LH307V - Technical Training - 100119

LH307 Technical Training
<
Training modules
TRAINING MODULES
Module Description Module Description
Module 1 Safety and Environment Module 10 Hydraulics system - Brake hydraulics
Module 2 Technical specification Module 11 Electrical system
Module 3 General overview Module 12 Control system
Module 4 Operator environment Module 13 Power pack - Engine
Module 5 Air conditioning system Module 14 Power train – Converter
Module 6 Frame structure Module 15 Power train – Transmission
Module 7 General hydraulic system Module 16 Power train - Axle
Module 8 Hydraulics system – Boom & Bucket hydraulics Module 17 Lubrication system
Module 9 Hydraulics system – Steering hydraulics Module 18 Fire suppression system
<
<
Home
SAFETY AND ENVIRONMENT
<
<
Training modules
Safety Labels
Safety labels are mandatory and they inform about,
• The severity level of the risk
• "DANGER" or "WARNING"
• Nature of the hazard

• Cutting parts, high pressure, falling objects, etc.
• Consequence of interaction with the hazard

• Cut, injection, crushing, etc.
• How to avoid the hazard
IMPORTANT!
• Keep the safety labels clean and visible at all
times
• Check the condition of safety labels daily
• Replace if needed <

<
Training modules
Safety Labels
General Hazard Symbol

<
<
Training modules
Safety signs
• Multiple safety signs are used in the machine
• Safety signs can be categorised mainly in three types,
Mandatory
• Must be followed
• Signs are indicated in blue
Prohibited or restricted
• Not allowed and must be avoided
• Signs are indicated with red circle
Hazard
• An environment which may lead to an incident
• Signs are indicated with yellow triangle
<
<
Training modules
Operator safety Operational safety
• ROPS/FOPS certified cabin • SAHR brakes (Spring Applied Hydraulic Release)
• Emergency exit • Proximity Detection Interface
• Seat belt • AutoMine™ compatibility
• Door interlock for, • Tire pressure monitoring system
• Brakes hydraulics • Turning signals and directional lights
• Boom & Bucket hydraulics • Cameras and secured visibility
• Steering hydraulics • Reverse alarm
• Three-point contact access system • Flashing beacon
• Gauges, alarms and light signals • Neutral brake
• Comfortable cabin ergonomics • Automatic brake activation system
<
<
Training modules
8

Maximum inclination angle
• Incorrect operating or parking procedures may cause death or severe injury
• Do not load, haul, dump, park or operate the machine on a slope that exceeds the maximum inclination angle
• Avoid sudden up-and-down boom motion, especially when machine is articulated
• Be careful and drive slowly when approaching the dumping station
<
<
Training modules
9

Operator visibility
• When operating the machine, always remember that visibility is limited
• Ensure that any unauthorized persons are not present in the vicinity of the machine
• Visibility area decal can be found on the operator’s cabin
• Visibility area differ from cabin and canopy version
Cabin version Canopy version
<
<
Training modules
10

Emergency stop
• Unit is equipped with three emergency stop buttons
• In case of an emergency use the closest emergency stop button to shut down the engine
• Pressing the emergency stop button,

• Shuts down the engine
• Applies the brakes
• All functions stops working
<
<
Training modules
11

Emergency exit
• The cabin has one natural exit and two emergency exit
• The right hand side window or front window can be used as an emergency exit
• In an emergency situation, use the safest emergency exit
• To use the emergency exit

1. Pull the exit sign/ring and move the sign round the window
2. Keep moving until the whole string comes out of the window seal
3. Push the window out of place and go out through the window opening
4. Go through the opening and use exit points on the frame
<
<
Training modules
12

Maintenance safety Fire safety
• Anti-slip strips • Handheld fire extinguisher as standard
• Lockable battery isolation switch • Two optional fire suppression systems
• Ground level daily checks • Ansul Fire suppression system
• Eclipse Fire suppression System
• Wheel chokes
• Fire retardant materials
• Boom support device (2 pcs.)
• Separated cool and hot side design
• Frame articulation locking device
<
<
Training modules
13

Fire risk control
<
<
Training modules
14

For your safety
• While operating or servicing the machine, always follow all safety regulations and check-lists!
• Wear approved PPE’s, which includes but is not limited to:

• Safety helmet
• Eye protector
• Hearing protector
• Safety footwear
• Protective gloves
• High visibility clothing
• Never service the vehicle alone
<
<
Training modules
TECHNICAL SPECIFICATION
<
<
Training modules
Drive train – main components
1. Engine - Volvo TAD850VE Tier2
2. Torques converter - DANA C273.1 series
1
3. Axle – Rear - Kessler D91, with Limited slip differential and SAHR brakes
4. Transmission - DANA RT32421 series

2
5. Axle – Front - Kessler D91, with Limited slip differential and SAHR brakes, fixed
4 3
<
<
Training modules
17
Bucket
• Loader payload capacity is the payload capacity of the axles
• Correct bucket must be selected from options available
• Mine height and ore type should also be considered before selecting a bucket
• Choosing the wrong bucket may lead to underload or overload the loader
Available option (GET) 2,7 m3 3,0 m3 3,3 m3 3,7 m3
Available option (Bare lip) 3,0 m3 3,3 m3 3,7 m3
<
<
Training modules
GENERAL OVERVIEW
<
<
Training modules
8/30/2019
GENERAL OVERVIEW
Walk around
1. Fuel filter assembly
2. Hydraulic & Transmission cooler
3. Fuel tank
1 3 4 5
4. Hydraulic tank 6
2
5. Right hand side doser assembly
6. Lubrication assembly
7. Hand held fire extinguisher
8. Left hand side doser assembly

9. Electrical box – rear
10. Battery compartment

7 11
11. Air filter assembly 9
8
12
12. Exhaust pipe 10
<
<
Training modules
8/30/2019
GENERAL OVERVIEW
Walk around inspection
• Check for defect tags or warnings
• Frame articulation locking device is not mounted
• Condition of the bucket and related components visually
• Condition of the boom and related components visually
• Condition of the front and rear frame hydraulic components

• Hydraulic tank door is closed and secured
• Amount of grease in the central lubrication system is correct
• Fill the tank if necessary

