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Original instructions

REVISION 0

Maintenance Manual
lh208l
FOR SERIAL NUMBER: LH208L-4882
Contents

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.1 How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Scope of the Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Intended User of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 About the Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Intended Use of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5.1 Restrictions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Incident Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Warning and Information Symbols Used in this Manual. . . . . . . . . . . . 11
1.9 Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.1 Safety Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Warning and Information Symbols Used in This Manual . . . . . . . . . . . 14
2.2.1 Safety Symbols Pertaining to the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Main Safety Risks of Equipment Operation or Maintenance Work . . 17
2.3.1 Making modifications to the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.1 Disposal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Restrictions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7.1 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7.2 Fire Suppression System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7.3 After a Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8 Emergency Stops and Stopping Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.9 Operation Prevention Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.9.1 Operator’s Compartment Door (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10 Locking Devices (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10.1 Frame Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10.2 Boom Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.11 Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.12 Escape Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.13.1 Seat Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.14 Back-Up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.15 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.16 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.17 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.18 Hydraulics Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.19 Pressure Accumulators Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.20 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.20.1 Working on Live Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.21 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.22 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.23 Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.23.1 Working With Inflated Tires and Multi-Piece Wheel Rims . . . . . . . . . . . . . . . . . . 33
2.23.2 Safe Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.23.3 Tire Handling Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.24 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.25 Noise Level and Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.26 Vibration Emission Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.27 Warning Decals on the Equipment (General) . . . . . . . . . . . . . . . . . . . . . . 36
2.27.1 Warning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.27.2 Danger Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.27.3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.27.4 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.28 Warning Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.28.1 On Machine Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.28.2 Inside the Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3 MACHINE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41


3.1 Terminology and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3 Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4 Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.5 Description of Controls and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5.1 Operator’s Display (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5.2 Ignition Switch (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5.3 Front Lights Switch (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5.4 Rear Lights Switch (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5.5 High/Low Beam Switch (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.5.6 Blinker Switch (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.5.7 Service Indicator Lights (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.5.8 Alarm Light (8) and Warning Light (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.5.9 Bucket Counter Button (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.10 Stop Engine Override Button (SEO) (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.11 Brake Test Button (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.12 Brake Release Pump Button (13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.13 Cabin Light Switch (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.14 Park/Emergency Brake Light/Button (15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.15 Main Circuit Breaker Release Button (16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.16 Emergency Stop Button (17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.17 Engine Diagnostic Tool Connector (If Equipped) (18) . . . . . . . . . . . . . . . . . . . . . . 48
3.5.18 Steering Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.19 Bucket and Boom Control Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5.20 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
3.5.21 Service Brakes Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5.22 Weighing System Display (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6 Control System Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6.1 Common symbols on the display windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.6.2 Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4 PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65


4.1 Importance of Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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4.2 General Notes on Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2.1 General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3 Special Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3.1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3.2 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.4 First Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5 Every Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.6 Every Week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.7 Every 125 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.8 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.9 Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.10 Every 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.11 Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.12 Every 2000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83


5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1.1 General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1.2 Check All Controls are Functioning Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1.3 Test the Bucket and Boom Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.1.4 Test Service and Parking Brake Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1.5 Check Brake Release System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1.6 Test Transmission Hydraulics, Test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1.7 Test Bucket Hydraulics, Test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1.8 Test Steering Hydraulics, Test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2.1 Check Portable Fire Extinguisher (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2.2 Check Operator’s Compartment Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2.3 Check the Fire Suppression System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2.4 Drain Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2.5 Check Oscillating Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.3.1 Grease the Driveshafts, Yokes and Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . 94
5.3.2 Grease the Central Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3.3 Lubricate Operator Seat Linkages, Brake and Throttle Pedal Linkages. . . . . . . 96
5.3.4 Lubricate Door and Hatch Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.4 Powerpack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.4.1 Change Engine Oil and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.4.2 Clean the Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.4.3 Change Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.4.4 Service Air Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.4.5 Check Intake Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.4.6 Check Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.4.7 Check Engine Mountings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.4.8 Check Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.4.9 Change Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.5 Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.5.1 Check Tire Pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.5.2 Check Wheel Nuts’ Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.5.3 Change Transmission Oil and Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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5.5.4 Check the Torques of the Powertrain Flanges and Bolts . . . . . . . . . . . . . . . . . . 107
5.5.5 Change the Oil in the Plantetary Hubs and Differential . . . . . . . . . . . . . . . . . . . 107
5.5.6 Check the Torque of the Axle Fastening Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.5.7 Measure the Brake Lining Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.6 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.6.1 Wash Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.6.2 Change Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.6.3 Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.6.4 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.6.5 Change Brake System Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.6.6 Test the Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.6.7 Check the Pressure Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.6.8 Check Major Components for Oil Leaks and Mounting . . . . . . . . . . . . . . . . . . . 116
5.7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.7.1 Check Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.7.2 Check Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.7.3 Check the Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.7.4 Check Junction Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.7.5 Check Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.7.6 Check Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

6 LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119


6.1 Importance of Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2 General Notes on Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2.1 General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.3 Lubricant and Coolant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . 122
6.3.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
122
6.3.2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
6.3.3 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
122
6.3.4 Brake Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3.5 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
123
6.3.6 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
123
6.3.7 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.4 Filling Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.5 Special Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.5.1 Cooling System (Non Air Cooled Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.5.2 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.6 First Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

7 ADDITIONAL INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127


7.1 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.2 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.3 Lifting Methods and Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.4 Storing Intructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.4.1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.4.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.5 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.6 Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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8 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
8.1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
8.1.1 Torque Values for Standard Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
8.1.2 Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
8.1.3 Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
8.1.4 UNC (Coarse Threaded) Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.1.5 UNF (Fine Threaded) Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.1.6 Torque Values for Locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.3 Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.4 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8.5 Steering Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8.6 Bucket Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8.7 Standard Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.8 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.9 Other Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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8 Copyright © Sandvik Mining and Construction
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MAINTENANCE MANUAL lh208l

1. Introduction

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1. INTRODUCTION

1.1. How to Use this Manual


The manuals are designed and intended to: guide the use and maintenance of the machine;
describe its abilities; and identify important safety risks and maintenance concerns.

The manuals are an important part of the machine. The manuals should be:

• available to the operator and maintenance personnel at all times;


• read fully and carefully by anyone who helps maintain or operate the machine; and
• read fully and carefully before the machine is started, operated, and before preventative or
other maintenance is performed.
For operating instructions, please refer to the Operator’s Manual. For preventative maintenance
information, please refer to the Maintenance Manual. For repair procedures, please refer to the
Service and Repair Manual. For spare parts information, please refer to the Parts Manual.

1.2. Scope of the Manual


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 maintance 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 Service and Repair Manual provides
detailed service and troubleshooting procedures, schematics, complete technical specifications,
and vendor material.

1.3. Intended User of the Manual


The Operator’s Manual should be read, understood, and used by any person operating or providing
daily maintenance to the machine. The intended users of the Maintenance Manual are
maintenance personnel providing scheduled or preventative maintenance to the machine. The
Service and Repair Manual should be used by skilled service personnel performing overhaul or
repair procedures on the machine.

1.4. About the Warranty


Sandvik Mining and Construction warrants new equipment to be free from defects in material and
workmanship. The warranty period for this machine is twelve (12) months or two thousand (2000)
operating hours, whichever comes first, calculated from the date of start-up inspection at the first
end user.

The warranty is subject to terms and conditions. Contact your local Sandvik Mining and
Construction representative for more information regarding the warranty on your equipment.

1.5. Intended Use of the Machine


The following guidelines are recommended not only to ensure the long life of your machine, but also
to provide a safe working environment. The manufacturer or supplier will not be liable for any
damage resulting from product misuse. Please read and follow these guidelines carefully before
operating the machine:

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1. This machine shall only be used:
• For its intended use
• When it is in proper technical condition
• By a trained operator aware of safe operating procedures and possible danger
• In strict notice, use, and regard of the Operator’s Manual
2. This machine is designed to load, haul, and dump rock material exclusively and should be
used for that purpose only.
3. All operators and service personnel should be familiar with the operation, inspection, and
maintenance instructions provided in this manual.
4. Always obey local safely rules related to accident prevention and environmental protection.

1.5.1. Restrictions of Use


1. Only trained and authorized personnel shall operate and service this machine.
2. Operators and all persons in the machine’s general area will follow all safety rules at all
times.
3. Only one person will operate or ride in this machine at any one time.

1.6. Unit Identification


All machines are assigned a model and serial number. These numbers can be found on the
machine identification plate, located in the operator’s compartment.

Figure 1: Unit Identification Plate

1.7. Incident Reporting


In the case of an accident involving the machine, follow mine site reporting and investigation
procedures and report the incident to Sandvik Mining and Construction as soon as possible.

Mechanical or other failures on the machine must be reported to your supervisor. Lock out the
machine and do not operate it until corrective action has been taken.

1.8. Warning and Information Symbols Used in this Manual


Warning and information symbols are used throughout the manuals to emphasize general
information, mechanical concerns, or important safety messages that everyone using or maintaining
the machine should know. It is highly recommended that the reader review and follow all of these
messages.

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1.9. Contact Information


Technical Publications Department
Sandvik Mining and Construction Canada Inc.
4445 Fairview Street
Burlington, Ontario
Canada L7L 2A4
Tel: +1 (905) 632-4940
E-mail: tech.pubs@sandvik.com
Website: www.sandvik.com

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2. Safety

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2. SAFETY

2.1. Safety Essentials

Read and understand the operation and maintenance instructions. Do not


operate or perform maintenance unless you are qualified, and familiar with
these instructions. Do not take personal risks.

Make sure that a current copy of this manual is available for any persons installing, using,
maintaining or repairing the machine.

Only trained personnel should be allowed to install, set, operate, maintain, or decommission the
machine.

Training MUST be provided to make sure that safe working practices are followed. Exclusive
responsibility for proper training, operation and maintenance of the machine rests with the owner of
the equipment.

The manufacturer declines all responsibility for injury or property damage if the instructions and
precautions in this manual are not strictly followed.

2.2. Warning and Information Symbols Used in This Manual


The following is a description of the standard warning and information symbols used in this manual.

DANGER
This danger banner indicates an immediate danger related to a feature of the
device that will cause serious injury or death if the proper safety precautions
are not taken.

WARNING
This warning banner indicates a dangerous or unsafe manner of operation
that may cause serious injury or death if the proper safety precautions are
not taken.

NOTICE
This notice banner indicates a feature of the machine or manner of operation
that may cause damage to the machine.

The hazard symbol is used to alert the user of potential hazards. Safety
messages followed by this MUST be obeyed to avoid possible harm.

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2.2.1. Safety Symbols Pertaining to the Machine
The safety symbols found in this manual may also be posted on the machine. All personnel who
operate, repair, or service the machine must be familiar with and observe all safety symbols, labels
and instructions.

• Keep safety instructions and safety labels clean and visible at all times.
• Replace any illegible or missing safety instructions and safety labels before operating the
machine.
• Make sure replacement parts include safety instructions and labels.
Mandatory Action Symbols

These symbols are comprised of a white symbol on a blue background, and are used to alert the
user to an action that MUST be obeyed to avoid possible harm. These symbols cover the
mandatory use of personal protective equipment.

Wear Safety Wear Safety Wear Safety Wear Safety


Gloves Eye Protection Helmet Harness

Wear Safety Wear Safety Wear Tight Wear Safety


Ear Protection Steel Toe Boots Fitting Clothing Visibility Vest

Wear Safety Disconnect Power Switch Off and Read the Manuals
Respirator From Supply Lock Out Equipment or Instructions

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Prohibited Action Symbols

These symbols are comprised of a red circle with a red diagonal line on a white background, and
are used to alert the user to an action that MUST NOT be performed, in order to avoid possible
harm.

No Climbing No Smoking Do Not Touch No Open Flames

Restricted Access Do Not Weld Do Not Remove


Safety Guard

Hazard Symbols

These symbols are comprised of a black symbol in a triangular yellow background. Hazard symbols
are used to alert the user of potential hazards. Safety messages that follow these symbols MUST
be obeyed to avoid possible harm.

General Hazard Crushing Hazard Crushing Hazard Crushing Hazard Falling Load
Feet Hand Body Hazard

Entanglement Entanglement Entanglement Chemical Burn Cutting Injury


Hazard Hand Hazard Hand Hazard Body Hazard Hazard

Electrical Electric Shock Electrocution Silica or Other


Hazard Hazard Hazard Dust Hazard

Trip Hazard Falling Hazard Lifting Hazard Environmental


Pollution Hazard

Explosion Hazard Flying Material Flammable Poisonous Material


Hazard Hazard Hazard

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2.3. Main Safety Risks of Equipment Operation or Maintenance Work

Ensure that there are no unauthorized persons in the working area during
operation.

Ensure sufficient ventilation. When operating in confined spaces, exhaust


gases and dust must be directed so that they do not return to the working
area and create a health hazard.

Insufficient machine stability. Never exceed the specified maximum


inclination angles when operating, tramming, or parking.

Dangerous machine movement. To avoid death or serious injury, NEVER


work beneath the machine, or a load, unless supported.

Hazardous moving parts (lift arm, forks, haulage bed, QDS attachments).
Make sure that there are no unauthorized persons in the danger area during
tramming or servicing.

Danger of slipping, tripping, or falling. Keep the ladders, steps, hand rails,
handles, and working platforms clean of oil, dirt, ice, tools, etc.

Danger of slipping and falling. Avoid working on top of the machine covers.
If it is necessary to work in this area, ensure appropriate safety measures
are in place. Avoid working near the edges.

Danger of crushing. Can cause severe injury. Be careful when mounting


locking device. Do not stand in the area where the crushing hazard warning
labels are located.

Danger of burns. Avoid hot surfaces. Wear suitable protective equipment.


RISK OF FIRE. Keep flammable materials and chemicals such as fuel and oil
away from the machine whenever conveying flammable or hazardous
products such as coal, etc.

Danger of high pressure oil jets. High pressure oil jets can cause serious
personal injuries. Release the pressure in the hydraulic circuit before
opening caps or connections.

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Entanglement hazard. Loose clothes, jewelry, long hair or body parts can
get caught in running machinery.

Prolonged exposure to loud noises can cause impairment or loss of hearing.


Wear a suitable hearing protection device such as earmuffs or ear plugs to
protect against objectionable or uncomfortably loud noises.

Ensure sufficient lighting. Working in poor lighting conditions increases the


risk of hazardous situations.

Operation of the equipment is prohibited if any of the safety devices are not
working or are not in appropriate condition.

2.3.1. Making modifications to the Product


SANDVIK EQUIPMENT IS DESIGNED TO BE SAFE TO OPERATE AND TO COMPLY WITH
INTERNATIONAL AND LOCAL STANDARDS AND LEGISLATION. DO NOT DO ANYTHING
THAT MAY HAMPER SAFETY FEATURES ON EQUIPMENT.

It is stricly forbidden to make ANY modification to a Sandvik product without prior written approval of
the factory. If ANY modifcations are made without written approval, Sandvik cannot be held
responsible for any accidents, incidents, or damage to persons or property that are related to use of
the equipment after said modifications, especially if modifications are made on any safety feature
including, but not limited to, safety-critical circuits or components.

In many cases, the affect of a modification to a machine’s total performance is unknown and there is
a risk of injury. Therefore, if a machine is modified for any reason, even if safety is not affected,
Sandvik warranty shall be void.

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2.4. Safety Instructions

Operation, maintenance, and adjustments are only allowed by persons with


specific training in operation and maintenance of the equipment. Read the
operator and maintenance instructions before using or servicing the
equipment.

Plan your work carefully in advance to avoid possible accidents and injuries.
The operator must be familiar with the functions of the equipment before
taking it into use.

The operator must always wear required personal protection, such as a


safety helmet, protective clothing, safety boots, hearing protection, safety
goggles, etc., as dictated by company policy or local regulations.

Maintenance work, such as cleaning, lubricating, or adjusting components,


should be carried out only when the machine is stopped and protected
against unprejudiced start of the engine. Use the correct tools suitable for
the work. Replace or repair faulty tools and equipment. Ensure that there
are no unauthorized persons in the working area when you carry out
maintenance and repair work.

In the case of machine malfunction, stop immediately and safeguard the


machine. Have the malfunction repaired immediately.

Always have a fire extinguisher at hand, and learn how to use it. Have the
extinguisher inspected and serviced regularly according to the local
regulations.

If you have to weld on the machine, disconnect the alternator cables and
open the main switch before starting to weld. Consider also the fire and
explosion risk caused by welding. Ensure that the machine and its
surroundings are clean and fire-safe.

Always test the machine after any service or maintenance work, prior to
starting regular operation.

2.5. Environmental Precautions

2.5.1. Disposal Considerations


All fluids and lubricants used in the machine may meet the requirements of a hazardous waste
classification. Check your local, provincial, and federal environmental standards before disposing of
waste materials.

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2.6. Restrictions of Use


1. Only trained and authorized personnel shall operate and service this machine.
2. Operators and all persons in the machine’s general area will follow all safety rules at all
times.
3. Only authorized persons shall be present in the working area.
4. Safety systems shall be in working order at all times.
5. The loader shall not be used in an area charged with explosives, or an environment which
has been contaminated with explosive gases or explosive dust.
6. The loader will not be operated or maintained in areas with insufficient ventilation,
insufficient lighting or high water levels.
7. The machine will not be used for the transportation of persons.
8. The machine will not be used for towing other vehicles.
9. Care shall be taken in slippery conditions or in the presence of loose boulders.

2.7. Fire Prevention

In the case of a fire, evacuate the area to reduce the risk of injury from
flames, heat, hazardous vapors, explosions, and other hazards that may be
created.

Always obey local mandatory rules in the case of a fire.

In general, the following recommendations will help prevent the likelihood of a fire on the machine:

1. Keep the machine clean. Clean any and all fuel or oil spills as quickly as possible.
2. Repair all electrical wiring and electrical component malfunctions immediately.
3. Ensure the engine air intake, fuel, and exhaust systems are maintained properly.
4. Inspect the machine regularly for hydraulic oil leaks and make the necessary repairs
immediately.

2.7.1. Fire Extinguisher


Hand-held fire extinguishers provided with the machine contain multi-purpose dry chemical and
come in 10 and 20 pound (lb.) capacities. They are intended for small fires only.

The specific location of the hand-held fire extinguisher is determined by the customer.

