazard - hands Cutting hazard
Entanglement hazard Entanglement hazard Entanglement hazard
Entanglement hazard -
Slipping hazard Tripping hazard
rotating drill
High pressure injec-

Falling hazard Skin injection hazard
tion hazard
Sideways tipping haz-

Hanging load hazard Run over hazard
ard

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Forward/backward tip- Sideways tipping haz- Sideways tipping haz-

ping hazard ard, from level position ard
Forward/backward tip- Sideways tipping haz-

ping hazard ard, from level position
Electrical hazard symbols
Dangerous electrical volt- Electrical shock / Electrocu-

Electrical hazard
age tion hazard
Thermal hazard symbols
Hot coolant splashing haz-

Hot surface hazard
ard
Noise hazard symbols
Noise hazard
Radiation hazard symbols
Laser hazard Radioactive hazard

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Material/substance hazard symbols
Hazardous/poisonous material haz-

Explosion hazard Fire hazard
ard
Chemical burn hazard Dust hazard Environment pollution hazard
Ergonomic hazard symbols
Lifting hazard
2.1.6 Labels on the product

Safety labels communicate the following:
• The severity level of the risk (i.e., signal word, ”DANGER”
or ”WARNING”)
• The nature of the hazard (i.e., the type of hazard – cutting parts, high
pressure, falling objects, dust, live parts, etc.)
• The consequence of interaction with the hazard (i.e., cut, injection,
crushing, explosion, electrocution etc.)
• How to avoid the hazard
IMPORTANT! Keep the safety labels clean and visible at all times.
Check the condition of safety labels daily. Safety labels and
instructions, which have faded, been damaged, been painted over,
come loose or that do not meet the legibility requirements for safe
viewing distance must be replaced before operating the product.

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Location of the safety and information labels
Front frame - left side Front frame - right side
7 36 107 118 6 5 113 19 18

119 104 121 27 30 102 43 103
110 117 46 31 30
Front frame - urea system option Front frame - Diesel Particle Filtering option
201 44
202
202

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Articulation area - left side Articulation area - right side
106 103 42
108 102 106 1
102 103
11
24
119
28
108 11
26
117 104 8 107 7 36

32 103 8 107 117
Left side Right side
30 41 41 30

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Front frame Rear end
105 23 104 122 8

8 106
Upper side Upper side - rear, both sides
9 120 16
109 39 107
Anti-slip tape
04910301

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Upper side - AC refill
45
Cabin - right-hand corner Cabin - left-hand corner
203 38 111 7 14 36 101
4 15

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Door - inside Cabin - opposite wall of door
116
113
115
112
114

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Front frame - Top Brake oil tank compartment
13 12 27 11 24
22 22
12 13
24 28 21

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Fast filling points in brake oil tank compart-

Hydraulic oil tank compartment
ment (option)
22 24 11 28 10 29 10 26

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Under the machine Inside filling points
25 37 40
23

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Safety and information labels
1 3
56026777 EU area (CE marking)

56026776 outside EU area
4 5
-25 -20 -15 -10 -5 0 5 10 15 20 25

40
30
20
10
-10
56035975
-20
-30
-40

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6 7
56211546
10 11 23
24 25 26
27 28 29
12 13

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18 19
21 22
111 14
56024640
31 46
Optional (urea system)

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36 38
44 45
Optional, used with Diesel Particulate Filter

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101 102 103
104 105 106

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107 108 109
110 122 30

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32 41 112
113 114 115
116 116
Optional (urea system)

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43 117
201 202 203
Optional (urea system) Optional (urea system) Optional (urea system)

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Symbol labels
8 9
Centre of gravity Lifting point

56004224 00003850
15 37 39
Box operation
56005450 Window washer fluid Factory filling coolant
40 42 118
Factory filling oil

Factory filling oil Engine oil

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119 120 121
Transmission oil Hydraulic oil Fuel filling
2.1.7 Visual and audible signals

The machine is equipped with the following visual and audible safety
signals:
• Reverse alarm: The reverse alarm switches on when the drive selector
is set to reverse position. The alarm sound is frequent beeping.
• Warning and function signals: The warning and function signals give
important information on the machine operating status, functions,
warnings and alarms. Warning and function signals inform the operator,
for example, of oil levels, brake pressures and engine functions.
Audible alarm inside the cabin when the dump box is up.
Start up alarm: when you turn the key to the starting position, there is a 3
second audible alarm (horn) before engine starts.
• Horn: The horn releases a loud sound and can be used to warn others in
dangerous situations. The horn push button is located in the combination
switch. The horn can be used also in jacking mode with the system
remote controller.
• Beacon: The beacon is located at the top of the safety cabin/canopy.
The beacon flashes a light when the machine is on gear.
• Fire suppression system signals (with fire suppression system
option): Visual and audible signals will be set when the fire suppression
system is activated.
• Indicator lights: Directional lights showing the direction of travel (red &
green).
In addition to the provided signal and alert lights, the machine driving lights
can be used for signaling, according to site specific procedures.

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2.2 User obligations
WARNING
IGNORING INSTRUCTIONS HAZARD!
If you do not understand any information related to your duties in the
operator's or maintenance manual you MUST make sure that you get
clarification from a person who is well trained with regard to the task
you want to do. When necessary, you or your representative must
contact a Sandvik representative to seek clarification as to how you
should do the task.
The safe use of a product depends on, among other things, a combination
of the design and construction measures taken by the manufacturer, the
skills of the operators, and protective measures taken by the user.
Instructions are an essential and integral part of the product and they must
be always available for users. It is important to pass on the information for
use to any subsequent user of this product.
Sandvik prohibits the consumption of drugs and/or alcohol or any other
substance likely to impair judgement while using, being in the hazard zone
of, or supervising the use of a Sandvik product.
Safety information covers the following: transport, commissioning, use,
operation, cleaning, troubleshooting, maintenance and disposal of
machinery. If you need more detailed instructions, you must contact your
local Sandvik representative.
As part of ensuring the safe use of the product, you as the user are
responsible for the following:
• Use of Personal Protective Equipment (PPE)
• Scheduled testing and maintenance of safeguards and protective devices
• Provision and use of additional safeguards
• Regular training regarding site safety and safe working procedures
In addition, you must always be familiar with the following:
• Site organization and supervision
• Workplace safety, including safe working procedures
• Permit-to-work systems
All near-miss incidents and accidents where a Sandvik product has been
involved must be reported to your local Sandvik representative without
delay. See also the section, "Incident reporting".
The following safety guidelines apply to each person working with the
product or in the vicinity of the product. Every single person is responsible
for his or her own safety and for the safety of his or her colleagues. In case
of violation of any safety guidelines or regulations, everyone has a duty to
warn others and report near misses or any safety violation to the
responsible supervisor.

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2.2.1 Managing work related hazards

The user must always perform a local risk assessment before every new
task, e.g., work phase or shift. This assessment, also known as a Real
Time Hazard Analysis, ensures that the user stops and thinks about what
he or she is going to do before starting to work:
• Identify potential hazards that could impact you, your colleagues, the
environment, your product and/or work method while you are performing
the task.
• Assess the risks and implement the actions needed to eliminate or
reduce the risks.
Only competent persons may carry out operation and other tasks. The
employer must on a regular basis:
• Provide training and orientation
• Validate training methods
• Verify competence and skills
• Monitor and evaluate user performance
2.2.2 Scheduled safety inspections and preventive maintenance
WARNING!
Use of unauthorized parts present an uncontrolled risk and could
cause death or severe injury. The use of unauthorized parts will also
invalidate warranty.
It is the user's responsibility to use only authorized parts as listed in
the parts manual!
It is important to thoroughly inspect the product before use to make sure it

is safe to operate. Look for defects and damage before any operations.
Report any defects. Do not operate the machine if critical defects are
present. For more information, see the section "Operating Instructions" in
the operator's manual.
Scheduled maintenance is an essential procedure to ensure and maintain
safety and performance of the product. Follow the specified instructions for
the maintenance and inspection of product. For more information, see the
section "Periodic Maintenance" in the maintenance manual.

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2.2.3 Personal Protective Equipment

Operators and anyone in the vicinity of the product MUST wear approved
personal protective equipment, which includes but is not limited to:
• Safety helmet
• Eye-protector
• Hearing protectors
• Safety footwear
• Respirator
• Protective gloves
• Protective clothing
• Safety harness when working at heights
• High visibility clothing
Do not wear loose clothing or jewelry that can get caught on controls or
pulled into moving parts of the product.
Tie back long hair. Long hair can get entangled, which could cause death or
severe injury.
Beware of the cap lamp cable. The cable can get caught or entangled on
the control devices which could cause death or severe injury.

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2.3 Product limitations

2.3.1 Intended use
This SANDVIK dump truck is intended to transport and dump rock material
in underground mining operations. Any other use different from this is not
considered as intended. The intended use also includes following the
instruction manuals and adhering to the inspection and maintenance
instructions.
Careless use or use which is not in accordance with the intended use, may
cause damage to health or property. The manufacturer or supplier will not
be liable for any damage resulting from use other than intended.
This dump truck shall be used only
• for its intended use
• in underground mining operations
• when it is in proper mechanical and operational condition
• with awareness of safety and possible danger
• in strict adherence to and use of the instruction manual.
In addition, the dump truck is intended to be used in following conditions:

• Ambient temperature from 0 °C to +40 °C (if the ambient operating
temperature is not within these limits, contact your Sandvik
representative)
• Within altitude limits of max. +3000 m to min. -2000 m (if the operating
altitude is not within these limits, contact your Sandvik representative)

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2.3.2 Prohibited use

The following uses are prohibited:
• Use which is not in accordance with the intended use as described
above.
• Use of product for any other purposes than those instructed in the
operator's and maintenance manuals.
• Use of product without required and approved training.
• Use of product without required and approved personal protective
equipment.
• Use of product when unauthorized personnel are in the working area.
• Bypassing or overriding machine safeguards for any reason.
• Use of product when safety systems are deficient or out of order.
• Use of product when the area where you are operating has being
charged with explosives
• Use of product in environment containing explosive gases or explosive
dust.
• Use of product for personnel transport.
• Use of product when there is insufficient ventilation or too high water
level in working area
• Use of product when a fault is detected.
• Use of product as a person lifting device.
2.3.3 Centre of the gravity
Location of the center of gravity varies depending on the optional devices.
Location of the center of gravity when the box (28 m³) is in hauling position
is represented in the figure below.
Coordinate system is located at center hinge , axle level.

∆x 298 mm
∆z 355 mm

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2.3.4 Maximum inclination angles
WARNING
ROLL OVER HAZARD!
Incorrect operating or parking procedures could cause death or
severe injury.
Do not load, haul, dump, park or operate the machine on a slope that
exceeds the maximum inclination angles.
The inclination angle indicators of the machine are located in the operator
compartment.

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During hauling and parking
Angle max 15° Angle max 15°
Angle max 15°
Angle loaded max 7°

Angle unloaded max 10°
During dumping procedure
Angle max 10°
Note! Avoid sudden up-and-down box motion, especially when machine is

articulated!
Note! Be careful and drive slowly when approaching the dumping station!

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During jacking the machine

MOBILE MACHINERY HAZARD!
Jacking the machine in decline may cause machine run away. Being
run over or being crushed by a mobile machine will cause death or
severe injury.
Do not exceed maximum permitted gradient angles.
Angle max 2° Angle max 2°
Angle max 2°

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2.3.5 Operator visibility

When operating the machine, always remember that visibility is limited.
Ensure that unauthorized persons are not present in the vicinity of the
machine.
The following visibility drawing has been prepared by means of computer
simulation based on the standard ISO 5006:2006 Earth-moving machinery -
Operator's field of view - Test method and performance criteria.
Visibility from the tramming position is represented in the figure(s) below.
Blind area (meters) Visible area (meters)

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2.3.6 Modifications
WARNING
MODIFICATION HAZARD!
Unauthorized modifications could lead to death, severe injury or
property damage.
Always contact a Sandvik representative in order to get advance
written approval for any modification.
All modifications and corrections not authorized in the product manuals or

which may affect the maintenance, operation, safety, and availability of the
product need to be approved in writing by the manufacturer before
implementation. Approval requires careful risk assessment taking into
consideration any new risks that the modifications may bring.
Changes and modifications without proper risk assessment, elimination or
reduction of risk and without appropriate safety measures may lead to
death, serious personal injuries or damage to property or environment.
Unauthorized modifications will also void the warranty.
If modifications and alterations that affect the maintenance, operation,
safety, and usability of the product are made without the written permission
of the manufacturer, the manufacturer is not responsible for any incidents
resulting in death, injury, or property damage brought about by such
modifications and corrections.
If a modification or correction as described above has been implemented
without the manufacturing organization’s permission, its effect on warranty
liability will be considered case-by-case. Thus, the warranty application
may be rejected altogether.
Should you consider a modification or alteration necessary, you must
contact the organization that manufactured and designed the product. No
modification is permitted unless you first obtain the written approval of the
manufacturer.
In order to plan and implement the modification you must deliver adequate
documentation:
• Product model/type
• Serial number of product
• Description of the modification or correction
• Related blueprints
• Related photos
• And other material, if necessary

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2.4 Hazard zone
DANGER
Being run over or being crushed by a mobile machine will cause
death or severe injury.
Ensure there is nobody in the hazard zone during operation.
Dump truck is a mobile machine with a large hazard zone when it is in

operation. The best way to avoid the hazard is to avoid entering the area
where the dump truck is being operated. Unauthorized access to the area
must be prevented. Before operating the machine, the operator must make
sure there are no persons in the hazard zone.
Visibility from the cabin is limited, as shown in the visibility chart. If you
must bypass the machine, bypass from the cabin side so that the operator
could see you better. Always wear approved high visibility clothing.
To further increase safety, the users are required to implement site specific
procedures to ensure proper communication and signaling. This can be
done e.g. by means of a communication radio and/or signaling with vehicle
lights or lamps, according to the procedures defined by the mine.

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2.5 Safeguarding
2.5.1 Safety functions
WARNING
TAMPERING HAZARD!
Bypassing or overriding of a safety function could cause death or
severe injury.
Do not make any alterations to safety functions. Make sure that they
work properly before operating the machine.
The following machine function is considered to be a safety function as

identified by the analyses.
• Parking brake door interlock [ISO 13849-1:2006 Category B PL a] with
following functional requirement:
- When the door is opened, the parking brakes will be activated.
The following functions are functions of the machine that have been given a
performance level requirement, even if they are not safety functions.
• Emergency Stop [ISO 13849-1:2006 Category 1, 3 PL c] with functional
requirement:
- When an Emergency Stop pushbutton is pressed, an emergency
stop will occur, stopping all dangerous movements.
• Parking brake [ISO 13849-1:2006 Category B PL a] with functional
requirement:
- When the parking brake button is pressed, the parking brakes will be
activated.
2.5.2 Guards
WARNING
DO NOT REMOVE OR MODIFY GUARDS!
Operation without the guards in place is dangerous and could cause
Removing or modifying the guards is strictly prohibited! Before
operation, always make sure that the guards are undamaged and in
place.

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Roll Over Protective Structure (ROPS) and Falling Object Protective Structure
(FOPS)
The machine is equipped with a safety cabin. The cabin has been granted
ROPS approval according to EN ISO 3471 and FOPS approval according
to EN ISO 3449. Never make any unauthorized alterations to the ROPS/
FOPS structures. In the event of an accident, a modified ROPS/FOPS can
fail to protect the operator. Alterations or repairs, which have not been
authorized by the manufacturer, will void the ROPS/FOPS approval.
Where a machine has been involved in an incident which has resulted in
discernible deformation of the protective structure, the damaged structure
shall not be reused. In case of damage to the ROPS/FOPS structure,
contact your local Sandvik representative for further instructions.
Despite the protective structure, you must never drive with the machine into
a potentially dangerous area, such as open stope, where a risk of fall of
ground exists. If such mining methods are used, the machine must be
remotely operated.

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Location of the guards
1 Safety cabin 2 Guard on rear glass 3 Machine covers
Thermal insulation for tur-

4 5 Muffler 6 Drive shaft cover
bo and exhaust manifold
Guards for air filters and

7 Guards on rotating fans 8 9 Mudguards
muffler

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2.5.3 Protective devices
WARNING
TAMPERING HAZARD!
Bypassing or overriding of a safeguard or a protective device could
cause death or severe injury.
Do not make any alterations to protective devices. Make sure that
they are in place and work properly before operating the machine.
The machine is equipped with several protective devices which are

designed to reduce risks to the users. Do not modify the protective devices;
they must always be operable and in place. Remember that regular
preventive maintenance is required. Follow all the instructions for
scheduled maintenance provided in the maintenance manual. In addition to
the maintenance manual, section "Description of controls and functions" in
the operator's manual, as well as these safety and environmental
instructions give information on the protective devices.
The protective devices in the machine include but are not limited to the
following:
• Fire extinguisher
• Fire Suppression System (optional)
• Emergency stop buttons
• R.O.P.S./F.O.P.S. certified safety cabin with A/C
• Emergency exit
• Lockable battery isolation switch
• Lockable engine starter isolation switch
• Lockable pressure release cap with coolant expansion tank
• Main circuit breaker release button
• Pressure relief valves for pressure accumulators
• Wheel chocks
• Frame articulation locking device
• Dump box support device
• Neutral brake
• Preventative functions for machine movements
• Emergency steering (optional)
• Reverse alarm
• Reverse camera
• Flashing beacon
• Directional lights
• Dump box up alarm buzzer in the cabin

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• Windows defrost (optional)

• Mirrors defrost (optional)
• Adjustable operator seat
• 4-point seat belt for operator
• 3-point seat belt for trainer
• Anti-slip strips on access ways
• Safety rails (optional)
• Safety labels
Note that some of the protective devices are delivered as optional
equipment and must be ordered by the purchaser.

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Seat belt
WARNING
FAULTY SEAT BELT CAUSES A HAZARD!
Faulty seat belt does not provide adequate protection in an accident,
which could result in death or severe impact injuries.
Check the seat belt condition before every working shift. If any
malfunction occurs or visual damage can be noticed, replace the
seat belt immediately with the new one.
Also after any accident or collision, replace the seat belt.
In any case, Sandvik recommends to replace the seat belt once a
year or every 5000 hours, which ever comes first.
The seat belt is a four-point belt with adjustable straps. Its purpose is to
secure the operator of a machine against harmful movement that may
result from a collision, loss of balance or a sudden stop.
The trainer seat has a three-point lap belt with an adjustable strap.
The seat belt must always be fastened during hauling.

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Frame articulation locking device
DANGER
CRUSHING HAZARD!
Unexpected articulation movement of the machine will cause death
or severe crushing injuries, if a person is at the center articulation
area.
Never enter the center articulation area when the engine is running.
The frame articulation locking device is located at the articulation area of

the machine.
The locking device is provided to prevent unplanned movement of the
frame joint and its main purpose is to protect personnel during
maintenance. The locking device has been constructed from solid steel bar.
The locking device must be installed before starting any maintenance work,
before transportation or before lifting the machine.

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Installing the frame articulation locking device
DANGER
CRUSHING HAZARD!
area.
1. Align the dump truck (no angle between the front and rear the frame) on
an even surface.
2. Turn off the engine and remove the ignition key.
3. Open the bar (A) that holds the rear locking pin of the frame articulation
locking device.
4. Lift the locking pin (B) from the hole.

5. Turn the frame articulation locking device to its forward position.
6. Lock the frame articulating locking device to the front frame with the
removed locking pin.
7. If the locking pin does not go all the way into the hole, start the engine
and slowly turn the dump truck until the locking pin drops down to its
correct position.

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Note! To avoid damage, it is advisable to have a second person giving

steering signs to the operator from a safe distance, because it is not
possible to observe the frame articulating locking device from the
cabin.
Removing the frame articulation locking device
DANGER
CRUSHING HAZARD!
area.
1. Remove the locking pin from the front frame.

If the locking pin is stuck:
• Start the engine and slowly turn the dump truck, to release the
pressure against the locking pin.
• Turn off the engine and remove the ignition key.
• Step out from the cabin and remove the locking pin.
2. Turn the frame articulation locking device to its storing position.
A
B
3. Lock the frame articulating locking device with the locking pin (A).
4. Secure the locking pin by tightening the secure bar (B).

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Box support device
DANGER
CRUSHING HAZARD!
Unexpected movement of box will cause death or severe injury.
Never enter under the box until it is supported accordingly with the
box support device.
The box support device is located under the box.

The support device is provided to prevent unplanned movement of the box
and its main purpose is to protect personnel during maintenance.
The support device must be installed before starting any maintenance work
that requires raising the box up.

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Installing the box support device

1. Start the engine and lift the box up.
2. Turn the box support device to up position.
• Make sure that you don't walk under th ebox under any
circumstances.
3. Lower the box slowly onto the support device.
4. Shut down the engine.

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Removing the box support device

1. Start the engine and lift the box up.
2. Turn the box support device to down position.

• Make sure that you don’t walk under the box under any
circumstances.
3. Lower the box slowly onto the stoppers.

4. Shut down the engine.

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Safety rails
WARNING
TRIPPING, SLIPPING OR FALLING HAZARD!
Tripping, slipping or falling could result in death or serious injury.
Always wear required personal protection, such as safety helmet,
safety gloves, safety boots, etc. Keep ladders, steps, handrails,
handles, and working platforms clean of oil, dirt, and ice. Obey local,
site and mine regulations concerning working on places where there
is a risk of falling. Always wear safety belts and lines when required.
Do not remove the safety rails. Check the safety rails and their
locking systems regularly.
The safety rails are designed to prevent a person from accidentally falling
down 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 safety rails are locked in their resting position and
have to be build up before maintenance work.
Note! Never drive with the safety rails in built up position.

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Building the safety rails up

Raise and lock all safety rails according to the following procedure.
1. Unlock the safety rail from the rubber clamp(s) by pulling it up.
2. Raise the safety rail.

3. Lock the safety rail.
4. Build the safety rails according to the following sequence.
3 1
5 4
2
6

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Lowering the safety rails down

Lower and lock all the safety rails in reverse order compared to building
them up.
1. Unlock the safety rail.
2. Lower the safety rail.
3. Lock the safety rail by pushing it into the rubber clamp(s).
Tailgate service pins (ejector box)
DANGER
CRUSHING HAZARD!
Being crushed between the ejector box and the tailgate will cause
When the tailgate is open it must be supported with the tailgate
service pins during any inspections of the ejector box interior.
Make sure that there are no unauthorized persons in the hazard
zone.

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How to install the tailgate service pins
DANGER
CRUSHING HAZARD!
Being crushed between the tailgate and the box will cause death or
severe injury.
zone.
RISK OF PROPERTY DAMAGE.

Operating the tailgate with the service pins installed can result in
NOTICE bended components.
Put a sign in the cabin to inform about installed service pins.
1. Make sure that the machine is on a level surface and the parking brake is
applied.
2. Open the tailgate.
3. Stop the engine.
4. Remove the tailgate service pins from their storage bracket (1) and install
them (2).
5. Start the engine and close the tailgate so that the tailgate rests against
the service pins.
Note! Have another person to observe and to give a sign, when the tailgate
makes contact with the pins.

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How to remove the tailgate service pins
DANGER
CRUSHING HAZARD!
Being crushed between the tailgate and the box will cause death or
severe injury.
zone.
1. Make sure that the machine is on a level surface and the parking brake is
applied.
2. Open the tailgate.
3. Stop the engine and remove the service pins (2).
4. Place the pins to their storage bracket (1).