• Climbing steps and handles are not damaged
• Condition of the cabin and the door lock
• Check guards (fan guards, belt guards, etc.) for proper mounting
Note! Operating the machine without original protective guards is prohibited

<
<
Training modules
OPERATOR ENVIRONMENT
<
<
Training modules
22
Operator safety
• ROPS/FOPS certified cabin
• Emergency exit
• Seat belt
• Three-point contact access system
• Comfortable cabin ergonomics
• Air conditioning
• Dust and noise free cabin
<
<
Training modules
8/30/2019
Operator cabin
1. Ignition key
2. Front lights switch
3. Rear lights switch
4. Low/high beam switch
5. Blinkers (optional)
6. Gear mode, manual/auto (optional)
7. Torque converter lock (optional)
8. Bucket counter/VCM-integrated scale (optional)

9. Boom floating (optional)
10. Ride control (optional)
11. Front & rear window wiper
12. Side window wiper
13. Side window washer

<
<
Training modules
8/30/2019
Operator cabin
14. SEO (Stop engine override)
15. Brake test button
16. Brake release pump
17. Emergency steering test (optional)
18. Wiper intermittent potentiometer
19. Parking brake control button
20. Main circuit breaker release
21. Emergency stop button
22. Remote control switch (optional)
23. DDR-connector
24. Fan speed potentiometer
25. Air conditioning switch
26. Temperature potentiometer <
< 27. ACS by-pass switch (optional)
Training modules
8/30/2019
Operator cabin – overview
• The boom & bucket movement is controlled by right hand side joystick
• The steering function is controlled by left hand side joystick
<
<
Training modules
8/30/2019
Operator seat
• Seat is an important feature in operator safety and needs to be comfortable
• Seat is equipped with 2-point contact seat belt, always wear seat belt while operating the machine
• The seat needs to be adjusted properly and to the best operating comfort level
• Wrong seat adjustment may lead to fatigue
• Do not make adjustment while driving
• Various seat adjustment can be done
1. Weight & height adjustment 7. Armrests
2. Fore/aft adjustment 8. Seat belt
3. Absorber adjustment 9. Head rest
4. Seat pan angle adjustment 10. Lumbar support adjustment
5. Seat depth adjustment 11. Backrest adjustment
6. Armrest adjustment 12. Left/right adjustment

13. Fore/aft isolator <
<
Training modules
AIR CONDITIONING SYSTEM
<
<
Training modules
AIR CONDITIONING
Air conditioning system
• System is designed to provide cooling effect inside the cabin
• The cabin inlet air temperature is adjusted by the control knobs
• The air conditioning is switched ON/OFF from the operator compartment
• All the components are placed inside the air-conditioning unit
• Heating option is also available and engine coolant is used for heating
<
<
Training modules
AIR CONDITIONING
Air conditioning unit
• The air conditioning unit is mounted outside of the operator cabin
• Main components inside the unit are,
• Air compressor
• Hydraulic motor
• Condenser
• Condenser fan
• Evaporator
• Blower fan
• Expansion valve
• Thermostat
• Receiver/drier
• Cyclone filter(optional)
<
<
Training modules
AIR CONDITIONING
Air conditioning unit – Hydraulic motor
• The air conditioning compressor is driven by a hydraulic motor
• Cooler pump section deliver the required oil flow for the hydraulic motor
• Air conditioning hydraulic motor is connected in series with cooler motor
• When air conditioning is switched on solenoid Y3019 directs oil flow through the motor
<
<
Training modules
AIR CONDITIONING
Air conditioning unit – Hydraulic motor
• Hydraulic connections for motor are conncted at the bottom of the air conditioning unit
1. Leakage line
2. Pressure line
3. Return line
1 2 3 <
<
Training modules
AIR CONDITIONING
Solenoid valve – Y3019
• When air conditioning is switched on,
• Solenoid Y3019 enerzises and directs oil flow through the motor
• When air conditioning is switched off,

• Solenoid valve is de-energized and hydraulic oil flow, bypass the motor
• The air conditioning is not operational
• The pressure switch on high and low side controls the status of the solenoid valve
<
<
Training modules
AIR CONDITIONING
Compressor
• Compressor circulates refrigerant throughout the system
• The compressor’s pistons draw in refrigerant through the suction valve and force it out through the discharge valve
• Compressor is attached to a hydraulic motor
• The oil flow through the hydraulic motor is controlled by the solenoid valve Y3019
• Relief valve built into the compressor, protects it from extremely high pressure
• It is designed to open and release the A/C charge if the pressure reaches 37bar
• The Pressure Relief Valve is a secondary protection device in the A/C system
• The Pressure Switch will shut down the system at 28bar
<
<
Training modules
AIR CONDITIONING
Evaporator coil
• Removes the heat from the cabin and delivers cooled air to the cabin
• The Evaporator cools and dehumidifies the air before it enter the cabin
• The amount of liquid refrigerant passing through the evaporator is controlled by the expansion valve
<
<
Training modules
AIR CONDITIONING
Expansion valve
• The Expansion Valve controls the amount of the refrigerant entering the evaporator coil
• The expansion valve is located at the inlet of evaporator and controls the refrigerant to the evaporator coil
• The expansion valve separates the high-pressure side of the system from the low pressure side of the system
• The valve controls the amount of refrigerant into the coil by sensing the heat load on the coil
<
<
Training modules
AIR CONDITIONING
Blower
• The blowers are used to Blow/suck air through the evaporator coils and into the cabin
• Operator controls the blower speeds with the blower potentiometer
• The blower pulls the air through the outside filter, or the re-circulation air filter inside the unit
• The blower speed is stepless
• Direction of air flow is marked on the filter, always place the filter in a correct way
<
<
Training modules
AIR CONDITIONING
Stepless blower module
• The Stepless motor drive, is an electronic module that is used to control the blower speed
• The Stepless motor drive provides infinite variable speed control
• A Stepless motor drive,

• Allows more precise control
• Requires little maintenance
• Operates more efficiently than a traditional speed control devices
• A Stepless motor module controls, motor speed by interrupting the current flow
• The motor’s speed is controlled by the frequency of interruptions