Never attempt to fight a large or out of control fire with a hand-held fire
extinguisher.

If it is necessary to use the hand-held fire extinguisher, do the following:

1. Immediately bring the machine to a stop, apply the park/emergency brake, and shut down
the engine.
2. Exit the machine and stand at a safe distance away from the fire.

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3. Do not remain in the area if it is unsafe to do so. Refer to your local mine site regulations
for information on emergency exits and other related procedures.
4. Determine the location and size of the fire.
5. Prepare the fire extinguisher and familiarize yourself with its use according to the
instructions provided on the tank.
6. If safe to do so, approach the fire from the upwind side.
7. Hold the fire extinguisher upright and aim the spray of the fire fighting chemical at the base
of the fire until the fire is out.
8. Make sure the fire is out and can not start again.
9. Report the fire immediately to the appropriate personnel.
10. The fire extinguisher must be refilled immediately by trained, authorized personnel.
11. The machine must be cleaned and serviced by trained, authorized personnel before it is
put into operation again.

2.7.2. Fire Suppression System


The manual activation of the fire suppression system is actuated by two actuator buttons located in
the operator’s compartment and in the engine area. Each button is equipped with a ring pin to
prevent accidental activation of the fire suppression system.

NOTE: Ensure the ring pins are present before the start of each shift.

1. Actuator Button 3. Cartridge


2. Ring Pin

Figure 1: Fire Suppression Button/Actuator

NOTE: There is considerable noise accompanied by clouds of dry chemical when a fire suppression
system is discharged. While breathing foreign particles may be unpleasant, the dry chemical
agen used is non-toxic and exposure during a fire is not harmful.

NOTE: Fire suppression systems do not extinguish fires, they suppress them.

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If it is necessary to manually activate the fire supression system, perform the following actions:

1. Immediately bring the machine to a stop, apply the park/emergency brake, and shut down
the engine.
2. Remove the ring pin from the manual actuator and strike the red button. When the actuator
is activated, the engine is automatically turned off and fire suppressing chemicals are
expelled into various sections of the machine to suppress the fire.

NOTE: The fire suppression system can only be used once before it must be refilled and serviced.

The fire suppession system is designed to suppress fires in their early


stages. Do not hesitate to activate the fire suppession system immediately if
you detect a fire on the machine. The earlier the system is activated, the
more effective it will be.

3. Quickly exit the operator’s compartment and move to a safe distance.


4. The machine, including the fire suppression system, must be cleaned and serviced by
trained, authorized personnel before it is put into operation again.

2.7.3. After a Fire


1. Report the fire immediately to the appropriate personnel.
2. The machine must be cleaned and serviced by trained, authorized personnel before it is
put into operation again.

2.8. Emergency Stops and Stopping Devices


This machine is equipped with three emergency stop buttons, one in the operator’s compartment
and two on the rear frame.

Figure 2: Emergency Stop Button Locations

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.

Always ensure free access to the emergency stop buttons.

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Check the operation of the emergency stops daily.

2.9. Operation Prevention Functions


The following features prevent unsafe operation of the machine.

2.9.1. Operator’s Compartment Door (If Equipped)


The operator’s compartment door is equipped with an internal sensor to ensure it is closed fully
during operation. The steering control lever is disabled when the door is opened. The park/
emergency brakes will apply whenever the door is open.

The park/emergency brakes will apply if the door is opened while the
machine is tramming. Be prepared for a sudden stop.

The steer control lever is only disabled when the transmission shifter is in
the neutral position and the operator’s compartment door is open. Never
exit the machine while the transmission shifter is in the forward or reverse
position.

2.10. Locking Devices (If Equipped)

2.10.1. Frame Locking Pin


The frame lock is a safety device designed to prevent the machine from articulating while operators
or service personnel are working in the centre articulation area.

Always install the frame lock before working in the centre articulation area.

To install the frame lock, do the following:

1. Apply the park/emergency brake, set the transmission in neutral, and attempt to straighten
the machine as much as possible.

NOTE: The frame may also be locked when articulated in either direction as well as in the center
position.

2. Remain in the operator’s compartment and have a second person remove the frame lock
from its storage position.

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Figure 3: Frame Lock Pin in Storage Position

Do not articulate the machine while other personnel are working the centre
articulation area.

An operator must be in the operator’s compartment and in full control of the


machine while it is active.

3. Have the second person align the pin with the holes in the frame in the centre articulation
area.

Figure 4: Frame Lock Installation Point

4. If the second person is unable to install the frame lock, have the second person step away
from the machine.
5. Gently articulate the machine in attempt to properly align the holes in the frame.

Ensure that all personnel are clear of the centre articulation area before
articulating the machine.

6. Have the second person attempt to install the frame lock again.
7. Once the frame lock is installed, shut down the machine and follow the lock-out procedure
defined by your local mine site.

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2.10.2. Boom Locking Pin
The boom lock is a safety device designed to prevent the boom from lowering while operators or
service personnel are working in the boom/lift arm area.

Always install the boom lock before working in the area of the raised boom/
lift arm.

To install the boom lock, do the following:

1. Apply the park/emergency brake, set the transmission in neutral, and attempt to straighten
the machine as much as possible.
2. Remain in the operator’s compartment and have a second person remove the boom lock
from its storage location.

Figure 5: Boom Lock Storage Location (Left Side)

Do not articulate the machine while other personnel are working the centre
articulation area.

An operator must be in the operator’s compartment and in full control of the


machine while it is active.

3. Raise the boom/lift arm high enough that the boom lock pin can be installed without the
boom lock support touching the front frame.
4. Have the second person insert the boom lock pin the boom/lift arm.
5. If the second person is unable to install the boom lock support, gently adjust the boom/lift
arm height.

Ensure that all personnel are clear of the moving parts before adjusting the
boom/lift arm.

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6. Have the second person attempt to install the boom lock support again.
7. Repeat this procedure to install the second boom lock pin on the opposite side of the
boom/lift arm.
8. Once the boom lock pins are installed, gently lower the boom until the supports are in
secure contact with the front frame.

Ensure that all personnel are clear of the moving parts before adjusting the
boom/lift arm.

Always install both boom lock supports. Using only one boom lock support
does not properly secure the boom/lift arms.

9. Shut down the machine and follow the lock-out procedure defined by your local mine site.

2.11. Main Switch


The location of the main switch is on the rear frame of the machine on the left side. This unit is
equipped with a master disconnect lock, which prevents the electrical system from being turned on,
typically for safety purposes.

Figure 6: Master Disconnect

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Only authorized personnel should be permitted to lock and unlock the


master disconnect.
1. To unlock the master disconnect, obtain the key for the lock from your supervisor or
maintenance personnel, remove the lock, and flip the locking plate up.
2. To remove power from the machine’s electrical system, locate the master disconnect panel
and turn the master disconnect switch to the OFF position.

NOTE: Always turn the master disconnect switch to the off position before leaving the machine
unattended.

Only in an emergency should the master disconnect be turned off while the
engine is running. Turning the master disconnect switch to the off position
while the engine is running causes permanent damage to the machine’s
electrical system.

3. To return power to the machine’s electrical system, turn the master disconnect switch to
the ON position.

2.12. Escape Procedures


In the case of an emergency, exit the operator’s compartment as shown:

NOTE: The operator’s compartment is equipped with a removable window on the left of the operator’s
seat. It is also equipped with a removable panel on the right of the operator’s seat. The window
and panel are held in place by cotter pins, which can be removed if other methods of escape
are obstructed.

Figure 7: Operator’s Compartment Escape Routes

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Figure 8: Escape Window, Escape Panel, and Release Pins

2.13 ROPS/FOPS Canopy (If Equipped)


NOTE: ROPS/FOPS canopies are optional on open cab units and standard on closed cab units.

Rollover Protective Structures (ROPS) are overhead structures designed to reduce the possibility of
operators - who are wearing seat belts - being crushed if the machine they are operating should roll
over.

Falling Object Protective Structures (FOPS) are overhead structures that provide operators with
protection from falling objects such as loose rock.

WARNING

Always wear the seat belt when operating the machine.

Each new ROPS/FOPS has a certification plate that lists the SAE (Society of Automotive
Engineers) and ISO (International Standards Organization) standards to which it was certified. This
certification plate should be displayed on the ROPS/FOPS at all times.

NOTE: If the certification plate is missing or becomes illegible it should be replaced as soon as
possible.

Welding, drilling, cutting, or any addition of attachments, including fire


extinguisher brackets, voids SAE/ISO certification. To ensure the safety of
the operator, the ROPS/FOPS canopy must be replaced if it has been
damaged or altered in any way.

2.13.1. Seat Belt


A seat belt is standard on all machines equipped with a ROPS/FOPS canopy and must be worn by
the operator when the machine is in motion.

Never place the belt over your stomach. For safety reasons, the belt should
be placed over your lap only.

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2.14. Back-Up Alarm
The audible alarm sounds when the transmission is engaged in reverse direction. This notifies
other personnel in the area who may not be visible to the operator.

2.15. Refuelling

Smoking, open flames and sparks are dangerous when the fuel tank is being
filled!

• Do not fill the fuel tank when the engine is running.


• Do not overfill
• Take care not to spill fuel on hot surfaces
• Adding fuel should be done in a well ventilated space
• Clean up spilled fuel before starting the engine
• Keep the filling pipe in contact with the fuel tank, or arrange grounding to prevent sparking
caused by static electricity
• If fuel quick fill system is to be used, ensure that you are familiar with the system
manufacturer’s operating and safety requirements
• If the ambient temperature is less than 0°C, winter grade fuel (suitable down to -20°C)
should be used.

2.16. Cooling System

Never open the filler cap when hot. When checking the engine coolant level,
stop the engine and allow it and the radiator to cool down. If an overheated
engine must be stopped, allow the radiator to cool down before checking the
coolant level.

The cooling system may be very hot. Wear protective gloves and eye
protection before opening the radiator fill cap.

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2.17. Lubricants

Use caution when draining hot oil. Danger of scalding. Dispose of used oil
according to your local environmental regulations or mine site procedures.

Antifreeze/coolant may contain an ethylene glycol based solution or similar


chemical designed for use in engine cooling systems. Wear protective
equipment (such as splash goggles, rubber gloves, ventilation masks, etc.)
and ensure that the area is well ventilated. Refer to the material safety data
sheets (MSDS) provided by your supplier before handling antifreeze/coolant.

If antifreeze/coolant comes in contact with your skin and/or eyes, wash


immediately with water for a minimum of 15 minutes. If the fumes from
antifreeze/coolant are inhaled, move immediately to an area with fresh air.

2.18. Hydraulics Maintenance


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

• Do not attempt any such repairs that you do not fully understand.
• Never do any repair work on the hydraulic circuit when the system is pressurized.
• Always stop the engine before tightening or repairing a leaking hose connection.

Do not try to locate a leak in a hose or a connection by using your hand. The
high pressure oil spray from the leak can penetrate the skin and cause
serious injury.

• High pressure oil spray can also start a fire.


• Avoid direct skin contact with oil. Prevent oil from getting into your eyes; use eye
protection.
• Do not work under a device or component that is held up only by the hydraulics. Use
separate supports in conjuction with maintenance and repair.
• Do not remove boom cylinders or their valves unless the boom is properly supported and
the system is non-pressurized.
• Pipe connections, hose lengths and hose types must correspond with the specifications.
When replacing or repairing hoses, use original Sandvik spare parts or hoses and fittings
recommended by the manufacturer. Ensure that the pressure ratings of the hoses and
connecting fittings correspond with the working pressures.

2.19. Pressure Accumulators Maintenance


Hydraulic pressure must be fully exhausted in all stored-energy hydraulic circuits before any service
is conducted on related components.

Performing maintenance on components connected to an energized hydraulic circuit or “cracking”


hydraulic lines to relieve pressure in an energized hydraulic circuit is strongly discouraged by
Sandvik Mining and Construction.

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The following describes how to verify and/or relieve pressure in common hydraulic circuits and
equipment types. Including these steps in your regular maintenance procedures will help support
safe work practices in the work place.

Equipment and vehicles that use spring-applied, hydraulically-released brakes are equipped with an
automatic bleed-down valve that allows hydraulic oil in the brake circuit to drain to the hydraulic tank
once the engine and electrical system have been turned off.

There are currently two methods for verifying that the hydraulic brake pressure has been drained:

1. If the truck, loader, or hauler is equipped with a manual bleed-down valve, turn the rotary
dial counter-clockwise (left) to open a path between the hydraulic brake circuit and the
hydraulic tank.
2. If the truck, loader, or hauler is not equipped with a manual bleed-down valve, verify the
hydraulic brake pressure at the brake (or accumulator) test port. The test port is typically
located on the central hydraulic test port manifold. To measure the brake pressure, attach
a hand-held pressure gauge to the test port using a mini-check coupling connector and
monitor the gauge. The pressure reading should be zero.
If the accumulator pressure reading is higher than zero, it is possible that
the automatic bleed down valve is functioning incorrectly. If this is the case,
attempt to manually activate the spool (if equipped) or remove the
accumulator pre-charge gas in an attempt to remove pressure from the
circuit. Proceed to repair or replace the automatic bleed down valve only
after pressure in the circuit has been removed.

2.20. Electrical System Maintenance


• Work on electrical equipment or components is only to be carried out by qualified
personnel.
• Local electrotechnical and electrical safety regulations must always be observed.
• Always use only original electrical components.
• If disturbances in the electricity supply occur, stop the vehicle at once.
• Voltage must be cut off from the parts of the equipment or devices that are to be checked,
serviced or repaired. Ensure that the parts to be disconnected are not live and then lock
the main switch and properly ground the work area.
• Do not touch battery terminals, alternator terminals or wiring while the engine is operating.
Severe electrical shock, which may result in injury, could occur due to improper shielding of
electrical components.
• Check the electrical devices of the machinery regularly. Faults, such as loose wires and
damaged insulation, must be repaired at once.

2.20.1. Working on Live Components


• If the component must be live during the work, another worker must be standing by to cut
off voltage at the emergency or main switch should an emergency situation occur. Follow
electrical safety regulations.
• Use a red-and-white safety chain and warning signs to encircle the working area.
• Use only insulated tools.
• Observe special caution.

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2.21. Battery Maintenance

Batteries emit hydrogen gas when being charged at high voltage or in high
ambient temperature conditions. Never smoke or permit any kind of spark
or open flame near the batteries. If the batteries ignite, serious personal
injury could result in the form of acid and heat burns.

Batteries contain sulphuric acid. Always wear protective goggles and


rubber gloves when servicing or working with batteries. If you come in
contact with acid, flush the affected area with large amounts of water,
followed immediately by a baking soda and water mixture. To further
neutralize the acid, seek medical aid immediately.

• Always disconnect the negative (-) pole first, then the positive (+) pole. Always connect the
positive (+) pole first, then the negative (-) pole.
• Reversing battery polarity can result in personal injury caused by sudden discharge of
electrolyte from the battery vents and/or sudden rupture of the battery case due to
explosion of internal hydrogen gas.
• To prevent sparking when connecting a battery charger, disconnect the charger supply
cord or switch the charger off before connecting the charging wires to the battery terminals.
Open the battery’s cell caps slightly during charging to allow the gases generated to
escape.
• The acid in the battery burns skin, eats holes in clothing and can cause blindness if it gets
in the eyes. If you get battery acid on your skin, flush the spot at once with water. Flush
the eyes with plenty of water and call a doctor.
• When servicing batteries, remember that lead-acid batteries generate oxygen and
hydrogen during charging and discharging, which form a highly explosive mixture. A spark
or an open flame can cause an explosion. If necessary, ventilate the battery compartment
properly before disconnecting or connecting the cables.
• To prevent explosion, the electrolyte level must be maintained and checked regularly. Add
distilled water, if required, before starting, never immediately after use. With a high enough
electrolyte level, the cells have less space for gases.
• Use a flashlight when checking electrolyte levels, never an open flame.
• The battery terminals should never be shorted as sparks can cause the battery to explode.
• Do not test electrical devices by making contact with the battery terminal.

2.22. Welding
Most Sandvik trucks and loaders are equipped with specific electrical components that are sensitive
to stray currents. If steps to prevent electrical current from reaching certain electrical components
are not taken, serious damage to the component and expensive repair or replacement costs could
occur.

For this reason, the following components must be turned off or removed from the electrical system
before welding occurs on the machine:

1. Turn the master disconnect switch to the OFF position.


2. Disconnect the engine harness at the back of the instrument panel. This protects the
engine’s Electronic Control Module (ECM).
3. Disconnect all electrical connections from the alternator.
4. Disconnect all electrical wiring from the automatic lubrication system (if equipped).
5. If the machine is equipped with an automatic fire suppression system, remove the squib.

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6. If the machine is equipped with an Automatic Powershift Control (APC), disconnect all
wiring from the APC unit located in the operator’s compartment.
7. Position the ground wire as close to the area to be welded as possible.

Never place the ground wire near electrical wires.

2.23. Tire Maintenance


The regular maintenance and attention to tires and multi-piece wheel rims is important for two
reasons: it not only helps to prevent the possible dangers that can occur when a tire and/or rim is
poorly maintained, it also helps to avoid costly repairs or replacements.

NOTE: Maintenance of tires and wheel rims together is integral to the long service life of each. To
avoid costly repairs or replacements, tires and wheel rims should be viewed as a single unit
with each affecting the performance of the other.

2.23.1. 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.

An exploding tire or rim part, or the sudden release of air can cause severe
personal injury or death.

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.

Figure 9: Wheel Rim Trajectory Zones

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.

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2.23.2. 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.

2.23.3. Tire Handling Recommendations


1. Always use a suitable lifting device capable of supporting the weight of the tire.

Never stand under or near a suspended 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.

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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.

2.24. Safety Equipment


To ensure the safe operation of the machine, it has several standard safety features, plus additional
options available:

• Fire extinguisher
• Fire suppression system
• Emergency stop button in the operator’s compartment
• Emergency stop buttons on the machine’s rear frame
• Safety interlocks for machine movements
• Frame lock pin
• Boom lock pins
• Reverse alarm
• Rotating beacon
• Lockable main switch
• Seat belt
• Anti-slip tape strips
• Emergency exit
• Warning decals

2.25. Noise Level and Noise Emission


The noise emission and noise level at the operator’s position have been measured in accordance
with European Directive 98/37/EC.