5. Start the engine and close the tailgate.

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2.6 Complementary protective measures

2.6.1 Use of Emergency stop function
The machine is equipped with several emergency stop devices. To stop the
machine immediately in an emergency, use the nearest emergency stop
device.
When one of the emergency stop devices is activated, all ongoing functions
are stopped. The emergency stop remains engaged until it is manually
reset. This manual resetting does not restart the machine. It only permits
restarting the machine.
CHECK THE FUNCTIONING OF THE EMERGENCY STOP DEVICES
DAILY.
Make sure that the emergency stop devices can be accessed at all
times.
Emergency stop buttons

The machine emergency stop buttons are red push buttons. The
emergency stop function is activated by pressing down one of these
buttons. When an emergency stop button is pressed, the brakes will
engage and the engine will stop. The engine cannot be started until the
emergency stop button has been released.

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2.6.2 Emergency exit

The cabin has one natural exit and two emergency exits, which can be
used as emergency exits. In an emergency situation, use the safest escape
way.

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Escape procedure
WARNING
FALLING HAZARD!
Falling could cause severe injury.
Use extreme caution when escaping out of the cabin.
The front and the right side window of the operator cabin can be used as an
emergency exit.
Note! The following pictures may differ from your machine but the essential
information in the pictures is correct.
1. Pull from the exit sign/ring and move the sign round the window until the
whole string comes out of the window seal.
2. Push the window out of place and go out through the window opening.

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2.6.3 Safe access to machine and three-point support
WARNING
SLIPPING, TRIPPING AND FALLING HAZARD!
Slipping, tripping or falling could cause death or severe injury.
Use access ways and maintain three-point support. Keep all access
ways clean.
Use proper working platforms to prevent falling.
Three-point support is feature of an access system that enables a person to

use simultaneously two hands and one foot or two feet and one hand while
ascending, descending or moving about on the machine.
Use grab handles and steps provided to maintain 3 or 4 points of body
contact with the machine and keep your face towards the machine while
ascending or descending on the machine.
Keep all stairs, rails, anti-slip surfaces, steps, etc. clean of oil, grease,
snow, ice, debris, unnecessary items, and dirt to prevent accidents. Never
use the components of the machine as steps. If the work is carried out at
height, or in an otherwise dangerous position, use proper working platforms
covered with anti-slip tape and safety harness, when required, to prevent
falling. Do not step aboard or hop out of a moving machine.

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2.6.4 Isolation and energy dissipation
WARNING
HAZARDOUS STORED ENERGY!
This machine contains stored energy in various forms. The energy
could cause unexpected consequences, death or severe injuries, if
not dealt properly.
Before any maintenance or service work, make sure the machine is
isolated and stored energy is released. Leave maintenance work to
professionals. Follow applicable instructions.
The machine should be isolated before performing any maintenance work.

The purpose of isolating machinery is to allow work to be undertaken safely
with no danger to life, or injury to people, or possibility of property damage.
Any instructions given in laws and regulations, any orders given by local
authorities, and all protective measures must be strictly adhered to. Check
the isolation requirements and ensure compliance before starting the job.
Maintenance and repair work on the pressurized systems may only be
carried out by persons who have received the training required for the work.
Do not start work that is not fully familiar to you.
Depressurization of hydraulic system

When the machine is switched off, make sure that in a fault situation there
can still be stored pressure in the hydraulic system. Hydraulic system can
store pressure in the accumulators, as well as in machine components,
such as the jacking cylinders, which are supported by the hydraulic system.
All major machine assemblies should be lowered down or supported to
isolate any hydraulic energy.
Release charging pressure from the brake accumulators as follows:

• Shut down the engine.
• Turn the ignition switch to the "1" position.
• Review the pressure values in the VCM display to verify that the brake
system has released pressure. Pressures should be 0 bar.
• To be sure that the pressure is released, connect a 400 bar pressure
gauge to the accumulator pressure measuring point with caution.
Release any stored accumulator pressure from the suspension

accumulators as follows:

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1. Open the hydraulic tank compartment door.
2. Open the locking cover (2) of the discarge valve .
3. Open the discharge valve (1).

WARNING! The front frame will lower down when the valve is
opened. Make sure there is nobody in the hazard zone!
4. To be sure that the pressure is released, connect a 400 bar pressure
gauge to the accumulator pressure measuring point with caution.
Release the hydraulic tank pressure as follows:

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1. Press the release button (3) on the side of the tank.
3 4
2. Make sure from the gauge (4) that all pressure is relieved.
In spite of these precautionary measures, some of the hydraulic
subsystems may still be pressurized. Always use approved personal
protective equipment and proceed with caution.
Fuel system disconnection

Shut off the fuel valve(s) of the fuel system. This will prevent any
environmental contamination during maintenance.
Electrical system isolation

Before performing any maintenance work, always make sure that the
machine is disconnected from the power supply. Make sure that the
machine cannot be started accidentally. Disconnect the electrical system of
the machine as follows:
• Turn off and lock the main switch.
• Turn off the starter isolator switch.
• Remove the ignition key.
Earthing the machine

Earthing the machine frame reduces the risk of electric shock.
Make sure that the machine front and rear frame are earthed prior to
service and repair work.
Follow the local regulations and guidelines set by your employer and the
authorities.

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Suspension system isolation

The machine front axle is made to oscillate by the hydraulically operated
cylinders.
The cylinders linked to the front axle are designed to return to the default
height setting each time the parking brakes are released.
Isolate the axle movement in case the engine needs to be running during
maintenance procedures as follows:
1. Turn off the engine.
2. Turn the main switch off.

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4. Open the suspension discharge valve (1).

• The locking cover (2) is locked by the locking pin.
• WARNING! The front frame will lower down when the valve is

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5. Disconnect the solenoid Y2087 and Y2088 wirings from the suspension
block in valve V2205.
• Suspension control is disabled until the wirings are reconnected.
Y2087 Y2088
2.6.5 Location of the isolation switches
Battery isolation switch Starter isolation switch

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Battery isolation switch

The battery isolation switch turns on/off the current from the battery to the
machine electric circuit.
Note! The SCR (Selective Catalytic Reduction) system must be let drain for
90 seconds after shutting down the engine and before cutting the
power off.

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Starter isolation switch

RISK OF PROPERTY DAMAGE!
Turning the switch OFF while engine is running can cause an
NOTICE alternator failure.
Lock the switch in any case to prevent accidental usage.
The starter isolation switch enables / disables the engine starting.

The switch can be used in maintenance situation when current from the
battery to the machine electric circuit needs to be ON but the engine
starting needs to be disabled.
Engine prelube and fuel pump operation are NOT disabled with this switch.

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2.7 Fire risk control measures
WARNING
FIRE AND EXPLOSION HAZARD!
An explosion hazard could exist in addition to the fire hazard.
Ignition sources like smoking, open flames, welding work and sparks
together with combustible materials like fuel, can cause fire and if
not avoided, could lead to death or severe injury.
Ignition sources are prohibited in the vicinity of the machine ready
for operation or in operation.
During maintenance appropriate fire prevention and protection
measures must be followed including but not limited to trained
personnel, proper fire extinguishing equipment and agents. Before
any maintenance or repairs requiring ignition sources like welding or
flame cutting, a proper risk assessment must be carried out prior to
the start of the work to control the risk.
Smoking and open fire are prohibited in the vicinity of the product. Access
to all fire-fighting equipment must be granted at all times, especially during
maintenance and repair works.
All fire-fighting equipment must be inspected and serviced regularly,
according to local regulations. Damaged fire-fighting equipment and used
fire extinguishers must be replaced immediately.
Know the various types of fires and the appropriate fire-fighting methods.
Be aware that various fires must not be extinguished with water. In most
cases special extinguishing agents, dry powders or deoxygenating are
required.
All personnel must be trained regularly in fire-fighting methods, in
cooperation with local authorities and rescue organizations. In case of fire,
the fire alarm must be activated and all available personnel must contribute
in the fire-fighting according to the predetermined fire plan of the workplace.

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2.7.1 In case of fire

Always follow local guidelines and regulations regarding the fire fighting
procedures.
Fight the fire as follows:
1. Stop the machine safely.
2. Press the emergency stop push button.
3. Press the main circuit breaker release button to isolate the electrical
system.
4. Activate the fire suppression system (if fitted).

• NOTE! Actuation of the fire suppression system releases
immediately a notable amount of foam/ powder which may obscure
vision.
5. Escape from the cabin.
6. Use a hand held fire extinguisher to fight any new fire pockets, if needed.

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2.7.2 Fire prevention

Fires in any environment are extremely dangerous and can quickly get out
of control if not properly dealt with.
The following recommendations will help prevent the likelihood of a fire on
the machine:
• Always keep the machine and general area clean of flammable materials
such as fluids and lubricants, dirt and debris, and any material that could
cause or amplify fire. Clean all fuel or oil spills as quickly as possible.
• Report all electrical wiring and electrical component malfunctions to a
service personnel immediately.
• Ensure that the engine air intake, fuel and exhaust systems are
maintained properly.
• Inspect the machine regularly for hydraulic and oil leaks.
• Ensure that you are aware of and are familiar with all fire fighting
equipment on the machine. Also ensure that all fire fighting equipment is
inspected regularly and kept in working order. If the machine does not
have any fire fighting equipment, ensure that required fire fighting
equipment is available.
2.7.3 Fire retardant and flammable materials
The machine fire safety has been taken into consideration during product
engineering and manufacturing. When possible, fire retardant materials
have been chosen to improve fire safety. Examples of these measures and
material choices to prevent and control fires are the following:
• Cables used are in compliance with the IEC 60332-1 standard (Test on
electric and optical fibre cables under fire conditions).
• Surface materials of the hydraulic hoses, cable protective hoses and fire
suppression system (Ansul) hoses are MSHA approved and their inner
tubes are made of nitrile-rubber.
• Switchgears and slip ring unit are mainly made of metal.
• Fire area with fire wall has been made for the diesel engine.
• Roof panels in the cabin are made of fire retardant material.
• Cables in the engine compartment are inside a fireproof sleeve.
In spite of engineering and use of fire retardant materials, there are also
flammable materials in the machine e.g. inside switchgears, in valves,
plastic components, batteries and tires. Also oils, greases and paints used
in the machine are flammable materials. Keep the machine clean at all
times; dirt in the machine increases fire risk.
2.7.4 Fire extinguisher(s) (optional)
A fire extinguisher is an active fire protection device which is used to
extinguish or control small fires, often in emergency situations.

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Location of the fire extinguisher

The hand-held fire extinguisher is located on the left side of the front frame.
Using a fire extinguisher

All workers must know how to operate a fire extinguisher. Fire extinguishers
are different and that is why the user has to know how to use that specific
extinguisher which is available in case of fire.
The instructions below are indicative. Familiarize yourself with the
instructions printed on your extinguisher in advance.
1. Take the extinguisher from the bracket.

2. Pull out the locking pin.
3. Take out the extinguishing gun from the holder and press down the
release lever.
4. Extinguish the fire source from the bottom at a distance of 4 m.
5. Press the extinguishing gun, fan out the extinguishing agent.
6. Send the fire extinguisher immediately for refilling after use.
Maintenance must be performed annually by an authorized party:

distributor, supplier, dealer or equivalent. Always follow local regulations.

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2.7.5 FS1000 Fire suppression system (optional)

The FS1000 fire suppression system is installed in the machine for fire
suppression. The system is a fixed foam fire suppression system. Due to
the water content in the foam extinguishing agent, this fire suppression
system is suitable for ambient temperature above 0 °C. The primary
function of the system is to protect the operator. It greatly reduces risk to
people and property by providing effective fire protection and, therefore,
safer operating conditions. The system has been specifically designed to
suppress hydrocarbon fuel oil fires by application of foam extinguishing
agent. The foam will cut the fire's oxygen supply off and act as a vapour
seal over the fuel. The foam's water content cools the area down, which
reduces risk of re-ignition.
The discharge circuit nozzles are arranged in the form of a ring. It consists
of fire rated hose with a series of nozzles aimed at the risk areas.
The system is empty when delivered to the customer and has to be made
operational before it can be used. See separate manufacturer's manual
attached to the Service & Repair Manual for more information.
Location of nozzles and actuators
1 2 3 4 5 6
8 9 10 11 12
Fire suppression nozzles:

1 Engine, front end side 2 Engine, right side
3 Engine, right side 4 Central frame, tipping valve
5 Central frame 6 Brake hydraulic oil tank
7 Front box, left side 8 Engine, left side
9 Engine, left side 10 Engine, left side
11 Central frame, transmission 12 Hydraulic oil tank

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Activating the FS1000 system

The system can be actuated both manually and automatically. After
activation, the nozzles spray fire extinguishing foam for about 60 seconds.
Manual activation of the FS1000 system
1 2
Actuate the system by turning the activation module valve handle (1) 90
degrees in direction of arrows (counter clockwise).
The safety tie (2) breaks itself. The safety tie must always be replaced after
activation.
Automatic activation of the FS1000 system

The system is activated automatically by the fire detection and system
activation tubing when the heat caused by the fire reaches approximately
150 °C.
Note! The system may activate automatically, but if you observe fire on the
machine, always activate the system manually.

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Engine switch-off system with FS1000
Engine shutdown kit

The basic function of engine shutdown kit is to detect fire suppression
system activation, give the operator an audiovisual alarm and shut down
the engine after a given delay period.
The kit contains a twin pressure switch (near electrical system) and an
automatic engine shutdown panel (in the cabin).
Twin pressure switch

The twin pressure switch is factory set to 900 kPa falling and will switch
contacts if and when the system pressure falls below the setting of the
switch. Such a drop of pressure can be due to system activation or
pressure loss from a leak.
Engine shutdown panel
1 2 3 4 5 6
1. Green light for system OK status

2. Low pressure warning light
3. System fault or discharge warning light
4. Engine shutdown delay timer of 6 seconds with 20 second time extension
button
5. Engine shutdown test button (simulating system discharge)
6. Key operated engine shutdown override (for authorized personnel only)
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.

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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.
2.7.6 ANSUL fire suppression system (optional)
The ANSUL fire suppression system is installed in the machine for fire
suppression. The system is a cartridge operated dry chemical system with
fixed nozzle distribution network. The system can be either manual or
automatic.
Note! The system is not designed or intended to extinguish all fires. It
extinguishes mainly fires in the engine compartment. It is extremely
important that alternative fire fighting equipment is available in case the
system does not totally extinguish a fire.
Location of nozzles and actuators
1 2 5 6
3 4 7 8
Fire suppression nozzles:

1 Engine front end, right side 2 Engine, right side
3 Engine front end, left side 4 Engine, left side
5 Gear box, middle 6 Corner box, rear end left
7 Gear box, rear end 8 Corner box, rear end right

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Manual ANSUL fire suppression system

The manual fire suppression system is actuated manually by push buttons.
When a push button is pushed down, fire extinguishing chemicals are
released through the system nozzles.
Actuate the system as follows:
1 2
1. Remove the ring pin (1) on the actuator.

2. Strike the red button (2).
Engine switch-off system with Ansul

The engine switches off automatically immediately after the fire
extinguishing system has been actuated.

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ANSUL Checkfire system (optional)
System description
The ANSUL CHECKFIRE 210 detection and actuation system alerts
operators about potential fire hazards and actuates the fire suppression
system if a fire occurs, offering protection for both the vehicle and the
operator itself.
If a fire is detected, the system discharges an expellant gas cartridge
initiating fire suppression system operation. The operation releases fire
extinguishing chemicals through the nozzles that are placed all over the fire
hazard locations.
Checkfire system consists of detection wiring, control module, interface
control module (ICM), actuator with nitrogen cartridge, mounting brackets
and cables.
Checkfire system contains its own internal battery as the power source.
The 3.6 VDC internal battery is in the control module. The battery must be
replaced annually or when the sounder and the amber Power LED are
pulsing.
The Checkfire system includes an isolate mode that is operated by the
isolate switch. The switch is located on the side of the ICM. When
performing service and maintenance on the machine, the isolate mode
must be used to prevent automatic release of the fire supression system.
4 6 1
2
5
3
1 Checkfire 210 display module 2 EOL device

3 Linear detector 4 Interface control module
5 Electric-pneumatic actuator 6 Gas cartridge

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Actuation of the system
The fire suppression system can be actuated by 4 different ways.
Manual actuation
Fire suppression system is activated by striking 1 of the red strike buttons
located in the machine cabin and the rear end of the machine. This
immediately discharge the fire suppression system. .
Automated actuation
Automated activation is triggered by the short circuit of the linear detector of
the Checkfire system. Short circuit is caused by the heat and this cause
alarm condition in the Checkfire system.
Alarm condition cause 2-phase automated actuation cycle before the
discharge of the fire suppression system.
• First phase (Time Delay #1) of the actuation cycle is by default 10
seconds. During this phase the operator has opportunity to restart the
Time Delay #1 phase and delay the automated actuation of the fire
suppression system by pressing the Delay/Reset/Silence button in the
Checkfire system display module.
• After the Time Delay #1 is over the system enters to second phase (Time
Delay #2) which is by default 10 seconds. After Time Delay #2 the fire
suppression system automatically discharges.
• Is it not possible to delay the automated actuation once the Time Delay
#1 phase is over.
• Both phases (Time Delay #1 and #2) can be programmed to 0,5,10,15
seconds.
• Number of allowed Time Delay #1 re-starts can programmed to 2 or
unlimited number.
Manual actuation from display module

Pressing the Push to activate/Alarm when lit button in the Checkfire system
display module immediately activates and discharges the fire suppression
system.
Remote actuation
Pressing the remote control fire suppression button immediately activates
and discharges the fire suppression system.

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Display module
3
1
4
2
5 6 7 8 9
1 Release indicator LED 2 Discharge indicator LED

3 Power LED 4 Guard door
5 Delay/Reset/Silence button 6 Detection indicator LEDs for
two circuits
7 Isolate LED 8 Shutdown LED
9 Manual activation button and
Alarm LED
Internal sounder
Internal sounder indicates all fault and alarm conditions by an audible
notification.
The sounder pulses at same rate as corresponding indicator LED. The
sounder is rated at 85 Db at 1 m.
Release indicator LED

Release indicator LED starts to pulse amber light at a rate of one pulse per
10 seconds when a fault condition indicated. The internal sounder pulses at
sam rate as LED.
The LED will automatically return to normal when the fault is cleared.
Discharge indicator LED

Discharge LED is only active when Pressure Switch Feedback is
programmed.
Power LED
Power LED pulses green once per every 3 seconds:
• System status OK.
Amber power LED and sounder pulse once every 10 seconds:
• Internal battery life fault: power from the internal power source dropped
below acceptable level causing a fault condition.

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Fault conditions will continue pulsing amber as long as fault exists or until
system powers down.
Delay/Reset/Silence button
Delay/Reset/Silence button is use to manage fault or alarm conditions.
Pushing the button causes the following results:
• Audible fault silence
- The button silences the internal sounder for two hours. Fault LED
continue pulsing until the fault or the alarm is cleared.
- Any new alarm or fault will activate the internal sounder.
- After two hours the audible notification starts again if fault condition
isn't cleared.
• Restart Time Delay Sequence
- The button restarts the time delay circuit during an alarm condition.
Restart must be done before Time Delay #1 (default 10 seconds)
phase expires.
• System restart
- Press and hold the button for 3 seconds to restart the system.
Detection indicator LEDs for two circuits

LEDs indicate an alarm condition by pulsing red light and a fault condition
pulsing by amber light at a rate of one pulse per 10 seconds. The internal
sounder pulses at sam rate as LED during the fault condition.
The LEDs will automatically return to normal when the fault or the alarm is
cleared.
Isolate LED
The isolate LED starts to pulse amber light 2 pulses per 30 seconds when
the isolate mode activated.
When performing service and maintenance on the machine isolate mode
need to use to prevent automatic release of the fire suppression system.
Shutdown LED
The shutdown LED indicates the phase of automated actuation during
alarm condition.
• LED pulses 4 times per second for 4 seconds starting in the last 5
seconds of automated actuation Time Delay #1 phase.
• LED light steady for the last second of the Time Delay #1 phase.
• LED pulses 4 times per second for 4 seconds during the automated
actuation Time Delay #2 phase.
After the fire suppression system has been released the shutdown LED
pulses 1 time per 10 seconds until the system has been reset.

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Manual activation button and Alarm LED

Pressing the manual activation button and alarm LED immediately activates
the fire suppression system and the alarm LED light red for the 10 seconds.
The alarm LED indicates the automated actuation phase during alarm
condition.
• LED pulses 2 times per second from the start of Time Delay #1 phse.
• LED pulses 4 times per second for 4 seconds starting in the last 5
seconds of automated actuation Time Delay #1 phase.
• LED stays OFF for the last second of Time Delay #1.
• LED pulses 4 times per second for 4 seconds during the automated
actuation Time Delay #2 phase.
• LED lights for 10 seconds during the activation of the fire suppression
system.

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Interface Control Module

Interface control module communicates with the CHECKFIRE 210 display
module and is the central connection point for input/output circuits.
The Interface control module includes an isolation feature that minimizes
the occurence of a false discharge during maintenance.
The battery, mini usb port and programming interface can be found beneath
the battery cover.
1 2 3 4
1 Battery well 2 Battery cable

3 Mini usb port 4 Programming interface
5 Battery 6 Isolate switch

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Changing the Checkfire battery (option)

Ouside of maintenance schedule the Checkfire battery needs to be
changed when low power is indicated.
1. Switch the isolate switch (1) to isolate mode.
2. Remove the battery compartment cover.
3. Disconnect the battery cable (1) from battery pigtail (2).

4. Remove the old battery from battery well.
5. Insert new battery into battery well.
6. Connect the battery cable (1) with battery pigtail (2).
7. Install the battery compartment cover.

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8. Reset battery life indicator.
• Press and hold the programming button (1) at least five seconds.
• If resetting of the battery life indicator is completed successfully all
programming LEDs pulse three times in one second.
9. Return the isolate switch to the normal position.
2.7.7 After a fire
Once the fire is out and the machine has cooled down, open the ventilation
hatches to clear the machine of smoke and gases. Avoid breathing in the
combustion gases. Keep a hand-held fire extinguisher close and ready to
use during ventilation.
Wash the machine with plenty of water as soon as possible after
extinguishing, because the powder used can cause corrosion, especially to
the cables.
Empty tanks and gas cartridges must be replaced before using the
machine. Only authorized service personnel may remove and fit powder
tanks and gas cartridges.
Do not start the machine again until the cause of the fire has been
established and the fault has been repaired.
Report all fires to the supervisor.
2.8 Protection against emission hazards

2.8.1 Noise
DANGER
NOISE HAZARD!
Noise level emitted by the machine exceeds 80 dB(A). Continuous
exposure to noise will cause hearing impairment.
Always wear approved hearing protection outside the operator's
compartment.

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Measured sound level
Operational conditions
The sound pressure level at the operator’s position was determined in
stationary conditions at high idle (2000 rpm).
Test results
In accordance with ISO 4871
Unit with Volvo TAD1662VE engine:
Measured A-weighted emission sound pressure level at operator’s
74
position, LpA [dB re 20 μPa]
Uncertainty, KpA [dB] 3
Unit with Volvo TAD1642VE engine:

Measured A-weighted emission sound pressure level at operator’s
75
position, LpA [dB re 20 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.
2.8.2 Vibration
WARNING
VIBRATION HAZARD!
Exposure to vibration could cause severe health effects.
Follow the maintenance schedule and keep the machine on good
operating condition. Participate in the health surveillance and
training programs offered by your employer.

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Measured vibration level
Operational conditions
Whole body vibration was determined while loading, unloading and driving
with and without load.
The driving was done following a course on a test track, including driving on
two ramps. The surface of the test track was partly asphalt and partly
coarse gravel road.
Test result
Driving Driving
Whole body vibration Loading Unloading
with load w/o load
Maximum r.m.s. value aw
0,32 0,24 0,69 0,90
[m/s2]
VDVw over 15 min period
4,02 3,72 8,37 7,73
[m/s1.75]
Values determined applying standards EN 1032 and ISO 2631-1.