• At top speed, there is no current interruption
<
<
Training modules
AIR CONDITIONING
Blower speed control
• The blower speed is controlled by the knob on the dash board
• The knob is connected to the potentiometer
• The potentiometer must meet the requirements,

• 10kΩ with a ±10% tolerance
• End resistance of 3% of nominal resistance or less
<
<
Training modules
AIR CONDITIONING
Thermostat
• The Thermostat is used to control the operation of the valve for the hydraulic motor
• Controls the temperature on the air out from the coil
• Acts to prevent icing in the cooling coil
• Thermostat switches the control current of solenoid valve Y3019
• Solenoid status changes (on/off) depending on the cabin temperature and the set limit value
• The solenoid valve Y3019 de-energizes if,
• The pressure on the high pressure side is more than 28bar
• Pressure switch on low pressure side is less then 1,8bar
<
<
Training modules
AIR CONDITIONING
Condenser
• Removes the heat picked up at the evaporator
• Refrigerant condenses to a liquid, giving off a large amount heat in the process
• Condenser fans are controlled by a pressure switch and runs on a low speed
<
<
Training modules
AIR CONDITIONING
Receiver/drier
• Receiver/drier is mounted inside the unit on the high-pressure side of the system
• Receiver/drier receives refrigerant from condenser and,
• Temporary store refrigerant until needed by the evaporator
• Remove moisture from the refrigerant
• The sight glass on the receiver/drier is used to check the refrigerant level
• Bubble in the sight glass, indicates that the system is low on refrigerant
• The high pressure side pressure switch is mounted on the receiver/drier

• It is recommended that the drier is replaced if a system is opened for service
Note! Both fittings on the drier are the same size so the hoses could be mounted incorrectly, causing the oil in the
system to accumulate in the drier and, this will cause compressor failure due to the bearings are drying up
<
<
Training modules
AIR CONDITIONING
Pressure switch
• The pressure switches control the status of solenoid valve Y3019
• High pressure side switch is mounted to the receiver/drier
• Prevents compressor clutch engagement,

• Will disengage the compressor clutch at high pressure reading of 28bar
• Will not allow the compressor clutch to engage at low pressure reading of 1,8bar on the high side
• The pressure switch is a safety device used to protect the A/C compressor
• Pressure switch on low pressure side will,

• Cut the power to the solenoid valve at low amount of refrigerant
<
<
Training modules
AIR CONDITIONING
Cyclone filter
• The cyclone filter is used to make sure that, cleaned air enters the intake pipe
• The centrifugal force caused by the spinning impeller separates the dirt, dust and other particles from the air
• The dirt is expelled through the louver, back into the atmosphere
• Cyclone filter is self cleaning and maintenance free
<
<
Training modules
AIR CONDITIONING
Heating system
• The operator set the cabin temperature by adjusting the potentiometer on the control panel
• The amount of coolant flow through the heating coil is controlled by the water valve
• The opening of electrical water valve is controlled by the temperature potentiometer
• To avoid water leakage through the valve, the water direction has to be correct
<
<
Training modules
AIR CONDITIONING
Air-conditioning control schematic
<
<
Training modules
FRAME STRUCTURE
<
<
Training modules
47
FRAME STRUCTURE
Frame material properties
• Frames are made of fine grain, high strength structural steel
• Almost all frame cracks or damage can be repaired by welding
• For repairing critical parts (frame, cabin,tanks, etc.) contact factory
• Front axle is fixed type and mounted to the front frame
• Rear axle is mounted on oscillation cradle and have + 8° oscillation
Front frame assembly Middle hinge Rear frame assembly <

<
Training modules
48
FRAME STRUCTURE
Boom support device
• Boom support device must be used during any maintenance under the boom
• Both side boom support must be used
• Two boom support device is located in the front frame on the mudguard
• The support device is provided to prevent unplanned movement of the boom
• To protect personnel during maintenance

• It is recommended to use secondary support device under the boom
<
<
Training modules
49
FRAME STRUCTURE
Frame locking pin
• The frame articulation locking device is located at the articulation area of the machine
• The locking device must be installed before starting any maintenance work
• The locking device is provided to prevent unplanned movement of the frame joint
• To protect personnel during maintenance
<
<
Training modules
50
FRAME STRUCTURE
Middle hinge assembly
<
<
Training modules
51
FRAME STRUCTURE
Upper hinge assembly
• Upper joint carries both axial and radial load
• Assembly contains,
• Pin
• Steel bushing
• V-seal
• Upper flange
• Steel bushing (in frame)
• Flange
• Ball joint bearing
• Adjusting shims
• Sleeve
• Lower Flange
• Spacer ring
• Lubrication lines
<
<
Training modules
52
FRAME STRUCTURE
Lower hinge assembly
• Lower joint carries both radial and axial load
• ”Floating” type spherical bearing
• Assembly contains,
• V-seal
• Flange
• Upper flange
• O-ring
• Lower hinge pin
• Seal
• Ball joint bearing
• Seal
• Lower flange
• Steel bushing
• Lubrication lines
<
<
Training modules
53
FRAME STRUCTURE
Pins & bushings
• The front frame components, are connected together with pins and bushings
• Lift arm top end pin (2ps)
• Lift cylinder pins (4ps)
• Tilt cylinder pins (2ps)
• Swinglever pin (1ps)
• Dog bone pins (2ps)
• Bucket pins (2ps)
• The clearance of pin/bushing needs to be maintained <1mm
<
<
Training modules
54
FRAME STRUCTURE
Pins & bushings - Bucket Pin
• Pins identical on both sides of the arm
• The clearance can be adjusted with spacer of different sizes
• 6.5 mm
• 7.5 mm
• 8.5 mm
• 9.5 mm
• 10.5 mm
• Bucket clearance will determine the spacer plate size
<
<
Training modules
55
FRAME STRUCTURES
Middle hinge – Adjustment
• Always follow all safety regulation and procedures before starting the work
• Make sure that the machine is parked on a level surface
• The boom is resting on the stops and engine is not running
• Place the dial gauge magnetic stand as close as possible to the upper hinge
• Start the engine

• Press the bucket down to the ground till the front wheels are off the ground
• Stop the engine (if running) and read the dial gauge
• The axial play should be 0,1 – 0,3 mm
• Adjust hinge bearing play if required with the shim
• Shims are available in different sizes