• Sound pressure level at the operator’s position at high idle is to be determined during the
machine’s test phase.

Hearing protection should be worn when operating equipment with a noise


level greater than 85 dB.

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2.26. Vibration Emission Level


The vibration emission level has not been determined for this machine.

NOTE: Vibration values are highly sensitive to driving speed and terrain.

The vibration emission level given in this manual has been measured in
accordance with a whole body vibration standard ISO 2631-1:1997. The
vibration emission level may vary because of the different ways in which the
vehicle can be driven, including driving speed and surface smoothness, and
may increase above the level give in this manual. This could lead to
significantly higher exposure values when the vehicle is used regularly in
such a way, for example, when driven regularly at high speeds in very rough
terrain.

To be accurate, an estimation of the level of exposure to vibration


experienced during a given period of work should also take into account the
times when the vehicle is standing by and when it is running but not doing
work. This may significantly reduce the exposure level over the total
working period.

2.27. Warning Decals on the Equipment (General)


Machine decals should be considered a safety device. They are intended to alert personnel to
specific dangers and remind them of important procedures and practices.

All operators and service personnel should be familiar with the contents and locations of the
machine decals before using the machine.

NOTE: The decals shown below are examples only and may not appear on the machine. Refer to the
Parts Manual for a full listing of decals applicable to your unit.

Decals should be replaced immediately if damaged, missing, or illegible.

2.27.1. Warning Decals


Warning decals alert personnel to possible hazards in an area that could cause personal injury.
These decals typically warn of slipping dangers, high temperatures, or areas where high hydraulic
pressure could be released. Warning decals also remind personnel of safety devices at their
disposal. These decals should be understood and adhered to by all personnel working with the
machine.

Headings for these decals are orange with the word WARNING in bold, black lettering.

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Figure 10: Temperature Warning (Example)

2.27.2. Danger Decals


These types of decals highlight situations, areas, and/or components that could cause severe
personal injury or death when utilized or approached without care. These decals are typically
affixed near the area in which it refers to. For example, crushing hazard decals are located near
parts of the machine that move, instructing personnel to not stand in that area.

Banners for these decals are red with the word DANGER in bold, white lettering.

Figure 11: Dust Hazard Decal (Example)

2.27.3. Safety Instructions


These decals repeat important procedures and instructions found in the Operator’s and
Maintenance Manuals. Such instructions may cover brake test procedures, towing procedures, and
machine controls. These decals may also include Warning, Caution, Danger, and General
Information decals inside the overall decal.

Instruction type decals are typically located in the operator’s compartment or in the area of a control
device(s). The banner for the decal is typically green with a heading in bold, white lettering.

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Figure 12: Door Instructions Decal (Example)

2.27.4. General Information


These decals include symbols for control devices, important components, and/or fluid and lubricant
fill points.

64120722

Figure 13: Hydraulic Oil Decal (Example)

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2.28. Warning Label Locations
The following illustration details the location of warning labels on the machine. For your safety,
please observe all warning decals and follow their instructions.

2.28.1. On Machine Frame

2 3 5 8

9 3
1 1 4 6 7
8 13 16

15

14

11 10 1 3

SLIPPING
HAZARD.

10 3

7 5
12
1. Hazardous Boom Motion Warning 9. Explosion Hazard Warning (Batteries)
2. Roll Over Hazard Warning 10. Temperature Hazard Warning
3. Slipping Hazard Warning 11. Hydraulic Oil Label
4. Crushing Hazard Warning (Fingers) 12. Cutting Hazard Warning
5. High Pressure Hydraulic Oil Injection 13. Transmission Oil Label
Hazard Warning 14. Engine Oil Label
6. Safety Instructions (Door) 15. Explosion Hazard Warning (Accumulators)
7. Crushing Hazard Warning (Body) 16. Splashing Hazard Warning
8. Diesel Fuel Label

Figure 14: Warning Label Locations

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2.28.2. Inside the Cabin


The following illustration details the location of the safety labels located inside the operator’s
compartment and that pertain specifically to the safe operation of the machine.

1
7 3
6 5 4

1. Safety Instructions (Door) 5. Safety Instructions (Operating)


2. Restricted Visibility Warning 6. Safety Instructions (General)
3. Dust Hazard Danger 7. Loud Noise Hazards Warning
4. Safety Instructions (Parking)

Figure 15: Labels Inside Operator’s Compartment

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3. Machine Description

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3. MACHINE DESCRIPTION
The LH208L is an agile, low-profile loader designed for rigorous underground hard-rock mining
applications.

Figure 1: Sandvik LH208L Loader

NOTE: An analysis of the machine and the environment in which it is to be operated must be performed
before the machine is commissioned. This analysis must consider road conditions, altitude, air
quality, height and width restrictions, gradients, etc.

Read and understand the manuals prior to operating or maintaining the


machine.

Operating or maintaining the machine without proper training may result in


serious injury or death.

3.1. Terminology and Abbreviations


This section provides an explanation of some common abbreviations that may be used throughout
this manual:

• LHD = Load Haul Dump


• VCM = Vehicle Control and Management

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3.2. Technical Data

The mine/machine owner is responsible for performing an assessment of


the environment to determine whether it is appropriate for this machine.
This analysis must consider road conditions, altitude, air quality, height and
width restrictions, gradients, etc.

Operating Conditions
Maximum Ambient Temperature 43ºC @ 5000 FASL
Altitude

Measures of Components
Total Length 8788 mm 346 in
Maximum width 2692 mm 106 in
Height without canopy 1388mm 55 in
Height with canopy 1575 mm 62 in

Weights Operating Loaded


Total weight 17768 kg 39160 lb 25517 kg 56239 lb
Front axle 7541 kg 16620 lb 19089 kg 42042 lb
Rear Axle 10227 kg 22540 lb 6428kg 14167 lb

Capacities
Tramming capacity 7711 kg 17000 lb
Tipping load 20859 kg 45975 lb
Standard bucket 2.87 m3 3.75 yd3

Maximum Gradient and Tilt Angle


Maximum Gradient 11 degrees, 20%
Maximum Tilt Angle 8 degrees, 14%

Turning Radius Left Right


Inner 2769 mm 109 in 3023 mm 119 in
Outer 6020 mm 237 in 6045 mm 238 in
Turning Angle 42º

Seat Loading Capacity


Maximum Weight for Operator’s Seat 130 kg 286 lbs

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3.3. Main Component Locations

1 3 2

6 5 4 5 7
1. Rear Frame 5. Tires
2. Front Frame 6. Power Pack
3. Operator’s Compartment 7. Bucket
4. Center Hinge

Figure 2: Loader Components

3.4. Machine Orientation


When referring to the unit in this manual, the front is the bucket end of the machine, the rear is the
engine end of the machine, and the right and left sides are the operator’s right and left when looking
toward the front of the machine.

LEFT FRONT
REAR

RIGHT

Figure 3: Loader Orientation

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3.5. Description of Controls and Functions

1 7 8 9 10 15 18

3 4 5 6 2 11 12 13 14 16 17
1. Operator Display 10. Bucket Counter Button
2. Ignition Switch 11. Stop Engine Override Button
3. Front Lights Switch 12. Brake Test Button
4. Rear Lights Switch 13. Brake Release Pump Button
5. High/Low Beam Switch 14. Cabin Light Switch
6. Blinker Switch 15. Park/Emergency Brake Light/Button
7. Service Indicator Lights 16. Main Circuit Breaker Release Button
8. Alarm Light 17. Emergency Stop Button
9. Warning Light 18. Engine Diagnostic Tool Connector (If
Equipped)

Figure 4: Instrument Panel

3.5.1. Operator’s Display (1)


The display is situated on the left side of the front dashboard panel and the operator can use it for
checking gear selection, active statuses, clock, bucket count, alarm and faults, etc. For more
information, refer to Control System Display Module.

3.5.2. Ignition Switch (2)


Turn the ignition key in the ignition switch.

• Position P. parking lights on (only with key)


• Position 0. electric current off
• Position 1. electric power on
• Position 2. (not in use)
• Position 3. starting the engine

3.5.3. Front Lights Switch (3)


Press to switch on the front lights.

3.5.4. Rear Lights Switch (4)


Press to switch on the rear lights.

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3.5.5. High/Low Beam Switch (5)


Press the switch to turn on the high beam lights.

3.5.6. Blinker Switch (6)


The blinker switch activates the left and right turn signal lights.

Toggling the switch in one direction activates the left turn signals, and toggling it in the other
direction activates the right turn signals. Both front and rear turn signals are activated at the same
time.

3.5.7. Service Indicator Lights (7)

1 2 3 4 5

6 7 8

1. Charging light - on when 5. Transmission oil filter


alternator not charging clogged
2. Rear circuit breaker blown 6. Instrument Panel circuit
3. Engine air filter clogged breaker blown
4. Brake pressure filter clogged 7. Hydraulic oil filter clogged
8. Brake return filter clogged

Figure 5: Service Indicator Lights

3.5.8. Alarm Light (8) and Warning Light (9)


These indicator lights indicate the state of the machine and will give at a glance the same
information as the traditional gauges. Warning and alarm lights are there to inform if any of the
signals or measuring operations are in warning or alarm conditions or if any kind of action is
necessary.

Whenever a red or yellow indicator light is lit or whenever an alarm window appears on the display,
an abnormal functioning of the machine or control system will ensue. There is one exception: an
alarm light test can be run by turning the ignition key to 1-position, which makes the indicator lights
switch on for three seconds. Both lights must then go out.

The warning and alarm pop-up windows use big signs to indicate the reason for the alarm, the alarm
limit and the measured reading. Alarms from the engine control unit are also shown with the pop-up
windows on the display.

An active warning is indicated by a blinking triangle in the main window and the yellow warning light.
An active alarm is indicated by an exclamation mark inside a blinking triangle and the red alarm
light.

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3.5.9. Bucket Counter Button (10)
The bucket counter is on the upper left corner of the display’s main window (the bucket symbol and
a number).

The bucket counter value increases by one every time you press the bucket counter button on the
dashboard. The bucket counter can be reset by pressing the button for more than two seconds.

3.5.10. Stop Engine Override Button (SEO) (11)


During serious engine malfunction the red alarm light will go on and an alarm pop-up window will
appear on the display. Engine power will be reduced to a certain level for 30 seconds and after that
the engine will stop and the brakes will apply automatically. If the machine is operating in a critical
situation, the operator can select to “override” the automatic stop engine sequence by pressing and
holding the Stop Engine Override switch to prevent engine shutdown from occurring. It takes 30
seconds from the time the automatic shutdown sequence begins until the engine will shut down.
Therefore, the operator must press the override switch just prior to engine shutdown until the
vehicle can be brought to a stop in a safe location.

3.5.11. Brake Test Button (12)


Use the brake test button to test the park/emergency brake and service brake system condition.
Refer to the Operating Instructions chapter for the brake test procedures.

3.5.12. Brake Release Pump Button (13)


If the machine breaks down, the pressure needed for releasing the brakes can be produced with a
special brake release pump. After that the unit can be towed to a safe location. Refer to the Special
Instructions chapter for towing procedures.

Start the brake release pump by pushing and holding down the brake release pump button. Pull the
park/emergency brake light/button fully out and release it to the middle position. The pump
switches on/off to maintain brake release pressure until you release the brake release pump button
or the maximum pressure has been reached. The pump keeps the required pressure in the brake
system and the brakes will be released. When the brake release pump is used, the engine must be
stopped, the ignition switch must be in the RUN position, and the emergency stop must not be
activated.

3.5.13. Cabin Light Switch (14)


Press the switch to turn on the cabin light.

3.5.14. Park/Emergency Brake Light/Button (15)


Pushing the button down engages the park/emergency brake. Brakes engage automatically if

• Electrical current is cut off


• Emergency stop is activated
• Engine stops
• Door is open
• Hydraulic oil level is too low (optional)
• Accumulator pressure for brakes is too low
• Transmission oil pressure is too low
• Steering control valve fault is activated
• Gear is in neutral with 3 second delay (neutral brake option)
The brake is released by pulling the three-position button fully and releasing it to the centre position.

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3.5.15. Main Circuit Breaker Release Button (16)


In case of fire, lift the shield and press the button to release the main circuit breakers. If the main
circuit breaker release button has been pushed down, the rear frame circuit breaker box must be
opened and the circuit breakers must be reset to restore power.

NOTE: Pressing the main circuit breaker button may cut power to the communication radio (if
equipped).

3.5.16. Emergency Stop Button (17)


Pushing the emergency stop button engages the brakes and shuts down the engine. The button
must be pulled out before starting the engine. The emergency stop state also appears on the
display.

3.5.17. Engine Diagnostic Tool Connector (If Equipped) (18)


This is the connection port for the engine manufacturer’s diagnostic tool.

3.5.18. Steering Control Lever


The steering control lever is on the left side of the operator. The control lever is used to steer left
and right, change machine direction, declutch, and change gear.

4 5

3
1

1. Steering Lever 4. Higher Gear Selection Button


2. Declutch Button 5. Lower Gear Selection Button
3. Direction Selector Rocker Switch

Figure 6: Standard Steering Control Lever Functions

Steering

Pushing the lever forward turns the machine to the right and pulling the lever backward turns the
machine to the left.

The two forward and reverse gears (speeds) of the Power-Shift transmission are selected with
buttons on the steering lever.

DeClutch

It is possible to downshift gears or change driving direction while in DeClutch.

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When the machine is tramming in forward or reverse, and the operator presses the DeClutch
button, the transmission is shifted to neutral as long as this button remains pressed. Engine rpm can
be used for hydraulics without drive. Available gear range is set by a system parameter, usually first
and second gear. Releasing the button returns the transmission to the previously selected gear.

DeClutch mode can be set on or off. If the mode is on, the method of activation can be chosen from
the display: brake pedal, push button, both, or none.

Direction Selection

Driving direction is selected with the rocker switch. Forward (F) direction is selected by pushing the
lower end of the rocker switch down. Reverse (R) direction is selected by pushing the upper end of
the rocker switch down. The gear is in neutral when either Forward or Reverse is not selected
(middle position).

Gear Selection

When driving direction is selected, higher gears are selected by pushing the increase gear button
and lower gears by pushing the decrease gear button. Each time you push the button the gear will
increase or decrease by one, depending on which button you are using.

The selected gear, driving direction and the highest gear available are shown on the display in front
of the operator.

Under normal conditions, always bring the machine to a complete stop


before changing driving direction.

3.5.19. Bucket and Boom Control Lever


The bucket and boom control lever is on the right side of the operator. The control lever is used to
raise and lower the boom and to dump and roll back the bucket.

3
1

2 4

1. Boom/Bucket Lever 3. Windshield Washer Button


2. Bucket Float Button 4. Horn Button

Figure 7: Standard Bucket and Boom Control Lever Functions

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3
1

2 4

1. Boom/Bucket Lever 4. Horn Button


2. Bucket Float Button 5. Ejector Plate Control Rocker Switch
3. Windshield Washer Button

Figure 8: Ejector Bucket and Boom Control Lever Functions

Standard Movements

• To raise the boom - move the lever to the right.


• To lower the boom - move the lever to the left.
• To dump the bucket - move the lever forward.
• To roll back the bucket - move the lever backward.

NOTE: The functions of the bucket and boom control lever may be reoriented.

Button Functions

1. Horn
• Press the horn button to sound the horn.
1. Front and rear window washer/wiper (optional)
• The wipers can be controlled also with the switches on the instrument panel.
Wiper speed is controlled with an intermittent potentiometer.
• The front and rear window washer is controlled with the button 6. When pressing
the button, the front and rear window washers start and after an interval set with
a parameter the wipers start. When the button is released, the front and rear
window washers will stop after which the windows are wiped for a time period
set with a parameter. The intermittent timer does not affect this wiper function;
the wiping is continuous.
1. Bucket float
• Press the button to activate the bucket float.

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Rocker Switch Functions (Ejector Bucket Option)

• Push in the upper end of the rocker switch to retract the ejector plate.
• Push in the lower end of the rocker switch to extend the ejector plate.

NOTE: If the ejector bucket is in use, remember always to move the ejector plate in before loading.

3.5.20. Throttle Pedal


The throttle pedal controls the speed of the machine and its rate of acceleration. It is located on the
right side of the operator’s compartment, at the operator’s feet.

The further down the pedal is pressed, the faster the engine speed will increase. As the engine
RPMs increase, the machine will travel in the selected direction.

NOTE: If the load on the machine is less or equal to the machine’s capabilities, full ground speed can
be achieved.

NOTE: If the load on the machine exceeds its capabilities, ground speed will decrease regardless of
throttle position and engine speed. This helps to prevent engine stalling.

Figure 9: Throttle Pedal

3.5.21. Service Brakes Pedal


The service brakes pedal controls the application of the service brakes. It is located on the left side
of the operator’s compartment, at the operator’s feet.

Press the service brakes pedal to apply the service brakes during normal operations. The further
down the pedal is pressed, the greater the braking effort.

NOTICE
Whenever possible, use the deceleration of the engine to slow the machine
down, finally stopping it with the service brakes. Avoid resting your foot on
the service brakes pedal as even a light application of the brakes may result
in excessive heat and wear on brake components.

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Figure 10: Service Brakes Pedal

3.5.22. Weighing System Display (If Equipped)


If the machine is equipped with the optional Tamtron PKVS-300 weighing system, you will find the
scale’s electronic display located to the right of the operator in the operator’s compartment.

NOTE: For further information on operating the weighing system, refer to the Operating Instructions
chapter in the Operator’s Manual, or the Tamtron documentation in the Service and Repair
Manual.

Figure 11: Weighing System Scale Display

3.6. Control System Display Module


The system is used with the display module’s five buttons (buttons 1-5). By pressing the buttons,
the operator can move from one display window to another.

The functions of the buttons vary depending on the current display window. The symbols at the
bottom of the display window show which function is activated by pressing a button. For example,

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pressing the buttons on the main window shown in the picture above opens the following display
window options (the main window opens when the systems operating voltage is switched on):

Button Symbol Function


When the button is pressed, the service window opens.

When the button is pressed, the information displayed on the main


window changes.

When the button is pressed, the alarm log opens.

When the button is pressed, the information window opens.