NOTE 1 The measured whole body vibration values are strongly dependent
on the conditions under which the machinery is used, e.g. driving speed
and surface quality. The measured vibration values may be used in
comparing the vibration of machinery tested in similar conditions, but it may
not represent the actual vibration in particular operating conditions.
NOTE 2 Values above represent non-stop work. Any possible breaks are
not included in values above.
Hand-arm vibration
The magnitude of hand-arm vibration on the steering wheel and control
levers do not exceed 2,5 m/s2.

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2.8.3 Dust
DANGER
DUST HAZARD!
Breathing dust will cause death or severe injury.
Always wear approved respirator!
Breathing or inhaling dust particles will cause death or severe injury. Always
work with a respirator approved by the respirator manufacturer for the job
you are doing. It is essential that the respirator that you use protects you
from the tiny dust particles which cause silicosis and which may cause
other serious lung diseases. You should not use the product until you are
sure your respirator is working properly. This means the respirator must be
checked to make sure that it is clean, that its filter has been changed, and
to otherwise make sure the respirator will protect you in the way it is meant
to.
In any workplace where respirators are necessary to protect the health of
the employee, the employer must establish and implement a written
respiratory protection program with work site specific procedures and
elements including but not limited to the selection of respirators, proper
usage, maintenance and care, cleaning and disinfecting and training.
Regularly clean your working environment properly to minimize the dust
level in the air. Always make sure dust has been cleaned off your boots and
clothes when you leave your shift.
Respiratory silica dust is a hazard, which requires special attention. The
smallest particles of dust are the most harmful. They may be so fine that
you cannot see them. Remember, you must protect yourself from the
danger of breathing or inhaling dust.
2.8.4 Hazardous gases
In a workplace where hazardous gases are present, the employer must
monitor the air quality, define required actions to protect the employees and
provide protective equipment, such as respirators. The employer is
responsible for ensuring that the safety of employees is not compromised
due to hazardous gases in the environment.
A closed cabin with air conditioning system does not guarantee that the
cabin is free of harmful gases or particles. Wear an approved respirator.

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2.8.5 Diesel particulate matter
DANGER
DIESEL EMISSION HAZARD!
Prolonged exposure to diesel emissions will cause death or severe
injury.
Only operate and maintain the equipment according to all applicable
instructions, procedures, laws and regulations.
Always wear approved personal protective equipment.
Diesel particulate matter (DPM) is a component of diesel exhaust (DE) that

includes soot particles made up primarily of carbon, ash, metallic abrasion
particles, sulfates and silicates. In a confined environment such as
underground or in a workshop, the diesel exhaust particles can not
disperse or be diluted as in an open atmosphere. Exposure to DE/DPM
causes severe long term health effects, in addition to short term effects
such as eye and respiratory irritation.
The end user of this equipment must take additional steps addition to those
provided on the equipment in order to mange this risk. These include, but
are not limited to:
a) Ensure disposable filters are fitted where the equipment is designed to
allow use of these.
b) Ensure ventilation volumes in the areas where this equipment is used
are above those required to maintain the operator exposure rate below
those specified by local regulations or company determined levels.
c) Vehicle movement tracking and control to match the number of vehicles
in a ventilation split the acceptable DPM exposure limit.
d) Implement a monitoring program for worker exposure to DPM
e) Use low emission fuels
f) Establish and maintain a fuel management program to ensure fuel
quality is as high as possible
g) Establish an engine testing program to determine when engine DPM
levels are excessive
h) Establish and maintain a preventive maintenance program to minimise
increased production of DPM by the engine
Responsibilities of the machine operating/maintaining personnel

To reduce your and your colleague's exposure to diesel exhaust, you as the
operator or maintainer must:
• Follow proper operating and driving practices. Keep the engine
revolutions as steady as possible; avoid unnecessary acceleration and
deceleration. Do not lug the engine down.
• Avoid unnecessary idling of the engine.

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• If the equipment has a closed cabin, keep the windows closed during
operations. Keep the cabin clean and in good condition. Pay special
attention to the air conditioning unit and to it's filter as well as to the door
and window seals.
• Monitor the information provided by the control system as well as the
indicator lights. If any warning or alarms appear, take corrective action
immediately.
• Maintain the equipment according to the instructions, especially the
engine manufacturer's instructions.
• Follow any site specific procedures and guidelines relating to monitoring
emission levels and trends. Follow also any site specific instructions
relating to means of controlling exposure to diesel emissions.
• Wear approved PPE according to site requirements.
2.9 Emergency procedures

It is the employer’s responsibility to plan and prepare site specific
instructions to be followed in case of an emergency or an accident. The
machine manufacturer can also give certain general guidelines which can
be used as help in establishing the required procedures. The following
information should be considered when devising a site specific emergency
plan. This list is not meant to be comprehensive.
• Emergency stop: If the machine has to be stopped immediately, use the
emergency stop functions. Emergency stopping stops all the ongoing
functions excluding lowering suspension cylinders. For more information,
see the section, "Emergency stop function".
• Emergency exit: In an emergency situation, use the safest escape way
or emergency exit. Also rescue personnel can use these exits to reach a
user in the operator station. For more information, see the section,
"Emergency exit".
• Loss of stability: If there is sudden loss of stability during tramming, the
safest place for the user is usually inside operator station, seated on the
operator seat and seat belt fastened.
• Falling objects: In case of falling objects, the operator should stay inside
operator station until it is safe to leave the machine. The operator may
also, when possible, move the machine away from the hazard zone,
without leaving the operator station.
• Fire: In mining conditions, it is extremely important to avoid fires. If an
accident does happen and there is a fire, it has to be extinguished as
soon as possible. For more information, see the section, "Fire risk control
measures".
• Accidents with chemicals: In an emergency situation or accident where
chemicals are involved, see the required first aid measures and
instructions in the material safety data sheets.
• Electric accidents: If the machine touches an electric power line, the
following instructions may prevent injuries or death.

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- If you are standing outside the machine, do not touch any part of the
machine or try to get onto the machine. Keep everybody away from
the machine.
- If you are on the machine, do not try to get off it. If the machine is
touching a power line, the machine can catch on fire. If the machine
has rubber tires, leave the machine as soon as the tires start
smoking. JUMP OUT! Do not make yourself a conductor for the
electric current to flow from the machine to the ground. Move away
from the machine by jumping, or by leaping so that only one foot at a
time touches the ground. The electric field in the ground can cause a
dangerously high voltage between your legs. You will not be in safety
until you are about 20 meters away from the machine.
- If some component of the machine touches an electric power line,
the whole machine becomes live. Although the insulating rubber tires
may make the situation seem safe, a person standing on the ground
and touching the machine can get a fatal electric shock. Machine
needs to be isolated at least for 24 hours before taking any actions to
the machine.
- If you come to a place where an electric accident has taken place, do
not risk your own life by acting incautiously to save others. Try to find
out whether a high or a low voltage is involved. Where high voltage is
involved, do not start any rescuing attempts until the power company
has cut off the voltage. It can be dangerous even to approach a
person in contact with the electric conductor, or with the machine that
touches the conductor. Remember that high voltage power lines
have no fuses that blow; the conductors are always dangerous, until
a qualified electrician has made them dead.
- If a person is in contact with a low voltage line or with a machine that
is touching a low voltage line, rescuing can be attempted by using a
dry and clean rope, or a dry and unpainted piece of wood. Anyone
who is attempting the rescue must keep as far away from the victim
as possible. The victim must not be touched until he is completely
disconnected from the live components. If the victim is unconscious,
first aid measures must be started immediately.
After an accident or emergency situation: Being on site where an
incident has occurred, do not take any actions with the equipment involved.
Do not speculate or give opinions on the cause. Contact your Sandvik
representative to get more information.
2.10 Safety considerations for maintenance

Before carrying out any maintenance, read and understand the
maintenance instructions. Make sure that you have all the required training,
skills and authorization before starting any maintenance work. The
maintenance instructions support maintenance personnel performing

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preventive maintenance for the product. The maintenance instructions also

provide information for maintenance and operating personnel on scheduled
mechanical inspections of components and installed equipment.
Ensure all necessary machinery isolations (see the section "Isolation and
energy dissipation") have been carried out prior to commencing any
maintenance work. Before carrying out any maintenance work, ensure that
necessary original spare parts or materials are available, or can be ordered
and supplied in time to meet the work schedule. You should only use parts
recommended by Sandvik. Failure to do so can cause death or injury or
damage to equipment. Note all completed maintenance activities in a
maintenance log or maintenance program.
2.10.1 Daily inspections and tasks for operators
Daily inspections and tasks, that are allowed for the operators, can be
found in the operator's manual section "Operator's maintenance
instructions". Operators are required to perform the inspections and tasks
described in the operator's manual. Note that in addition to the instructions
given in the operator's manual, the employer must provide operator
training.
All other inspections and tasks are allowed only for personnel with specific
maintenance training.

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2.10.2 Tasks which require definite technical skills and maintenance training
WARNING
SPECIAL SKILLS REQUIRED!
Incorrect maintenance procedures could cause death or severe
injuries.
Maintenance procedures require professional knowledge and
thorough training regarding the tasks and working methods.
Do not do any maintenance tasks without proper training. Always
follow the instructions. Use appropriate personal protective
equipment, depending on the task.
To avoid hazardous situations and severe consequences, leave all

maintenance work to professionals. Tasks mentioned here below are
examples of tasks which are allowed only for trained personnel. More
details on the risks related to the tasks and instructions for carrying out
these tasks safely can be found in the maintenance manual. Read the
instructions.
Tasks that require definite technical skills and training include, but are not
limited to:
• Hydraulic system maintenance
• Pneumatic system maintenance
• Electric system maintenance
• Battery maintenance
• Tire maintenance
• Brake system maintenance

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2.10.3 Getting on top of the machine

1. Unfold the ladder.
2. Use grab handles and steps provided to maintain 3 points of body

contact with the machine while climbing up the ladder.

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2.10.4 Working on top of the machine
WARNING
TRIPPING, SLIPPING OR FALLING HAZARD!
Tripping, slipping or falling could result in death or serious injury.
Always wear required personal protection, such as safety helmet,
safety gloves, safety boots, etc. Keep ladders, steps, handrails,
handles, and working platforms clean of oil, dirt, and ice. Obey local,
site and mine regulations concerning working on places where there
is a risk of falling. Always wear safety belts and lines when required.
Do not remove the safety rails. Check the safety rails and their
locking systems regularly.
1. Make sure that the box is lowered.

• The box acts as a safety barrier towards the rear of the machine.
2. Build the safety rails up.
3. Keep ladders, steps, handrails, handles, and working platforms clean of
oil, dirt, and ice.
2.10.5 Working under the machine
DANGER
CRUSHING HAZARD!
Axle suspension cylinders lowers the machine front end. Being
crushed under the machine will cause death or severe injury.
Take all safety precautions before entering under the machine.
1. Make sure that the engine is not running

2. Make sure that the engine starting is disabled.
3. Install the frame articulation locking device.
4. Install the wheel chocks
5. Lower the suspension fully down.
6. Jack and block the machine using approved safety stands.

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2.10.6 Supporting the machine for maintenance procedures
DANGER
CRUSHING HAZARD!
Unexpected movement of the machine will cause death or severe
crushing injuries, if a person is under the machine.
Never go under the machine if it has not supported securely. Make
sure the blocks used for supporting have sufficient loadbearing
capacity.
1. Ensure the machine is on an even surface and movement is prevented

by wheel chocks.
2. Install frame articulation locking device.
3. Depressurize the suspension circuit.
• Open the discharge valve.
• Leave the valve open during maintenance.
4. Depressurize the hydraulic oil tank.
• Push the pressure relief button.
• Make sure from the gauge that all pressure is relieved.
5. Raise the front of the machine until the front tires are just off the ground.
6. Place support blocks under the front of the machine.
• Make sure the blocks used for supporting have sufficient loadbearing
capacity.
7. Lower the weight of the machine on to the blocks.

8. Raise the rear of the machine until the rear tires are just off the ground.
9. Place support blocks under the rear of the machine.
• Make sure the blocks used for supporting have sufficient loadbearing
capacity.
10. Lower the weight of the machine on to the blocks.

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Note! Ensure proper balance of the machine when lowering. Visually check
that the blocks are properly in contact with the surface and the
machine.
2.10.7 Tire maintenance
Working with inflated tires and multi-piece wheel rims

Due to the high inflation pressures applied to multi-piece wheel rims, tire
and wheel rim assemblies house enormous amounts of energy. If this
energy is handled improperly, the tire and wheel rim assemblies have the
potential to explode or release air suddenly, possibly causing death or
severe personal injury to those in the area. By reading this section
thoroughly and following your local mine site standards, the risk of this
danger occurring can be reduced.
DANGER
EXPLOSION AND FLYING MATERIAL HAZARD!
During handling the full pressurized tire may burst and will cause
severe injury or material damage.
A broken rim part under pressure can fly apart and will cause severe
injury.
Tire inflation must always be done inside a tire cage. Do not stand in
front of the wheel during tire inflation. Use an extension hose, so
that you are able to stand to one side.
Never remove, move or store a tire that is inflated to full
pressurization.
When excess pressure is applied to a tire, it has the potential to explode or

release air suddenly out from its sides. It is important for all persons in the
area of tires to stand outside the area of trajectory.

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Safe maintenance procedures

Each person involved in servicing the wheel rim assemblies should be
familiar with the following before any maintenance is performed:
1. Always deflate the tire and then remove its valve core before removing
the wheel rim assembly from the axle.
2. Always apply rubber lubricant to the bead and rim mating surfaces during
assembly of the tire and rim, unless explicitly stated otherwise by the tire
manufacturer.
3. Always de-mount tires from the wheel rims before repairs are made to
the rims.
4. Always inflate tires using a restraining device and remote inflation
equipment. Tires should only be inflated outside of the restraining device
if:
• The rim is mounted to the vehicle and the tire is already inflated more
than 80% (as recommended in the "Tire and Rim Safety Awareness
Program" document published by the Mine Safety and Health
Administration in 1996).
• Inflation is required to hold the tire bead onto the rim ledge and
create an airtight seal with the tire and bead.
5. After inflation, always inspect the tire and rim assembly while it is in the
restraining device to ensure it is properly seated and locked. If
adjustments are necessary, deflate the tire before the adjustments are
made.
6. Never install a tube in a tubeless tire.
7. Never weld or cut in the proximity of inflated tires.
8. Never allow equipment or any part of your body to rest or lean against
the restraining device during tire inflation.
9. Never hammer, strike, or force the lock ring into the correct seating while
the tire is pressurized.
10. Never rework, weld, braze, or otherwise heat any cracked, broken, or
damaged wheel rim component.
11. Never apply heat to a multi-piece wheel rim.
12. Never stand or allow others to stand in the area of trajectory of a multi-
piece rim assembly unless the purpose of which can be proven to be
absolutely necessary.
13. Never inflate the tire until the entire lock ring is fully seated in the rim
assembly.
14. Never mismatch wheel rim components. All wheel rim components
should be the same size, type, and from the same manufacturer.
15. Never re-inflate a flat tire without first inspecting the entire wheel rim
assembly for unsafe conditions.

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Recommended tools
• Air pressure gauge with filter
• Inflation tool (clip-on chuck, hose, and in-line valve or preset regulator)
• Air compressor
• Valve core removers and reamers
• Spare valve caps
• Valve cap wrenches
• Tire restraining device or other suitable restraining device
Note! Release a small amount of air from the inflation valve before
applying the air gauge. This will prevent air from clogging the gauge
assembly.
Note! All pressure gauges should be tested against a master gauge.
Note! Do not use steel hammers on rim assemblies. Use only rubber, lead,
plastic, or brass head hammers so as not to damage rim
components.
Tire handling recommendations
DANGER
HANGING LOAD HAZARD!
Accidental falling of a hanging load on people will cause death or
severe injury.
Never stand under or near a hanging load. Always use a suitable
lifting device with adequate lifting capacity.
1. Always use a suitable lifting device capable of supporting the weight of

the tire.
2. Always use flat straps when lifting tires. Do not lift tires directly with a
crane hook.
3. When using a forklift, lift the tire with the forks underneath the tread. Do
not lift the tire from the bead.
4. When available, use specialized tire handling equipment.
• When using special equipment, be careful not to hold the tire too
tightly. This will distort the shape of the tire.
5. If supplied, leave bead protectors in place until the tire is to be mounted
to a rim.

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2.11 Environment
WARNING
ENVIRONMENTAL HAZARD!
The machine contains substances that could cause harm to the
environment.
Handle the chemicals and machine components according to
instructions and local regulations.
WARNING
CHEMICAL HAZARD!
The machine contains substances that could cause harm to your
health.
Wear approved personal protective equipment. Follow the
instructions given in material safety data sheets and other
instructional material.
This section of the chapter gives general information on how to

decommission, dismantle and dispose of the product and how to handle
harmful waste, hazardous substances and liquids without causing harm to
people or environment. These instructions give general knowledge of what
needs to be considered when decommissioning and recycling the product.
Always take into account that disassembly, disposal and recycling
operations must be conducted in accordance with all applicable local, state
and federal rules and regulations, in addition to complying with all
environmental, health and worker safety instructions.
2.11.1 Decommissioning
When the machine is decommissioned or put out of service for a longer
period of time, it has to be prepared and stored properly. Correct
preparations and storage conditions are essential to maintain the machine
in an operating condition and reach the expected lifetime. Appropriate
decommissioning procedures also facilitate work when the machine is put
back into service again.
Prior to storing, wash the machine, drain the water circuits and empty the
pressure accumulators. Change the fluids that may have deteriorated
during use. Protect the machine components with appropriate protective
substances. After all the preparations are complete, store the machine in a
location that is protected from direct sunlight and rain. The ambient
temperature shall be +0 - 35 °C and the relative humidity shall be below
90 %. Refer to the operator’s and maintenance instructions for further
details.

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2.11.2 Dismantling
WARNING
SPECIAL SKILLS REQUIRED!
Incorrect dismantling procedures could cause death or severe injury.
Dismantling shall only be done by persons with professional
knowledge and training.
When the product has reached the end of its life-cycle, it has to be
disposed of in a proper way. The end user of the product is responsible for
the product disposal. If the end user does not have the ability or the
resources to disassemble and dispose of the product, the work must be
performed by someone who does possess the necessary knowledge and
skills.
When dismantling the product, the following shall be considered:
• There are certain tasks which require special professional skills to ensure
the work is done in a safe and proper manner. Follow the local
regulations and guidelines set by your employer and the authorities.
• Carry out the work in a well ventilated space in a safe area that will not
be a traffic hazard for other machinery or personnel.
• Use appropriate personal protective equipment.
• Prior to beginning, ensure there are proper waste collection and recycling
points for spare parts and materials. Fluids and chemicals shall be
handled, separated and stored in compliance with all local, state and
federal rules and regulations.
• Note that during dismantling some special tools are needed. These can
be e.g., equipment for draining refrigerant, cutting torches, welding or
similar equipment, lifting gear, stands, crowbars, adjustable wrenches,
hammers, screw drivers etc. Ensure that correctly rated lifting equipment
is used to disassemble heavy components.
• Clean the machine before dismantling for better visibility and empty out
all loose parts from the cabin.
• Keep equipment for fire extinguishing, first aid and eye-washing closely
available.
• Before any dismantling operations, prevent accidental start-up of the
machine and make sure that the machine will not move.
• Note that there can be stored energy in various forms in the machine;
follow the procedures for isolation and energy dissipation. Ensure that all
energy sources are isolated and depressurized.
Before the actual disassembly of the machine, drainage must be
completed. Drainage means the removal of chemicals, fluids and materials
that are harmful to the environment. When carrying out the drainage
operations, avoid spilling fluids and liquids on the ground. Use a sink or a
container to avoid leakage. Any oil that is spilled onto the ground, including
biodegradable oil, must be collected as quickly andas carefully as possible.

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Refer to the maintenance manual for further information concerning the

lubricants and filling capacities of your machine.
Information on chemical safety can be found in material safety data sheets

and chemical technical data sheets. Material safety data sheets include
detailed instructions on chemical safety and give information, for example,
on identification of the substance, hazards related to the substance,
substance properties, first aid measures, fire fighting measures, personal
protection measures, toxicological information, environmental information
and information on storage, transportation and disposal.
After the drainage is completed, the recyclable parts can be separated from
the machine.

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2.11.3 Disposal
This section gives useful advice to identify which parts of the product are
recoverable, with a view to recycling or reusing the materials or
components for new applications. To ensure environmentally sound
treatment of a product and all of its components, the recovery issues are
already taken into account during the design phase of the product. Correct
handling of waste materials reduces costs and promotes the best use of the
components and materials.
• Machine 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.
• Plastic: 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 and tires: Tires can be recycled, and used as recovered
material. Worn-out tires can be returned to the dealer from whom they
were originally bought. Rubber tubes and hoses must be cleaned before
they are disposed of.
• Glass: Glass can be recycled, as well as laminated glass such as
windshields and windows. Various types of glasses shall be sorted
according to local rules and regulations.
• Electrical and electronic waste: Electrical and electronic components
contain valuable and recyclable materials, and in addition a set of
chemicals and heavy metals. 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. Never dump
hazardous electrical or electronic waste.
• Gas discharge / xenon lamps: Gas discharge lamps contain mercury
and are hazardous waste. They must not be dumped. Lamps must be
taken care of by an authorized hazardous waste disposal company.
• Air conditioning units: Air conditioning units, which contain CFC and
HCFC compounds, must always be delivered for treatment to a licensed
waste disposal facility.

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• Batteries: Batteries are classified as environmentally hazardous material

and require special handling and storing in accordance with applicable
ordinances, rules and regulations. Batteries can cause serious harm to
the ecosystem; lead in the batteries is highly toxic and it accumulates in
the body over time. The disposal shall be taken care of by an authorized
waste disposal company. According to producer responsibility, producers
of batteries and accumulators are also responsible to accomplish the
waste management of batteries that they have placed on the market.
Batteries also contain diluted sulphuric acid. The acid is extremely
corrosive and it burns skin, eats holes in clothing, and can cause
blindness if it gets in the eyes. If you get battery acid on your skin, or
clothes, rinse them immediately with water. Use sodium bicarbonate to
neutralize the acid. If it gets in the eyes, flush the eyes with water, and
call a doctor.
• Oils and fluids: Oil waste must not be disposed of by burning, and
under no circumstances must oil be poured down the drain or into water
systems. Waste oil shall be collected in appropriate containers. The best
containers for collecting oil waste are the original containers for the oils.
The original containers 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".
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.
Greases, fuels, solvents, and other substances must not be mixed with
oil waste.
• Solid waste containing oil: Oil filters, oil rags, fuel filters, and oil
absorbents must be collected in a separate container.
• Solvents and oil trap sludge: Solvents and sludge that has collected on
the surface of the oil traps can both be collected in a 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.
• Radiator, brake, and clutch fluids: 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.
2.12 Potential product related hazards identified by the user

Sandvik has taken all necessary precautions to design a safe machine. If,
in spite of these efforts, you observe a hazard for which you believe there
are insufficient safety measures, immediately inform your supervisor. If
necessary, also inform the other employees working with the product.
Report the hazard to your local Sandvik representative. Do not perform a
task if you are unable to perform the task in a safe manner.

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2.13 Incident reporting

Product safety issues to be reported are events where a product
manufactured by Sandvik Mining and Construction has been involved in an
accident or near-miss incident. Safety-related feedback, such as
unauthorized modifications, missing manuals and safety labels, negligence
of maintenance or misuse shall be reported to your local Sandvik
representative as well.
Reporting is mandatory to ensure safe working conditions for employees, to
provide information for the risk assessment process, and to initiate product
improvements.
Contact your local Sandvik representative to report safety issues, such as
those mentioned above.