• 0,2 mm
• 0,5 mm
<
< Note! The measurement must be performed with empty bucket and without the frame articulation locking device being installed
Training modules
56
FRAME STRUCTURE
Bucket stopper - Adjustment
• Bucket stopper adjustment should be checked always when bucket or bucket stopper absorber is changed
• Start the machine and rise the boom so that bucket pin (B) is one meter off the ground (the bucket in haul position)
• Roll back the bucket and measure the extended cylinder rod of the tilt cylinder (dimension A)
• Lower the boom against boom stops (bucket in haul position)
• Measure the cylinder rod length (A) again
• The dimension should be between 10-15 mm shorter
• If not, the bucket stopper thickness needs to be adjusted accordingly
• Stopper adjusting is made by adding or removing spacers of different thicknesses under the bucket stops
• If the dimension change is too big the stopper thickness should be reduced
• If the dimension change is less than 10 mm the spacers should be used under the bucket stoppers
<
<
Training modules
BUCKETS
<
<
Training modules
BUCKET
• Different types of buckets are available
• Choose the right bucket according to the application and ore grade
• Buckets can be categorized as,
• Differences in bucket functions

• Standard bucket
• Ejector bucket
• Side tipping bucket
• Differences in wear parts
• Bare lip
• Sandvik Half Arrow
• Sandvik Blue Pointer 2
<
<
Training modules
BUCKET
Differences in bucket functions
• Standard bucket
• Multipurpose use
• Ejector bucket
• Used when loading height is limited or tipping is not possible
• Normally used for dump truck loading and backfilling situations
<
< Standard bucket
Training modules
BUCKET
Differences in bucket functions
• Side tipping bucket
• For special applications, usual in tunneling
<
<
Training modules
BUCKET
Differences in wear parts
• Bare lip
• Traditional welded lip plate made of wear plate
• Best penetration, light, low price, no wear parts, short life time
<
<
Training modules
BUCKET
• Sandvik Half Arrow,
• Cast wear parts welded on bucket lip
• Welded wear parts
• High strength
• High resistance to wear
• Added material compared to bare lip
• Wear indicator (like in blue pointer)
<
<
Training modules
BUCKET
• Sandvik Blue Pointer 2
• Cast wear parts bolted on bucket lip
• Used in most applications
• Replaceable bolt-on wear parts
• Lots of wear material
• Multiple layouts available
• Easy to read wear indicator
• Self sharpening
• Protector strips underneath bucket
<
<
Training modules
BUCKET
Blue pointer 2 – Sectional view
1. Shroud
2. Bucket lip
3. Welded boss
4. Seal
5. Piston
6. Pin Block
7. Wedge Lock
8. Spacer
9. Cap screw
<
<
Training modules
BUCKET
Blue pointer 2 – Wear indicators
• A small opening at bottom of a shroud indicate wear
• When opening is noticeable – replace the shroud
• Replacement half corners can be used to extend straight and transition shroud life time
<
<
Training modules
BUCKET
Sandvik Blue pointer 2 wear parts
1. Primary lip
2. Straight shrouds
3. Cast corners
4. Heel shrouds
5. Transition shrouds
6. Corner shrouds
<
<
Training modules
GENERAL HYDRAULIC SYSTEM
<
<
Training modules
GENERAL HYDRAULICS
Hydraulic System
• Hydraulic system is divided mainly in two categories

• Main Hydraulics
• Brake Hydraulics
• Hydraulic system have three main pumps

• Steering and Cooler pump mounted directly to converter
• Boom & Bucket and Brake pump mounted directly to converter
• Engine cooler fan pump mounted to engine
<
<
Training modules
GENERAL HYDRAULICS
Oil specification
• Oil specification for main & brake hydraulics are same
• Oil specification meet DIN 51524--3 (HVLP) or ISO 6743--4 HV
• Lubrizol reduces noise during braking and frictional wear of brake disc
• Recommended lubrizol quantity is 1% of oil volume in the tank
Note! Choose the lubricant which meets the classification requirement and is suitable under your local production circumstance when changing
or adding oils.
<
<
Training modules
GENERAL HYDRAULICS
Hydraulic oil tank
• Common hydraulic tank for main and brake hydraulics
• Oil level can be checked from the sight glasses
• Oil level should be between the sight glasses (boom down)
• Oil level switch and temperature sensors mounted on the tank
Temperature sensor
<
< Level Switch
Training modules
GENERAL HYDRAULICS
5 6 8
7
Hydraulic oil tanks 4
3
1. Sight glass
2. Brake hydraulic oil return filter 2
1
3. Quick coupling, oil filling
4. Main hydraulic oil return filter
5. Pressure bleed valve

6. Breather 9
7. Filter blockage sensor, Brake hydraulic return filter 10
8. Filter blockage sensor, Main hydraulic return filter 11

9. Oil level sensor, Warning
10. Oil level sensor, Alarm
11. Temperature sensor

12. Drain valve 12
<
<
Training modules
GENERAL HYDRAULICS
Hydraulic oil tank
• Tank is equipped with a pressurized breather
• Maintain pressure up to 0,4 bar to avoid cavitation
• Pressure bleed valve, to de-pressurize the tank
• Two return filters

• Main hydraulic oil return filter (Z3421)
• Brake hydraulic oil return filter (Z3821)
• Both return filters are equipped with by-pass valve

• Main hydraulic oil return filter – 1,5 bar
• Brake hydraulic oil return filter – 0,4 bar
B3001
<
<
Training modules
GENERAL HYDRAULICS
Hydraulic oil tank
• Clogging indicator pops up for filter blockage warning if pressure increase by,
• Main hydraulic oil return filter – 1,2 bar (S3076)
• Brake hydraulic oil return filter – 0,3 bar (S3077)
• Sensor (B3001) monitors the hydraulic oil temperature

• Level switch S3012 & S3056 monitors the oil level in the tank
B3001
<
<
Training modules
GENERAL HYDRAULICS
Pump – location & application
• The cooler fan pump location differs with Volvo & Mercedes engine
Volvo
Mercedes
<
<
Training modules
GENERAL HYDRAULICS
Pump – location & application (Volvo Engine)
• Engine fan cooler pump (1) 1
• Electronically controlled
• Provides necessary oil flow for cooler fan motors
• Steering & Cooler pump (2)