When the button is pressed the gauge window 1 opens.

3.6.1. Common symbols on the display windows


To make using the user interface easier, the same symbols with the same functions are used in
various display windows.

Moving from one display window to another

Moving in the menu windows

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Adjusting the setting values

NOTE: Entering to the system service functions level requires a service level password. Entering is
allowed only by Sandvik Mining and Construction’s trained technical personnel.

3.6.2. Main Window


In normal use, after the main power is switched on, the main window appears on the display.

1. Gear indication 7. Alarm log window


2. Function status 8. Information window
3. Bucket counter 9. Forward screen (Gauge
4. Time display)
5. Service window 10. Tachometer
6. Display options 11. Fuel gauge

1. Gear Indication
Manual mode

The transmission mode can be selected from the gear mode switch. The selected mode is shown
on the display in front of the operator.

When Manual mode is selected, the operator can select gears upwards and downwards by pressing
the buttons on the steering joystick.

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The bar middle of the display indicates the following information:

1. Gears available forward 4. Reverse direction arrow


2. Forward direction arrow 5. Gears available reverse
3. Gear engaged 6. Manual mode selected
(Manual text darkened)

The selected driving direction (2, 4) is shown by darkened arrow.

Automatic mode (optional)

When automatic mode is selected, the operator selects only the driving direction with buttons on the
steering joystick and presses the throttle. The system automatically selects the most suitable gear
for operating conditions.

Operator can also limit a particular gear to be the highest available (3rd gear set to highest available
in the attached picture).

1. Gears available forward/ 4. Reverse direction arrow


highest gear limitation 5. Gears available reverse/
2. Forward direction arrow highest gear limitation
3. Gear engaged 6. Automatic mode selected
(Automatic text darkened

The selected driving direction (8, 10) is shown by darkened arrow.

2. Function Status
There are status symbols in the main display which indicate the status of various functions.

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Automatic central lubrication

The symbol to the upper left on the main window warns of malfunctions of the automatic central
lubrication. The symbol tells that the grease reservoir is empty (the picture of the grease gun
becomes darker) or that there are malfunctions in pressurizing (the picture of the grease gun and
the arrows above and below become darker).

Torque converter lock (not used on this model)

Boom float (optional)

The symbol to the left on the main window tells the status of the boom float functions. The symbol is
grey when float is not activated. When you press the float button, the symbol becomes darker to
indicate active float functions.

Ride control (optional)

The symbol to the left on the main window tell the status of ride control. The symbol is grey when
ride control is off. When you press the ride control button, the symbol becomes darker. Ride control
system is now on and will activate when operational parameters are fulfilled.

Blinkers

The symbol on the lower left corner of the main window shows whether the blinker is on or off. The
symbol flashes from grey to a darker grey when the blinker is on.

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DeClutch

The symbol to the upper right on the main window shows the status of the DeClutch. The symbol is
grey when DeClutch is not activated, and becomes darker when you activate DeClutch.

Emergency steering (optional)

The symbol to the right on the main window shows the status of the emergency steering. The
symbol is grey when emergency steering is not activated, and becomes darker when emergency
steering automatically activates.

Park/Emergency Brake

The symbol to the right on the main window shows the status of the park/emergency brake. The
symbol is grey when the park/emergency brake is released, and becomes darker when the park/
emergency brake is applied.

Brake accumulator pressure low

The symbol to the right on the main window shows the status of the brake accumulator pressure.
The symbol is grey when the accumulator pressure is at an acceptable level, and becomes darker
when the accumulator pressure is too low.

High beam driving lights

The symbol at the lower right corner of the main window shows whether the high beam lights are on
or off. The symbol is grey when the high beam lights are off, and becomes darker when the high
beam lights are on.

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3. Bucket Counter

The bucket counter is on the upper left corner of


the main window (the bucket symbol and a
number). The bucket counter value increase by
one every time you press the bucket counter button
on the dashboard. The bucket counter can be
reset by pressing the button for more than two
seconds.

The bucket counter reading can be set manually in


the service menu. Bucket counter can be reset
with the RESET button and the bucket counter
value can be increased or decreased with the “+/-”
button to its right.

4. Time and Date

The current time is shown in the upper right corner


of the main display. To adjust the time, use the
following instructions:

• Enter the maintenance window


by pressing “service” button.
After that, enter the time and
date window by pressing “>>”
button.
• Press “+” or “-” button until
hours or minutes field becomes
dark.
• Press “OK” button and after that
“+” or “-” button to increase or
decrease the value.
• Press “OK” button to accept the
value entered.
Set the date using the same instructions as those
used for setting the time.

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5. Service Window

The service window is entered by pressing the


“service” button in the main or some other menu.

In the service menu, you can for example adjust


DeClutch or display settings. DeClutch settings
can be entered only if the DeClutch mode is
available (DeClutch button is shown in the menu).

If the DeClutch mode is available, the way of


activation can be selected from the display: brake
pedal, push button, both or none.

From the service window, use “+” or “-” button to


highlight the “DeClutch” option, and press “OK”
button.

Use “+” or “-” button to select required activation


mode, pedal, button, both or none. Press “OK”
button to confirm selection.

In the display setting LCD contrast and brightness


can be adjusted.

From the service window use “+” or “-” button to


highlight the “display settings” option, and press
“OK” button.

Use “+” or “-” and “OK” button to adjust parameter


between 0-15 to suit operating conditions. Press
“OK” button to confirm.

In the display setting the display text language can


be changed to suit the country of operation.

Select display settings. Use “+” or “-” button to


highlight language field, and press “OK” button.

Use “+” or “-” button to select suitable text


language. Press “OK” button to confirm.

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6. Display Options

The display information can be selected from mode


switch (1). The selected mode is shown on the
display (2).

• speed (km/h)
• distance (km)
• distance (m)
• load (kg)
• engine hourmeter (he)
• machine hourmeter (hm)

7. Alarm Log Window

The alarm display is entered by pressing the “alarm


display” button in the main or some other menu. As
a default, by pressing the “alarm display” button,
display shows only the active alarms and on the
button 4 has text “All”.

By pressing the button 4 (“All”), all the alarms


except those that have been removed by pushing
the CLEAR button will be shown in the display.
Concurrently, the text on the button 4 changes to
“Active”.

By pressing the button 4 (“All”), all the alarms


except those that have been removed by pushing
the CLEAR button will be shown in the display.
Concurrently, the text on the button 4 changes to
“Active”.

Alarm messages warn the operator of a system,


component or operational fault. Window shows the
date and time when alarm or event has occurred.
Alarms and events are logged also into display’s
memory.

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To the left of the alarm line shows alarm status,


OFF or ON.

If the alarm mode is ON, alarm is active.

If the alarm mode is OFF, alarm is no longer active


and is recorded as history.

First time when the alarm appears, there can be


seen text New.

NOTE: If any warning or alarm appears in the


display, do not operate with the loader
until the cause has been determined and
possible fault has been repaired. Call a
service person.

Operator can scroll the alarms pressing the up and


down arrow buttons. Press “>>” button to move to
the next window.

Alarm messages can be removed from the display


by pressing the CLEAR button. Removed
messages can be restored by pressing the History
button.

Log file can be sent through the serial port to PC by


pressing the Send Log button.

If necessary, log file can be read also to display’s


memory by pressing the To File button.

8. Information Window
The information window is entered by pressing the
“question mark” button in the main or some other
menu.

For example, the information windows for the


following gauge displays are showing you the alarm and warning upper and lower limits for
pressure, temperatures and voltage.

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9. Gauge Display
Enter the gauge window by pressing next window “>>” button on the main window. there are four
gauge windows and they can be seen by using next window “>>” and previous window “<<“ buttons.

p moves back to main window.

1. Hydraulic oil temperature 4. Brake hydraulic oil


2. Transmission oil pressure temperature
3. Transmission oil temperature 5. Brake temperature left
6. Brake temperature right

Figure 12: Gauge display 1/4

1. Engine oil pressure 5. Turbo pressure


2. System voltage 6. Hourmeter (engine)
3. Engine coolant temperature 7. Hourmeter (unit)
4. Engine oil temperature

Figure 13: Gauge display 2/4

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1. Brake circuit charging 3. Brake circuit 1 pressure, rear


pressure 4. Brake circuit 2 pressure, rear
2. Brake pressure (with
automation unit)

Figure 14: Gauge display 3/4

1. Boom pressure (with ride 3. Boom/bucket pump pressure


control) (with automation unit)
2. Steering pump pressure (with
automation unit)

Figure 15: Gauge display 4/4

Active alarms and warnings are shown with the following symbols on the gauge window (the symbol
appears on the left hand side of the symbol for the sensor that the alarm or warning applies to):

Warning appears in the display with warning triangle.

Alarm appears in the display with warning triangle, an exclamation mark


inside.

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NOTE: If any warning or alarm appears in the display, do not operate the loader until the cause has
been determined and possible fault has been repaired. Call a service person.

10. Tachometer

The tachometer is in the center of the main window.


The arch aligned bars become darker according to
the engine rpm. Underneath the bars, rpm is also
shown in numeric value.

Engine idle . . . . . . . . . . . ~600 rpm


Max . . . . . . . . . . . . . . . . . . ~2300 rpm

11. Fuel Gauge

The fuel gauge is in the main window on the righ-


hand side of the tachometer. The vertically aligned
bars become darker according to the fuel level (all
bars dark = the tank is full).

The symbol of the gauge flashes if the fuel level is


low. Refuel immediately.

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4. Periodic Maintenance

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4. PERIODIC MAINTENANCE

4.1. Importance of Periodic Maintenance


The LH208L is designed for hard work in difficult and demanding mine conditions. To ensure
trouble-free and economical operation, it is extremely important to adhere to the service schedule
indicated. By paying close attention to the service schedule, you can easily detect possible defects
in the machine or other problems that can be addressed before they become serious. This will
ensure low repair costs and minimize disturbances in production.

The following pages give information for servicing various LH208L components and other items for
servicing, with their corresponding service intervals. All end users should review the Engine
Manuals for additional information regarding servicing.

This chapter describes the everyday and scheduled preventative maintenance guidelines and
procedures that will protect the machine from failure. This chapter includes information on:

• Fluid and lubricant specifications


• Preventative maintenance schedules and procedures
• Troubleshooting tips and tools

NOTE: For more information on preventative maintenance specifications and guidelines, refer to the
component-specific equipment manufacturer documentation provided in the Appendix.

A quality preventative maintenance program, coupled with safe and consistent work practices,
should be included in any mine site’s preventative maintenance program to ensure the extended life
of the machine and its individual components.

NOTE: The maintenance schedule is based on applicable OEM service schedules and Sandvik
standards for machine maintenance and is provided as a recommendation. Some intervals
may need to be adjusted based on mine-specific applications and/or environments. Be aware
that adjusting some service intervals may void warranties on specific components. Contact
your local Sandvik Mining and Construction regional office before adjusting service intervals.

The recommended schedule below lists, by maintenance interval, components that require regular
inspection or maintenance and refers to the section in this chapter where the procedure for
performing the inspection or maintenance can be found.

NOTE: For MSHA-approved permissible machines, all inspections and service listed in the
Preventative Maintenance Schedule should be performed in addition to the inspections listed in
the Permissibility Checklists. Where there is duplication between the preventative maintenance
schedule and the checklists, these items are indicated with an asterisk. For these items,
always follow the inspection interval and procedure listed in the permissibility checklist. Where
applicable, the checklists are provided in Appendix E.

4.2. General Notes on Maintenance Work


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

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

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Personnel must not wear long, loose hair or loose clothing, nor should they wear jewellery, including
rings, because of the risk of injury.

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

Do not perform any modifications, extensions or rebuilding of the machine that would affect safety.
Consult the supplier or manufacturer. This also includes the built-in and adjustment of safety
devices and valves, as well as the welding of frame structures.

Spare parts must meet the manufacturer’s technical specifications. Conformity to these standards is
guaranteed only when genuine spare parts are used.

Know the location and proper use of fire extinguishers

It is absolutely necessary to have suitable specialized workshop equipment to ensure high-quality


maintenance work.

Any maintenance or repair work on the machine must be performed by properly trained or instructed
personnel only. Work must be performed on electrical appliances by electricians and on hydraulic
appliances by mechanical technicians with knowledge and experience particular to the work to be
done.

Carry out any activity specified in this manual with respect to adjustment, maintenance and
inspection times, in addition to heeding any indications for replacement of parts.

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

Never attempt to clean, adjust, repair or lubricate the machine while it is in motion or the
engine is running.

4.2.1. General Repair Instructions


The person responsibility for maintenance and repairs should be clearly identified.

- Do not do any work that you are not authorized to do.


- Secure extensively, as far as necessary, the area where the maintenance work will be
performed.
- Inform the users of the equipment of the start of maintenance or any special work on the
loader.
- If the equipment or a part of it has been stopped for maintenance or repair, make sure that
it cannot be started accidentally.
- Turn the master switch off and lock out the machine according to your local mine site
procedures.
- Remove the ignition key
- Put a DANGER DO NOT START or corresponding warning sign on the main master
switch. The sign must be removed only by a person who is fully aware of the situation.
- If required, ensure that suitable and safe ladders or working platforms are available for use
in repair and maintenance work.
- Do not use any of the equipment as steps. If maintenance work must be done high up, or in
an otherwise dangerous place or position, use the safety devices necessary to prevent
falling.
- All platforms, steps, grips, rails, ladders and other similar parts must be kept clean of oil,
dirt, snow and ice to prevent accidents.
- Always use the right tools for the maintenance task.

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- Before commencing maintenance or repair work, ensure that the vehicle is on level ground
and won’t move.
- Pay special attention to the exhaust pipe-work and the exhaust gas cleaning system.
Ensure sufficient ventilation.
- Use a lift jack only on level, hard and firm ground. Before using a jack, always be sure that
the wheels on the other side of the vehicle are blocked. To prevent the possibility of the
jack slipping, secure the vehicle by using adequate supports and blocks underneath it.
- Remove all the air from the tire before loosening the wheel nuts/bolts. Should you forget to
do this, a broken rim part under pressure can fly apart and cause serious injury.
- Do not try to repair wheel parts by brazing, welding or reworking. Be sure to replace them
with new parts of the same size, type and make.
- Never transport a fully inflated spare tire mounted on demountable rims. Such tires should
have just enough air pressure to hold the rim parts firmly in place. Only after the tire and
rim assembly have been fastened with proper torque applied to all the wheel nuts/bolts,
should the tire be inflated to the correct operating pressure.
- In inflating, mounting or dismounting tires, a safety rack, cage or some other protection
should be used.
- During tire inflation, do not stand in front of the assembly. Use an extension hose so that
you can stand to one side.
- When replacing heavy parts, use correct lifting apparatus and techniques.
- After preventive maintenance and repairs, always tighten fasteners that have been
unscrewed. Reassemble all dismantled safety appliances immediately after the work is
done. Ensure that all safety systems are tested before the machine is returned to
normal work.
- Pay attention to safety and environmental protection when disposing of process materials
and old parts.

4.3. Special Notes


If the machine is fitted with optional equipment such as an automatic central lubrication system,
please read the instructions for the additional equipment carefully and adhere to the service
schedule given in the maintenance instructions.

4.3.1. Cooling System


• Drain and clean if the engine overheats or the solution is dirty

NOTE: Overheating indicates a fault. Stop the engine and repair the fault before more serious damage
is caused. Make sure that the engine radiator is not covered and that it is not clogged.

• Whenever draining and refilling the cooling system, always recheck the coolant level after
the engine reaches its normal operating temperature

Never open the filler cap when hot. When checking the engine coolant level,
stop the engine and allow it and the radiator to cool down. If an overheated
engine must be stopped, allow the radiator to cool down before checking the
coolant level.

• Adding new coolant too fast can cause air pockets in the cooling system.
• Operate with a thermostat in the cooling system all year round.

NOTE: Refer to the Manufacturer’s Engine Operation Manual for further details.

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4.3.2. Refuelling
The following precautions must be observed when adding fuel:

Smoking, open flames and sparks are dangerous when the fuel tank is being
filled.

• Do not fill the fuel tank when the engine is running.


• Do not overfill
• Take care not to spill fuel on hot surfaces
• Adding fuel should be done in a well ventilated space
• Clean up spilled fuel before starting the engine
• Keep the filling pipe in contact with the fuel tank, or arrange grounding to prevent sparking
caused by static electricity
• If fuel quick fill system is to be used, ensure that you are familiar with the system
manufacturer’s operating and safety requirements
• If the ambient temperature is less than 0°C, winter grade fuel (suitable down to -20°C)
should be used.

NOTE: See the Manufacturer’s Engine Operation Manual for further information.

4.4. First Service


Check that the lubricants being used meet site--specific operating requirements as per Sandvik
Lubricant Specifications.