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3 Machine Description

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3.1 Recommended operating conditions

Because the dump truck is intended to operate in underground mining
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.
3.2 Machine specifications
Machine dimensions
Total length 11570 mm 455 in
Maximum width 3200 mm 126 in
Height 3160 mm 124 in
Height of the box 3160 mm 124 in
Measured A-weighted emission sound pressure (At high idle 2000

level rpm)
At operator’s position, LpA [dB re 20 μPa] 74 dB
Uncertainty, KpA [dB] 3 dB
Driving
Whole body vibra- Driving
Loading Unloading without
tion with load
load
Maximum r.m.s. value
0,32 0,24 0,69 0,90
aw [m/s2]
VDVw over 15 min
4,02 3,72 8,37 7,73
period [m/s1.75]
Dump box motion times

Discharging time 14 sec

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Speeds forward (level / loaded)

1st gear 6.3 km/h 3.9 mph
2nd gear 9.5 km/h 5.9 mph
3rd gear 12.7 km/h 7.9 mph
4th gear 18.8 km/h 11.7 mph
Maximum gradient and tilt angle

15° upgrade
Maximum Gradient
15° downgrade
10° box up
15° unarticulated, box down
Maximum Tilt Angle
7° articulated, loaded, box down
10° articulated, unloaded, box down
Turning radius
Inner 5,0 m 200 in
Outer 9,4 m 370 in
Turning angle ± 44°
3.3 Main component locations
3 6 7
1 4 5 2 4
1 Front frame 2 Rear frame

3 Powerpack 4 Tires
5 Center hinge 6 Operator's compartment
7 Dump box

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3.4 Machine orientation

When referring to the unit in this manual, the front is the engine end of the
machine, the rear is the dump box end of the machine, and the right and
left sides of the unit are designated in reference to the operators seat,
looking toward the front of the unit.
1 2 3 4
Truck Orientation
1 Front 2 Right
3 Left 4 Rear

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3.5 Description of controls and functions

3.5.1 Instrument panel
2 3 4 11 12 13 14 15 16 17 18
1 10
5 20 19
6 7 8 9
21 22 23 24 25 26 27
1 Emergency stop button 2 Temperature controller

3 Fan speed controller 4 Air conditioning switch
5 Circuit breaker release 6 Brake release pump
7 Stop engine override 8 Emergency steering test (op-
tional)
9 Brake test 10 Window / mirror heater (op-
tional)
11 Weighing page / User zero- 12 Wiper intermittent potentiom-
ing eter
13 Window wiper 14 Window washer
15 Driving lights 16 Loading lights
17 Box counter 18 Hydraulic retarder
19 Ignition key 20 Parking brake control
21 12 V output connector 22 Connector for gear box diag-
nostics
23 Connector for engine diag- 24 24 V output connector
nostics
25 USB-connector for display 26 CAN-Open connector
programming
27 J1939 connector

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Switch functions
1. Emergency stop button

Pushing the button engages the brakes and shuts down the engine. Button
must be pulled out before starting the engine. The emergency stop state
appears also on the display.
2. Temperature controller
Controls the cabin temperature. See also the Air Conditioner manual.
3. Fan speed controller

Controls the air conditioning unit fan speed stepless from 0–100%. See
also the Air Conditioner manual.
4. Air conditioning switch

Activates / deactivates the air conditioning. The light on the switch indicates
the status of the air conditioning (the light is on => the air conditioning is on)
5. Main circuit breaker release

Open the transparent security cover and push the button to release the
main circuit breakers (e.g. in case of fire or sparking contact/electrical
malfunction). When the main circuit breaker release button has been
pushed down, you must open the front frame fuse box X2056 and reset the
main circuit breakers to supply the power back to the machine. Pressing
the main circuit breaker release button may cut the power to the
communication radio (optional).
6. Brake release pump

If the brake circuit pressure drops down by any reason, brakes can be
released using the electric (power from the battery) brake release pump .
(e.g. the unit can be towed to a safe location, see also the Towing section).
Start the brake release pump by pushing the button and holding it down.
Pull the parking brake control button fully out and release it to middle
position. The pump switches on/off and maintains brake release pressure,
until you release the button or the maximum pressure 140 bar (2030 psi)
has been reached. The brakes are released now. When the brake release
pump is used, the engine must be shut down, the ignition key must be in
the position 1 and the emergency stop must not be activated.
7. Stop engine override

Press to keep engine running for extra 30 s. in an engine malfunction
situation (the ECU is stopping the engine).

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8. Emergency steering (optional) test

The operation of the emergency steering pump can be tested by pressing
the button. The pump should start and the status symbol appears on the
main display . The test's duration is limited to ten seconds maximum. Test
with the ignition key in POSITION 1, engine not running.
9. Brake test
Test service and parking brake function.
10. Window / mirror heater (optional)

Press to switch on the window and mirror heater.
11. Scale view / Zeroing (optional)

Press shortly to change the display to the scale view.
Longer pressing starts zeroing the scale.
12. Wiper intermittent potentiometer

The interval of the wiper sweep can be set with a potentiometer. The
minimum interval is 2 seconds and the maximum interval is 12 seconds.
13. Window wiper

Press to switch on the window wiper.
14. Window washer

Press to switch on the window washer.
15. Driving lights

Press to switch the front and rear lights on/off.
16. Loading lights

Press to switch the loading lights on/off. The lights switch off during the
starting of the engine.
17. Box counter or Manual weighing / User zeroing (optional)

The box counter is on the display's main window (the box symbol and a
number).
The box counter value increases by one every time you press the box
counter button on the dashboard. The box counter can be reset by pressing
the button for more than two seconds.
With VCM integrated scale option: Short pressing starts manual weighing.
Longer press resets the user counters, box counters and total tons.
18. Hydraulic retarder

Switch to use the hydraulic retarder.

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Using the retarder saves you from having to make systematic use of your
service brakes, which therefore remain cold, available and efficient in
situations in which they are really needed - stopping the truck, emergency
braking, helping the retarder for speed control etc.
The retarder is controlled with a control switch on the dashboard. There are
four different retarding effects available:
• 25%
• 50%
• 75%
• 100%
19. Ignition key

The ignition key positions are:
• Position P. Not in use.
• Position 0. Machine power on. Shuts down the engine.
• Position 1. Machine power on. Front/rear lights can be switched on.
• Position 2. Not in use.
• Position 3. Starts the engine, returns to position 1.
Turning the main switch to the "ON" position switches the parking lights on.
20. Parking brake control

Pushing the button down engages the wheel/parking brakes.
Brakes engage also automatically, if
• Electric current is cut off
• Emergency stop is activated
• Engine stops
• Door is open
• Hydraulic oil level too low (engine shutdown)
• Brake oil level too low (engine shutdown)
• Accumulator pressure for the brakes too low
• Transmission oil pressure too low
• Gear in neutral with 3 seconds delay (Neutral brake)
To release the brakes pull the three position button fully up and release it to
the centre position (engine must be running and brake system pressure
high enough).
WARNING! CRUSHING HAZARD!
The cylinders linked to front axle are designed to return to default
position each time the parking brakes are released. The machine
movement could cause death or severe injury.
Clear the surroundings before releasing the brakes.

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21. 12 V output connector

Supplies 12 V output.
22. Connector for gear box diagnostics
23. Connector for engine diagnostics
24. 24 V output connector

Supplies 24 V output.
25. USB-connector for display
26. CAN-Open connector

Supplies information on Vehicle Control Management System.
27. J1939 connector

Supplies information on Vehicle Control Management System.

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Alarm and notice lights and display pop-up windows
1. Notice light yellow & 2. Alarm light red

These indicator lights indicate the state of the machine. Notice and alarm
lights are there to inform if any of the signals or measuring operations are in
notice or alarm conditions or if any kind of action is necessary. Whenever a
red or yellow indicator light is lit or whenever an alert 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.
3. Pop-up windows
The pop-up windows use big signs to indicate the reason for the alert, the
alert limit and the measured reading. Alerts 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 notice 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 notice or the alarm is active. If the notice 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 notice is indicated by an alarm bell in the main window and yellow
notice light. An active alarm is indicated by a ringing alarm bell and red
alarm light:
Symbol Explanation
Above or below the notice limits
Above or below the alarm limits

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All notices and alarms that have taken place will be marked in the alarm
log.
When going over from an alarm condition to a notice condition, the notice
window will not be shown in the display.
3.5.2 Cabin ceiling fixtures
2 3 4
1 Reverse camera LCD monitor

2 Ambient light
3 Cabin light
4 Stereo and audio equipment

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3.5.3 Inclination gauges
WARNING
ROLL OVER HAZARD!
Roll over of the machine could cause severe injury or death.
Do not exceed maximum permitted gradient angles shown in the
warning decal. On slippery surfaces, e.g. ice or smooth rock, safe
tramming gradients are much smaller than on surfaces with good
grip.
Cabin is equipped with two bubble level inclination gauges, one for
checking the longitudinal gradient angle and the other one for the lateral
gradient angle of the unit. Inclination gauge has two scales, the upper fine
scale for maximum 5 degrees gradient angles and the lower one for bigger
angles.
1 2
1 Inclination gauge for longitudinal gradient angle

2 Inclination gauge for lateral gradient angle
3 Warning decal for maximum gradient angles
1. Inclination gauge for longitudinal gradient angle

Shows the longitudinal gradient angle for the unit.
2. Inclination gauge for lateral gradient angle

Shows the lateral gradient angle for the unit.
3. Warning decal for maximum gradient angles

Shows the maximum permitted gradient angles for the unit.

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3.5.4 Monitor: Stonkam SV-MO700125DC
The monitor is connected to a camera on the machine that assists the

operator.
10
M S
1 2 3 4 5 6 7 8 9
Buttons
1. Light level sensor
2. Remote control sensor (not in use).
3. Power switch
4. Multifunction button
• Brightness increase
• Moving horizontally in the menu
5. Multifunction button:
• Brightness decrease
• Move horizontally in the menu
6. Multifunction button:
• Move vertically in the menu
• Turn the grid lines on / off
7. Menu
• There are four different menus. Move to the next menu by pushing
the menu button again.
8. Camera selector
9. Loudspeaker
10. Grid lines
• When the operator selects a reverse gear, the grid lines will
automatically appear on the reversing camera monitor.

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SCALE ADJUST (adjusting grid lines)

Push the buttons in the following order:
• Menu (7)
• Move vertically in the menu to SCALE ADJUST (6)
• Select vertical or horizontal grid adjustment (4)(5)
• Wait until the menu disappears
• Turn on the grid lines (6)
• Move the grid area (4)(5)
• Turn off the grid lines (6)
Go to SCALE ADJUST in the menu and select OFF.
Note! It is only possible to move the whole grid line area. It can not be
broadened or narrowed.
Note! The edges of the vehicle might be outside the grid line area,
depending on the size of the vehicle.
3.5.5 Box payload indicator lights
The box payload indicator lights (optional) are integrated to the VCM scale
and indicate the box loading status for the loader operator:
• Green light: Ready to load (<80% load)
• Yellow light blinking: Box almost full (80 % load)
• Yellow light: Box fully loaded
• Red light: Box overloaded (>110%)

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3.5.6 HJS ServiceCheck display module for DPF (optional)
2 3 4
1
5
1 The display 2 The yellow indicator lamp

3 The red indicator lamp 4 The blue indicator lamp
5 The pushbuttons
The display of the HJS ServiceCheck display module displays
instantaneous measured values, fault messages and display settings.
Constant illumination of the red indicator lamp indicates pre-alarm. Flashing
of the red indicator lamp indicates main alarm. The yellow and blue
indicator lamps indicate systems alarms. The pushbuttons are used to
navigate through the menu and to acknowledge alarm messages.
When the ignition is switched on, the yellow, red and blue indicator lamps of
the ServiceCheck display module light up for approximately 10 seconds.
The HJS Service Unit is then ready for operation.
Displayed in the actual display of the unit are functions assigned to each
pushbutton positioned immediately below. These functions depend on the
system's instantaneous operating state. The standard function displayed
above the left button is "Menu", while the other buttons are not assigned a
function. By pressing the "Menu" button, you open the submenus below it.
Note! If the three indicator lamps do NOT light up when the ignition is
switched on, there is a serious fault in the system. In this case, take
the vehicle to a specialist workshop immediately!

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Submenu functions
The display enables you to select from a range of different functions. By
pressing the right button, you scroll through the following submenus:
"Language", "Measured values" and "Service". Press the "Ok" button to
open submenu in which you want to make settings. The "Back" button
enables you to quit the menu currently displayed whenever you want.
Setting the language

Use the right pushbutton to scroll through the various versions available.
Once you have found the language you want, press the "Ok" button to set
it. Then quit the menu by pressing "Back" button.
"Measured values" submenu

This submenu contains a number of measured values that differ depending
upon the configuration of the system and that can be called up. To open
this sub menu, press "Ok" button.
Measured data can be displayed with the right and the left pushbuttons.
The "back" button enables you to quit the menu currently displayed.
Note! The driver/operator must monitor the display of the ServiceCheck
display module regularly. Increased temperature and/or exhaust
backpressure levels can cause serious damage to the system and/or
vehicle.
Alarm function
Alarm thresholds for exhaust Backpressure
The HJS ECU makes a distinction between two alarms: "pre-alarm" when
the lower pressure threshold is exceeded and "main alarm" when the upper
pressure threshold is exceeded.
"Pre-alarm" red indicator lamp lit constantly
If the lower alarm threshold is exceeded, pre-alarm is given and indicated
on the HJS ServiceCheck display module by means of the red indicator
lamp lighting up constantly. Pre-alarm remains activated until the pressure
falls below the threshold again.
Note! If pre-alarm is triggered, you should arrange for a filter service as
soon as possible.
"Main alarm" indicator lamp flashes

Main alarm is activated if the upper alarm threshold for the exhaust
backpressure is exceeded for longer than 5 seconds. Main alarm cannot be
deactivated automatically.
Note! If main alarm is triggered, a filter service must be carried out
immediately.

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Main alarm can be deactivated as soon as the exhaust backpressure drops

below the upper alarm threshold. This is done by pressing and holding the
"Ok" button for approximately 5 seconds, and the acknowledgement is
stored in chronological order in the fault memory. Pre-alarm remains
indicated by red indicator lamp as long as the lower alarm threshold
remains exceeded.
To return to the main menu, press the "Menu" button. This is acknowledged
by all three buttons flashing.
"Exhaust temperature window" yellow indicator lamp lit constantly
Constant illumination of the yellow indicator lamp indicates that the
temperature profile is not within the optimum range. The diesel particulate
filter can be "overload". To prevent this overloading of the particulate filter,
the engine must be run in the required temperature range (see the Diesel
Particulate System Operator's Manual).
Fault memory
If the HJS Service Unit registers one or more faults or indications, it
displays them in the form of numerical codes. These codes can be
displayed as plain text by pressing the "Ok" button. Further information on
the numerical codes can be found in the detailed fault list.
The right and the left pushbuttons can be used to display the faults as plain
text messages. Quit the menu by pressing "Back" button.
If no communication takes place between the HJS ServiceCheck display
module and the HJS ECU for approximately 5 seconds, a message is
displayed on the ServiceCheck module.

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3.5.7 Control levers and pedals
1 2 3 4
5 6 7 8
1 Multi switch 2 Steering wheel adjustment

3 Box control lever 4 VCM Display
5 Foot rest 6 Brake pedal
7 Throttle pedal 8 Gear range selector

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Brake and accelerator
1 2
The Brake pedal (1) is foot operated and is used to stop the dump truck.
Pressing the pedal applies the brakes and stops the vehicle. The brakes
will be released by removing your foot off the pedal.
Note! Transmission does not engage a gear, if the brake pedal is fully
pressed. For more detailed braking explanation, see section "Braking".
The Accelerator pedal (2) is also foot operated and is used to control the
engine or vehicle speed. Pressing the pedal increases, and removing your
foot off the pedal decreases the engine or vehicle speed. With certain
predefined engine speeds and according to selected range, the
transmission will upshift or downshift to another gear depending on
corresponding parameters increasing or decreasing the vehicle speed.
Box control lever
The box is controlled with the box control lever located at the right-hand
side in the dashboard. Turning the control lever upwards lifts the box and
turning the lever downward lowers the box.
The buzzer gives an audible signal when the box is in the up position (box
is not lowered on the stoppers).

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Ejector box control lever (option)
When the ejector box is installed, the tailgate and the ejector blade are
operated with the dump box control lever.
Emptying the ejector box

To empty the ejector box, push and hold the box control lever in backward
position.
When the tailgate is fully open, the ejector blade starts to move towards the
tailgate and empties the box.
The movement stops if the operator releases the box control lever at any
time of the emptying process.
Return mode for the ejector box

Manual or Automatic return mode for the ejector box can be chosen from
the VCM. In both modes the tailgate has to be fully closed before the
ejector blade starts to retract.
Manual mode
The operator has to hold the box control lever in forward position during the
whole return process.
The movement stops if the operator releases the box control lever.
Automatic mode
To start the return process the operator pushes the box control lever
forward once and then releases it.
If the operator wants to stop the return process, he pushes the box control
lever backwards once and the movement stops.
Note! The automatic mode only functions when the cabin door is closed.
Gear limitation during emptying the ejector box

Only Parking, Neutral and 1st gear forward and reverse can be used when
the tailgate is open.
When the tailgate is closed, all gears are available, even if the ejector blade
is still retracting.

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Gear range selector
WARNING!
If the machine starts to move without the operator, it could cause
death, severe injury or property damage.
Whenever it becomes necessary to leave the vehicle, even
momentarily, while engine is running, place the transmission shift
selector in N (Neutral), set the parking brake and block the wheels.
Note! Completely stop the vehicle before shifting from forward to reverse,
or from reverse to forward!
Gear range selector
The lever shift selector is an electro-mechanical control. The typical lever

positions provided are R (Reverse), N (Neutral), D (Drive) and some
number of lower forward range positions. This application has been
programmed to have six forward and two reverse ranges. The shift selector
positions provided should agree with the programming of the transmission
electronic control unit. The lever selector contains a hold override button, a
MODE button, a digital display, and a display mode button.

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A, HOLD Override Button

The lever shift selector has 3 locked positions to prevent accidentally
selecting R (Reverse), N (Neutral) or D (Drive). Select R N, or D by
pressing the hold override button and moving the lever to the desired
position. Once D (Drive) is selected, lower forward range positions may be
selected without pressing the hold override button.
B, MODE button
The MODE button may allow the driver to enable a secondary shift
schedule or other special function that has been previously programmed
into the electronic control unit. This particular application has a shift
schedule for empty and cold driving, when the shifting occurs with lower
revolutions. The MODE button can also be used to view diagnostic code
information. After viewing the first diagnostic code which appears in the
digital display, press the MODE button to view the 2nd diagnostic code
logged. Repeat this procedure to view 3rd, 4th and 5th code positions.
In case secondary mode is activated transmission program limits the
ranges following:
• Position D: ranges 3 to 6 are attainable
• Position 5: ranges 3 to 5 are attainable
• Position 4: ranges 3 to 4 are attainable
• Position 3: range 3 is holded
C, MODE Indicator
The diagnostic code displayed is active when the MODE INDICATOR is
illuminated.
D, Digital Display
Display shows the corresponding selected range, whenever the lever is
moved. During normal operation, when D (Drive) is selected, the digital
display shows the highest forward range attainable for the shift schedule in
use. Abnormal operation is also indicated by the digital display (e.g. All
Segments On, Blank Display, Cat-Eye). Conditions which illuminate the
CHECK TRANS light will disable the shift selector and the digital display
will show the range actually attained. The transmission will not shift into
range if a CHECK TRANS code is active. When the display shows either R
or D has been requested and the display is flashing, the requested range
has not been achieved due to an inhibit function. Some inhibit functions are
vehicle-related and will not result in diagnostic codes.
E, Display Mode Button

Allows access to diagnostic code information.

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Note! The gear indicator in control systems display is not same as Allison
digital gear display. Control system display only shows the gear that is
currently engaged.
For more detailed information look Allison Operator’s Manual.
Position R
Use this to reverse the vehicle. Completely stop vehicle before shifting from
forward to Reverse or from Reverse to forward. The reverse warning signal
and reverse lights are activated, and the digital display will display R when
Reverse is selected. Reverse has two ranges.
Position N
Use this position when you start the engine. If the engine starts in any other
position, the neutral start switch is malfunctioning. Neutral position is also
used during stationary operation (loading, dumping etc.) Do not allow your
vehicle to coast in neutral. This practice can result in severe transmission
damage. The digital display will show N when Neutral is selected. Always
select N (Neutral) before turning off the vehicle engine.
Position D
The transmission will initially attain first range when D (Drive) is selected
(except for those units programmed to start in second range). As vehicle
speed increases, the transmission will upshift automatically through each
range. As the vehicle slows, the transmission will downshift automatically.
The digital display will show the highest range available in D (Drive). The
highest possible speed to achieve in this application is restricted to 40
km/h.
Optional setup:
• When box load less than 20 tons the 3rd gear set as the lowest gear
• When box load over 20 tons all gears available
• In case MODE button activated the 3rd gear set as the lowest gear (load
information ignored)
Position 5
Occasionally, road conditions, load or site traffic conditions will make it
desirable to restrict automatic shifting to a lower range. The vehicle will
start in first range. As the accelerator is depressed, the transmission will
upshift to second, third, fourth, and fifth ranges automatically. As the vehicle
slows, the transmission will downshift to the correct range automatically.
Optional setup:
• When box load less than 20 tons the 3rd range set as the lowest
attainable
• When box load over 20 tons ranges 1-5 attainable

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• In case MODE button activated the 3rd range set as the lowest attainable
(load information ignored)
Position 4
Highest possible range when selected. As the vehicle slows, the
transmission will downshift to the correct range automatically and vice
versa.
Optional setup:
• When box load less than 20 tons the 3rd range set as the lowest
attainable
• In case MODE button activated the 3rd range set as the lowest attainable
(load information ignored)
Position 3
Automatic shifting to a lower range. When conditions improve, return the
shift selector to the normal driving position. These positions also provide
progressively greater engine braking effect (the lower the range the greater
the braking effect).
Optional setup:
• When box load less than 20 tons the 3rd range is held
• In case MODE button activated the 3rd range is held
Position 2
This is second range - use this when pulling through mud or driving up
grades.
Optional setup:
• When box load less than 20 tons the 2nd range is held
• In case MODE button activated the 2nd range is held
Position 1
This is first (low) range hold. No upshift will occur when the shift selector is
in this position. This position provides the greatest tractive advantage. It
also provides maximum engine braking effect. Use this range when
maneuvering in tight spaces, while driving up or down steep grades, or
when maximum output power is required.

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Multi switch
The multi switch located on the left side of the steering wheel has
operations for Turn signals, Hi/Lo beam switch, High beam sign, Horn and
both windscreen wipers and washers.
Turn the switch left or right to use the turn signals, pull the switch forward
for hi-beam forward lights and pull the switch second time for lo-beam.
Rotate the switch for wipers, and push the switch in for washers. Pushing
the button on the switch causes the horn to toot.
Steering wheel adjustment
1. Pull the steering wheel adjustment lever to elevate the steering wheel.
2. Push the adjustment lever to move the wheel forward or backwards.
3. Release the lever to lock the steering wheel to desired position.
3.5.8 Vehicle Control and Management System
Preface
This section introduces the Vehicle Control Management system.
The system is used with the display module’s five buttons. By pressing the
buttons, the user can move from one display window to another and adjust
the system’s functions and setting values.