• Tandem type gear pump
• Provides necessary oil flow for Steering & Cooler motors
• Circuit oil through the cooler for hydraulic oil cooling
• Transmission pump (3)

2
• Provides necessary oil flow for transmission & converter operation
• Boom & Bucket and Brake pump (4)

• Tandem type gear pump 3
• Provides necessary oil flow for Boom & bucket and Brake system
4
<
<
Training modules
GENERAL HYDRAULICS
Pump – location & application (Mercedes Engine) 1
• Engine fan cooler pump (1)




3
4 <
<
Training modules
GENERAL HYDRAULICS
Hydraulic Pumps Specifications
2 1 2 1
Steering pump section (1) Boom & Bucket pump section (1) Engine fan cooler pump section
- Gear pump - Gear pump - Piston pump
- Displacement: 41 cm3 - Displacement: 41 cm3 - Electronically controlled
- Flow 90 l/min@2300 rpm - Flow 90 l/min@2300 rpm - Displacement: 28 cm3
- Flow 74 l/min@2650 rpm
Cooler pump section (2) Brake pump section (2) - Max. pressure 180bar
- Gear pump - Gear pump - Stand-by pressure 25bar
- Displacement: 16 cm3 - Displacement: 16 cm3 <
< - Flow 35 l/min@2300 rpm - Flow 35 l/min@2300 rpm
Training modules
GENERAL HYDRAULICS
Suction lines
1. Main suction hose
2. Cooler pump
3. Brake pump
4. Boom & Bucket pump
5. Steering pump
6. Engine cooler fan pump
6
5
2
1 3 4
<
<
Training modules
GENERAL HYDRAULICS
Cooling hydraulic
• Hydraulic oil is cooled in the hydraulic oil section of the cooler assembly
• The cooler assembly is divided in two sections, main hydraulic oil cooling and transmission oil cooling
• Cooler pump supplies the necessary oil flow for the air conditioning motor and cooler motors
• Oil after passing through the cooler motors enters the cooler section and to tank
<
<
Training modules
GENERAL HYDRAULICS
Cooling hydraulic – cooler assembly
• Cooling effect in the coolers are created by two hydraulically driven fans 3
• Fans are coupled to two 10,8 cc hydraulic motors

• Transmission cooler fan motor (1)
• Hydraulic oil cooler fan motor (2)
• A check valve or back valve (3) in the hydraulic line of the two motors,
• Prevents sudden stoppage of fan, when hydraulic supply is cut
FAN DIRECTION
1
<
<
Training modules
GENERAL HYDRAULICS
Cooling hydraulic
• Hydraulic oil is cooled in the hydraulic oil section of the cooler assembly
• The cooler assembly is divided in two sections, main hydraulic oil cooling and transmission oil cooling
• Cooler pump supplies the necessary oil flow for the cooler motors and air conditioning motor
• Oil after passing through the air condition motor enters the cooler section and to tank
<
<
Training modules
GENERAL HYDRAULICS
Cooling hydraulic – cooler assembly
• Cooling effect in the coolers are created by two hydraulically driven fans 3
• Fans are coupled to two 10,8 cc hydraulic motors

• Transmission cooler fan motor (1)
• Hydraulic oil cooler fan motor (2)
• A check valve or back valve (3) in the hydraulic line of the two motors,
• Prevents damage of fan due to sudden stoppage of fan, when hydraulic supply is cut
FAN DIRECTION
1
<
<
Training modules
GENERAL HYDRAULICS
Cooling hydraulic - Schematic
• Cooling hydraulics has been updated
• New - Oil from cooler pump flows to Hydraulic/transmission cooler motor and then to air conditioning motor
• Old - Oil from cooler pump flows to air conditioning motor and then to Hydraulic/transmission cooler motor
<
<
Training modules
STEERING HYDRAULICS
<
<
Training modules
STEERING HYDRAULICS
Steering system description
• Hydraulic system designed to steer the machine using two hydraulic cylinders
• Hydraulic cylinder movement is controlled by the joysticks in cabin
• Main components:
• Steering pump
• Directional control valve
• Two steering cylinder
• Joystick (left hand side)
• Pilot pressure valve
• Gear pump mounted to converter provides necessary oil flow for steering system
• Steering valve main spool movement is controlled by the pilot pressure
<
<
Training modules
STEERING HYDRAULICS
Locations – Steering system
1. Steering cylinders 1
2. Pilot pressure valve
3. Direction control valve
4. Steering pump
3
<
<
Training modules
STEERING HYDRAULICS
Steering pump
• Gear type tandem pump pump mounted to converter
• One section of the pump provides necessary oil flow for Steering system
1. Steering section
2. Cooler section
• When steering function is not in use, oil flow is used for Boom & Bucket movement
1
2
Boom & Bucket valve
Steering valve
<
<
Training modules
STEERING HYDRAULICS
Direction control valve
• Directs hydraulic oil flow and control pressure for the steering system
• Main relief valve limits the pump pressure up to 220bar
• Main spool movement function is made by applying the pilot pressure
• Proportional solenoid valves directs the pilot pressure to the main spool
• The signal for proportional valve activation is controlled by the joystick
<
<
Training modules
STEERING HYDRAULICS
• Steering pump supply oil flow to the direction valve
• Main components,
1. Shock valves – Steering right 1 2
2. Shock valves – Steering left
3. Main relief valve
4. Main spool 3
6 4
5. Solenoid valve Y3023 - Steering right
6. Solenoid valve Y3022 - Steering left
5 2
5 6
3
<
< 1
Training modules
STEERING HYDRAULICS
• Shock valves (1 & 2)
• Limit pressure spikes caused by the external load
• Both shock valves are of same pressure rating of 125 bar
1 2
• Main relief valve (3)
• Limits pump pressure up to 220 bar
3
• Main spool (4) 4
• Directs oil flow to the steering cylinders
• Movement is controlled by the joystick
• Proportional solenoid valves (5 & 6)