The following steps should be carried out during the first week of use (in addition to the normal,
scheduled services):

After the first 20 hours

- Change the transmission filters


After the first 50 hours

- Change the hydraulic oil filters


- Change the brake cooling filter
- Change engine oil and filter elements
- Change fuel filters
- Check and tighten the exhaust manifold bolts
- Check the air filter and pipes are tight
- Check and tighten the oil sump and engine mount bolts
- Check and tighten the bolts on the axles, wheels, gearbox and other major components
- Tighten the bolts on the oscillation Axle
- Tighten the bolts on the drive shafts
- Check the V-Belts
- Check electrical connections and enclosures
- Make a visual overall check for leaks and possible damage

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After the first 100 hours

- Change the axle oil


- Check and Tighten the bolts on the Axles
- Check and lubricate the centre articulation assembly
- Service the transmission and torque converter breather
- Service the dry type air cleaner assembly
After the first 500 hours

- Check and adjust the engine valve lash

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4.5. Every Shift
Page Done
Check engine oil
Check drive belts
Check air filter assembly condition visually
Check intake and exhaust ducting and connections for leaks
Check transmission oil level
Check tires and wheel nuts
Check hydraulic oil level
Check engine coolant level
Test service and parking brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check major components for oil leaks and mounting
Check hand portable fire extinguisher
Check the driving/working lights
Check the indicator lights
Wash the radiator
Wash the charge air cooler (Machines equipped with air cooled engine)
Fill the fuel tank
Check fire suppression system visually
Check the automatic lubrication system (option)
Grease all points on central lubrication system

When Completed
Date Engine Hours
Special Notes

Approved

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4.6. Every Week


Page Done
Check engine oil
Check drive belts
Check air filter assembly condition visually
Check intake and exhaust ducting and connections for leaks
Check transmission oil level
Check tires and wheel nuts
Check hydraulic oil level
Check engine coolant level
Test service and parking brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check major components for oil leaks and mounting
Check hand portable fire extinguisher
Check the driving/working lights
Check the indicator lights
Fill the fuel tank
Check fire suppression system visually
Check operator’s door, canopy and lock condition
Check the automatic lubrication system (option)
Grease all points on central lubrication system
Wash the charge air cooler
Wash the hydraulic oil cooler
Check the tire pressures
Test transmission hydraulics, Test A Record =
Test transmission hydraulics, Test B Record =
Test transmission hydraulics, Test S Record =

When Completed
Date Engine Hours
Special Notes

Approved

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4.7. Every 125 Hours
Page Done
Check engine oil
Check drive belts
Check air filter assembly condition visually
Check intake and exhaust ducting and connections for leaks
Check junction boxes
Check cables
Check the instrument panel
Check tires and wheel nuts
Check transmission oil level
Check tires and wheel nuts
Check hydraulic oil level
Check engine coolant level
Test service and parking brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check major components for oil leaks and mounting
Check hand portable fire extinguisher
Check the driving/working lights
Check the indicator lights
Fill the fuel tank
Check fire suppression system visually
Check the automatic lubrication system (option)
Grease all points on central lubrication system
Grease driveshaft universal joint at center articulation
Wash the coolers
General cleaning
Check tire pressures
Check wheel nut torque
Test transmission hydraulics, Test A Record =
Test transmission hydraulics, Test B Record =
Test transmission hydraulics, Test S Record =

When Completed
Date Engine Hours
Special Notes

Approved

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4.8. Every 250 Hours


Page Done
Check intake and exhaust ducting and connections for leaks
Check junction boxes
Check Cables
Check the instrument panel
Check tires and wheel nuts
Check the hydraulic level
Change engine oil and filter
Change brake system return filter
Check transmission oil level
Check oil level in axle hubs and differential
Check engine coolant level
Test service and park brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check driving/working lights
Check indicator lights
Check major components for oil leaks and mounting
Check engine mountings
Check center articulation
Check batteries
Check alternator
Check hand portable fire extinguisher
Fill fuel tank
Check the fire suppression system
Check the operator’s door, canopy, and lock condition
Check automatic lubrication system (option)
Grease all points on central lubrication system
Grease driveshaft universal joint at center articulation
Grease driveshafts and shaft bearings
Lubricate door and hatch hinges
Service the air filter elements
Wash the coolers
General cleaning
Check the tire pressures
Check the wheel nut torques
Test transmission hydraulics, Test A Record =
Test transmission hydraulics, Test B Record =
Test transmission hydraulics, Test S Record =

When Completed
Date Engine Hours
Special Notes

Approved

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4.9. Every 500 Hours
Page Done
Check intake and exhaust ducting and connections for leaks
Check exhaust system fastenings
Check fan shroud
Check axle fastenings and oscillation axle torque
Measure wear to the brake linings
Check junction boxes
Check Cables
Check the instrument panel
Check tires and wheel nuts
Check the hydraulic level
Change engine oil and filter
Drain the water from the fuel tank
Change brake system return filter
Check transmission oil level
Change breather filter element for hydraulic tank
Change return oil filter element for hydraullic tank
Change high pressure oil filter element for brake hydraulics
Change transmission oil filter element
Check oil level in axle hubs and differential
Check engine coolant level
Test service and park brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check driving/working lights
Check indicator lights
Check major components for oil leaks and mounting
Check engine mountings
Check center articulation
Check batteries
Check alternator
Check hand portable fire extinguisher
Fill fuel tank
Check the fire suppression system
Check the operator’s door, canopy, and lock condition
Check automatic lubrication system (option)
Grease all points on central lubrication system
Grease driveshaft universal joint at center articulation
Grease driveshafts and shaft bearings
Lubricate door and hatch hinges
Service the air filter elements
Wash the coolers
General cleaning
Check the tire pressures
Check the wheel nut torques
Test transmission hydraulics, Test A Record =
Test transmission hydraulics, Test B Record =
Test transmission hydraulics, Test S Record =

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When Completed
Date Engine Hours
Special Notes

Approved

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4.10. Every 1000 Hours
Page Done
Check valve clearances
Check drive belts
Check intake and exhaust ducting and connections for leaks
Check exhaust system fastenings
Check catalytic exhaust gas purifier
Check fan shroud
Check axle fastenings and oscillation axle torque
Measure wear to the brake linings
Check junction boxes
Check Cables
Check the instrument panel
Check tires and wheel nuts
Change hydraulic oil
Change engine oil and filter
Drain the water from the fuel tank
Change brake system return filter
Change breather filter element for hydraulic tank
Change return oil filter element for hydraullic tank
Change high pressure oil filter element for brake hydraulics
Change transmission oil and filter element
Change the oil in the axle hubs and the front and rear differentials
Inspect the cooling system
Test service and park brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check driving/working lights
Check indicator lights
Check major components for oil leaks and mounting
Check engine mountings
Check center articulation
Check batteries
Check alternator
Check hand portable fire extinguisher
Fill fuel tank
Check the operator’s door, canopy, and lock condition
Check automatic lubrication system (option)
Grease all points on central lubrication system
Grease driveshaft universal joint at center articulation
Grease driveshafts and shaft bearings
Lubricate door and hatch hinges
Service the air filter elements
Wash the coolers
General cleaning
Check the tire pressures
Check the wheel nut torques
Test hydraulic pressures
Check pressure accumulators
Service fire suppression system
Test transmission hydraulics, Test A Record =

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Page Done
Test transmission hydraulics, Test B Record =
Test transmission hydraulics, Test S Record =

When Completed
Date Engine Hours
Special Notes

Approved

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4.11. Every 1500 Hours
Page Done
Check intake and exhaust ducting and connections for leaks
Check exhaust system fastenings
Check catalytic exhaust gas purifier
Check fan shroud
Check axle fastenings and oscillation axle torque
Measure wear to the brake linings
Check junction boxes
Check Cables
Check the instrument panel
Check tires and wheel nuts
Check hydraulic oil level
Change engine oil and filter
Drain the water from the fuel tank
Change brake system return filter
Change breather filter element for hydraulic tank
Change return oil filter element for hydraullic tank
Change high pressure oil filter element for brake hydraulics
Change transmission oil filter element
Change the oil in the axle hubs and the front and rear differentials
Drain and renew engine coolant
Check cooling system hoses
Test service and park brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check driving/working lights
Check indicator lights
Check major components for oil leaks and mounting
Check engine mountings
Check center articulation
Check batteries
Check alternator
Check hand portable fire extinguisher
Fill fuel tank
Check the fire suppression system
Check the operator’s door, canopy, and lock condition
Check automatic lubrication system (option)
Grease all points on central lubrication system
Grease driveshaft universal joint at center articulation
Grease driveshafts and shaft bearings
Lubricate door and hatch hinges
Service the air filter elements
Wash the coolers
General cleaning
Check the tire pressures
Check the wheel nut torques
Test hydraulic pressures
Check pressure accumulators
Service fire suppression system
Test transmission hydraulics, Test A Record =

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Page Done
Test transmission hydraulics, Test B Record =
Test transmission hydraulics, Test S Record =

When Completed
Date Engine Hours
Special Notes

Approved

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4.12. Every 2000 Hours
Page Done
Check valve clearances
Check drive belts
Check intake and exhaust ducting and connections for leaks
Check exhaust system fastenings
Check catalytic exhaust gas purifier
Check fan shroud
Check axle fastenings and oscillation axle torque
Measure wear to the brake linings
Check junction boxes
Check Cables
Check the instrument panel
Check tires and wheel nuts
Change hydraulic oil
Change engine oil and filter
Drain the water from the fuel tank
Change brake system return filter
Change breather filter element for hydraulic tank
Change return oil filter element for hydraullic tank
Change high pressure oil filter element for brake hydraulics
Change transmission oil and filter element
Change the oil in the axle hubs and the front and rear differentials
Inspect the cooling system
Test service and park brake function
Check that all the controls are functioning correctly
Check the brake releasing system function
Check driving/working lights
Check indicator lights
Check major components for oil leaks and mounting
Check engine mountings
Check center articulation
Check batteries
Check alternator
Check hand portable fire extinguisher
Fill fuel tank
Check the operator’s door, canopy, and lock condition
Check automatic lubrication system (option)
Grease all points on central lubrication system
Grease driveshaft universal joint at center articulation
Grease driveshafts and shaft bearings
Lubricate door and hatch hinges
Service the air filter elements
Wash the coolers
General cleaning
Check the tire pressures
Check the wheel nut torques
Test hydraulic pressures
Check pressure accumulators
Service fire suppression system
Test transmission hydraulics, Test A Record =

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Page Done
Test transmission hydraulics, Test B Record =
Test transmission hydraulics, Test S Record =

When Completed
Date Engine Hours
Special Notes

Approved

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5. Maintenance Instructions

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5. MAINTENANCE INSTRUCTIONS

5.1. General

Figure 1: Sandvik LH208L Loader

5.1.1. General Cleaning

Be careful when using high-pressure cleaning units. Make sure you have a
minimum gap of one half meter between the core and nozzle.

• Operator’s compartment (do not use high pressure water when cleaning the compartment.)
• Engine Compartment:
Before cleaning the machine with water, or by steam jet or other cleaners, cover the alternator,
connection boxes, and major connections.

Do not direct the steam, water or solvent directly to the alternator, starter motor, or ECM electronic
components. Do not apply solvents to hot surfaces.

When cleaning the machine, ensure that all belly pans and other areas that may collect oil and dirt
have been cleaned thoroughly.

After the machine has been cleaned, apply multi-purpose grease to the grease ports on the central
lubrication manifold to ensure that all hinge points are properly lubricated.

5.1.2. Check All Controls are Functioning Correctly


Raise the lift arms, dump the bucket, roll back the bucket, and lower the lift arms with the engine at
1000-1500rpm.

Articulate the machine from left to right.

1. Steering Lever
Pushing the lever forward turns the machine to the right and pulling the lever backward turns the
machine to the left.

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Figure 2: Standard Steering Control Lever Functions

The two forward and reverse gears (speeds) of the Power-Shift transmission are selected with
buttons on the steering lever.

2. DeClutch
When the machine is tramming in forward or reverse, and the operator press DeClutch button, the
transmission is shifted to neutral as long as this button remains pressed. Engine rpm can be used
for hydraulics without drive. Available gear range is set by a system parameter, usually first and
second gear. Releasing the button returns the transmission to the previously selected gear.

It is possible to downshift gears or change driving direction while in DeClutch.

DeClutch mode can be set on or off. If the mode is on, the method of activation can be chosen from
the display: brake pedal, push button, both, or none.

1. Not in use.
2. Rocker switch for driving direction Forward (F), Neutral (N), Reverse (R)
3. Higher Gear (Upshift)
4. Lower Gear (Downshift)
Gear Selection Manual mode: Select with gear mode switch.

Driving direction is selected with the rocker switch. Forward (F) direction is selected by pushing the
lower end of the rocker switch down. Reverse (R) direction is selected by pushing the upper end of
the rocker switch down. The gear is in neutral when either Forward or Reverse is not selected
(middle position).

When driving direction is selected, higher gears are selected by pushing the increase gear button
and lower gears by pushing the decrease gear button. Each time you push the button the gear will
increase or decrease by one, depending on which button you are using.

The selected gear, driving direction and the highest gear available are shown on the display in front
of the operator. The word Manual under the display’s gear indication bar is darkened.

Gear selection Automatic mode (optional): Select with gear mode switch.

The system selects automatically the most suitable gear for the driving conditions. The operator
selects the direction with the rocker switch (change will occur when machine speed is reduced to a

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safe speed, set by parameter) and if needed, can also limit a particular gear to be the highest
available. The highest gear limitation is activated by pushing the increase gear button when the
current gear is set to the highest available, in both driving directions. The highest gear limitation is
deactivated by pushing the decrease gear button.

The selection gear, driving direction and the highest gear limitation are shown on the display in front
of the operator. The word Automatic under the display’s gear indication bar is darkened.

Under normal conditions, always bring the machine to a complete stop


before changing driving direction.

5.1.3. Test the Bucket and Boom Control Lever


The bucket and boom control lever is on the right side of the operator. The control lever is used to
raise and lower the boom and to dump and roll back the bucket.

Standard Movements

• To raise the boom - move the lever to the right.


• To lower the boom - move the lever to the left.
• To dump the bucket - move the lever forward.
• To roll back the bucket - move the lever backward.

NOTE: The functions of the bucket and boom control lever may be reoriented.

Button Functions

1. Horn
• Press the horn button to sound the horn.
2. Front and rear window washer/wiper (optional)
• The wipers can be controlled also with the switches on the instrument panel.
Wiper speed is controlled with an intermittent potentiometer.
• The front and rear window washer is controlled with the button 6. When pressing
the button, the front and rear window washers start and after an interval set with
a parameter the wipers start. When the button is released, the front and rear
window washers will stop after which the windows are wiped for a time period
set with a parameter. The intermittent timer does not affect this wiper function;
the wiping is continuous.
3. Bucket float
• Press the button to activate the bucket float.
Rocker Switch Functions (Ejector Bucket Option)

• Push in the upper end of the rocker switch to retract the ejector plate.
• Push in the lower end of the rocker switch to extend the ejector plate.

NOTE: If the ejector bucket is in use, remember always to move the ejector plate in before loading.

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Figure 3: Standard Bucket and Boom Control Lever Functions

Figure 4: Ejector Bucket and Boom Control Lever Functions

5.1.4. Test Service and Parking Brake Function


Leakage and Brake Function

Brake Test:

Check that the pressure in the brake system is 70 bar before testing.

Use brake test button to test the parking brake and service brake condition. Testing procedure is as
follows:

1. With the parking brake released, press the brake test button and keep it in the down
position. “Brake test, Please engage parking brake” text will be shown on the display (if you
release the test button, the text “Brake test aborted” will be shown). engage the parking
brake by pushing the brake control button 19 in the down position.

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Figure 5: Screen view from step 1

2. Do not press the brake pedal (service brake). Select the driving direction with the left hand
joystick’s FNR rocker switch. First gear (set by parameter) will be selected automatically.

NOTE: The system is allowed to select the first gear automatically only if:

• parking brake is engaged


• engine is running
• FNR rocker switch is set to F or R position after the brake test button has been
pushed in the down position.

Figure 6: Screen view from step 2

3. When the first gear is engaged automatically by the system, press the accelerator pedal
down.

Figure 7: Screen view from step 3

NOTE: When you press the accelerator pedal in down position:

• system limits the maximum RPM to 2030


• test is carried out to good effect if the maximum RPM is held 3 seconds without
the unit moving (park brake is okay) or the unit moves before the maximum RPM
is reached (park brake not okay). Otherwise, there will not be any entry in the log
file and the test accepting window will not be shown during the test.

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4. When the parking brake test is done the following window will appear. Release the
accelerator pedal and the brake test button. Set the gear to neutral.

Figure 8: Screen view from step 4

5. The test will proceed automatically to the service brake test.


Press the service brake pedal fully down.

Release the parking brake by pulling the brake control button fully up and release it to the center
position. Set the engine to idle.

• The system is now checking that the parking brake is released and after the
certain delay set by parameter, measures the brake pressures on both of the
brake circuits. After the brake pressures have been measured, the system
engages the parking brake automatically.

Figure 9: Screen view from step 5

6. The following window appears. “You have done brake test” Release the service brake. The
window will go off automatically after three seconds.

Figure 10: Screen view from step 6

7. The brake test accepting window will be shown. LH208L brake test requirements are as
follows:
• with RPM 2030 (1st gear) the machine is not moving.

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• front and rear brake circuit pressures must be zero.


The operator must either accept or discard the test.

Figure 11: Screen view from step 7

8. If the operator accepts the brake test, the display will show the text “Brake test done.” The
window will go off automatically after three seconds.

Figure 12: Screen view from step 8

9. If the operator discarded the brake test and pushed the fail button, the display will show the
text “Parking brake test aborted engine RPM under required limit.”
The operator has to set off the window by pushing the lower left hand button on the panel.

Figure 13: Screen view from step 9

10. As a result of the brake test, the “All alarms” log will have three lines.
When the operator accepted the brake test, the two lower lines in the window were added to the log
(if the operator did not accept the brake test, the lowest line in the log states “Operator did not
accept brake test results.”

The third lowest line was added to the log after the brake test button was released.

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Figure 14: Screen view from step 10

5.1.5. Check Brake Release System Functions


1. Push the brake releasing pump button on the instrument panel and keep in down position.
The pump should start. The pump stays on until releasing the button.
2. Pull the brake release button out and release to middle position.

NOTE: When using the brake release pump, the engine must not be running, the emergency stop must
not be activated.

Figure 15: Brake Release Control

5.1.6. Test Transmission Hydraulics, Test A


The transmission and hydraulics should be at operating temperature during the test.

1. Press the brake pedal.


2. Select the highest gear.
3. Accelerate the engine.
The engine should achieve about a 2250 -2350 rpm stall speed.

5.1.7. Test Bucket Hydraulics, Test B


1. Lower the boom against the stops.
2. Keep the control valve in the “boom down” position.
3. Accelerate the engine.
The engine should achieve about a 2250 -2350 rpm stall speed.

5.1.8. Test Steering Hydraulics, Test S


1. Turn the loader against the stops.
2. Keep the control valve in the selected position.

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3. Accelerate the engine.


The engine should achieve about a 2250 -2350 rpm stall speed.

5.2. Frame

5.2.1. Check Portable Fire Extinguisher (option)


• Gauge pointer in green area.
• No corrosion.
• Secure in mounting
• Visually check all seals are in place.

Figure 16: Portable Fire Extinguisher

5.2.2. Check Operator’s Compartment Condition


• Check that the operator’s door and latch is functioning correctly.
• Check the condition of the operator’s seat and adjustment levers are functioning.
• Check that the compartment is clean and free of debris.
• Check that the operator’s and safety manuals are present.