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System architecture
6 4 12 5 16 10 11 8
1 14 2 9 15 3 13 7
Components of typical system

1 Front module 2 Middle module
3 Rear module 4 Dash module
5 Chair module 6 Display module
7 Engine Control Module 8 Transmission Control Module
(ECM) (TCM)
9 Tyre Pressure Measurement 10 ECM diagnostics
System receiver (TPMS)
11 TCM diagnostics 12 Gear select
13 Scale 14 Jacking control, THMI, CAN
controller
15 CANbus, CanOpen protocol 16 J1939, SAE J1939: vehicle
bus standard used for com-
munication and diagnostics
among vehicle components

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Information display
The information display helps you to monitor the operation of the machine.
Information presented on the screen allows you to use and adjust the
machine efficiently and economically, reducing the risk of failures and
downtime and increasing your work productivity.
Key information provided by the control system display include real-time
system information, such as temperature and pressure (presented in the
main view), alert history (Log) and productivity statistics (Counters).
2 3
1. The indicator row presents various events and alerts that require your
attention.
2. The main view provides real-time information related to your current task
and the machine. The information bar at the bottom of the screen allows
you to select what information you want to see: press to toggle

between different information sets.
3. The button labels on the screen are linked to the physical buttons at the
bottom of the display. Use the buttons to navigate in the user interface
and select items, for example.
You can always return to the main view from any other view by pressing
button 1 repeatedly.

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Using the information display

The user interface is controlled with five buttons labelled with numbers 1-5.
The actions linked to the buttons change according to the context. The
icons on the screen describe the current action.
For example, press and to navigate in the user interface, press
to open the Menu and press to access Log. Pressing
closes a view without saving changes and returns back to the

previous view.

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Tabs and navigation

The screen uses a tabbed structure to divide information. The currently
selected tab is highlighted with a blue color. You can move between
different tabs with the and buttons. Press to move the

highlight from the tabs to the content, such as a list.
When inside the content area, press and to move the blue
highlight on the screen. You can get back to the tabs again with .
Pressing on a highlighted element selects the element. For example,

you can view detailed information for an alert in Log by first highlighting the
alert and then pressing .

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The actions that are available depend on the highlighted element. For
example, pressing allows you to modify the element. Editing

commands depend on the element being modified: sometimes it means
selecting a pre-defined value from a list and sometimes modifying a value
with and buttons, for example. See the example below.

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Menu and navigation structure
Press to open the Menu. The Menu provides actions related to the
current view (left column) and access to functions such as Log and Settings
(right column). Press the arrow keys to navigate in the menu and access to
functions such as Log and Settings (right column). Press the arrow keys to
navigate in the menu and to select a menu item. Press to

close the menu without selecting any item.
The following figure presents the navigation structure of the user interface.
Different views can be accessed through the Menu by pressing .
Pressing takes you back to the previous view. Note that you can
check your current location in the hierarchy at all times from the navigation
path shown at the top of the screen:

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Navigation between views

The different views on the information display are connected via menus and
links. Access to some views is restricted to certain user levels.
The User roles are:
• Operator
• Maintenance (requires password)
The User role is changed via the following route:
• Main menu (via button 3)
• View actions
- Switch user
Main view
Button 1 toggles info bar.
Button 2 opens alert log.
Button 3 opens main menu.
Buttons 4 and 5 navigate the main view between drive, temperature,
pressure, brake and tyre info.
Navigation in Main menu

Operator level Maintenance level
Main view Main view
• Drive monitoring • Drive monitoring
• Temperature monitoring • Temperature monitoring
• Pressure monitoring • Pressure monitoring
• Tyres monitoring • Tyres monitoring
• AutoMine monitoring • AutoMine monitoring
View Actions View Actions
• Switch User • Switch User
• Help • Help
• Switch Light Mode • Switch Light Mode
• View Alert Limits • View Alert Limits
View content various, depends on View content various, depends on
the action the action

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Operator menu / Operator Operator menu / Maintenance

• Brake test • Brake test
• Counters • Counters
• Log • Log
• Troubleshooting Diagram • Troubleshooting Diagram
- Box - Box
- Brake - Brake
- Gearbox - Gearbox
- RPM - RPM
- Button/Function - Button/Function
• Settings • Settings
- Display - Display
- Language - Language
- Units - Units
- Display brightness - Display brightness
- User interface theme - User interface theme
- Machine - Machine
- Central lubrication cycle
- System
- Operator identification
- Date
- Time
• USB Data Transfer • USB Data Transfer
- Export alert log - Export Alert Log
- Backup Parameters
- Restore Parameters
- Open File Browser
• Machine Info • Machine Info
• Suspension Adjustment • Suspension Adjustment
• Scale • Scale

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Maintenance menu / Operator Maintenance menu / Maintenance

• Troubleshooting Diagram
- Box
- Brake
No access
- Gearbox
- RPM
- Button/Function
• Testing
- Brake Test
- Stall Test
- Central Lubrication Test
- Fuel Pump Test
No access - Engine Cooling Fan Pump
Test
- Steering Pump Test
- Fuel pump test
- ABA Test
- Fire Suppression test
- Camera Test
• Calibration
- Input Device Calibration
- Throttle Pedal
- Box Lever
- Tailgate lever
No access
- Sensor Calibration
- Install tyre sensor
- Install tyre receiver
- Axle suspension
- Retarder actuator

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Maintenance menu / Operator Maintenance menu / Maintenance

• Emergency control
- Door
- Engine
No access
- Drive
- Box/Ejector
- Tailgate
• Jacking control
• Browse system
- Modules
- CAN diagram
- Status
- File system
• Option Management
No access - List of options
• Parameter Management
- Parameter sets overview
• USB System Tools
- Install system software
• Install Spare Part
• Machine Identification

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Main view
The main view provides real-time information related to your current task
and the machine.
1 5
2 4
3
6
The gear indicator (1) indicates your current gear (blue highlight), the
current drive direction and the current drive mode (automatic/manual).
The fuel gauge (2) indicates the amount of current fuel in the tank.
The AdBlue gauge (3) indicates the amount of urea solution in the tank.
The RPM gauge (4) indicates the current engine usage. Avoid running the
engine in the red zone for extended periods of time, as this may damage
the engine.
The following tabs (5) are available:
• Drive view
• Temperature monitoring tab
• Pressure monitoring tab
• Brake pressure monitoring tab
• Tire pressure monitoring tab
The information bar (6) allows you to select what information you want to
see: press to toggle between different information sets. The following

sets are available:
• Machine speed and trip meters
• Engine and transmission hours
• Box counter
During the use of the machine, indicator symbols such as the following may
appear on the screen.

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These symbols are part of the normal operation of the machine. Refer to
the icon map for a description of the all symbols.
Box Box Fill- Box Fill- Box Up Engine Down- Emer- Pre-
Filling ing ing Al- Cooling hill gency heater
Ok Over- most Down Brake Steering
load Full Active

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Icon map
Icon Name Explanation
Infobar Infobar (toggles the infobar content in main view)
Log Log (when no alerts on the New tab)
Active notice One or more active notices.
Active alarm One or more active alarms.
Menu Menu
Modify Modify (used to edit values)
Move Up Move up
Move Down Move down
Increase Increase
Decrease Decrease
Reset Reset
Navi Left Navi left
Navi Right Navi right
Navi Up Navi up
Navi Down Navi down
Ok Ok
From Tab From tab

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Temporary Edit Temporary edit icon for rock type
Language Indicates path to Change Language setting
Led Red Red led or lamp on/off
Green led or lamp on/off. Used in troubleshooting views

Led Green
and for digital signal states in module I/O view
Def Grey Diesel exhaust fluid, DEF. Used with TIER4 engines
Def Diesel exhaust fluid, DEF. Used with TIER4 engines
AdBlue Low Warning light for low AdBlue level
Ad Blue Low day Warning light for low AdBlue level
Converter Lock Closed Converter lock closed indicator
Converter Lock Open Converter lock open indicator
Parking Brake Parking brake indicator
Danger24 Danger/Warning/Caution symbol for safety popups
The emergency stop has been pressed and the machine

Estop
has stopped
Expired emergency stop indicator for lists and alert de-
Estop Expired
tails
Turn Signal Left day Blinking turn signal indicator
Interlock The operation of the function to be used is blocked
Turn Signal Right day Blinking turn signal indicator
Turn Signal Right Blinking turn signal indicator
Turn Signal Left Blinking turn signal indicator

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High Beam Indicator for high beam light
High Beam day Indicator for high beam light
Estop Troubleshoot Emergency stop indicator for troubleshooting views
Gear In Neutral Gear in neutral
Cabin Door Open Indicates that cabin door is open
Transmission Oil Transmission oil
Parking Brake Parking brake indicator
Brake Charge Brake charge
Pedal Pressed Indicates that pedal should not be pressed
Engine Not Running Engine not running
Box Up Box up
Out Of Lubrication Out Of Lubrication
Power Power ON/OFF
Check mark for use as overlay on other icons (e.g. "cali-

Check Overlay
bration done")
Battery Battery charge or voltage
Fuel Grey Fuel icon for main view use
Fuel Fuel (general) or fuel level

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Box Up Box up
Lubrication Unit Lubrication unit
Hydraulic Pump Hydraulic Pump
Dump Truck Machine Time Machine time (hours)
Engine Rpm Engine rotational speed (revolutions per minute)
Engine Time Engine running hours
Engine Oil Engine oil (pressure and general use)
Engine Oil Temperature Engine oil temperature
Coolant Temperature Engine coolant temperature
Engine cooling down takes time. Can be used e.g. in an

Engine Cooling Down
indicator while engine is still too hot.
Brake Charge Indicates low brake pressure
Transmission Time Transmission time
Transmission Oil Transmission oil (pressure and general use)
Transmission Oil Tempera-

Transmission oil temperature
ture
Hydraulic Oil Hydraulic oil icon for general use
Hydraulic Oil Temperature Hydraulic oil temperature
Brake Oil Brake oil for general use
Brake Oil Temperature Brake oil temperature

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Turbo Turbo (pressure and general use)
Generic downhill brake icon, used for retarder and en-

Downhill Brake
gine brake
Emergency Steering Active Emergency steering active
Preheater Diesel preheat (engine start aid)
Tail Gate Open Tail gate open
Ejector Plate Out Ejector plate out
Axle Up Axle up
Engine Not Running Engine not running for troubleshooting diagrams
Engine Rpm Engine RPM for troubleshooting diagrams
Brake Cylinder Brake cylinder for troubleshooting diagrams
Engine Cooling Down Engine cooldown popup. Used e.g. in machine shutdown
Tyre Illustration for normal tyre pressure
Tyre Notice Illustration for tyre under pressure
Tyre Focused Illustration for focused tyre
Tyre Alarm Illustration for tyre leak

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Total Tonnage Total tonnage of loads
Tonnage Tonnage of a load
Total Distance Total distance and trip meter
Box Counter Number of loads
Box Increase To increase box counter
Box Filling Ok Box Filling degree
Box Filling Overload Box Filling degree
Box Filling Almost Full Box Filling degree
Shift Reset Shift reset
Load And Dump Point Loading and dumping point management
Zeroing Automatic zeroing
Scale Off Scale if OFF
Scale Error Scale error
Priviledged Account Lock icon indicates a priviledged account e.g. in login list
Locked White Indicates locked values and functions
If the duration is not known, spinner wait indication is

Spinner
used instead of progress bar
Various faults related to electric circuits. Often related to

Elecric Circuit Fault I/O pins, can be shortcuts or wire cuts, voltage problems
etc.
Unknown Unknown (used for unrecognized alarms and events)
Wizard Step Completed Indicates completed steps in wizards

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Wizard Step Failed Indicates failed steps in wizards
VCM Display Display for troubleshooting diagrams
Hydraulic Pump Hydraulic pump for troubleshooting diagrams
Remote Control Icon for remote control use with wire
Electrically controlled hydraulic valve for troubleshooting

Electric Valve
diagrams
VCM Module VCM PLC module for troubleshooting diagrams
Pedal Brake or accelerator pedal
Gear Box Gear box for troubleshooting diagrams
Gear Selector Gear selector for troubleshooting diagrams
Disabled version of VCM PLC module for troubleshoot-

VCM Module disabled
ing diagrams
Feedback Positive feedback popup
Question Question or confirmation popup

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Information Information popup
Tilt Wheels Hazard Roll-over hazard for safety popups
Crushing Crushing hazard for safety popups
Dump Truck Top Profile

Top profile for small dump truck
Small
Flip Lever Move and release the lever
Pedal Press / release pedal
Checkmark Blue "Ready (to proceed)"
Checkmark Grey "Ready (to proceed)".
Used as an indicator in emergency control dump truck il-

Emergency Control Up
lustrations
Emergency Control Left
lustrations
Emergency Control Right
lustrations
Emergency Control Down
lustrations

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Cabin Door Door is open / closed
Pedal Release Indicates releasing the pedal
Indicates pressing the pedal

Pedal Press Down
down
Detach the fire suppression

Detach Cable
cable
Attach the fire suppression ca-

Attach Cable
ble

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Filling Empty Filling degree: Empty
Filling Loading Filling degree: Loading
Filling Almost Full 1 Filling degree: Almost full
Filling Ok Filling degree: OK
Filling Overload Filling degree: Overload
Box is not in weighting posi-

Lower Box
tion: lower box

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Loading Instructions Loading Instructions
Wait Indicator Wait indicator
Dump Truck Profile Dump truck profile
Dump truck top profile without

Dump Truck Top Profile
tyres
Dump Truck Top Profile Dump truck top profile without

Red tyres

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Dumper Emergency Steer-

Driving the dump truck
ing Drive

Moving the dump truck box
ing Box

Moving the dump truck ejector
ing Ejector
Dumper Emergency Steer- Moving the dump truck tail-

ing Tail Gate2 gate
Dumper Emergency Steer- Moving the dump truck tail-

ing Tail Gate gate
Sandvik Logo Sandvik Logo
Reacting to notices and alarms

If the machine control system detects an important event, the system
generates a notice or an alarm. These can be caused by, for example, high
temperatures or pressure, broken cables or short-circuits in the electrical
system.
If a notice or an alarm is displayed, proceed as follows:
1. Check the severity.
• Yellow notices may not require immediate actions, but you should
investigate the reason especially for repeated notices.
• Red alarms require your immediate attention: stop working
immediately and correct the error situation.
2. Follow possible on-screen instructions or go to the Log to read more
about the cause of the alert and possible troubleshooting instructions.
3. Correct the error situation.

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Alert symbols
The following symbols are used to present notices and alarms:
No active notices or alarms.
One or more active notices. Notices are medium level alerts that
do not require your immediate attention or block the use of the
machine. However, you should check the reason for the alert, es-
pecially if the alert persists.
One or more active alarms. Alarms require your immediate atten-
tion. Stop using the machine, check the reason for the alert and
correct the situation.
The emergency stop has been pressed and the machine has
stopped. You can continue working only after all emergency stops
have been released and safety ensured.
The operation of the function you are trying to use is blocked. The
blocked state is resolved automatically after the cause of the er-
ror is removed.
The alerts are shown on the right side of the indicator bar at the top of the
screen. The symbol indicates the severity of the alert. The following
example presents an active alarm.
Note that a physical lamp mounted to the machine also indicates alerts. An
orange light indicates active notices and a red light indicates active alarms.

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Log
Log allows you to view current and history data (such as problem duration,
frequency and measurement value and associated limit value) about alerts
during the use of the machine. This information helps you to assess the
seriousness of the error and to decide actions needed for correcting the
problem, such as ordering service for the machine.
Press to access Log.

Alerts are listed in chronological order with most recent alerts shown on
top. The New tab lists active alerts and expired alerts that have not been
previously displayed.
Browse the alert list to view additional information on the alert. Date and
time define when the alert situation started. The counter tells you how many
times the alert has occurred, which helps to evaluate the seriousness of the
alert: high frequency calls for further inspection of the alert cause. Alert
code is a reference number that can be used for finding alert information
from the machine operator manual.
For more information, open alert details by pressing . Alert details

view contains instructions for recovering from the alert and alert details.

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Alert pop-ups
Some of the alert notifications are presented as pop-up dialogs on the
screen. The pop-up dialog remains on the screen until you have read it and
close the dialog. There can be several alert pop-ups at the same time.
Note! Some alerts, like some concerning the Allison gearbox, disappear
only when the operating temperature has raised to a certain level.
• Pressing closes the foremost pop-up, pressing closes all pop-
ups.
• There are different types of alert pop-ups:
• The Alarm pop-up dialog (red) is displayed when the machine control
system detects a major problem.
- Alarms require your immediate attention and action in order to
prevent damage to the machine components.
- The control system may stop some or all machine operations during
an Alarm.
- Do not use the machine before the cause of the Alarm is resolved
and corrected.

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• The Notice pop-up dialog (yellow) is displayed when the machine control
system detects a medium problem.
- This does not require immediate action from you.
- If the alert persists or is repeated often, the reason for the alert
should be investigated and corrected.
• The Blocked pop-up dialog is displayed when the machine control

system prohibits you from performing an action that could cause personal
injury or damage to the machine.
- The pop-up disappears automatically after the cause of the error is
removed.
- The blocked state may be caused by an open door, for example.

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• The Emergency Stop pop-up dialog is displayed when one of the

emergency stops have been activated.
- The machine engine will automatically stop and all machine
operations are stopped.
- Resolve the reason why the emergency stop was activated before
continuing the use of the machine.
USB data transfer
The USB data transfer view opens automatically after inserting a USB drive
into the USB port. You can also open the view from the Menu when a USB
drive is available. Use and to navigate the view and

to select an action. Then follow the on-screen instructions.
Note that USB data transfer actions for individual views may also be
available in the Menu.

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3.6 Operator's seat

3.6.1 General instructions
Read through the operating instructions before using seat and keep it in the
machine and always at hand.
The operator seat may only be fitted, serviced and repaired by specialist
personnel, in accordance with national regulations and the machine
manufacturer’s fitting instructions. In the event of incorrect assembly and/or
repair, all warranty and liability claims shall be null and void. The fitting
regulations can be obtained from Sandvik Mining and Construction.
The functional checks of seat should be carried out at least as regularly as
machine services.
A correctly functioning and individually adjusted operator seat is essential
to your health. Take adequate care of your seat and have it serviced
regularly to ensure that it functions correctly.

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3.6.2 Safety instructions

Sandvik Mining and Construction can provide no guarantee for damage
resulting from incorrect assembly, use or repair of the operator seats.
If you make any changes to the standard seat (for example fitting parts
which are not original Sandvik Mining and Construction parts) it may no
longer meet the safety standards to which it is tested. Functions may be
impaired, threatening your safety. For this reason, any change in design of
the seat must be approved by Sandvik Mining and Construction
Check seat
To eliminate any risk of accident and injury seat must be check. If the seat
does not function correctly or malfunctions are detected the machine must
not be drive before they are repair. Contact a specialist workshop
immediately to arrange for repairs to be carried out.
Check every time before driving the machine:
• The function of any switched fitted in the seat.
• Ensure that settings are correctly engaged.
• The moving area of the operator seat are empty and there isn't any
objects.
Check regularly :
• Tightness of fasteners. If the seat wobbles there may be loose bolts or
other faults.
Seat adjustment
Do not made adjustments while driving.
Incorrectly adjustment can cause damage to the operator's back. The seat
must be adjusted for the operator’s weight before use and before every
change of operator.
Backrest
When the backrest upholstery has been removed, the backrest frame must
be supported, for example held in place, before the backrest adjuster is
operated. If you fail to do so, there is a danger that the backrest frame may
jerk forward and cause injury.
Seat belts and seat belts fitted
Use always seat belts when operated machine and fastened they before
start up engine to prevent injury.
The seatbelts must be replaced after an accident. Where seat belts are
fitted to the operator seat, the seat and seat mounting must be checked
additionally by specialist personnel after an accident has occurred.
Seat belts can be refitted to the operator seat. Seat belts may only be fitted
on the approval of the machine manufacturer, as they increase the load in
the seat mounting area. Seat belts must be fitted in accordance with
specific national regulations and guidelines, and must be approved by
Sandvik Mining and Construction.

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Seat with a built-in switch

Seats with a built-in switch (to deactivate component units when leaving the
seat or the machine) may only be installed with the prior approval of the
machine manufacturer, and may only be operated together with additional
safety devices in the machine.
For minimize risk of accident not be place any loads, except for the
operator's weight during normal use on the seat, when used seats with a
built-in switch. Otherwise machine may start to move by itself.
Electricity
When making connections to the machine electrical system, pay attention
to the information on the rating plate (on the rear spring; push seat right
forward to read). The seat connection must be separately fused:
• at 24V 10A (15A at seat heater)

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3.6.3 Seat functions and operation
10
7
11
5
3 12
2
1
13
1 Weight & height adjustment 2 Fore/aft adjustment

3 Absorber adjustment 4 Seat pan angle adjustment
5 Seat depth adjustment 6 Armrest adjustment *
7 Armrests * ** 8 Seat belt
9 Head rest * ** 10 Lumbar support adjustment
11 Backrest adjustment 12 Left/right adjustment
13 Fore/aft isolator
*) if fitted
**) optional extra
Fore/aft adjustment
1. Lift the locking lever to move the seat forward or backward.
• NOTE! 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.

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Left / right adjustment

1. Lift the locking lever to move the seat left or right.
• NOTE! 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.

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Backrest adjustment
1. Sit down on the seat or hold the backrest with hand.
2. Adjust the backrest by using the locking lever.

3. Make sure that the locking lever latches into the desired position
• It should not be possible to move the backrest into another position when
it is locked.
Absorber adjustment
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 (recommended)

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Fore/aft isolator
1. To activate the fore/aft isolator turn the knob to the position 1.
• This means that shock impacts in the driving direction can be better
absorbed by the operator seat.
• Position 1 = fore/aft isolator on
• Position 1 = fore/aft isolator off
2 1
Weight adjustment
To avoid injury, the setting for the operator's weight must be checked
and adjusted always before the machine is driven.
Note! Before adjusting the weight, adjust shock absorbers to the position
"soft".
1. Adjust the seat suitable for your weight by pulling briefly the actuator
lever of the automatic height adjuster.

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• This must be done with the machine at a standstill and the operator
sitting absolutely still on the seat.
Height adjustment
NOTICE Do not use compressor for more than 1 minute to avoid damage.
The seat height can be set pneumatically and is infinitely adjustable.

1. Chance the seat height by pulling or pressing the actuator lever fully out
or in (arrow).
• If the adjustment reaches the top or bottom end stop, the height is
adjusted automatically in order to guarantee a minimum spring travel.
Seat pan angle adjustment

The angle of the seat pan can be individually adjusted.
1. To adjust the angle of the seat pan, lift the L/H handle (see arrow).
• Now the seat pan angle can be adjusted to the desired position.

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Seat depth adjustment

The depth of the seat pan can be individually adjusted.
1. To adjust the depth of the seat cushion, lift the R/H handle (see arrow).
2. Move the seat cushion backwards or forwards to reach the desired
seating position
Lumbar support adjustment

1. Adjust both the height and curvature of the backrest cushion individually
by turning the adjustment knob to the left or right.
• This increases both the seating comfort and the performance of the
operator.

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Armrests adjusting
1. Remove the cover cap (see arrow).
2. Loosen the hexagon nut.

3. Adjust the armrest to the desired position.
4. Tighten the nut.

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5. Turn the adjustment knob to modify the angle of the armrests.
Upholstery cleaning
Take care with the backrest frame when removing it - backrest may
jerk forward and cause injury.
1. Keep your set clean, because dirt can impair the function of the seat.
2. Upholstery can be quickly and simply removed from the seat frame for
easy cleaning, or replacement.
3. During cleaning the upholstery should not be soaked through.