• Directs pilot pressure to the main spool
5. Solenoid valve Y3023 - Steering right
6. Solenoid valve Y3022 - Steering left
5 6
<
<
Training modules
STEERING HYDRAULICS
Hydraulic cylinders hose connections
4
1. Right side steering cylinder rod side
2. Right side steering cylinder piston side
3. Left side steering cylinder rod side

2
4. Left side steering cylinder piston side
3
5. MP103 – Steering right
6. MP104 – Steering left 1
5
6
<
<
Training modules
STEERING HYDRAULICS
Direction valve connection ports
1. T1 – Main tank line
2. P1 – Pump pressure – In
3. A – Working pressure – Steering left T1

P1
4. B – Working pressure – Steering right
B
<
<
Training modules
STEERING HYDRAULICS
Pilot control pressure unit
• Pilot pressure is used for Steering, Boom & Bucket and Lubrication function
• Steering and brake pump provide necessary oil for pilot pressure
• Main components of pilot pressure unit are:

• Reducing valve 35bar
• Relief valve 45bar
• Pressure accumulator
• Accumulator drain solenoid valve
• Shuttle valve
• Check valve
<
<
Training modules
STEERING HYDRAULICS
• Shuttle valve (1)
• Directs the hydraulic pressure from inlet connections P1 or P2 to the reducing valve
• P1 - pressure from steering pump
• P2 – pressure from brake pump
• Reducing valve 35bar (2)

• Reduces pilot control pressure to 35bar
• Relief valve 45bar (3)

• Limits the reducing pressure up to 45bar
P2
1 P1
2 3
<
<
Training modules
STEERING HYDRAULICS
• Check valve (4)
• Prevents hydraulic oil flow from the pilot control pressure line to pressure reducing valve
• Pressure accumulator (5)

• Store pilot pressure
• Accumulator has pre-charge pressure of 15bar
5
• Accumulator drain solenoid valve (6)
6
• Drain the pressure accumulator with ignition off
5
P2
4 P1
<
<
Training modules
STEERING HYDRAULICS
Pressure testing – Pilot pressure
MP405
• Always follow all safety regulations and wear proper PPE’s
• Install the frame locking device
• Make sure that the machine is on a level surface
• The parking brake is applied and movement is prevented with wheel chocks
• Connect a 400–bar pressure gauge to the measuring point MP405

• Start the engine and let it idle
• Record the pressure value from the gauge
• The correct pressure is 35 bar (±10bar)
Note! Never adjust the pressure when engine is running
<
<
Training modules
STEERING HYDRAULICS
Pressure testing – Pilot accumulator charge pressure
• Connect a 40–bar pressure gauge to the measuring point MP405
• Shut down the engine and switch the ignition current back on immediately
• Do not start the engine
• Switch the ignition current "off" and "on" repeatedly and follow the pressure
• Pressure decrease, each time the ignition is switched "off"
• When the ignition current is switched "on" the pressure should stop decreasing
• When the transition point 15 bar (± 2bar) is reached the pressure will drop to 0 bar
• Take the measuring hose away from measuring point MP405
<
<
Training modules
STEERING HYDRAULICS
Steering – schematic
• Engine running - No steering
• Pump oil is directed to tank
• Pilot pressure is waiting

behind the proportional
valves
<
<
Training modules
STEERING HYDRAULICS
• Engine running – Left steering
• Proportional valve Y3022 energizes
• Pilot pressure is directed to the main spool
• Main spool shifts,

• Directs oil to cylinder
• Return oil is directed to tank
• Steering function is made
<
<
Training modules
STEERING HYDRAULICS
• Engine running – Right steering

• Steering function is made
<
<
Training modules
STEERING HYDRAULICS
The emergency steering pump is activated for 2 seconds every time the engine is started
Emergency Steering
• The emergency steering function is designed to steer the machine if,
• The engine stops or stalls in an unusual way
• This function allows the operator to safely steer the machine away of danger area
• When the engine stops suddenly,

• The system activates and an electric pump
• The pump will be activated for 10 sec.
• Oil flows to the steering system and steering function can be done
• Relief valve limits the emergency steering pump pressure up to 100bar
• Emergency steering is allowed, even when the parking brake is on
• The emergency steering will not function, if the emergency stop is active
<
<
Training modules
BOOM & BUCKET HYDRAULICS
<
<
Training modules
Box hydraulic system description
• Hydraulic system designed for Boom & Bucket operation

• Boom & Bucket hydraulic main components :
• Boom and bucket pump
• Direction control valve
• Two lift cylinders (for boom movement)
• One tilt cylinder (for bucket movement)
• Boom & Bucket pump provides necessary oil flow for the system
• Directional control valve main spool movement is controlled by the pilot pressure
• Boom and Bucket function is controlled by the right hand side joystick inside the cabin
<
<
Training modules
Locations – Boom & Bucket hydraulic
1
1. Tilt cylinder
2. Two lift cylinder
3. Directional control valve
4. Solenoid valve block 3
5. Boom & Bucket pump 4
5
<
<
Training modules
Boom & Bucket pump
• One section of the pump provides necessary oil flow for Boom & Bucket system
1. Boom & Bucket section
2. Brake charging section
• When steering function is not in use, oil flow is used for Boom & Bucket movement
2 <
<
Training modules
• Directs hydraulic oil flow and control pressure for the Boom & Bucket system
• Main relief valve limits the pump pressure up to 210 bar
• Main spool movement function is made by applying the pilot pressure
• Proportional solenoid valves directs the pilot pressure to the main spool
• The signal for proportional valve activation is controlled by the joystick
<
<
Training modules
Direction control valve 1 2
• Boom & Bucket pump supply oil flow to the direction valve
• Main components,
1. Shock valves – Boom
2. Shock valves - Bucket
4
3. Check valve
4. Main relief valve 5 6
7
5. Main spool – Boom 3
6. Main spool - Bucket 7
7. Back valve (check valve)
8. Solenoid valve block
3
<
< 8
Training modules
• Shock valves (1 & 2)
• Limit pressure spikes caused by the external load
• All the shock valves are of same pressure rating of 250bar
• Check valve (3)

4
• Check valve prevents oil flow towards the steering pump
5 6
• Main relief valve (4) 7
3
• Limits pump pressure up to 210bar
• Main spool (5)