Figure 17: Operator’s Compartment

5.2.3. Check the Fire Suppression System (If Equipped)


The fire suppression system must be thoroughly inspected on a regular basis to ensure it will
function in an emergency situation.

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Figure 18: ANSUL Fire Suppression System

The procedure for inspecting the automatic fire suppression system is as follows:

1. Park the machine in a safe area clear of traffic and pedestrian flow, preferably on flat
ground.
2. Ensure the dump box is resting on the rear frame. If the machine is equipped with an
ejector box, ensure the ejector plate is fully retracted and the tailgate is closed.
3. Install wheel chocks on all four wheels.
4. Remove all actuator cartridges, install shipping caps, and store the cartridges in a safe
area for re-installation later on.
5. Visually inspect the actuator buttons, fire suppression hoses, connections, spray nozzles,
fire suppression tank, and pneumatic pressure switch for corrosion or damage.
6. Ensure that all fire suppression system components are securely mounted and that all
hose fittings are tight.
7. Ensure that all decals and labels on fire suppression system components are clean,
readable, and secured properly to the component. Replace any decals or labels that are
either missing or illegible.
8. Remove the fill cap from the fire suppression tank and ensure the level of FORAY dry
chemical inside is approximately 3” (76 mm) from the bottom of the fill opening. Further
ensure that the dry chemical is free of lumps. If lumps are present, drop one of the lumps
from a height of 4” (102 mm) onto a hard surface. If the lump does not disintegrate
completely, the dry chemical must be replaced.
9. Visually inspect the threads on the fire suppression tank fill cap and opening. Ensure the
cap and opening are free of nicks, burrs, and cross-threading.
10. Inspect the fill cap gasket and quad ring for elasticity, cuts, or other damage. Replace the
gasket or quad ring if necessary.

NOTE: Coat the fill cap gasket and quad ring with an extreme temperature silicate grease or gel before
re-installing the fill cap.

11. Disconnect the hose from the bursting disc located at the base of the fire suppression tank.
Visually inspect the bursting disk and ensure it is free of wrinkles, dents, or other
deformities. Reconnect the hose and tighten the fitting.

NOTE: Coat the thread of the bursting disc with an extreme temperature silicate grease or gel before
re-installing the fire suppression hose.

12. Ensure all nozzles are clean, unobstructed, properly aimed, and equipped with a blow-off
cap.

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13. Remove the pneumatic actuator(s) from the cartridge receiver(s) and inspect all threaded
areas for nicks, burrs, and cross threads. Further disassemble, clean, and replace all
gaskets in the pneumatic actuator. Re-install the actuator when finished.

NOTE: Refer to the manufacturer’s documentation in Appendix A for further information on


disassembling and cleaning the pneumatic actuator.

14. Remove the shipping caps from the actuator cartridges and re-install.

NOTE: Always weigh actuator cartridges, new or old, before installing them on the machine. If a
cartridge is 1/4 ounce (7.1 g) less than the weight stamped on the cartridge or more, it must be
replaced.

Ensure the actuator pin is retracted and the safety pin is installed before re
installing an actuator cartridge.

5.2.4. Drain Water from Fuel Tank


When the fuel in the tank is at a low level, drain the water from the fuel tank using the drain plug on
the bottom of the tank.

5.2.5. Check Oscillating Axle


Fastener Torques (lubricated)

Wheel Nuts 420 ft-lb. (569 Nm)


Axle Mount Nuts 500 Nm (368 lb.-ft)
Axle Mount Locking Nut 500 Nm (368 lb.-ft)
Oscillation M 12 70-80 Nm (52-60 lb.-ft)
Oscillation M 16 SHCS 176-180 Nm (130-140 lb.-ft)

Figure 19: Oscillating Axle (Exploded View)

5.3. Lubrication

5.3.1. Grease the Driveshafts, Yokes and Shaft Bearings


Grease the support bearings, driveshaft yokes and bearings with a hand grease gun.

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Figure 20: Driveshaft Lubrication Points

5.3.2. Grease the Central Lubrication System


Central lubrication points are located on the front and rear of the machine. The number stamped on
the lubrication block corresponds to the number on the grease information plate.

Figure 21: Central Lubrication Block (Typical)

Figure 22: Central Lubrication Front

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Figure 23: Central Lubrication Rear

5.3.3. Lubricate Operator Seat Linkages, Brake and Throttle Pedal Linkages

Figure 24: Brake and Throttle Pedal Linkages

5.3.4. Lubricate Door and Hatch Hinges


Lubricate the doors and hatch hinges, check that all doors and hatch covers are working properly.

Figure 25: Door Latches and Hinges

5.4. Powerpack

5.4.1. Change Engine Oil and Filters


1. Position the machine so it is on level ground.
2. Run the engine until it reaches operating temperature; then shut the engine off.
3. Place a drain pan under the engine oil pan to catch the used oil.
4. Remove the drain plug from the engine oil pan.
5. Allow the used oil to drain completely.
6. Re install the drain plug with a new sealing ring and tighten to 40 lbs. ft (55 Nm)
7. Place a drain pan below the engine oil filter.
8. Loosen the oil filter cartridge and remove it from the oil filter adapter.

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9. Clean the oil filter adapter housing.
10. Lightly oil the rubber o-ring on the new filter cartridge.
11. Screw on the new oil filter cartridge by hand until the seal makes contact.

Figure 26: Oil Filter Cartridge

12. Tighten the oil filter cartridge three quarters (3/4) of a turn. 7 lbs. ft (10 Nm).
13. Remove the oil filler cap and fill the engine with the specified oil.

NOTE:See the Filling Capacities section for quantity and oil specification

14. Start the engine and check for oil leaks.


15. Shut off the engine, wait 5 minutes to allow the oil to settle back into the oil pan, then check
the oil level on the dipstick.
16. Adjust oil level as needed.

5.4.2. Clean the Charge Air Cooler

Be careful when using high-pressure cleaning units. Make sure you have a
minimum gap of one half meter between the core and nozzle. Hold the nozzle
at a 90 degree angle to the core fins.

NOTE: Due to the difference in mine conditions it may be needed to wash the coolers more than once
a week.

HOT WATER CLEANING WITH SOAP (biodegradable detergent) CAN BE USED, MAX.
PRESSURE 82 bar. (1200 psi)

Figure 27: Charge Air Cooler Access Cover

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1. Ensure the machine is parked and that the master switch is off and locked out.
2. Remove the four socket head cap screw from the charge air cooler grill.
3. Using a pressure washer clean the charge air cooler core.
4. Remount the charge air cooler grill and secure with the four socket head cap screws.

5.4.3. Change Drive Belts


Change the Alternator V-Belt

Never turn the main switch off when the engine is running. This may
damage the alternator or the voltage regulator and machine electronic
equipment.

1. Turn off the master disconnect switch and lockout/tagout according to your mine standard
operating procedures.

1 7 8
9
10

5
4
6

3
4

11 12 13

1. V-Belt 8. Heax Head Cap Screw (1/2” x 1-3/4”)


2. Alternator (Delco Remy) 9. Lock Washer (1/2”)
3. Hex Head Cap Screw (3/8” x 6”_UNC) 10. Flat Washer (1/2”)
4. Flat Washer (3/8”) 11. Hex Head Cap Screw (M8X110 10.9)
5. Hex Nut (3/8”-16_UNC) 12. Lock Washer (M8)
6. Alternator Bushing 13. Flat Washer (M8)
7. Alternator Support Bracket

Figure 28: Alternator Mounting Bolts and Components

2. Loosen the outer hex head cap screw (M8X110 10.9) securing the alternator support
bracket to the engine.
3. Loosen the bottom hex head cap screw (3/8” x 6”_UNC).
4. Remove the hex head cap screw (1/2” x 1-3/4”), 1/2” lock washer and 1/2” flat washer
securing the alternator support bracket to the alternator.
5. Pivot the alternator towards the engine and remove the old v-belt.
6. Pivot the alternator towards the engine and install the new v-belt onto the pulley.
7. Install the 1/2” flat washer, 1/2” lock washer and hex head cap screw (1/2” x 1-3/4”)
securing the alternator support bracket to the alternator.

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8. Lever the alternator away from the engine to the desired belt tension and then tighten the
hex head cap screw (1/2” x 1-3/4”) to set the tension. Tighten the outer hex head cap
screw (M8X110 10.9) to secure the alternator support bracket to the engine.
9. Tighten the hex head cap screw (3/8” x 6”_UNC) attaching the alternator to the front engine
mount.
10. Remove the lockout/tagout according to your mine standard operating procedures and
place the master disconnect switch to ‘ON’.
11. Start the engine and observe the belt is functioning correctly.
Change the Drive Belt

1. Turn off the master disconnect switch and lockout/tagout according to your mine standard
operating procedures.
2. Remove the rubber extension with the 14” - 16” hose clamp.

11 10 9
3
4
2
1

13

8
12

6 7 5

1. Rubber Extension 8. Hex Bolt


2. 14” - 16” Hose Clamp 9. Spacer
3. Cowl 10. M8 Washer
4. Hex Head Cap Screws - 3 places 11. Lock Nut (M8 10.9)
5. LHS Belt Guard 12. Drive Belts
6. Hex Head Cap Screw (M8X16) 13. Tensioning Pulley
7. M8 Washer

Figure 29: Drive Belt

3. Remove 3 hex head cap screws, also remove one hex bolt with, one lock nut (M8 10.9),
one M8 washer and one spacer securing the cowl and the LHS belt guard to the engine.
4. Remove the cowl.
5. Remove a hex head cap screw (M8X16) and M8 washer, remove the LHS belt guard.
6. Pivot the tensioning pulley to loosen the drive belts.
7. Remove the drive belts.
8. Pivot the tension pulley to install the new drive belts.
9. install the belt guard onto the engine with an M8 washer and a hex head cap screw
(M8X16).

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10. Position the cowl in place and attach the cowl and the LHS belt guard to the engine with a
spacer, an M8 washer, a lock nut (M8 10.9) and a hex bolt. Also install 3 hex head cap
screws to finish fastening the cowl to the engine.
11. Attach the rubber extension to the cowl with a 14” - 16” hose clamp.
12. Remove the lockout/tagout according to your mine standard operating procedures and
place the master disconnect switch to ‘ON’
13. Start the engine and observe the belt is functioning correctly.

5.4.4. Service Air Filter Elements


The air filter must be replaced when the control system activates the alarm on the display.

Figure 30: Air Filter Housing

1. Clean the outside of the air filter housing thoroughly before removing the cover to access
the filter element.
2. Replace the air filter element. Be sure to keep the safety element in place.

NOTE:The safety element must be changed every second time the air filter element is replaced.

3. Clean the inside of the housing with a damp cloth.


4. Install a new air filter element.
5. Reinstall the air filter housing cover.

5.4.5. Check Intake Ducting


Check that all clamps and ducting are secure.

Check for cracks, leaks or other damage to the intake ducting.

Figure 31: Intake Ducting

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5.4.6. Check Exhaust System
Check that all clamps and piping are secure.

Check the exhaust manifold secure and free from cracks, leaks or other damage.

Check for any exhaust leaks, (soot marks on joints) cracks or other damage to the exhaust piping.

Figure 32: Exhaust System

5.4.7. Check Engine Mountings


Check the condition of the engine mounting pads. Re torque and or repair if necessary.

ENGINE
REAR ENGINE
FRONT

Figure 33: Engine Mount Bolts

Engine Mount Bolts (3/4” x x 4-1/2”) (rubber pad) - 6 places 100-120 lbs. ft (136-163 Nm)
Rear Mount Bracket to Engine Bolts (M12X45) - 12 places 74-85 lbs. ft (100-115 Nm)
Front Mount Bracket to Engine Bolts (M14X110) - 4 places 118-133 lbs. ft (160-180 Nm)

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5.4.8. Check Alternator


Check the alternator terminals for loose or corroded connections.

Check the alternator mounting bolts are secure.

Check the V-belt (s) Replace if necessary.

Figure 34: Alternator (BF6L-914C Deutz Engine)

5.4.9. Change Fuel Filters


Primary Filters

Figure 35: Primary Fuel Filters

1. Close the fuel shut off valve.


2. Place a drain pan under the fuel filters.
3. Unscrew the fuel filter cartridge from the fuel filter adapter mount.
4. Clean any dirt from the sealing surface of the filter cartridges and the fuel filter adapter
mount surface.
5. Wet the seal on the filter cartridges with fuel and install the filter cartridges back onto the
fuel filter adapter mount.

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6. Open the fuel shut off valve.
7. Check for leaks.
Pre Filter

Figure 36: Fuel Pump Pre-Filter

1. Clean the exterior of the fuel pump assembly with fuel.


2. Close the fuel shut off (if equipped).
3. Place a drain pan under the fuel pump.
4. Screw out and remove the filter cap.
5. Remove the o-ring.
6. Remove the strainer and clean with fuel.
7. Coat the new o-ring with light oil.
8. Screw on filter cap and strainer with new o-ring.
9. Reconnect the fuel inlet and outlet lines.
10. Open the fuel shut off valve and bleed the fuel system.
11. Check for leaks.

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Bleeding the Fuel System

1
3

1. Hand Priming Pump 3. O-ring


2. O-ring 4. Strainer

Figure 37: Fuel Pre-Filter Components

NOTE: Follow the fuel system bleeding procedure detailed in the manufacturer’s operation manual.

1. Unlock the fuel hand pump on the pre filter by pressing the knob inward and rotating anti-
clockwise. The pump plunger will extend by spring pressure.
2. Pump the plunger until a very strong resistance is felt and the pumping becomes very slow.
3. Continue pumping a few more times until the return pipe is filled.
4. Start the engine and run for approx. five minutes at idle or low load.
5. Check the pre-filter for leaks.
6. Pump the plunger as necessary to fill the return pipe.
7. Lock the fuel hand pump by pushing the knob inward and rotating clockwise.

5.5. Powertrain

5.5.1. Check Tire Pressures


Check the condition of the tires, rims and for any missing wheel nuts.

Visually check the tire wear.

Check and adjust the tire air pressure to 80 psi.

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Figure 38: Tire and Rim Assembly

5.5.2. Check Wheel Nuts’ Torques


Check the wheel nut torque is 569 Nm (420 lb-ft.) Adjust torque as needed.

24 1 3
22 5
20 7
18 9

16 11

14 13

12 15

10 17
8 19
6 21
4 2 23

Figure 39: Wheel Nut Nut Tightening Sequence

5.5.3. Change Transmission Oil and Filter Element

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3
4

1. Visual/electrical Service 3. Water Separator


Indicator 4. Drain Plug
2. Filter Element Housing

Figure 40: Transmission Pressure Filter

1. Drain the transmission and remove sump screen. Clean screen thoroughly and reinstall
using new gaskets.
2. Drain oil filters, remove and discard the filter element.
3. Refill transmission to LOW mark.
4. Run engine at 500-600 RPM to prime the converter and lines.
5. Recheck level with the engine running at 500-600 RPM and add oil to bring the level to the
LOW mark. When the oil temperature is hot 82-93°C (180-200°F) make the final oil check.
Bring the level to the full mark.

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5.5.4. Check the Torques of the Powertrain Flanges and Bolts

Figure 41: Powertrain Flanges and Bolts

Torques (Dry)
UNF 3/8 45 Nm (33 lb-ft.)
UNF 1/2 110 Nm (81 lb-ft.)
M10 49 Nm (36 lb-ft.)
M12 85 Nm (63 lb-ft.)
M16 210 Nm (155 lb-ft.)
Driveshaft bearing 410 Nm (302 lb-ft.)

5.5.5. Change the Oil in the Plantetary Hubs and Differential


Draining is best accomplished immediately after the vehicle has been operating. The lubricant is
then warm and will flow freely allowing full drainage in minimum time. This is particularly desirable in
cold weather.

Only people who have been given specialized operation and service training
are allowed to perform operation, service and adjustment procedures. Read
and ensure you understand the following instruction before servicing the
equipment. to avoid potential damage and injuries, carefully plan your work
before hand.

Only perform maintenance work when the machine is parked on a level, hard
surface. Use the appropriate tools for the task and be sure you understand
how to use them before performing any maintenance work. Replace or repair
faulty tools and equipment. When performing maintenance and repair work,
make sure there are no unauthorized persons in the working area.

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1. To drain the planetary wheel ends, rotate the wheel until lubricant drain hole is at the
bottom.

2. Remove both drain and fill plugs. Allow oil to drain into a suitable container.
3. Inspect the magnets and oil for metal or other contaminates.
4. To drain differential oil, remove drain plug at bottom of axle housing and the filler plug.
Allow sufficient time for lubricant to drain. Inspect the drain plug and oil for metal or other
contaminates.

5. Clean the plugs and refit them. Be sure planet cover oil level hole is in proper position when
refilling wheel ends (arrow is in down position).

NOTE: When filling the axle housing, planetary wheel ends, and brakes, allow enough time for lubricant
to flow through the various components in the differential, planetary housing, and the brake
assembly. After filling is completed, allow a few minutes for lubricant to attain its level and
recheck each wheel end and the differential. Always ensure that the arrow is in down position
when checking oil level in planetary hubs. Add lubricant if necessary.

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5.5.6. Check the Torque of the Axle Fastening Bolts
Check the axle mounting nuts torque are 500 Nm (368 lb-ft.)

Check the axle mounting locking nuts torque are 500 Nm (368 lb-ft.)

Figure 42: Axle Mount Bolts, Nuts, and Lock Nuts

5.5.7. Measure the Brake Lining Wear


Only people who have been given specialized operation and service training
are allowed to perform operation, service and adjustment procedures. Read
and ensure you understand the following instruction before servicing the
equipment. to avoid potential damage and injuries, carefully plan your work
beforehand.

Only perform maintenance work when the machine is parked on a level, hard
surface. Use the appropriate tools for the task and be sure you understand
how to use them before performing any maintenance work. Replace or repair
faulty tools and equipment. When performing maintenance and repair work,
make sure there are no unauthorized persons in the working area.

NOTE: The brake must be applied to make the wear indicator check. This means all hydraulic pressure
to the brake must be released as the brakes are applied with spring pressure.