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4. Use a standard commercially available upholstery or plastics cleaning

agent.
• First test the suitability on a small, concealed area.
3.7 Trainer's seat

Trainer's seat is intended to be used only in training situations. The seat is
not intended for a continuous use.
The seat is equipped with a three-point seat belt. Fasten the seat belt
before engine start up and keep it fastened always when the machine is
being operated.

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3.8 Circuit breakers

3.8.1 Location of circuit breaker boxes
Note! Ensure main electric switch is off when re-setting circuit breakers.
1. Instrument panel in the cabin

2. Box X2021 at the left side of the articulation area
3. Box X2056 at the left side of the front frame

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3.8.2 Circuit breakers descriptions and values

Circuit breakers in instrument panel and boxes X2021, and X2056 protect
electric items in the case of overload or short circuit. Circuit breakers
cannot be held in the ON position against overload by force. If circuit
breaker, after it has triggered, cannot be switched to ON position again, the
triggering is probably caused by overload. If the circuit breaker trips again
immediately when trying to close it, a complete short-circuit or earth
connection can be assumed. Do not try continuously re-close circuit
breaker if there is an existing short circuit, earth fault, or fault in wiring or
some component. In that case the electrical wiring and components must
be examined. Triggering of the circuit breaker can be caused also, for
example, temporary and/or transient disturbance in electricity distribution.
In that case, the circuit breaker is reset and the situation monitored in order
to determine whether the disturbance is recurring. Circuit breaker blown
gives separate alert in the display.
Circuit breakers F2035, F2060 and F2064 in box X2056 have a push button
that pops up when the circuit breaker is triggered. After clarification of the
fault situation, the circuit breaker can be reset by pushing the button back
down. These circuit breakers have also dual button manual release. Other
circuit breakers in instrument panel and boxes X2021, and X2056 are
switched on by switching the operating lever into the upper position (with
respect to the text block of the nameplate). After clarification of the fault
situation, the circuit breaker can be reset by turning the lever back to the
correct position.
Instrument panel in the cabin
F0024 F0137 F0130

F0020 F0220
F0074 F0127
F0005 F0088
F0089
F0056 F0021
F0052 F0140
F0007 F0139
F0116 F0075
F0053 F0071

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Fuse ID Description Capacity

F0005 +24V Auxiliary voltage for leds etc. 10 A
F0074 Seat compressor supply M1117 10 A
F0020 Wiper motors M1009, M1010 and M1011 supply 10 A
F0024 Window / mirror heating supply 16 A
F0137 Emergency stop supply 4A
Automine Remote Monitoring & Ethernet Switch
F0130 10 A
supply*
F0220 +24V Reverse camera supply 10 A
F0127 +24V Power outlet socket 10 A
F0088 Automation 16 A
F0089 Automation cooling 16 A
F0056 Cabin front corner light supply E1056* 10 A
Loading and rear cabin corner light E1024 and
F0052 10 A
E1027 supply, camera control
F0007 Scale and stereo supply 10 A
F0116 Emergency radio supply 6A
F0053 VCM display supply 4A
F0071 Chair module supply 10 A
F0075 Dash module supply 10 A
F0139 Transmission control supply 10 A
F0140 Gear selector supply 4A
F0021 Air conditioning (A/C) supply 16 A
* Optional

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Box X2021 at the left side of the articulation area
F2062 F2008 F2073

F2144 F2141 F2086
F2050 F2023 F2143

F2002 F2072 F2085

F2062 Brake release pump supply M2018 100 A
F2050 Hydraulic oil filling pump M2019 25 A
F2144 Fuel transfer pump M2057 25 A
Rear lights, above tanks, E2026, E2040 and
F2002 10 A
E2057*
Rear lights E3022 and E3023, directional lights
F2008 10 A
E3031* and E3032*
Retarder lights (brake) E3048* and E3049*, re-
F2023 10 A
verse warning horn H3002
Pilot pressure valve, emergency steering pump
F2141 control M2020 and brake release pump control 10 A
M2018
F2072 Middle module supply 10 A
F2073 Rear module supply 10 A
F2143 Tire pressure monitoring 4A
F2085 Box position and steering sensors supply* 4A
* Optional

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Box X2056 at the left side of the front frame
F2230 F2059 F2007 F2038 F2046 F2076
F2098 F2022 F2001 F2047 F2142 F2134
F2035 F2060 F2064

DC/DC converter G0012, communication radio, fire
F2230 25 A
suppression
F2059 Instrument panel supply 32 A
F2098 Instrument panel supply 2 32 A
Front lights, high beam, E2005 and E2006, Step
F2022 10 A
lights, below cabin E2036
F2007 Front lights, above tank, E2025 and E2061* 10 A
Front lights E2003 and E2004, directional lights
F2001 10 A
E2028* and E2029*
Signal horn H2001, washer front M2012 and wash-
F2038 10 A
er side/rear M2013
Engine control module, ECM supply, engine start
F2047 16 A
Cummins
F2046 Engine control module, ECM supply 16 A
F2142 Window/mirror heating supply 10 A
F2076 Front module supply 10 A
F2134 Jacking system remote control* 4A
Main fuse. Main switch S2001, battery G2004 and
F2035 400 A
jump start

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Box X2021 supply, Engine lubrication pump (Cum-
F2060 150 A
mins) M2056
F2064 Box X2056 supply 150 A
* Optional

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4 Operation Instructions

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4.1 Starting procedure

4.1.1 Turn the main switch to the "ON" position
WARNING
PERSON IN HAZARD ZONE!
Turning the main switch on while the danger/service tag is attached
could cause death or severe injury.
Do not switch the main switch on if there is a danger/service tag
attached.
1. Unlock the main switch.
2. Turn the main switch to the "ON" position.

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4.1.2 Close the suspension discharge valve

2. Close the suspension discharge valve (1) by turning the tap clockwise
3. Close the locking cover (2) of the suspension dischage valve and lock it
with the locking pin.

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4.1.3 Open the fuel lines shut off valve

1. Make sure that the fuel line shut off valve is open, i.e. the valve handle is
in vertical position.

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4.1.4 Getting into the cabin

WARNING!
Do not grab any control devices when climbing into the cabin.
Use only grab handles and foot steps as climbing assistance.
1. Open the door.

2. Make sure that there is no clutter on the floor when entering into the
cabin.
3. Use grab handles and steps provided to maintain 3 points of body
contact with the machine while entering the cabin.
4. Close the door.

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4.1.5 Activate brakes

1. Activate brakes by pushing the brake control button in.

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4.1.6 Check fuel level

1. Check fuel level at the VCM-system display.
The fuel gauge is in the main window on the left side.
The arrow shows the fuel level.
The symbol of the gauge flashes if the fuel level is low, refuel
immediately.
2. Stop the engine and refuel the machine as necessary.
4.1.7 Starting the engine
Always make sure before starting that there are no unauthorized
persons in the danger areas, and that no controls are in the
operating position.

The starter motor will be damaged if it will be run for more than 20
NOTICE seconds at a time.
Allow the starter motor to cool down for one minute before a new
starting attempt.
Note! Do not use throttle until engine starts.
1. Turn the ignition key to “START” position.

• There is a delay before the engine turns.
2. Let the key return to the ”POWER ON” position when the engine starts.

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4.1.8 Switch the lights on

1. Press to switch on the front lights (1).
1 2
2. Press to switch on the loading lights (2).

• The lights switch off during the starting of the engine.
3. Switch the low/high beam lights on.
• High beams can be turned on from the combination switch.
• If the light switch is not activated, the high beams cannot be switched
on.
4.1.9 Check that the controls are functioning correctly

NOTE! When testing box functions, ensure sufficient height of the area.
1. Articulate the machine from left to right.
2. Raise and lower the box.

3. Check the gear selector functioning.

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4.1.10 Check that all the controls are functioning correctly (Ejector box)
1. Articulate the machine from left to right.
2. Test the operation of the ejector and the tailgate.
• Check that the tailgate raises and lowers.
• Check that the ejector moves outwards and inwards.
3. Check the functioning of the gear selector.

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4.2 Using driving controls

4.2.1 Setting unit in motion
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.
Never leave the vehicle running unattended.
In case of malfunction, stop immediately and safeguard the vehicle,

have the malfunction immediately repaired.
• Observe the alarm and warning lights and display pop ups.
• Make sure that there are no active alerts. Look in the chapter, where the
display function is explained!
• Note that some VCM system alerts, like some concerning the Allison
gearbox, disappear only when the operating temperature has raised to a
certain level.
• Do not let the engine idle unnecessarily. Always select Neutral during
engine idle operation.
• Do not let any persons in the box area, make sure that nobody is
endangered before starting/driving/operating the dump truck.
1. Fasten the seat belt and always have the seat belt fastened when
operating the dump truck.
2. Press the brake pedal (1) lightly.
3 1 2

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3. Release the parking brake by pulling the button.

• Ensure the red indicator light located in the same button does not
start to illuminate.

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4. Select the desired range.

• With the position of the lever shift selector you can determine
appropriate direction and range.
• The machine has six forward range, automatic forward drive (D),
neutral (N) for stationary operation and two range for reversing (R).
• Note! Transmission does not engage a gear from Neutral position, if
the parking brake is applied, or the brake pedal is fully pressed.
• Note! If the gear is not selected during 3 seconds after parking brake
has been released, the parking brake will engage again
automatically.
• 1 - Use this range e.g. while driving up or down steep grades, or when
maximum output power is required.
• 2 - 5 - Use these ranges, when road conditions, load, or site traffic
conditions will make it desirable to restrict automatic shifting to a lower
range.
- Lower ranges provide greater engine braking for going down
grades (the lower the range, the greater the braking effect).
• N - is a Neutral range. Use Neutral when starting the engine, to check
vehicle accessories, and for extended periods of engine idle operation.
Always select N when you have stopped the vehicle as well as before
turning off the engine.
• D - is an automatic forward Drive. Transmission upshifts automatically
through each range when speed increases and vice versa as the
vehicle slows, the transmission will downshift automatically. When D is
selected, the digital display shows the highest forward range attainable
for the shift schedule in use.
- When box load less than 20 tons the ranges 3rd to 6th are
attainable
- When box load over 20 tons all ranges are attainable
- In case MODE button is activated the ranges 3rd to 6th are
attainable (load information ignored)
• In case secondary mode is activated transmission program limits the
ranges following:
- Position D: ranges 3 to 6 are attainable
- Position 5: ranges 3 to 5 are attainable
- Position 4: ranges 3 to 4 are attainable
- Position 3: range 3 is holded
R1, R2 - are a Reverse ranges. Completely stop the vehicle before
connecting Reverse.

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5. Release the service brakes (1) and press the accelerator (2) evenly so
the machine begins to move.
3 1 2
If you just downshift or just use service brakes when going downhill,
you can lose control and cause injury and property damage. To help
avoid loss of control, use a combination of downshifting, braking
and retarding. Selecting a lower range increases engine braking and
helps you to maintain control.

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4.2.2 Braking
OVERHEATED BRAKES!
Driving with foot on the brake pedal causes overheating of the brake
NOTICE system and early wear or brake failure. If the brakes are overheated
the brake force might be lost!
Never drive with your foot on the brake pedal. Use the foot rest.
1. Press the brake pedal (1) to apply brakes to slow down or stop the
machine.
• The brake pedal is foot operated and is used to stop the machine.
• By pressing your foot on the pedal, the brake will apply and stop the
machine.
• The harder you press the pedal, the quicker the dump truck will stop,
and the greater the braking effort.
2. Removing your foot off the brake pedal, the brake will be released and
the machine will move.
• Use the foot rest (2), when driving the machine.
3. Brakes are also being activated automatically if one of the following
conditions is met:
• Electric current is cut off
• Emergency stop is activated
• Engine stops
• Door is open
• Hydraulic oil level too low (engine shutdown)
• Brake oil level too low (engine shutdown)
• Accumulator pressure for the brakes too low
• Transmission oil pressure too low
• Gear in neutral with 3 seconds delay (Neutral brake)
A sudden stop can cause personal injury. Observe the gauges and
indicators often and obey their signals.

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4. Use retarder and engine brake if available on the unit.

• Correct use of the retarder and the engine brake saves the service
brakes from wearing and overheating.
• For more information refer to the chapter Downhill driving.

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4.2.3 Parking
Never park/stop the dump truck where it may block traffic.
1. Try to park/stop the dump truck on level ground.

2. If it is impossible to park on a level ground, turn the machine against the
wall.
• Refer to the attached picture.
3. Put the transmission into neutral.

4. Release brakes.
• If the machine does not move, you are parked safely.
5. Apply the parking brake.
• Indicator light comes on.
• NOTE! Do not use the door interlock to apply the parking brake, use
the brake button.

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During long engine idling periods with the transmission and box
control lever in neutral, the engine coolant temperature may fall
NOTICE below the normal operating range.
Avoid long engine idle periods. When prolonged idling is necessary,
maintain at least 850 - 1000 rpm.
Never park the machine on a gradient resting on the brakes only.
Don’t leave the unit unattended unless the machine is safely parked,
brakes are set on and the engine is shut down.

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4.2.4 Stopping the engine

Note! In dangerous situations the engine can also be stopped with one of
the emergency stop buttons.

During long engine idling periods with the transmission and box
control lever in neutral, the engine coolant temperature may fall
NOTICE below the normal operating range.
Avoid long engine idle periods. When prolonged idling is necessary,
maintain at least 850 - 1000 rpm.

Stopping the engine by turning the main switch off may damage the
NOTICE alternator or the voltage regulator and the machine electronic
equipment.
Never turn the main switch off when the engine is running.
Fill the fuel tank at end of each day’s operation to prevent

condensation from contaminating the fuel.
Don’t leave the unit unattended unless the machine is safely parked,
brakes are set on and the engine is shut down.
1. Apply the parking brake.

• Indicator light comes on
2. Run the engine at low RPM with no load for at least 5 minutes. Let the
engine return to idle.

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3. Turn the ignition key to the 0-position to shut down the engine.
• Note! In case the delayed engine shutdown is active, the engine will
run until time set by parameters is up. Pop-up window informs the
timer status. If you open the door or activate the emergency stop, the
engine will stop immediately.
4. Turn the main switch off.

• Wait 90 seconds after shutting down the engine to protect the urea
dosage injector (if equipped).

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5. Close the fuel tank shut-off valve.

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4.3 Operating the machine

4.3.1 Hauling
DANGER
RUN OVER HAZARD!
Being run over by a machine will cause death or severe injury.
Make sure that there are no unauthorized people in the hazard zone
when the machine is being operated.
Unit malfunctions must be repaired immediately!
Keep all the safety and the danger signs on the machine in legible
condition, observe and follow them.
Do not start dumping full loads until the engine and hydraulics are
warmed up to the operating temperature.
Note! This dump truck is intended to transport and dump rock material
exclusively. Any other use different from this is not considered as
intended.
Note! Pay attention to the safety regulations and policy.
This chapter includes important references to the safe, competent and

economical operation of the machine. These references help to avoid
possible danger, to reduce repair costs and breakdowns, and to increase
reliability, lifetime and productivity of the dump truck. This manual must
permanently beavailable in the cabin when operating with the unit.
• 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.
• Never load the dump truck until the engine, transmission and hydraulics
have warmed up to the operating temperature.
• Off-center loads affect the truck's stability. Inform the operator of the
loader in case of off-center load. Be careful when handling off-center
loads which cannot be centered, especially when cornering and driving
on slopes.

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1. Use appropriate gear during operation.

2. Select the desired range according to corresponding driving speed and -
base.
• See the section of this manual where the gear range selector
operation is explained.
Uphill driving
1. Select the correct range for each driving condition manually with shift
selector.
• While upgrading, when maximum output power is required it might
be desirable to restrict automatic shifting to ranges 1 - 5.
2. Always remember to follow the tachometer, speedometer and
transmission temperature while driving.
3. Center the load on the box as well as possible.
4. Check the load weight from the load monitoring device (opt. ) .
• Avoid overloading, and inform the operator of the loader about
possible overloading.
The machine has an automatic torque converter lock-up capability. The

lock-up clutch is designed to engage and disengage at predetermined
equipment speeds in response to electronic signals from the ECM. When
engaged, the lock-up connects the engine directly to the transmission
gearing.

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Downhill driving
1. Select a gear which allows you to drive without unnecessary braking.

• Do not “rest” your foot on the brake pedal because it causes warming
in the brake system.
• As a general guideline, when driving downhill, select the same gear
that you would use if driving uphill.
• Select the gear so that the engine revolutions are close to the
maximum.
2. Always use the hydraulic retarder when driving downhill.
• Correct use of retarder saves the service brakes from wearing and
overheating.
• The hydraulic retarder is used to slow the vehicle on curves or
downgrades.
• The retarder is controlled with a control switch on the dashboard.
There are four different retarding effects available:
- 1=engine brake
- 2=engine brake +1/3 retarder

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3. The retarder connects, when the retarder switch is in position 1-4 and
accelerator pedal is fully raised.
• Automatic retarder control (optional)
- In the automatic retarder control mode the retarder is controlled
automatically by the machine VCM to prevent machine engine of
overspeeding regardless of the retarder switch position.
- The retarder connects, when the retarder switch is in position 1-4
and accelerator pedal is fully raised.
- if engine revolutions keep rising the effect is increased
gradually:
- - 2050 rpm: 50 %
- 2100 rpm: 75 %
- 2150 rpm: 100%
RPM at factory default settings
- Switch in 0-position:
- if engine revolutions rise over 2000 rpm while the accelerator
pedal is raised, 25 % retarding effect is connected
- if engine revolutions keep rising the effect is increased
gradually:
- - 2050 rpm: 50 %
- 2100 rpm: 75 %
- 2150 rpm: 100%
RPM at factory default settings
• The retarder connects every time, when the engine or the whole
vehicle is overspeeding (engine rpm >2200 rpm) (RPM at factory
default settings) regardless of the accelerator pedal position.
• The maximum retarder effect occurs with the lowest available range
and maximum engine rpm.
4. Try to keep the transmission temperature as low as possible.
• When the transmission oil temperature rises high, use lower range/
speed.
• When retarder is active the cooling pump is set to maximum for
maximum cooling effect.
• NOTE! When transmission oil temperature rises high enough,
retarder will automatically be disabled “retarder kick off” to protect the
transmission from damage.
5. Always follow the local site regulations!
Use of engine brake

The engine starts braking when the foot is lifted off from the acceleration
pedal.

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4.3.2 Dumping procedure

When backing up to a wagon feeder or a dumping place, do not drive
fast because it causes unnecessary stresses to the rear-axle
fastenings.

NOTICE Shift the transmission to neutral during idle periods.
Note all manners concerning safety.
Reverse camera will come on automatically when the gear selector is

shifted to reverse and the monitor is on “stand-by”. The monitor can also be
on all time if needed.
1. When you are at the dumping place, lock the dump truck with the brakes.
2. Select “Neutral” range and raise the engine revolutions.
3. Raise the box by pushing the control lever upwards.
4. When the box is fully up, release the control lever and the accelerator.
5. Empty the box completely.
• Note! When the box is lifted, the driving is possible only with gear 1
and reverse gears.
6. Lower the box by pushing the control lever downwards.
• Make sure the box is lowered completely against the stoppers before
driving.

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4.3.3 Dumping the ejector box

1. Engage the brakes and place the gear selector in the neutral position.
Note! • Only Parking Neutral and 1 st gear forward and reverse are
available when the tailgate is open.
• The tailgate will open to its maximum before the ejector blade
starts to move towards the tailgate.
2. Increase the engine revolutions.
3. Open the tailgate and operate the ejector blade backward with the box
control lever.
• See Control levers and pedals for detailed information.
Note! • All gears are available when the tailgate is closed but the ejector
blade is still retracting towards the cabin.

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4.3.4 Suspension adjustment
DANGER
CRUSHING HAZARD!
Axle suspension adjustment moves the machine. Being crushed
under the machine will cause death or severe injury.
Clear the surroundings and take safety precautions.
Suspension adjustment is used to set the machine height to desired level.

Suspension adjustment is done via the VCM-display.
1. Navigate to the suspension adjustment menu.
• Navigation route:
- Main menu.
- Operator menu.
- Suspension adjustment.
2. Adjust the suspension.

4.3.5 Scale control
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 on the instrument panel.

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User interface
Scale buttons
1 2
1 Zeroing button / Scale view

2 User zeroing
1. Zeroing button / Scale view

• Longer pressing starts zeroing of scale
• Short pressing change VCM display to scale view.
2. User zeroing / start weighing

• Longer pressing resets user counters, box counter and total tons
• Short pressing to start weighing (manual mode)
Sound signal
The system gives a short sound signal when a weighing is ready.
If a weighing is failed then the system gives a long discontinuous sound
signal.
Scale in the VCM display

Scale values are showed in the display info bar and a separate scale view.

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Info bar view and transient indicators
1 2 3
1 Number of loads 2 Weighing result and state of

scale
3 Total tons 4 Transient indicator
Symbol descriptions
Spinner Weighing ongoing
Transient indicators
Box is not in weighting position:

Box Up
lower box
Box Filling Ok Box Filling degree

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Box Filling Overload Box Filling degree
Box Filling Almost Full Box Filling degree
Scale view
8
7
1 2 3 4
1 Automatic/manual weighing 2 Shift reset

and zeroing indicators
3 Loading/dumping point man- 4 Scale ON / OFF
agement
5 User and shift counters of 6 Target load
loads and total tons
7 Load monitoring or state of 8 Filling degree
the scale
Zeroing Automatic / manual zeroing
Shift Reset Shift reset
Loading and dumping point man-

Load And Dump Point
agement
Power Scale ON/OFF

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Spinner Weighing ongoing
Filling Empty Filling degree: Empty
Filling Loading Filling degree: Loading

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Filling Ok Filling degree: OK
Filling Overload Filling degree: Overload
Box is not in weighting posi-

Lower Box
tion: lower box

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Automatic weighing procedure

1. In case an automatic weighing is set on, system start automatic weighing
when next condition is full fill:
• Box is loaded (Load is over low limit, set by parameter, default 10
ton)
• Machine has travelled about 30 m after loading.
• Machine speed is over the setting limit.
2. In info bar is showing the symbol every time when automatic
weighing try do weighing.

• Weighing pop up and audio signal are given when a good weighing
is done.
3. Weigihing result is recorded to the log.
• If quality of weighing is poor (machine shake too much) then result is
still recorded to the log but the system try to make a new weighing
after one minute.
Automatic weighing failed:
If automatic weighing failed for some reason, system gives
information pop-up when box is started to lift up.
In this case do the manual weighing:
4. Lower box to down position.
5. Wait some time that weighing system is ready to weighing (about 30
second).
6. Press the start weighing button on the instrument panel.
• Weighing is started. Weighing takes about 10 second.

7. When weighing is ready then result pop-p is showed and short sound
signal is given.
• Result pop up go away automatically after 3 second.
• Weighing is done and result recorded to the log.
8. Dump the box.
If operator doesn’t do manual weighing then the box weight is lost (No
value to weighing log).

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Manual weigihing procedure

Manual weighing can be done any time depend the situation of the
automatic weighing.
Manual weighing is done by next way:
1. Lower box to down position.
2. Wait some time that weighing system is ready to weighing (about 30
second).
3. Press the start weighing button on the instrument panel.
• Weighing is started. Weighing takes about 10 second.

4. When weighing is ready the result pop-p is showed and short sound
signal is given.
• Result pop up go away automatically after 3 second.
• Weighing is done and result recorded to the log.
5. Dump the box.
Zeroing function
Scale zeroing should be done every day.
When defined time has gone from the last zeroing the system gives a
zeroing reminder for the operator.
1. When the zeroing reminder popup is showed the user should do a
manual zeroing by pressing zeroing button for 3 seconds.
• Zeroing starts.
• When pop up window dissappears, zeroing is ready.