• Directs oil flow to the Boom cylinders
• Main spool (6)

• Directs oil flow to the Bucket cylinder
8
<
<
Training modules
• Back valve (7)
• Maintain back pressure up to 4,5bar
• Prevents cavitation in the system
• Proportional valves (8)

4
• Directs pilot pressure to the main spool
A. Solenoid Y3025 – Boom down 5 6
7
B. Solenoid Y3028 – Boom up 3
C. Solenoid Y3027 – Bucket roll back
D. Solenoid Y3024– Bucket dump
D
C
B
A
8
<
<
Training modules
Hydraulic cylinders hose connections
1. Boom cylinder rod side (Boom down)
2. Boom cylinder piston side (Boom up)
3. Bucket cylinder piston side (Bucket dump) 5

6
4. Bucket cylinder rod side (Bucket roll back)
5. MP207 – Bucket dump

6. MP206 – Bucket roll back
8
7. MP203 – Boom up
7 4
8. MP204 – Boom down
3
2
<
<
Training modules
Direction valve connection ports
1. T1 – Main tank line
2. A – Working pressure – Bucket roll back
3. B – Working pressure – Bucket dump 1
4. B – Working pressure – Boom up
5. A – Working pressure – Boom down

6. P1 – Pump pressure – In (Boom & Bucket pump) 2 7
3
7. P1B – Steering pump pressure -In
4
MP201
5
6
<
<
Training modules
Boom & Bucket function – schematic
• Engine running – No function made
• Oil flow from Steering and Boom & Bucket pump is
directed to the tank
• Pilot pressure is waiting behind the proportional valves
<
<
Training modules
Boom – Up – schematic
• Engine running
• Joystick movement is made

• Boom-Up function is made
<
<
Training modules
Boom –Down – schematic
• Engine running

• Boom-Down function is made
<
<
Training modules
Bucket – Roll back – schematic
• Engine running

• Bucket- Roll back function is made
<
<
Training modules
Bucket - Dump – schematic
• Engine running

• Bucket - Dump function is made
<
<
Training modules
Ride control
• The ride control is also known as boom suspension
• Ride control increases the machine’s driving comfort and reduces stress on the machine frame components
• The boom is suspending on the pressure accumulators during driving
• Automatic ride control function can be switched on by pressing the ride control button on the dash board
• Ride control will be activated automatically when,

• The machine’s tramming speed increased (2nd gear, speed over 5 km/h)
• Ride control can be switched off by pressing the ride control button again
• The ride control will be deactivated,
• For the time period when the bucket is used
• When RRC mode is activated
<
<
Training modules
Ride control
OFF ON
<
<
Training modules
Boom float
OFF ON
<
<
Training modules
Ride control – Valve assembly
1. Ride control valve block
2. Pressure accumulator Z2231

3. Pressure accumulator Z2232
4. Solenoid valve Y2036


8. Pressure measurement point MP211
<
<
Training modules
• Pressure accumulator (1)
• 4 ltrs., pre-charge pressure 15bar
• Pressure accumulator (2) 3

• 4 ltrs., pre-charge pressure 30bar
• Ride control block (3)

• Solenoids are mounted on the block
• Includes 3 valves
• Facilitate mounting of all the valves and solenoid for ride control
1 2
<
< 3
Training modules
5
4
• Ride control solenoid valve Y2059 (4)
• Connects rod side of the cylinder to tank line
• Ride control solenoid valve Y2036 (5)

• Connects the pressure accumulators to the piston side of the cylinder
7
• Boom float solenoid valve Y2037 (6)
6
• Activates when boom floating is on
• Drain solenoid valve Y2100 (7)

• Drain accumulator when machine is turned off
5 6 4
7
<
<
Training modules
Ride control
• When ride control is activated:
• Boom is lifted until the predefined lower limit of the switch S2034 is exceeded
• Solenoid valve Y2036 activates and lift cylinders piston side is connected to accumulators
• Accumulators drain valve solenoid Y2100 is activated
• Solenoid valve Y2059 is activated connecting the lift cylinder rod side to tank
• The symbol in the display informs about the status of ride control
• Boom might descends below the lower limit during the opening of the pressure accumulator
• Boom is again lifted until the boom is above the ride control limit switch S2034
<
<
Training modules
Boom float
• The boom float function will let the bucket trail the ground
• Boom float can be activated by pressing the boom float button on the dash board
• The boom lower limit sensor S2036 must be activate
• When float is engaged, boom must be lowered against the stoppers
• Boom float can be deactivated by pressing the float button again

• Controlling the boom or bucket will also deactivate float
<
<
Training modules
Boom float
• When boom floating is activated:
• Ride control valve Y2037 activates, connect lift cylinder piston side to tank line
• Solenoid valve Y2059 activates, connect lift cylinder rod side to tank
• The symbol in the display informs about the status of boom float
• Both sides of lift cylinder piston are connected to the tank line
• This allow external forces to move the boom without any resistance from the system
<
<
Training modules
BRAKE HYDRAULICS
<
<
Training modules
BRAKE HYDRAULICS
Brake system description
• Double circuit brake system with front and rear axles having separate circuits
• Spring applied, hydraulic release (SAHR) brakes
• Oil flow and pressure is provided by a gear pump
• Solenoid valve controls oil flow to the brake housing and accumulator drain
• Electrical brake release pump for emergency purposes
<
<
Training modules
BRAKE HYDRAULICS
Brake system - Locations
1. Pressure accumulator
2. Sequence valve 2
3
3. Pressure filter 4
4. Brake release pump 5

5. Brake pedal (Canopy version)
6. Pressure switch brake release pump
7. Brake charging valve block
<
< 7
Training modules
BRAKE HYDRAULICS
Brake charging pump
• One section of the pump provides necessary oil flow for Brake charging system
1. Boom & Bucket section
2. Brake charging section
2 <
<
Training modules
BRAKE HYDRAULICS
Brake charging valve block
• Limits and regulate brake charging pressure
• Charges the accumulators and control the brake pressure to the brakes
• Drain oil from accumulators when engine is shut down
• Components included in charging valve,