1. Ensure that themachine is on an even surface, the parking brake is applied and movement
in the driving is prevented by, for example, with wheel chocks.
2. Clean thoroughly the area around the wear indicator. Remove the acorn nut at the top rear
of the brake housing near the bleed screw to expose the wear indicator pin.

Figure 43: Brake Wear Indicator Acorn Nut

3. Press the pin in until it contacts the brake pack.

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Figure 44: Brake Wear Indicator Pin

4. When wear indicator pin is flush with indicator nut face, the friction and lining disc must be
inspected.

NOTE: This is based on all brakes plates being worn evenly, it may be possible due to uneven plate
wear that some plate are unserviceable while the overall pack wide represented by the wear
indicator appears to be serviceable.

5. Replace the cap and torque to 27- 34 Nm (19- 25 lb.-ft) as required.

See the separate DANA Maintenance and Service Manual for further
information.

5.6. Hydraulics

5.6.1. Wash Oil Cooler

• Wash Hydraulic Oil Cooler

Always wear required personal protection, such as safety helmet, protective


clothing, safety boots, hearing protectors, safety goggles, etc., as dictated
by company policy or local regulations

Never open the cooler hatch when the engine is running!

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Figure 45: Hydraulic Oil Cooler Access

Open the cooler hatches for proper cleaning.

Never open the cooler hatch when the engine is running.

Be careful when using high-pressure cleaning units. Make sure you have a minimum gap of one half
meter between the core and nozzle, and hold the nozzle at a 90 degree angle to the hydraulic oil
cooler core.

HOT WATER CLEANING WITH SOAP (biodegradable detergent) CAN BE USED, MAX.
PRESSURE 82 bar. (1200 psi)

NOTE: Due to the difference in mine conditions it may be needed to wash the coolers more than once
a week.

Never start the engine when the cooler hatch is open!

5.6.2. Change Hydraulic Oil Filters

Figure 46: Hydraulic System Return Filter

Change the hydraulic system return filter as scheduled or if the alarm is on screen on the operator’s
display.

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1. With the system depressurized, remove the four M10 bolts from the brake return filter
cover.
2. Remove the cover and discard the o-ring.
3. Remove the return filter element and discard.
4. Install a new filter element.
5. Lightly coat the o-ring with hydraulic oil and install.
6. Install the cover and the four M10 bolts.

5.6.3. Check Hydraulic Oil Level


Check the hydraulic oil level at the tank with the sight glass. The boom should be down and the
bucket resting on the ground. Oil should be seen in the upper sight glass at operating temperature.

Figure 47: Hydraulic Tank Sight Glass

5.6.4. Change Hydraulic Oil


The preferred time for draining the tank and changing the oil is after the system has been operating
for a period or at the end of a day’s run when the hydraulic fluid is thoroughly warmed up. By
draining when the oil is warmand immediately after the system is stopped, the used oil will usually
carry off the greatest quantity of impurities. It is also good practice to flush the tank and system for
further removal of impurities before the fresh change of hydraulic fluid is introduced. We
recommend that the regular hydraulic oil be used for flushing and the oil be circulated for 30 minutes
or more by running the pumps. When system is noticeable dirty, a small quantity (5 to 10 %) of
petroleum solvent (such as Mobisol A) may be added to the flushing charge to help loosen up
impurities in the system. Pumps may then need to run a longer period to secure the desired
cleaning action.

Only people who have been given specialized operation and service training
are allowed to perform operation, service and adjustment procedures. Read
and ensure you understand the following instruction before servicing the
equipment. to avoid potential damage and injuries, carefully plan your work
beforehand.

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Only perform maintenance work when the machine is parked on a level, hard
surface. Use the appropriate tools for the task and be sure you understand
how to use them before performing any maintenance work. Replace or repair
faulty tools and equipment. When performing maintenance and repair work,
make sure there are no unauthorized persons in the working area.
1. Make sure that the hydraulic system is at operating temperature. Oil flows more freely
when hot and carries away more dirt and foreign material with it.
2. Before performing any maintenance work on hydraulic system, the hydraulic oil tank must
be de--pressurised. Pressure is released by using the directional valve on top of the
hydraulic oil tank. Ensure the valve closes fully once all pressure is relieved.

Be careful when draining hot oil. Wear suitable protective gloves, protective
clothing and safety goggles when handling oil.

3. Remove the hose cap. Open the tank drain tap and pump the hydraulic oil from the tank to
a large container.
4. Open hydraulic line connections of the return filters. Plug open ends of lines and filters.
5. Remove all strainer, breather and filter assemblies (1, 3 and 4) from the tank as well as
sediment traps or magnets.
6. Clean the inside of the tank. If it is difficult to clean the tank, use amixture of five parts of
fuel oil to one part of clean lubricating oil. Be sure to flush the bottom of the tank. Make
sure that all of the flushing solution is removed from the tank.
7. Thoroughly wash the tank exterior with cleaning solvent.
8. Assemble all of the components removed from the tank. Re seal the hydraulic tank cover if
needed.
9. Reconnect all hoses and fittings previously disconnected.
10. Replace all filter elements and the breather element with new ones.
11. Ensure the tank drain trap is closed and the drain hose is plugged. Ensure all plates and
components have been installed and are properly tightened.
12. Refill the hydraulic oil tank to the recommended level. The oil level should be between the
sight glasses. At operating temperature the oil level should be in the upper sight glass.
13. Open the hydraulic hose connection and prime the variable displacement pump case drain
with hydraulic oil. When the pumps are primed attach all the hoses that were removed from
the pumps.
14. Bleed the air from the suction lines by opening the bleeding plug first from the suction
connection. When all air is bled through the plug close it. Then bleed the air through the
suction side plug of the blower pump. Pressurize the tank if needed.

Do not start the engine before all piston pumps are primed and air is bled
from the system

15. Make sure that all of the hydraulic system control levers are in the neutral position.
16. Start the engine and allow it to run at idle speed for 5 minutes.

Crushing hazard. Dangerous machine movement, can cause severe injury or


death. MAKE SURE THAT THERE ARE NO UNAUTHORIZED PERSONS IN
THE DANGER AREA. Use clear channels of communication.

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17. Position the control lever to raise bucket position and turn the machine from left to right.
This will fill the bucket and steering cylinders with hydraulic oil.
18. Operate the bucket and steering through their complete cycles a few times. This will
“bleed” the system of trapped air through the tank breather. Repeat this step until the
machine movements are functioning normally. This will indicate that all air has escaped
from the system.
19. Add enough hydraulic oil to the tank to bring the level once again to the recommended
mark.Oil level should be seen in the upper sight glass when bucket is on ground and
machine is at operation temperature.
20. Repeat steps 18 to 19 until you don’t have to add hydraulic oil anymore.
21. Carefully check all connections in the hydraulic system for leaks. Make sure that the tank
filter cap has been replaced and is secure.

5.6.5. Change Brake System Oil Filters


Brake Return Filter

Change the brake system return filter as scheduled or if the alarm is on screen on the operator’s
display.

Figure 48: Brake System Return Filter

1. With the system depressurized, remove the four M10 bolts from the brake return filter
cover.
2. Remove the cover and discard the o-ring.
3. Remove the brake return filter element and discard.
4. Install a new filter element.
5. Lightly coat the o-ring with hydraulic oil and install.
6. Install the cover and the four M10 bolts.
Brake High Pressure Oil Filter

Change the brake system high pressure filter as scheduled or if the alarm is on screen on the
operator’s display.

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Figure 49: Brake System High Pressure Filter Location

1. Ensure there is no pressure in the hydraulic system.


2. Place a drain pan under the filter housing.
3. Unscrew the filter bowl.
4. Remove the filter element off the adapter.
5. Remove the head to bowl seal and backing ring. Do not discard the backing ring. Discard
the o-ring.
6. Clean the filter bowl and refit backing ring onto the nose of the filter bowl and install a new
o-ring.
7. Lubricate the new o-ring and fill the bowl half way with clean hydraulic fluid.
8. Fit a new filter element onto the adapter.
9. Re install the filter bowl.
10. Start the machine to bleed air out of the system.
11. Check the hydraulic tank level and adjust as necessary.

Figure 50: Brake System High Pressure Filter

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5.6.6. Test the Hydraulic Pressures


The hydraulic oil temperature should be 60°C- 80°C when testing.

Connect and disconnect the pressure gauge only when the circuit is not
pressurized. Use the correct couplings for pressure testing. Do not
overtighten the couplings.

System Pressure
Pilot Pressure 35 bar (507 psi)
Bucket 210 bar (3046 psi)
Steering 125 bar (1813 psi)

5.6.7. Check the Pressure Accumulators


Pre-charge pressures

Brake system accumulator: 90 bar (1305 psi)

Pilot system accumulator: 15 bar (217 psi)

Figure 51: Hydraulic Pressure Test Points

5.6.8. Check Major Components for Oil Leaks and Mounting


With the appropriate safety locking devices in place, check all components for oil leaks and security
of fasteners.

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5.7. Electrical

5.7.1. Check Lights


Check the front and rear driving lights and any optional lighting if equipped.

5.7.2. Check Indicator Lights


Check the service indicator lights.

Check that there are no active alarms or warnings on the operator’s display.

Figure 52: Instrument Panel

5.7.3. Check the Instrument Panel


Open the instrument panel and check

- Mounting of components
- Condition of wiring

Figure 53: Instrument Panel Wiring

5.7.4. Check Junction Boxes


Open all junction boxes.

- Check that all boxes are dry


- Ensure that the components and junction boxes are mounted properly
- Visually check for possible loose wires inside the junction boxes

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Figure 54: Engine Compartment Junction Box

5.7.5. Check Wiring Harnesses


Visually check the wiring harnesses for

- Wearing
- Sharp bends
- Other possible damage
- Loose parts

5.7.6. Check Batteries


Open the battery compartment and check

- Electrolyte level
- Cable connections are secure and corrosion free
- Cleanliness

Alway wear eye protection, protective overalls and protective gloves when
servicing batteries. The acid in the battery burns skin, eats holes in clothing,
and can cause blindness if it gets in the eyes.

Figure 55: Battery Compartment

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6. Lubricants and Capacities

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6. LUBRICANTS AND CAPACITIES

6.1. Importance of Periodic Maintenance


The LH208L is designed for hard work in difficult and demanding mine conditions. To ensure
trouble-free and economical operation, it is extremely important to adhere to the service schedule
indicated. By paying close attention to the service schedule, you can easily detect possible defects
in the machine or other problems that can be addressed before they become serious. This will
ensure low repair costs and minimize disturbances in production.

The following pages give information for servicing various LH207L components and other items for
servicing, with their corresponding service intervals. All end users should review the Engine
Manuals for additional information regarding servicing.

6.2. General Notes on Maintenance Work


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

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

Personnel must not wear long, loose hair or loose clothing, nor should they wear jewellery, including
rings, because of the risk of injury.

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

Do not perform any modifications, extensions or rebuilding of the machine that would affect safety.
Consult the supplier or manufacturer. This also includes the built-in and adjustment of safety
devices and valves, as well as the welding of frame structures.

Spare parts must meet the manufacturer’s technical specifications. Conformity to these standards is
guaranteed only when genuine spare parts are used.

Know the location and proper use of fire extinguishers!

It is absolutely necessary to have suitable specialized workshop equipment to ensure high-quality


maintenance work.

Any maintenance or repair work on the machine must be performed by properly trained or instructed
personnel only. Work must be performed on electrical appliances by electricians and on hydraulic
appliances by mechanical technicians with knowledge and experience particular to the work to be
done.

Carry out any activity specified in this manual with respect to adjustment, maintenance and
inspection times, in addition to heeding any indications for replacement of parts.

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

Never attempt to clean, adjust, repair or lubricate the machine while it is in motion or the
engine is running.

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6.2.1. General Repair Instructions
The person responsibility for maintenance and repairs should be clearly identified.

- Do not do any work that you are not authorized to do.


- Secure extensively, as far as necessary, the area where the maintenance work will be
performed.
- Inform the users of the equipment of the start of maintenance or any special work on the
loader.
- If the equipment or a part of it has been stopped for maintenance or repair, make sure that
it cannot be started accidentally.
• Turn the master switch off and lock out the machine according to your local mine site
procedures.
• Remove the ignition key
• Put a DANGER DO NOT START or corresponding warning sign on the main master
switch. The sign must be removed only by a person who is fully aware of the situation.
- If required, ensure that suitable and safe ladders or working platforms are available for use
in repair and maintenance work.
- Do not use any of the equipment as steps. If maintenance work must be done high up, or in
an otherwise dangerous place or position, use the safety devices necessary to prevent
falling.
- All platforms, steps, grips, rails, ladders and other similar parts must be kept clean of oil,
dirt, snow and ice to prevent accidents.
- Always use the right tools for the maintenance task.
- Before commencing maintenance or repair work, ensure that the vehicle is on level ground
and won’t move.
- Pay special attention to the exhaust pipe-work and the exhaust gas cleaning system.
Ensure sufficient ventilation.
- Use a lift jack only on level, hard and firm ground. Before using a jack, always be sure that
the wheels on the other side of the vehicle are blocked. To prevent the possibility of the
jack slipping, secure the vehicle by using adequate supports and blocks underneath it.
- Remove all the air from the tire before loosening the wheel nuts/bolts. Should you forget to
do this, a broken rim part under pressure can fly apart and cause serious injury.
- Do not try to repair wheel parts by brazing, welding or reworking. Be sure to replace them
with new parts of the same size, type and make.
- Never transport a fully inflated spare tire mounted on demountable rims. Such tires should
have just enough air pressure to hold the rim parts firmly in place. Only after the tire and
rim assembly have been fastened with proper torque applied to all the wheel nuts/bolts,
should the tire be inflated to the correct operating pressure.
- In inflating, mounting or dismounting tires, a safety rack, cage or some other protection
should be used.
- During tire inflation, do not stand in front of the assembly. Use an extension hose so that
you can stand to one side.
- When replacing heavy parts, use correct lifting apparatus and techniques.
- After preventive maintenance and repairs, always tighten fasteners that have been
unscrewed. Reassemble all dismantled safety appliances immediately after the work is
done. Ensure that all safety systems are tested before the machine is returned to
normal work.
- Pay attention to safety and environmental protection when disposing of process materials
and old parts.

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6.3. Lubricant and Coolant Recommendations

6.3.1. Engine

Viscosity: Above -30°C SAE 5W-30/SAE 5W-40


0°C to 12°C SAE 15W-40
Above 20°C SAE 20W-50
Oil Classification:
ACEA E3-96 / E5-02, E7-04
API CF/CF-4
World wide Classification DHD-1

Sulphur content of diesel fuel should be below 0.5%. Sulphur content in diesel fuel above 0.5%
requires the engine oil and filter change interval to be halved. Do not use any fuel additives.

The use of engine oil brands which have not been approved may lead to increased wear or engine
damage. Refer to the Deutz Operation Manual for further details.

6.3.2. Transmission

Viscosity: 0°C to 32°C SAE 30 ISO VG 100


Above 32°C SAE 50 ISO VG 220
Oil Classification:
Above -1°C C2, C3 Grade 30
-23°C to -1°C C2, C3 Grade 10
API Above -1°C Engine Oil Grade 30 CF/SM or CF/
SM CF-4
-23°C to -1°C Engine Oil Grade 10 CD/SE or CF/
SM
Military Specification Above -1°C MIL-L-2104C Grade 30, MIL-L-
2104D Grade 30
-23°C to -1°C MIL-L-2104C Grade 10, MIL-L-
2104D Grade 10

6.3.3. Hydraulics
Unless otherwise specified by the original equipment manufacturer, use a petroleum based (mineral
type), premium quality oil with anti-wear additives.

Hydraulic oils meeting DIN 51524 HVLP or ISO 6743-4 HV can be used.

The chosen oil must not contain additives harmful to BUNA-N (Nitrite), Viton, or neoprene rubber
compounds.

This oil may only be used in hydraulic, hydrostatic, and brake actuation systems that operate
between 25° F and 175° F (-4° C to 73° C).

Engine oil being used as hydraulic oil must meet U.S. Military Specification MIL-L-46152 and
American Petroleum Institute (API) CC or CD standards.

Do not use an oil that exceeds 4000 SUS at start-up, or one that drops below 80 SUS during normal
operation.

It is the responsibility of the equipment owner to ensure that the oil is of a high quality. If possible,
obtain a copy of a manufacturer’s certified lab test report attesting to the contents, quality, and
performance limits of oils available.

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Engine oil being used as hydraulic oil must meet U.S. Military Specification MIL-L-46152 and
American Petroleum Institute (API) CC or CF standards.

Do not use an oil that exceeds 4000 SUS at start-up, or one that drops below 80 SUS during normal
operation.

It is the responsibility of the equipment owner to ensure that the oil is of a high quality. If possible,
obtain a copy of a manufacturer’s certified lab test report attesting to the contents, quality, and
performance limits of oils available.

Viscosity: 0°C to 32°C SAE 20 ISO VG 46


Above 32°C SAE 30 ISO VG 68

6.3.4. Brake Hydraulics


Hydraulic oils meeting DIN 51524 HVLP or ISO 6743-4 HV can be used.

Viscosity: 0°C to 32°C SAE 20 ISO VG 46


Above 32°C SAE 30 ISO VG 68

Normal Operating Temperature: approx. 45°C SAE 10W ISO VG 32


approx. 60°C SAE 20 ISO VG 46
approx. 70°C SAE 30 ISO VG 68

6.3.5. Axles

Viscosity: 0°C to 32°C SAE 85W-90


Above 32°C SAE 85W-90
Classification: API GL-5 LS (Limited Slip)
MIL-L-2105E

6.3.6. Grease
Unless specified otherwise in this manual or in the manufacturer’s documentation, use a multi-
purpose type grease manufactured with lithium soap and a NLGI No. 2 consistency grade on all
grease points. The grease used must also conform to ASTM D1743 rust test standards and pass
the ASTM D130 copper corrosion test.

Grease Extreme Pressure


Temperature Range -1.1°C to 93°C
Working Penetration 310-340
Texture 163°C
Resistance to Centrifuging High

6.3.7. Engine Coolant


Unless otherwise indicated by the engine manufacturer, use a concentrated ethylene glycol based
engine coolant solution mixed with clean distilled or deionized water. An antifreeze/water mixture
ratio of minimum 35/65 to a maximum 45/55 is recommended.