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Typical error situations

If weighing can be not done then reason can be
• Box is up position
• Box have been too short time on down position (30 second is needed)
• Zeroing is required
• Sensor failure, see error log of the system.
The reason is given by pop up for user.
Zeroing is required
When defined time has gone from the last zeroing then system give a
zeroing reminder for a user.
When the zeroing reminder popup is showed then the operator should do a
manual zeroing by pressing zeroing button on the instrument panel.
Sensor failure
If for some sensor is failed then weighing pop up should be removed
manually. This ensures that user gets information of poor quality weighing
and knows to take contact to service personnel.
ATTENTION! Weighing system can work with one failed sensor but
weighing accuracy can be poor and weighing result is a draft estimation.

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5 Operator's Maintenance Instructions

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5.1 Operator's maintenance responsibilities

Routine inspections prevent injury to personnel and damage to the
machine.
This chapter describes the various points on the machine that must be
inspected and serviced before and after an operator’s shift.
• Always perform inspections and maintenance before and after operating
the machine.
• Never service or adjust the machine while it is in motion.
• Always inspect and maintain the machine in a well-lit, sufficiently
ventilated place.
• Always apply the park/emergency brake before inspecting and
maintaining the machine.
• Install the frame articulation locking device before working in the centre
articulation area.
• Report all damage and faults to your supervisor or service personnel
immediately.
• Do not operate a damaged or faulty machine.
5.1.1 Typical work cycle
Aside from operating the machine, an operator’s daily routine should
include at the beginning and end of the shift a detailed inspection of the
machine, including some general maintenance.
The following describes a typical work cycle for the operator:
1. Begin the shift by inspecting the overall machine while the engine is off
and when it is on.
• During the inspection, replenish all fluids and lubricants in the
machine as required.
• If at any time the machine is not functioning normally, shut down the
machine and contact service personnel immediately.
• Do not operate the machine until all faults have been corrected.
2. If the machine passes all inspections, continue with the days shift.
3. At the end of the shift, inspect the overall machine again to catch any
faults or failures that may have occurred on the machine during
operation.
• Perform any required maintenance the operator is authorised to do
while the engine is off.

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5.2 Operator's maintenance tasks

5.2.1 Walk around inspection
1. Check for damaged or missing tags and labels.

2. Check that frame articulation locking device is not mounted.
3. Check condition of box and other components.
4. Check hydraulic components.
5. Check climbing steps and handles.
6. Check cabin and door lock condition.
7. Check that all lubrication points are well greased.
5.2.2 Check hand portable fire extinguisher
1. Check that the gauge pointer is in the green sector.
2. Check that there is no corrosion on the fire extinguisher.

3. Check that the fire extinguisher is firmly mounted.
4. Check that the seal is in place.

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5.2.3 Check engine oil

Wrong types of fluid and oil may cause damage to the machine.
NOTICE When changing or adding any type of fluid or oil, only use new fluid
and oil meeting manufacturer’s requirements.
1. Park the machine on level ground.
2. Shut down the engine before measuring the oil level.

• After shutting down the engine allow the oil drain to crankcase for
about 15 minutes before checking the oil level.
3. Check oil level.
• The oil level must be between the LOW and FULL marks on the
dipstick (1).
4. Refill through the filling pipe (2) if necessary.
• When adding oil, do not overfill.
5.2.4 Check window washer fluid level

The window washer fluid tank is located on the left side of the machine in
the engine compartment.
1. Check the fluid level and fill if needed.

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5.2.5 Check engine additional equipment
WARNING
FLAMMABLE MATERIAL HAZARD!
Failure to eliminate leaks could cause a fire.
Tighten any loose connections and replace damaged components.
1. Check the radiator and the intercooler visually for leaks and other
damage.
2. Check the fuel lines, hoses and filters visually for:

• leaks
• damage
• abrasions
• dirt
3. Check that the fuel hose connections are tight.
• Especially make sure that compression fittings are tight.
• Replace the whole hose if the compression fitting is loose.
4. Check the alternator and other electric components visually for loose
connections and damage.

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5.2.6 Check lights

1. Check front lights
2. Check rear lights
3. Check optional lights
5.2.7 Check guards and plates
WARNING
DO NOT REMOVE OR MODIFY GUARDS!
Operation without the guards in place is dangerous and could cause
Removing or modifying the guards is strictly prohibited! Before
operation, always make sure that the guards are undamaged and in
place.
1. Make sure that all guards and plates are present, secured, and free of
any damage that might affect the performance and safety of the machine.

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5.2.8 Check engine coolant level
WARNING
HOT LIQUID AND PART HAZARD!
Could cause severe injury.
Let the components cool down before touching them.
Only carry out work on the cooling system at coolant temperatures
below 50 °C.
Wear approved protective gloves, protective clothing and eye
protectors when handling coolant.
WARNING
HIGH PRESSURE INJECTION HAZARD!
A sudden pressure release from a heated cooling system can result
in a loss of coolant and possible personal injury e.g. scalding, eye
injury, etc. from the hot liquid.
Always use eye protectors.

Wrong types of fluid and oil may cause damage to the machine.
NOTICE When changing or adding any type of fluid or oil, only use new fluid
and oil meeting manufacturer’s requirements.

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1. Check engine coolant level.
• Coolant level should be seen on the sight glass.

2. Fill the tank to the recommended level if needed before starting the
engine.
• Expansion tank is equipped with a lockable 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.
5.2.9 Check fuel system
1. Make sure the fuel tank shut off valve is open.
2. Drain the water from the pre-filter.

3. Check the fuel filter assemblies for signs of leaks.
4. Check the fuel connections for leaks.
5. Check the fuel lines for abrasions, deterioration or wear.

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5.2.10 Fill fuel tank
WARNING
FIRE HAZARD!
A fire could cause death or severe injury.
Smoking, open flames and sparks are prohibited when the fuel tank
is being filled.
1. Ensure the engine is not running.
2. Ensure that the machine is suitably grounded.

• Electric discharge may cause hazardous situations
3. Do not overfill.
4. Do not fill the fuel tank to the top.
• Fuel expands when it becomes warm.
• Expanded fuel can overflow and cause hazard.
5. If using quick fill, ensure the system supplier's procedures are followed (if
equipped).

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5.2.11 Fill AdBlue tank
WARNING
CHEMICAL HAZARD!
Urea solution could cause some irritation on contact with skin or
eyes.
Wear suitable safety gloves, protective clothing and eye-protector
when handling urea solution.
In the case of any contact with eyes or skin the affected area must be
thoroughly rinsed with warm water. If you breathe in any fumes,
make sure you breathe fresh air.
RISK OF PROPERTY DAMAGE

Urea solution causes corrosion damage.
Do not spill. Do not overfill. If spilled, absorb with dry sand or other
NOTICE non-combustible material. Clean up solid or absorbed material and
place into appropriate waste container and dispose of it in
accordance with all applicable local and national regulations. Avoid
contact of spilled material with soil and waterways.
RISK OF PROPERTY DAMAGE

Filling other urea solutions than Volvo specified (conforming to ISO
22241-1) in the urea tank will damage the exhaust aftertreatment
NOTICE system permanently.
When changing or adding any fluid or oil, only use new fluid and oil
meeting manufacturer’s requirements.
1. Make sure that the engine is not running.
2. Make sure that the machine is suitably grounded.

3. Open the filler cap and fill the tank to the recommended level.

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5.2.12 Fill the grease tank

1. Attach the filling device to the grease filling connection (1).
• Pump until lubricant is coming out of the tank’s pressure relief valve
(2).

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5.2.13 Check upbox and dropbox oil levels

2. Check oil levels from the dipsticks:
• Dropbox dipstick (2)
• Upbox dipstick (3)
• The oil level must be between the LOW and FULL marks on the
dipstick.
1 2 3
3. If needed add oil trough the filler opening.

• Dropbox filling cap (B)
• Upbox filling cap (C)
A B

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5.2.14 Check brake hydraulic oil level

1. Ensure brakes are engaged.
2. Check brake hydraulic oil level.

• Brake hydraulic oil level should be between the sight glasses, when
brakes are engaged.
3. Refill the tank to the recommended oil level if needed before starting the
engine.
5.2.15 Check tires and wheel nuts
1. Check condition.
2. Check visually for wear and cracks.

3. Check visually for loose or missing wheel nuts.
4. Check air pressure visually.

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5.2.16 Check the jacking cylinders

1. Check the condition of the optional jacking cylinders.
2. Check for oil leaks and loose hoses.

3. Check for the proper mounting.
4. Make sure that the cylinders have been lifted to the highest position
before taking the machine in use.

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5.2.17 Check major components for oil, fuel and coolant leaks and mounting
WARNING
FIRE HAZARD!
Leaking fuel, hydraulic oil or coolant lines could cause a fire which
could cause death or severe injury.
Tighten any loose connections and replace damaged fuel, hydraulic
oil and coolant lines, tubes and hoses.
1. Make a general visual inspection around and under the machine.
2. Check for oil leaks and loose hoses, frayed wires or bent hydraulic
hoses.
3. Check the fuel system for leaks, especially around the fuel filters and the
fuel tank shut off valve (if equipped).
4. Check the coolant system for leaks. Check that there are no damage or
wear in hoses and tubing.
5. Visually check the engine mountings, the hydraulic cylinders and the air
cleaner.
6. If anything looks abnormal or is in apparent need of repair, inform the
service personnel.
Stop 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.

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5.2.18 Check the dump box
DANGER
CRUSHING HAZARD!
Unexpected movement of box will cause death or severe injury.
Make sure that the dump box is resting completely on the rear frame
or on the box support device, before working in the dump box area.
Note! Insufficient lubrication may cause premature wear and failure of pins
and bushings.
1. Inspect the dump box and the surrounding area.

• Look for signs of damage or wear to the frame, cylinders, weldments,
support bars, and hydraulic hoses.
2. Apply grease to all grease points.
5.2.19 Check and clean camera(s)
1. Check the fastening of the camera.
2. Check that there are no marks of mechanical shocks on the camera.
3. Check the condition of the camera cabling and connectors.
4. Clean the camera lens. Use antistatic fluid and a clean cloth to wipe dust
and dirt off the lenses. When using antistatic fluid, components remain
cleaner. Do not use any solvent for cleaning. Wipe vertically and very
lightly, avoiding dust scratching the plastic. If the lens is very muddy, use
a lot of unpressurized water first to avoid scratches.
5. If the camera lens is remarkably scratched, it should be replaced.
6. Check the camera alignment.
5.2.20 Check hydraulic oil level
1. Check hydraulic oil level.
• Hydraulic oil level should be between the sight glasses, when box is
lowered.
2. Refill the tank to the recommended oil level if needed before starting the
engine.

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5.2.21 Check seat belt condition
WARNING
FAULTY SEAT BELT CAUSES A HAZARD!
Faulty seat belt does not provide adequate protection in an accident,
which could result in death or severe impact injuries.
Check the seat belt condition before every working shift. If any
malfunction occurs or visual damage can be noticed, replace the
seat belt immediately with a new one.
After any accident or collision, replace the seat belt. In any case, Sandvik
recommends to replace the seat belt once a year or every 5000 hours,
which ever comes first.
1. Check anchor points of seat belt.
2. Inspect seat belt for fraying or wearing.
3. Check seat belt retraction. Pull the belt out slowly to check for smooth
action.
• There should not be any sticking, which might indicate a faulty
retractor.
4. Check seat belt locking. Pull the belt out quickly to see that it locks and
releases.
• The belt should lock when pulled suddenly, which is vital during
emergency braking or collisions.
5. Fasten belt locking mechanism and try to pull the locked sections apart.
• The belt should not release, which is vital during emergency braking
or collisions.
6. Operate the release mechanism while pulling on the belt to check that
the mechanism releases when required.
5.2.22 Check the alarm lights
1. Turn the ignition key to "POWER ON" position.
2. Do a check of the alarm lights operation.

a) The lights should light up for 3 seconds.
b) After 3 seconds the lights should go out.

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5.2.23 Check VCM system alerts

1. Make sure that there are no alerts on the display.
2. If there are alerts on the display, contact service personnel.
3. Don´t use the machine until the reason that caused the alert has been
solved.
5.2.24 Check emergency stop and shutdown system
1. Check all emergency stop buttons for damage.
• Emergency stop buttons are located in the cabin and at the front and
rear frame.
2. Check that none of the emergency stop buttons are pushed in.
3. Start the engine.
4. First check the Emergency Stop button in the cabin. Push the button in.
• The engine should stop instantly.
5. Pull the Emergency Stop Button out to release the emergency stop
circuit.
6. Restart the engine.
NOTICE Wait 30 Seconds before restarting - allows starting system to cool.
7. Push the Emergency Stop button at the rear side of the machine.
8. Pull the Emergency Stop Button out to release the emergency stop
circuit.
9. Restart the engine.
NOTICE Wait 30 Seconds before restarting - allows starting system to cool.
10. Push in the remaining Emergency Stop button at the front side of
machine.
11. If engine does not shut down, contact service personnel.

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5.2.25 Brake test
DANGER
CRUSHING HAZARD!
Testing may cause dangerous machine movements, which can cause
Clear surroundings and take safety precautions.
PURPOSE OF THE TEST

• Brake test measures wheel brakes holding power and brake system and
its components function.
• Test is performed via the machine VCM display.
• Operator is in response to perform the test and to accept or reject the
test result.
• Test must be performed at the beginning of every shift.
• NOTE! Ignoring the test or accepting failure test result is absolutely
forbidden.
1. Push the brake test button on the instrument panel to start the test.
2. Follow the instruction given on the display to perform the test.
3. When the test has been performed and the results meet the specification
the test ends automatically and you can continue operating the machine.
• Accepted test and result information will be marked in the event log.

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4. If the test results do not meet the specifications the result window opens
to inform the fault situation(s).
a) When brakes are engaged, machine movement during the test is

not allowed.
• If machine moves, test result is not acceptable.
- You must reject the test.
b) RPM (A):
• Engine max. RPM on 1st gear during the test.
• If measured RPM is over the requirement, test is done
correctly.
• If measured RPM is under the requirement, test results are not
acceptable.
- You must reject the test result.
c) Hydraulic oil pressure (B) to brakes when service brakes are
released:
• If measured pressures are between the requirement, brakes
are functioning properly.
• If measured pressures are under the requirement, brakes may
drag. This causes brakes overheating, early wear or total loss
of braking power.
• If the measured pressures are over the requirement, there is a
risk of sealing or brake assembly failure.
d) Residual pressure (C) in brakes when brake pedal pressed fully
down:
• If measured pressures are under the requirement, brakes are
functioning properly.
• If measured pressures are over the requirement, brakes are
functioning improperly and brake holding power is reduced.

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Test rejected
• Operating the machine after rejected test is prohibited.

• Rejected test and the results will be marked in the event log.
• Set off the window by pushing the display button 1
• Make sure the brakes are serviced and the accepted brake test has been
performed before operating the machine.
5.2.26 Checking the neutral brake function
1. Ensure that the machine is on level ground.
2. Ensure that the gear is in neutral position.
3. Release the parking and service brakes.
• NOTE! The machine may begin to move.
4. Check that the neutral brake engages the parking brake when the gear
has been on neutral and brake pedal not been pressed for a time period
defined with a parameter (the default value is 3 seconds).
• A window appears on the display that informs that the neutral brake
is activated.
5. If the neutral brake function does not engage the parking brake,
immediately press the parking brake button, shut down the engine and
place wheel chocks.
• Do not operate the machine before the faulty neutral brake function
has been repaired and tested.

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5.2.27 Check door interlock switch function and condition
DANGER
CRUSHING HAZARD!
A faulty door interlock switch may allow the machine to move
unexpected although the cabin door is opened. This will cause death
or severe injury.
The door interlock must be checked at the beginning of every shift. If
any malfunction is evident the interlock must be repaired and tested
before operating the machine.
Make sure there are no unauthorized persons in the hazard zone
while testing procedure.
2. Release the parking brake.

3. Open the cabin door.
• Brakes must engage.
• If brakes are not engaged do not operate the unit before the faulty
interlock has been repaired and tested.

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5.2.28 Check ANSUL fire suppression system (option)
1. Check the general appearance of the system components and make

sure that there is no mechanical damage or corrosion.
2. Check that there are no cuts or signs of abrasion in the hoses.

3. If the system has a CHECKFIRE® automatic detection and control
system, ensure that the green "POWER" LED blinks once every three
seconds.
• No other led should be blinking.

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5.2.29 Check gear box oil level

1. Start the engine and let it idle.
2. Check oil levels from the dipstick:
• Gear box dipstick (1)
• The oil level must be between the LOW and FULL marks when the
oil is at operating temperature.
1 2 3

4. If needed add oil through filler opening (A).
A B
5. Start the engine and recheck the oil level.

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6 Additional Instructions

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6.1 Using the brake releasing pump

NOTE! When using the brake release pump, the engine must not be
running and the emergency stop must not be activated.
1. Turn the ignition key to the position 1 (power on).
2. Check that the emergency stops are not activated.
3. Push the brake release pump button on the instrument panel and keep it
in down position.
• The pump starts and stays on until the button is released or the
maximum pressure value is reached.
4. Keep the release pump button pushed in and pull the brake release
button fully out and release it to the middle position.
• The brakes will be released now.
NOTE! Always engage brakes after usage by pushing the brake releasing
button in.

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6.2 Using the emergency steering system (optional)

The emergency steering pump is activated automatically when the engine
stops or stalls in an unusual way (the engine stops even though it has not
been switched off with the ignition key). Pump stays on for 10 seconds.
This function allows the operator to safely steer the unit away of danger
area.
System can also be used and checked manually by the following way:
1. Turn the ignition key to the position 1 (power on).
2. Check that the emergency stops are not activated.
3. Push the emergency steering button on the instrument panel.
• Power pack starts and the status symbol in the main display
appears, when the system is activated.
4. Keep the button pushed in and turn the machine.
6.3 Towing
6.3.1 Common safety messages
Only people who have been given specialized operation and service
training are allowed to perform operations, service, and adjustment
procedures. Read and ensure you understand the following
instructions before servicing the equipment. To avoid potential
damage and injuries, carefully plan your work beforehand.

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6.3.2 Dump truck to be towed
DANGER
CRUSHING HAZARD!
Dangerous machine movements can cause death or severe injury.
Releasing the steering may cause the machine to turn by itself,
especially on gradient level. Ensure the releasing does not cause
danger to other people or equipment.
Clear surroundings and take safety precautions.
WARNING
HIGH-PRESSURE OIL SPRAY HAZARD!
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.
Only authorized personnel are allowed to perform a towing

procedure.
Extreme caution must always be observed when towing the machine.
Never attempt to start the engine by towing.
Do not release the brake before the machine is properly connected to

the towing machine and the towing machine has an operator in the
operator’s compartment!

Towing can damage the transmission and the gearbox if drive shafts
NOTICE are connected.
Disconnect the driveshaft before towing.
If the machine must be towed follow the directions below:

1. Apply parking brake and block all four wheels.

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2. Connect the machines with a suitable towing bar (and a secondary safety
chain or wire rope).
• Towing vehicle must be as heavy as dump truck or heavier and it
must have enough power and braking capacity to move, stop and
hold both machines.
• Towing pin is located at the front end of the machine.
• Apply necessary warning signs.
3. Disconnect the front drive shaft (1) and the rear drive shaft (2).
• Mark the alignment of the flanges before disconnecting.
For more information refer to the Service and repair manual.
4. Release the steering hydraulics by disconnecting the lines to steering

cylinders at the main steer valve.

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5. Release the brakes with electric brake release pump.

• Push the brake release pump button on the instrument panel and
keep it in down position.
• The pump starts and stays on, until you release the button.
6. Keep the release pump button pushed in and pull the parking brake
control button out and release it to the middle position.
• Releasing the brakes may cause the machine to move (especially on
incline / decline). Be sure that this does not cause danger to the
other people or equipment.
• Note! Do not release the brake before the machine is properly
connected to the towing machine and the towing machine has an
operator in the operator’s compartment!
7. Start towing carefully.

• Tow as slowly and carefully as possible.
After towing:
• Apply brakes on both units.
• Block all wheels of both units.
• Disconnect the vehicles.
• Mount the previously disconnected drive shafts.
• Reconnect steering hoses and check for leaks.

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• Check hydraulic oil level. Fill if required.

6.3.3 Towing a disabled machine with the TH551
The maximum weight that the TH551 can tow is equal to the
operating weight (without load) of the TH551. That is 41000 kg.
The brakes of the TH551 must be in good condition and have enough
braking capacity to stop and hold both machines.
Extreme caution must be used when towing a vehicle with the TH551.
The procedures described should only be performed by trained,
authorized personnel.
1. Apply the park/emergency brake and block the wheels of the disabled
vehicle.
2. Back up the TH551 to the disabled machine and connect the two
machines with a rigid tow bar or an A-frame. Further install a secondary
safety chain or wire rope between both machines.
3. If necessary, ensure that the drive line of the disabled vehicle is released
to avoid damage to its components.
4. If the disabled machine can be steered, it must have an operator in the
operator’s compartment to steer the unit.
5. Release the brakes of the disabled machine and carefully remove the
wheel chocks.
Only release the brakes under the strict supervision of the service/
mechanical supervisor. Ensure the machine is being held in place
with wheel chocks or another suitable device, and is securely
connected to a towing machine before releasing the brakes.
Do not release the brakes on the disabled machine unless it is

properly connected to the towing vehicle.
6. Tow the disabled machine as slowly and carefully as possible.

7. When the machines reach the required destination, block the wheels and
apply the brakes on the disabled vehicle.
Before disconnecting the disabled machine from the towing vehicle,
the brakes of the disabled machine must be engaged and the wheels
blocked.
8. Disconnect the vehicles.

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6.4 Lifting methods and lifting points
DANGER
LIFTING AND CRUSHING HAZARD!
Faulty lifting practice will cause death or severe injury.
The objects being lifted are heavy. Assistance may be required when
lifting the object.
Ensure that lifting equipment is in good condition and correctly
rated.
Always make sure the attachment is properly fastened before
operating the machine.
Make sure there is no one in the hazard zone when attaching, testing
or detaching the attachment.
Always respect the law and all the local safety regulations in lifting
work.
Keep in mind the total weight of the dump truck.
1. Install the frame articulation locking device.

2. Shut down the engine. Turn the main switch off.

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5. The lifting points (four) are marked with hook symbols.

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6. The lifting device used must be of the correct type and have sufficient
lifting capacity.
• The machine or parts of it must not be lifted with any devices that are
not specifically designed for lifting purposes.
• Check the correct weight of the machine from the type plate or the
technical specification sheet.
• Never exceed the lifting capacity specified by the manufacturer of the
lifting device.
7. Make sure that the lifting equipment is in proper condition.
8. Wire ropes and chains used for lifting must be checked regularly.
• Damaged wire ropes and chains must be marked clearly and
discarded at once.
9. Never wind the ropes or the chains around the hook of the hoist.
10. The lifting ropes must be fastened according to the manufacturer’s

instructions.
11. The lifting routes must be planned so that the load is not moved over
persons or such places where persons may be present.
12. Lift the machine 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.
13. If control lines must be used, ensure they are long and strong enough.

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6.5 Jack system
DANGER
Lifting the machine with the jack system in a decline may cause the
machine to move or fall over. Being crushed by a moving machine
will cause death or severe injury.
Lifting the machine with the jack system is allowed only on a level
ground.
DANGER
CRUSHING HAZARD!
Lifting the machine with the jack system may cause dangerous
machine movements. Being crushed under the machine or being hit
by falling rocks from the box will cause death or severe injury.
Take care of all necessary safety precautions.
Make sure that there is no loose material in the box that could fall off
when using the jack system.
Make sure that the surface can carry the weight of the machine and
use protective plates under the jacks and the stands to prevent them
from penetrating the ground.