Anti Freeze Percentage Water Percentage Cold Protection


35% 65% -22°C
40% 60% -28°C
45% 55% -35°C

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Clear, clean water must be used for mixing with the anti freeze. The following values must be used
when analyzing the water.

Water Analysis Values min. max.


ph value at 20°C 6.5 8.5
Chloride ion content (mg/dm3) - 100
Sulfate ion content (mg/dm3) - 100
Total Hardness (°dGH) 3 12

6.4. Filling Capacities


Engine Oil* 24 liters 6.3 U.S Gallons
Cooling System** 23 liters 6.1 U.S. Gallons
Transmission 37 liters 9.8 U.S. Gallons
Hydraulics 189 litres 50 U.S. Gallons
Axles 2 x 22 litres 2 x 5.8 U.S. Gallons
Fuel Tank 230 litres 61 U.S. Gallons

*Capacity is approximate depending on application. The upper oil level mark on the oil dipstick is
always the accurate measure.

**Not applicable to air cooled engines

6.5. Special Notes


If the machine is fitted with optional equipment such as an automatic central lubrication system,
please read the instructions for the additional equipment carefully and adhere to the service
schedule given in the maintenance instructions.

6.5.1. Cooling System (Non Air Cooled Engines)


• Drain and clean if the engine overheats or the solution is dirty

NOTE: Overheating indicates a fault. Stop the engine and repair the fault before more serious damage
is caused. Make sure that the engine radiator is not covered and that it is not clogged.

• Whenever draining and refilling the cooling system, always recheck the coolant level after
the engine reaches its normal operating temperature

Never open the filler cap when hot. When checking the engine coolant level,
stop the engine and allow it and the radiator to cool down. If an overheated
engine must be stopped, allow the radiator to cool down before checking the
coolant level.

• Adding new coolant too fast can cause air pockets in the cooling system.
• Operate with a thermostat in the cooling system all year round.
Refer to the Deutz Operation Manual for further details.

6.5.2. Refuelling
The following precautions must be observed when adding fuel:

Smoking, open flames and sparks are dangerous when the fuel tank is being
filled!

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• Do not fill the fuel tank when the engine is running.
• Do not overfill
• Take care not to spill fuel on hot surfaces
• Adding fuel should be done in a well ventilated space
• Clean up spilled fuel before starting the engine
• Keep the filling pipe in contact with the fuel tank, or arrange grounding to prevent sparking
caused by static electricity
• If fuel quick fill system is to be used, ensure that you are familiar with the system
manufacturer’s operating and safety requirements
• If the ambient temperature is less than 0°C, winter grade fuel (suitable down to -20°C)
should be used.
See the Deutz Operation Manual for further information.

6.6. First Service


Check that the lubricants being used meet site--specific operating requirements as per Sandvik
Lubricant Specifications.

The following steps should be carried out during the first week of use (in addition to the normal,
scheduled services):

After the first 50 hours

- Change Engine Oil and Filter Elements


- Change Transmission Oil Filter Elements
- Change Fuel Filters
- Check and Tighten the Exhaust Manifold Bolts
- Check the Air Filter and Air Pipes are Tight
- Check the Valve Clearances
- Check and Tighten the Oil Sump and Engine Mount Bolts
- Check and Tighten the Bolts on the Axles, Wheels, Gearbox and other Major Components
- Tighten the Bolts on the Oscillation Axle
- Tighten the M12 Bolts on the Park Brake to 145 Nm
- Tighten the Bolts on the Drive Shafts
- Check the V-Belts
- Make a Visual Overall Check for Leaks and Possible Damage

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NOTES

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7. Additional Instructions

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7. ADDITIONAL INSTRUCTIONS
This section contains information that the operator may be required to know, but is not part of the
operator’s daily work.

Read and understand the manuals prior to operating or maintaining the


machine.

Operating or maintaining the machine without proper training may result in


serious injury or death.

7.1. Towing
It may become necessary at times to tow the machine if it is disabled or unsafe to operate. The
following procedure describes how to properly and safely move the machine without risking serious
personal injury to yourself and others, or damage to the machine.

NOTE: In this section, the machine being towed is referred to as the disabled machine, and the vehicle
performing the towing is referred to as the towing vehicle.

This procedure is not to be carried out on machines disabled by electrical or


brake system failures.

The procedures described should only be performed by trained, authorized


personnel.

To tow the machine, do the following:

1. Apply the park/emergency brake.


2. Lower the lift arms unil they are resting against the stop blocks and roll the bucket back.

The machine must not be towed with the lift arms raised. The lift arms must
be lowered before the machine is moved.

3. Ensure the engine is off.


4. Install wheel chocks at the front and rear of the machine.
5. Ensure the master disconnect switch is in the ON position.
6. Ensure the ignition switch is in the OFF position.

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7. Back up the towing vehicle to the 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.

The towing vehicle must have ample power and braking capacity to move,
stop, and hold both machines.

8. Turn the ignition switch to the RUN position. Do not start the engine.
9. Press and hold the brake release pump button to release the brakes on the disabled
machine.

NOTE: The brake release pump should start and stay on until the button is released. Release the
button when the brake accumulator pressure low symbol on the operator display turns grey.

10. Release the park/emergency brake by pulling the park/emergency brake light/button out
and releasing it to the middle position.

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.

11. Remove wheel chocks using extreme caution. Always be aware of hazards.
12. Place the towing vehicle into first gear and choose the direction of travel.

The disabled machine will be unable to turn during towing due to a lack of
flow in the hydraulic system. Use caution when negotiating turns.

13. If required, personnel should stand at a safe distance to guide the operator of the towing
vehicle.
14. Once the disabled machine is positioned safely in the service bay, install wheel chocks at
the front and rear of the machine.
15. Release pressure in the brake lines by pressing the service brake pedal. This applies the
brakes.
16. Press the park/emergency brake light/button in to apply the park/emergency brake.
17. Disconnect the towing vehicle from the disabled machine.

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7.2. Transporting

Roll back the bucket before driving the loader onto a transport wagon.
Never exceed the specified gradient angles.

• Suitable access ramps must be used when driving the loader onto and off of the transport
wagon. Driving must always be done on level ground.
• When driving over ramps, use bucket movements to balance the loader.
• Always use low speed and observe special caution when coming from the ramps to the
platform.
• Before transporting, lower the bucket down and install the frame lock pin.
• Fasten the loader to the platform at the bucket and both ends of the machine with strong
straps and chains so that the loader cannot shift during tranport.

When planning the transportation route, keep in mind the loader’s


dimensions.

7.3. Lifting Methods and Lifting Points

Always respect the law and all local safety regulation related to lifting work.

Keep in mind the total weight of the loader, given in the Technical
Specifications chapter of this manual.

• The lifting device used must be of the correct type and have
sufficient lifting capacity. The loader or parts of it must not be
lifted with any devices that are not specifically designed for lifting
purposes.
• You must always know the exact weight of the load, and never
exceed the lifting capacity specified by the manufacturer of the
lifting device.
• The lifting routes should be planned so that the load is not moved
over persons or such places where persons may be present.
• Make sure that the lifting equipment is in proper condition.
• Wire ropes and chains used for lifting must be checked regularly.
Damaged wire ropes must be marked clearly and discarded at
once.
• Always install the frame lock pin before lifting the loader.
• Lift the load 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.

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• Never wind the ropes around the hook of the hoist. The lifting ropes must be fastened
according to the manufacturer’s instructions.

7.4. Storing Intructions

7.4.1. Environment
• Storage temperature should be between 0 and 35ºC.
• The machine should be protected from direct sunlight and from rain.
• The humidity of the air should be below 90%.

7.4.2. Preparations
• Wash the loader thoroughly if it has come directly from use or if it has been transported by
sea. Use a high pressure washer or steam clean.
• Lubricate all grease points.
• Empty the pressure accumulators and place warning signs on the machine, reading
“Pressure accumulators must be filled before using the loader”.
• Apply protective grease to the piston rods of the cylinders.
• Change all lubricants and fluids.
• Check engine air filter and service if necessary.
• Protect electrical devices with corrosion inhibitor to prevent contact failures.
• Disconnect the batteries.
• Apply protective grease tot he following points:
• terminal strips
• battery terminals
• multipole connectors
• connectors at caps of magnetic valves, pressure switches, etc. Fill the caps with
grease.

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7.5. Circuit Breakers


The circuit breakers are located in the instrument panel in the operator’s compartment, and in the
circuit breaker boxes on the rear frame of the machine.

Figure 1: Circuit Breaker Locations

When a circuit breaker is tripped, one of the service indicator lights in the operator’s compartment
will illuminate.

It is recommended that only trained, authorized personnel be permitted to


reset the circuit breakers. If one of the circuit blow lights illuminates,
contact service personnel immediately. Do not operate the machine until
corrective action has been taken.

7.6. Operating in Cold Weather


This machine is designed to operate in typical mine conditions and is filled with engine,
transmission, and hydraulic fluids suitable for these conditions. Operating the machine in cold
conditions may cause the fluids to thicken, making starting more difficult and potentially leading to
component damage. If the machine must operate in very cold or very hot conditions, refer to the
Maintenance Manual and the engine manufacturer’s documentation for the correct fluid selections
for these conditions.

In temperatures below 0ºC, clear off any ice from steps and handles on the loader. Use winter-
grade fuel suitable for tempertures between 0 and -20ºC. Preheating the engine and hydraulic oil is
recommended in temperatures below -10ºC.

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8. Technical Specifications

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8. TECHNICAL SPECIFICATIONS

8.1. Tightening Torques

8.1.1. Torque Values for Standard Hardware


The following tables list torque values for standard hardware. They are intended as a guide for
average applications involving typical stresses and machine surfaces.

All torque values are measured in foot pounds (ft. lb.) and Newton meters (Nm), according to grade,
diameter, and application (i.e. dry or lubricated).

NOTE: The length of the nut or bolt does not affect the torque value.

In all cases, when an individual torque value is specified elsewhere in the Service Manual, it should
take precedence over values given in this table. Always replace original hardware with hardware of
equal grade.

NOTE: Unless otherwise stated, use ISO 10.9 metric bolts and SAE grade 8 imperial bolts.

NOTE: To convert Newton meters (Nm) to foot pounds (ft. lb.), multiply the Nm value by 0.7375621.

8.1.2. Metric Bolt Torque Values

NOTE: The lower values given should be used when a bolt has a surface finish (i.e. electro galvanized,
etc.). The higher values should be used for bolts that do not have a surface finish.

Component Nm Ft. Lb.

Wheel Nuts 569 420

Axle Nuts 500 369

8.1.3. Metric Bolt Torque Values

NOTE: The lower values given should be used when a bolt has a surface finish (i.e. electro galvanized,
etc.). The higher values should be used for bolts that do not have a surface finish.

ISO 10.9 (Dry) ISO 10.9 (Lubricated)

Grade Size Nm Ft. Lb. Nm Ft. Lb.

M6 14-16 10-12 12-14 9-10

M8 35-40 26-30 30-34 22-25

M10 68-77 50-57 59-67 44-49

M12 120-135 89-96 100-115 74-85

M14 190-215 140-159 160-180 118-133

M16 295-335 218-247 220-250 162-184

M18 405-455 299-336 240-385 177-284

M20 575-655 424-483 485-550 358-406

M22 780-885 575-653 655-740 483-546

M24 985-1100 727-811 835-950 616-701

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ISO 10.9 (Dry) ISO 10.9 (Lubricated)

Grade Size Nm Ft. Lb. Nm Ft. Lb.

M30 2000-2250 1475-1660 1650-1900 1217-1401

8.1.4. UNC (Coarse Threaded) Bolt Torque Values

SAE 8 (Dry) SAE 8 (Lubricated)

Grade Size Nm Ft. Lb. Nm Ft. Lb.

1/4 16 12 12 9

5/16 33 24 24 18

3/8 61 45 47 35

7/16 95 70 70 50

1/2 150 110 108 80

9/16 203 150 150 110

5/8 285 210 215 160

3/4 515 380 380 280

7/8 815 600 610 450

1 1235 910 920 680

1 1/4 2470 1820 1845 1360

1 3/8 3225 2380 2415 1780

1 1/2 4285 3160 3215 2370

8.1.5. UNF (Fine Threaded) Bolt Torque Values

SAE 8 (Dry) SAE 8 (Lubricated)

Grade Size Nm Ft. Lb. Nm Ft. Lb.

1/4 19 14 14 10

5/16 37 27 27 20

3/8 68 50 47 35

7/16 108 80 81 60

1/2 165 120 122 90

9/16 230 170 175 130

5/8 325 240 245 180

3/4 586 430 420 310

7/8 910 670 680 500

1 1385 1020 1030 760

1 1/4 2725 2010 2050 1510

1 3/8 3600 2720 2765 2040

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SAE 8 (Dry) SAE 8 (Lubricated)

Grade Size Nm Ft. Lb. Nm Ft. Lb.

1 1/2 4825 3560 3620 2670

8.1.6. Torque Values for Locknuts

SAE 8 (Dry) SAE 8 (Lubricated)

Grade Size Nm Ft. Lb. Nm Ft. Lb.

1/4 11 8 11 8

5/16 18 13 18 13

3/8 34 25 33 24

7/16 47 35 47 35

1/2 75 55 75 55

9/16 115 85 110 82

5/8 155 113 135 100

3/4 235 175 225 165

7/8 380 280 370 274

1 580 428 555 409

1 1/4 1375 1014 1240 916

1 3/8 1855 1367 1625 1200

1 1/2 2430 1793 2160 1593

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8.2. General Information
Measures of Components
Total Length 8788 mm 346 in
Maximum width 2692 mm 106 in
Height without canopy 1388mm 55 in
Height with canopy 1575 mm 62 in

Weights Operating Loaded


Total weight 17768 kg 39160 lb 25517 kg 56239 lb
Front axle 7541 kg 16620 lb 19089 kg 42042 lb
Rear Axle 10227 kg 22540 lb 6428kg 14167 lb

Capacities
Tramming capacity 7711 kg 17000 lb
Break out force, liftt 121.6 kN 27337 lbf
Break out force, tilt 125.2 kN 28151 lbf
Tipping load 20859 kg 45975 lb
Standard bucket 2.87 m3 3.75 yd3

Bucket Motion Times


Raising time 4.0 sec
Lowering time 3.0 sec
Dumping time 3.7 sec

Driving Speeds Forward and


Reverse (Loaded)
1st gear 4.0 km/h 2.5 mph
2nd gear 8.2 km/h 5.1 mph

Maximum Gradient and Tilt Angle


Maximum Gradient 11 degrees, 20%
Maximum Tilt Angle 8 degrees, 14%

8.3. Power Train


Engine
Diesel Engine Deutz TCD 2012 L06 2V, Tier III
Output 140.0 KW (187 HP) at 2400 rpm
Torque 730 Nm (538 lb ft) at 1600 rpm
Number of Cylinders 6
Displacement 7.1 l 436 in3
Cooling System Liquid cooled
Combustion Principle Turbo charged, air-to-air after cooled, direct injected
Air Filtration Donaldson, dry type
Electric System 24 V
Exhaust Purification Catalytic purifier
Fuel Tank Capacity 230 l 61 US gal

Torque Converter
Dana SOH C273 Single stage, stall torque ratio 3.095:1, offset ratio 1.042:1

Transmission
Dana SOH R32421 4-speed forward and reverse with modulation

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Axles
Front Axle Kessler 91.6595.3.
Rear Axle Kessler 91.6595.3

Tires
Tire Size 17.5 X 25, 20 PLY L5S
Air Pressure, Front 5.52 bar 80 psi
Air Pressure, Rear 5.52 bar 80 psi

8.4. Frame
Rear and Front Frame Welded steel box construction
Material G40.21 - 50wt Cat.3
Central Hinge Welded steel box construction with hardened steel spherical
bearings
Material G40.21 - 50wt Cat.3

8.5. Steering Hydraulics


Centre articulated, power steering with two double acting cylinders. Steering control system is
equipped with a proportional electronic joystick.

Turning Radius Left Right


Inner 2769 mm 109 in 3023 mm 119 in
Outer 6020 mm 237 in 6045 mm 238 in
Turning Angle 42º

Main Components
Hydraulic Pump Gear pump
Control Valve Parker
Steering Cylinders 100 mm bore x 50 mm rod
Filtration 10µm

Pressure Settings
Main Relief 220 bar 3188 psi
Port Relief Valves 125 bar 1812 psi

8.6. Bucket Hydraulics


Monostick bucket and boom control (electronic) equipped with gear pump that delivers oil to the
bucket hydraulic main valve. The oil flow from steering hydraulic pump is directed to bucket
hydraulics when steering is not used.

Main Components
Hydraulic Pump Gear pump
Control Valve Rexroth
Lift Cylinders 180 mm bore x 90 mm rod
Dump Cylinder 160 mm bore x 90 mm rod

Pressure Settings
Main Relief 215 bar 3118 psi
Bucket Dump 250 bar 3623 psi
Bucket Roll Back 100 bar 1450 psi
Lift Arms Raise 180 bar 2610 psi

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MM0803_01_10
MAINTENANCE MANUAL lh208l
Pressure Settings
Lift Arms Lower 100 bar 1450 psi
Hydraulic Oil Tank Capacity 200 l 53 US gal

8.7. Standard Brakes


Service brakes are spring applied / hydraulically released, liquid cooled multi-disc brakes on all
wheels. Service brakes also function as an emergency brake when the emergency brake system is
engaged.

Main Components
Pressure Accumulator Piston type with charge valve
Brake Pedal Valve Modulated

8.8. Electrical Equipment


Alternator 24 V 35 A min.
Batteries 2 x 12 V, 950 CCA
Starter 24 V Heavy Duty
Driving and Working Lights 2 front, 2 rear

8.9. Other Standard Equipment


• Electric indicator/warning lights
• Electric transmission shift controls
• Audible back-up alarm
• Central hydraulic pressure test points
• Central manual lubrication system
• SAE ORS hose fittings

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NOTES

140 Copyright © Sandvik Mining and Construction


MM0803_01_10
SANDVIK MINING AND CONSTRUCTION CANADA INC. BURLINGTON, ON, CANADA TEL +1 905 632 4940 FAX +1 905 632 2172

www.sandvik.com