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Note! Operate the jack system with the remote control standing in front of
the machine and outside the defined hazard zone.
Hazard zone when operating the jacks

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Remote controller configurations

1.Indication led:
• illuminating when any of the buttons are
pushed
1 2
2.Indication led:
• blinking when connected to machine
• illuminating when machine is in jack sys-
3 4
tem operating mode
3.Horn
4.Engine stop 5 6
5.Front left tire up
6.Rear left tire up
7 8
7.Front left tire down
8.Rear left tire down
9.Rear right tire up 9 10
10.Front right tire up
11.Rear right tire down
11 12
12.Front right tire down

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6.5.1 Jack system (lifting)

Always secure the dump truck with three external stands when the dump
truck is in lifted up position. Use only the approved stands available from
Sandvik. Each stand is equipped with a 20 mm and a 30 mm height
adjustment plate which can be used for compensating small differences in
the surface where the stands will be placed. The front stand is adjustable to
low and high position. The dump truck is equipped with two plastic blocks
that can be used under the front jack cylinders to get the front part of the
dump truck lifted higher up. The plastic blocks are attached to the tipping
cylinders. Use the wagon when moving the stands.
3 2
5 4
1 Wagon 2 Plastic block (2 pcs)

3 Rear stand (2 pcs) 4 Height adjustment discs
5 Adjustable front stand 6 Front stand high position
locking pin
1. Move the dump truck to a flat surface and a safe working area.
2. Make sure that the surface has enough load-bearing capacity. If needed
place protective plates under the jacks and the stands.
3. Install the frame articulation locking device and place the wheel chocks.
4. Place the plastic blocks under the front jack cylinders.
• If needed raise the front of the dump truck with the suspension until it
is possible to place the plastic blocks under the front jack cylinders.

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5. Connect the remote control to the dump truck.

• The correct VCM window opens automatically.
6. Start the engine if it is not already running.

7. Activate the remote control with the VCM display.
NOTE! This makes a mark in the event log.
8. Make sure that there are no people inside the defined hazard zone.
9. Give an audio signal by using the remote control before operating the
jacks.
10. Lift the dump truck by using the remote control, standing in front of the
machine and outside the defined hazard zone.
NOTE! Keep the dump truck straight by lowering all four jacks a bit in
turns.
11. Adjust the front stand to its high position.
12. Use the wagon to place the three stands under the dump truck (for
correct place, see black arrows).
NOTE! Use only the approved stands available from Sandvik.

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13. Raise the jack cylinders until the they support the dump truck equally
with the stands (seven-point support).
14. Turn off the engine with the remote control.

15. Leave the jack mode with the VCM display.
16. Disconnect the remote control and place it into the cabin.
NOTE! It is not possible to activate the remote control again before it
has been unplugged and plugged in again.
17. Open the suspension accumulators discharge valve.
If only the front of the dump truck has to be lifted up in case of a flat
front tire, lifting has to be carried out in two stages.
1. Lift the front of the dump truck by using the remote control, standing in
front of the dump truck and outside the defined hazard zone.
2. Keep the dump truck in balance by lowering the two front jack cylinders a
bit in turns.
3. Place the adjustable front stand (now in low position) under the dump
truck (Figure 1).
Figure 1
4. Raise the front jack cylinders.

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5. Place the plastic blocks under the front jack cylinders (Figure 2).
Figure 2
6. Lift the front of the dump truck with the front jacks.
7. Adjust the front stand to its high position (Figure 3).
Raise the front jack cylinders until the they support the dump truck
equally with the stand (three point support).
Figure 3
9. Open the suspension accumulators discharge valve.

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6.5.2 Jack system (lowering)

1. Close the suspension accumulators discharge valve.
2. Connect the remote control to the dump truck.
4. Activate the remote control with the VCM display.
5. Make sure that there are no people inside the defined hazard zone.
6. Give an audio signal by using the remote control before operating the
jacks.
7. Lift the dump truck using the remote control standing in front of the dump
truck and outside the defined hazard zone.
8. Remove the stands with the wagon.
9. Lower the dump truck by raising the jack cylinders to fully up position.
NOTE! Make sure that all four jack cylinders are in fully up position.
11. Leave the lifting mode with the VCM display.
12. Disconnect the remote control and place it into the cabin.
13. Remove the plastic blocks and attach them to the tipping cylinders.
• If needed start the engine and raise the front of the dump truck with
the suspension until it is possible to remove the plastic blocks.
6.6 Operation in cold weather

If the temperature is below 0 °C, clear off ice from all steps and handles of
the machine.
Because the machine is intended to operate in underground mining
conditions, its engine, transmission and hydraulic systems are filled with
oils suitable for these conditions. However, in cold conditions the oils 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
Maintenance Manual for the correct oils and the engine manufacturer's
instruction manual for the proper fuel.
Starting aids such as preheating the engine, the hydraulic oil and urea
solution (AdBlue/DEF, if equipped) are recommended in temperatures
below -10 °C. The urea solution (AdBlue/DEF) will begin to crystallize and
freeze at temperatures below -10 °C.
Be aware that starting the engine in cold conditions may require multiple
attempts.

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Operation in arctic conditions

The machines that are delivered to arctic conditions are typically equipped
with several different preheaters, extra insulation and other components to
ensure that the machines can be started and operated in extreme cold.
Make sure that all available preheaters are used.
To ensure reliable operation of the machine in arctic conditions (below
-20°C), the following additional actions are recommended:
• Make sure you use fuel, oil and coolant suitable for arctic conditions.
• Store the machine inside a heated tent when the machine is not in
operation.
• Try to minimize the engine idle time.
• Maximum exhaust gas temperature drop is 10°C to avoid urea (AdBlue/
DEF) crystallization (if equipped with an urea system). It is recommended
to measure this on site during the coldest period. If needed, add
insulation on the exhaust gas pipe.
• Note that urea needs to be heated up also during stocking and
transportation. The urea solution (AdBlue/DEF) will begin to crystallize
and freeze at temperatures below -10 °C.
• If needed, cover the engine compartment to keep it warm and to ensure
that engine heat generation is heating the air intakes.
• If needed, cover the cooling cells of the engine cooler partly. In extremely
cold climate cover them totally.
• If needed, add insulation on the engine coolant lines.
• If needed, add a fuel preheater outside the fuel tank.
• If needed and based on local measurements, the rotating speed of the
engine cooler fan motor can be adjusted by adjusting the hydraulic pump.
6.7 Arctic package (option)

The purpose of the arctic package is to preheat essential systems of the
machine before starting in cold climate conditions. The arctic package
includes heaters for the engine, the hydraulic oil, the brake oil, the drop
box, the up box and the gearbox.

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Plug an external electric cable to the electric plug of the machine to activate
the arctic package heaters. The system typically has the following heaters:
• a 2000W heater for the engine
• a 2000W heater for the hydraulic oil tank
• a 1000W heater for the brake oil
• 2 x 400W heating pads for the gearbox
• 2 x 400W heating pads for the upbox
• a 250W heating pad for the dropbox

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Depending on the climate conditions, the machine may also be equipped

with additional heaters and related components. Extra insulation and
covers might also be installed. The following are some examples of
additional heating equipment:
• Urea heater system based on coolant circulation in the urea tank
• External engine coolant heater on the cylinder block to improve engine
heating
• Suction air grid heater to preheat combustion air
• Fuel prefilter with heater
• Battery preheater
• Electric primer pump for fuel
• Double alternator or larger alternator to ensure electric supply for the
heating systems that are connected to the electric system of the machine
• Increased cable size between the battery and the starter motor
• Exhaust system insulation
• Urea tank insulation
6.8 Storing instructions

Storing 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%.
1. Wash the machine thoroughly if it comes directly from use, or if it has

been transported by sea (use high pressure washer or steam).
2. Lubricate all greasing points.
3. Empty the pressure accumulators and place warning signs on the
machine: ’Pressure accumulators must be filled before using the
machine’.
4. Apply protective grease to the piston rods of the cylinders.
5. Change all lubricants and fluids.
6. Check engine air filter and service if necessary.

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7. Protect electric devices with corrosion inhibitor to prevent contact

failures.
8. Disconnect batteries.
9. Apply protective grease to the following points:
• terminal strips
• battery terminals
• multipole connectors
• connectors at caps of magnetic valves, pressure switches, etc. Fill
the caps with grease.
6.9 Transporting the dump truck

Always keep the box in hauling position before driving the dump
truck onto a transport wagon. Never exceed the specified gradient
angles.
1. Use suitable access ramps when driving the dump truck onto and off
transport platform.
• Driving must always be done on level ground.
2. Always use low speed and observe special caution when coming from
the ramps to the platform.
3. Straighten the truck (no angle between the front and rear the frame)
4. Engage parking brake.

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5. Turn the ignition key to the 0-position to shut down the engine.
6. Install the frame locking bar.

a) Open the bar (A) that holds the rear locking pin of the frame
articulation locking device.
b) Lift the locking pin (B) from the hole

c) Turn the frame articulation locking device to its forward position.

ID: BG00408868 en-US I.001.1 2017-06-07
d) Put the the locking pin in place.
• If the locking pin does not go all the way into the hole, start the
engine and slowly turn the dump truck until the locking pin
drops down to its correct position.
7. Step out of the cabin and turn the main switch off.
• Wait 90 seconds after shutting down the engine to protect the urea
dosage injector (if equipped).

ID: BG00408868 en-US I.001.1 2017-06-07
9. Lower the machine front end down by opening the suspension discharge
valve (A).
• The locking cover (B) is locked by the locking pin.
10. Fasten the dump truck to the platform from both ends of the machine
with strong straps and chains so that the dump truck cannot shift during
transporting.

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7 Troubleshooting

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7.1 Faults on the instrument panel
For any and all controller, engine, and hydraulic faults displayed on the
instrument panel, shutdown the machine and contact service personnel
immediately.
7.2 Engine will not crank over
Cause Remedy
Master disconnect switch is in Turn the master disconnect switch to the
the OFF position ON position.
Starter isolation switch is in the Turn the starter isolation switch to the ON
OFF position position.
Emergency stop button is Pull all emergency stop buttons out until
pressed in they are fully released.
Gear selector not in neutral (N)
Set the gear selector to the position N.
position
Clean and/or tighten terminals. Turn off
Loose or dirty battery terminals the master disconnect before working
with the batteries.
Weak or dead battery Recharge or replace battery.
Any other problem Contact service personnel.
If these checks did not solve the problem, contact service personnel.
7.3 Engine will crank over but not start
Cause Remedy
Hydraulic oil level low Contact service personnel.
Fuel level low Replenish fuel.
Park/emergency brake not applied Apply the park/emergency brake.

ID: BG00408868 en-US I.001.1 2017-06-07
7.4 Engine stalls during operation
Cause Remedy
Hydraulic oil level
Contact service personnel.
low
Fuel level low Replenish fuel.
Stop the machine and put it into neutral. Depress the
throttle pedal until the engine is at approximately
High Engine Tem-
1000 RPM or above idle. Hold this engine speed for
perature
30 seconds. If the engine temperature does not de-
crease sufficiently, contact service personnel.
Note! If these checks did not solve the problem, contact service personnel.
7.5 Excessive exhaust smoke
Cause Remedy
Remove source of restriction. If no restriction is
Air intake restriction
present, check the air filter service indicator.
Hot working conditions Ambient temperature should not exceed 40 °C.
Engine overloaded Reduce the load on the engine.
Turn the machine off during prolonged periods
Excessive idling time
of inactivity or vary the engine speed.
Engine oil level exces-
sively high
Ambient temperature should not be below
Low ambient temperature
0 °C.
7.6 Engine misfiring
Shut down the engine and contact service personnel.

ID: BG00408868 en-US I.001.1 2017-06-07
7.7 Engine knocking
7.8 Engine oil pressure low
7.9 Engine overheats
Сause Remedy
Engine overloaded Reduce the load on the engine.
Clogged radiator core Clean the radiator.
Stop the machine and put it into neutral. De-
press the throttle pedal until the engine is at ap-
High Engine Tempera- proximately 1000 RPM or above idle. Hold this
ture engine speed for 30 seconds. If the engine tem-
perature does not decrease sufficiently, contact
service personnel.
Incorrect type/amount of
oil
Restricted air intake Remove the restriction.
Broken belts Contact service personnel.
Operating in wrong gear Contact service personnel.
7.10 Hydraulic oil foams
Cause Remedy
Incorrect type of hydraulic oil Contact service personnel.

ID: BG00408868 en-US I.001.1 2017-06-07
7.11 Machine will not move
Cause Remedy
Park/emergency brake applied Release the park/emergency brake.
Machine in neutral Select either forward or reverse direction.
No hydraulic power Contact service personnel.
Engine stopped Start the engine.
7.12 Machine will not turn
Cause Remedy
Frame articulation locking device Remove the frame articulation locking
installed device and put it in the storage position.
Obstruction (e.g. rock) between
Remove the obstruction.
frames.

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7.13 Little or no dump box action
Cause Remedy
Remove the box support device with
Box support device installed
the care and caution.
Obstruction (e.g. rock) between
Remove the obstruction.
frames
7.14 Defective lighting system
Cause Remedy
Defective light bulb Contact service personnel.
Light assembly wiring is loose or broken Contact service personnel.
Defective light control switch Contact service personnel.
Circuit breaker tripped Contact service personnel.

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8 Technical Specifications

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8.1 Machine specifications
Machine dimensions
Total length 11570 mm 455 in
Maximum width 3200 mm 126 in
Height 3160 mm 124 in
Height of the box 3160 mm 124 in
Measured A-weighted emission sound pressure (At high idle 2000

level rpm)
At operator’s position, LpA [dB re 20 μPa] 74 dB
Uncertainty, KpA [dB] 3 dB
Driving
Whole body vibra- Driving
Loading Unloading without
tion with load
load
Maximum r.m.s. value
0,32 0,24 0,69 0,90
aw [m/s2]
VDVw over 15 min
4,02 3,72 8,37 7,73
period [m/s1.75]
Dump box motion times

Discharging time 14 sec
Speeds forward (level / loaded)

1st gear 6.3 km/h 3.9 mph
2nd gear 9.5 km/h 5.9 mph
3rd gear 12.7 km/h 7.9 mph

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Maximum gradient and tilt angle

15° upgrade
Maximum Gradient
15° downgrade
10° box up
15° unarticulated, box down
Maximum Tilt Angle
7° articulated, loaded, box down
10° articulated, unloaded, box down
Turning radius
Inner 5,0 m 200 in
Outer 9,4 m 370 in
Turning angle ± 44°
8.2 Machine weights
Operating weights
Total operating weight 41 000 kg 90 400 lb.
Front axle 29 000 kg 63 900 lb.
Rear axle 12 000 kg 26 500 lb.
Loaded weights
Total loaded weight 92 000 kg 202 800 lb.
Front axle 40 700 kg 89 700 lb.
Rear axle 51 300 kg 113 100 lb.
Capacities
Payload 51 000 kg 112 450 lb.
Dump box volume 28 m³ 36,6 yd³

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8.3 Main components weights

Frame parts
Note! All weights are approximate.
Component Weight (kg) Weight (lb)

Front frame 6 800 14 991
Rear frame 3 615 7 970
Hydraulic tank 230 507
Brake hydraulic tank 108 238
Cover of the hydraulic tank 100 220
Cover of the brake hydraulic tank 75 165
Oscillation cradle 700 1 543
Box 28 m3 7 020 15 476
Reaction bars / support beams 70 154
Engine and cooling

Engine 1 440 3 175
Air filter 9 20
Upbox 381 840
Exhaust purifier 90 198
Flexible clutch 80 176
Engine radiator 340 750
Charge air cooler / radiator 250 551
Transmission oil cooler 150 331
Hydraulic oil cooler 85 187

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Transmission
Front axle 2 695 5 941
Front axle assembly 3 710 8 179
Rear axle 2 695 5 941
Rear axle assembly 2 715 5 986
Gear box (with PTO) 1 190 2 624
Dropbox 536 1 182
Power Take Off gear 38 84
Wheel assembly 1 600 3 527
Rim 490 1 080
Drive shafts 38-79 84-174
Drive shaft guard 25 55
Cabin
Cabin assembly 1 520 3 351
Hydraulic components
Piston pump, 145 ccm 76 168
Piston pump 45 ccm 18 40
Piston pump 18 ccm 12 26
Main valve 49 108
Orbitrol valve 22 49
Brake pressure accumulator 40 88
Suspension pressure accumulator 75 165
Tipping cylinder 309 681
Steering cylinder 110 243
Suspension cylinder 90 198
Jacking cylinder, front 215 474
Jacking cylinder, rear 390 860
Pilot pressure block 10 22
Emergency brake block 15 33
Prioritization block 15 33

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Others
Battery 45 99
Central lubrication pump 23 51
Circuit breaker box X2021 24 53
Circuit breaker box X2056 36 79
Ejector box
Ejector box with all its components 11 100 24 471
Tailgate 950 2 090
Tailgate cylinder 60 132
Ejector plate 2180 4 806
Ejector plate cylinder 210 462
8.4 Brake system

Brake system
Spring applied, hydraulically released
(SAHR), liquid cooled multi-disc brakes
Service Brakes
on all four wheels, two separate circuits
for the front and rear axles.
Service brakes also function as emer-
Emergency/Park brake gency brakes, when the emergency
brake system is engaged.
Actuates automatically when the en-
Park brake actuation gine is shut down (i.e. hydraulic pres-
sure is off).
Brake release pressure 110 bar (1595 psi)
Brake flushing pressure 2.0 bar (29 psi)
8.5 Engine
Standard engine
Type Volvo TAD1662VE-B, Euro stage 3B / Tier4i
Power Output 515 kW (691 hp) @ 1800 RPM
Torque 3220 Nm (2375 lb.-ft.) @ 1200 RPM
Number of cylinders 6
Displacement 16.1 l (982 cubic in.)
Cooling system Liquid cooled

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Standard engine
Combustion principle Turbocharged, after cooled, direct injection
Air filtration Donaldson PowerCore D120037
Electrical system 24 V
Exhaust system purifier Catalytic purifier with silencer
Fuel tank capacity 800 l (211 US gal)
Fuel consumption rate (aver-
Not measured l/h (US gal/h)
age)
8.6 Default pressure settings

Main principles for pressure measurement point numbering
Type
• MP = Measurement point
• MG = Measurement gauge
Circuit
• 1 = Steering circuit
• 2 = Box circuit
• 3 = Engine cooler circuit
• 4 = Others
• 5 = Brakes / Coolers circuit
Sequence number
• 0-9
Sequence number
• 0-9
Default pres-
MP System Checking Method
sure
MP511 Brake flushing pressure Engine running at idle 0.5 - 2.5 bar
Brake charging pump pres-
MP501 Engine running at idle 190 ± 10 bar
sure
Brake flushing pump pres-
MP536 Engine running at full rpm 60 ± 5 bar *
sure
MP504 Brake pedal pressure Brake released 110 ± 5 bar
MP505 Brake pressure front axle Brake released 110 ± 5 bar
MP506 Brake pressure rear axle Brake released 110 ± 5 bar
Brake release pump pres- Start brake release pump when ma-
MP501 140 ± 5 bar
sure chine is not running

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Default pres-
sure
Pump forced to stand-by pressure
Engine cooler pump stand-
MP301 (VCM mode) and engine running at 50 ± 5 bar *
by pressure
idle
Pump forced to max pressure (VCM
Engine cooler pump max
MP302 mode) and engine running at full 260 ± 10 bar *
pressure
rpm
MP405 Pilot pressure Engine running at idle 35 ± 10 bar
Steering pump max. pres- Pump forced to max pressure (VCM
MP101 290 ± 10 bar
sure mode)
Steering pump stand-by Pump forced to stand-by pressure
MP101 35 ± 2 bar
pressure (VCM mode)
MP103 Steering pressure right Steer against to right stopper 220 ± 5 bar
MP104 Steering pressure left Steer against to right stopper 220 ± 5 bar
MP203 Box up pressure Lift the box against the upper stop 290 ± 10 bar
MP204 Box down pressure Lower the box against the frame 100 ± 10 bar
Tailgate up pressure (ejec- Lift the tailgate against the upper 100 bar ± 10
MP209
tor box) stop bar
Tailgate down pressure 120 bar ± 10
MP210 Lower the tailgate against the frame
(ejector box) bar
Ejector out pressure (ejec- Operate the ejector against the stop 150 bar ± 10
MP213
tor box) (out) bar
Ejector in pressure (ejector Operate the ejector against the stop 150 bar ± 10
MP214
box) (in) bar
MP417 Suspension up pressure Lift suspension to upper position 150 ± 10 bar
MP418 Suspension down pressure Lower suspension to lower position 150 ± 10 bar
Brake accumulator 1 pre- Engine not running and hydraulics
MP521 90 bar ± 3 bar
charge non-pressurized from MP501
Brake accumulator 2 pre- Engine not running and hydraulics
MP522 90 bar ± 3 bar
Pilot accumulator pre- Engine not running and hydraulics
MP425 15± 2 bar *
Engine not running, suspension
Front suspension accumu-
MP451 down and hydraulics non-pressur- 35 ± 3 bar
lator 1 pre-charge low-side
ized from V2421
lator 1 pre-charge high-side
ized from V2421

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Default pres-
sure
lator 2 pre-charge low-side
ized from V2421
lator 2 pre-charge high-side
ized from V2421
* Value is suggestive

ID: BG00408868 en-US I.001.1 2017-06-07

ID: BG00408868 en-US I.001.1 2017-06-07
www.sandvik.com

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Original instructions

BG00408868 en-US I.001.1 2017-06-07

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2 Safety and Environmental Instructions ...................... 19

2.6.1 Use of Emergency stop function ................................................. 72

3 Machine Description ..................................................... 121

3.5.1 Instrument panel ..........................................................................125

4 Operation Instructions ..................................................193

5 Operator's Maintenance Instructions ..........................231

6 Additional Instructions ................................................. 255

6.3.3 Towing a disabled machine with the TH551 ................................ 261

7 Troubleshooting ............................................................ 281

8 Technical Specifications .............................................. 287

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Copyright © Sandvik 11 (298)

1.1 The purpose of these instructions

12 (298) Copyright © Sandvik

1.2 Identification of the product

Copyright © Sandvik 13 (298)

Identification plate location

1.2.2 Product manufacturer

14 (298) Copyright © Sandvik

1.2.4 Location of manuals on the product

1.2.5 How to identify the correct manual for the product

Copyright © Sandvik 15 (298)

1.3 Copyright notice

16 (298) Copyright © Sandvik

• Emergency stop: Function which is intended to 1) avoid dangerous

1.5 Terminology and abbreviations

Copyright © Sandvik 17 (298)

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18 (298) Copyright © Sandvik

2 Safety and Environmental Instructions

Copyright © Sandvik 19 (298)

2.1 Safety labels, safety messages and signals

This general hazard symbol identifies important safety messages in this

20 (298) Copyright © Sandvik

2.1.3 Mandatory action symbols

Wear protective gloves Wear eye-protector Wear safety helmet

Wear hearing protec-

Wear high visibility

Use cardboard for locat-

General mandatory action

Copyright © Sandvik 21 (298)

2.1.4 Prohibited action symbols

No climbing No smoking No open flames

Do not touch Limit or restrict access Do not weld

Do not remove safety General prohibited action

22 (298) Copyright © Sandvik

2.1.5 Hazard symbols

Mechanical hazard symbols

Falling load hazard Crushing hazard Flying material hazard

Crushing hazard - feet Crushing hazard - hands Cutting hazard

Entanglement hazard Entanglement hazard Entanglement hazard

High pressure injec-