• Main relief valve (300 bar)
• Reducing valve (205 bar)
• Charging valve (150 bar)
• Relief valve (40bar)
• Drain solenoid
• Directional solenoid valves
<
<
Training modules
BRAKE HYDRAULICS
<
<
Training modules
BRAKE HYDRAULICS
• Main relief valve (1)
1
• Limits brake charging pump pressure up to 300 bar
4
• Reducing valve (2) 3
• Reduces pump pressure up to 205 bar 3
• Prevents seal damage due to excess pressure 4
• Charging valve (3) 2

• Charge in the system if the pressure drops below 150bar
• Maintain minimum charging pressure
• Relief valve (4)

2
• Works along with 150 bar
• Opens when the charging pressure builds up to 190 bar 1
• Limits the maximum charging pressure
<
<
Training modules
BRAKE HYDRAULICS
• Drain solenoid Y3052 (5)
• Energizes with ignition ON
• De-energizing the solenoid drains accumulator pressure
• Directional solenoid valve Y3048 (6)

• Energized when parking switch is pulled up
6
• Directs brake pressure to rear brake housing
• Directional solenoid valve Y3001 (7)

5
• Energized when parking switch is pulled up MP501
• Directs brake pressure to front brake housing
5 7
7
6
<
<
Training modules
BRAKE HYDRAULICS
• Check valve (8)
• Acts as a quick drain valve, when brakes are released and when brake pedal is pressed
• Connects rear brake pressure line to tank
• Check valve (9)

• Acts as a quick drain valve, when brakes are released and when brake pedal is pressed 9
• Connects front brake pressure line to tank
• Check valve (10) 10

• Keep the charging pressure in the system ones it’s charged
• The pressure difference keeps the check valve closed 8
• Not allowing the charging pressure to enter the reducing valve
8 9
10
<
<
Training modules
BRAKE HYDRAULICS
• Pressure transducers monitors the pressures in the brake circuit
• The pressures can be checked from the control system display
1. B3057 - Rear brake pressure
2. B3058 – Brake pedal out pressure
3. B3056 - Front brake pressure

4
4. B3034 - Brake charging pressure
2
1
<
<
Training modules
BRAKE HYDRAULICS
• The pressures can also be measured from the measuring points
1. MP506 – Rear brake pressure
2. MP505 – Front brake pressure
3. Front brake pressure (alternative to MP505)
4. MP511 – Brake flushing pressure
5. MP503 – Brake charging pressure
6. MP501 – Brake pump pressure
<
<
Training modules
BRAKE HYDRAULICS
Brake pedal valve assembly
• Brake pedal assembly is different for cabin and canopy version, but the brake valve is same
Canopy
Cabin
<
<
Training modules
BRAKE HYDRAULICS
• Spool type reverse modulating proportional valve
• Pressing the pedal decreases pressure from preset value to actuate brakes
• Brake pedal (1)
• Brake valve (2)
• Acts as a pressure reducing valve, reduces pressure to the axles up to 121 bar
P
• Adjustment screw to adjust pedal-out pressure
T
A
• Pressing the brake pedal
• Connects pedal valve`s A-port with T-port
• Directs brake housing pressure to tank
• Brakes are applied
• Check valve(3) inside the brake pedal,

• Maintain pressure difference between pedal-in and pedal-out pressure
• Acts as a quick drain valve when the engine is shut down or power is cut-off
<
<
Training modules
BRAKE HYDRAULICS
• Spool type reverse modulating proportional valve
• Pressing the pedal decreases pressure from preset value to actuate brakes
• Brake pedal (1)
• Brake valve (2)
• Acts as a pressure reducing valve, reduces pressure to the axles up to 121 bar
• Adjustment screw to adjust pedal-out pressure
• Pressing the brake pedal


• Maintain pressure difference between pedal-in and pedal-out pressure T
P
• Acts as a quick drain valve when the engine is shut down or power is cut-off
A
<
<
Training modules
BRAKE HYDRAULICS
Sequence valve block
• Ones the accumulators are charged, sequence valve shifts
• Shifting the valve, directs brake pump pressure for brake cooling and flushing
<
< Brakes are charging Brakes are charged
Training modules
BRAKE HYDRAULICS
Brake accumulators
• Brake charging circuit have one 6 liters piston type accumulators
• Stores hydraulic oil when the system pressure is over the pre-charging pressure
• Rated pre-charge pressure for accumulators are 90 bar
• Protects system components from pressure spikes
• Measuring points on the accumulators to check pre-charge pressure
<
<
Training modules
BRAKE HYDRAULICS
Brake accumulator charging
• All safety precaution must be followed before charging the accumulators
• Appropriate charging kit must be used
• Confirm the correct pre-charge pressure values for the accumulators before charging
• The accumulator must be charged with correct pressure ratings
• Re-check the pressure after charging
<
<
Training modules
BRAKE HYDRAULICS
Pressure filter
• Separates particles from oil and deliver clean oil to the brake charging valve 1
2
• Filter is equipped with in-built 7bar by-pass valve
• Clogging indicator S3078 (1)

• Warning pop up if filter is blocked and pressure increases by 5bar
• Filter head (2)

• For correct installation oil direction is marked with arrow on the filter head
• Filter bowl (3)

• The filter element with filtration of 10μm is located inside the filter bowl
3
<
<
Training modules
BRAKE HYDRAULICS
Brake release pump
• Enable brake release in case of engine or brake pump failure
• Activated by a switch in dashboard
• Electric motor drives the gear pump and charge the accumulators
• Pressure switch S3048, activates if the pressure increases more than 140 bar
• Cuts-off brake release pump motor electric supply and pump stops
• Relief valve limits the pump maximum pressure up to 210 bar
• Check valve prevents main brake pump oil flow, going to the brake release pump
<
<
Training modules
BRAKE HYDRAULICS
Functional description - Brake activation
• The drain solenoid valve Y3052 is energized with ignition on
• Brake charging pump deliver oil flow to the sequence valve
• From sequence valve oil is directed to,

• Brake charging valve block via pressure filter
• Brake flushing (partial oil flow)
• Ones the accumulators are charged and pressure builds up to 190 bar ,
• Charging valve (150 bar) shifts and relief valve (40 bar) opens
• Pressure in CP (control pressure) line drains to tank through the relief valve
• The sequence valve shifts and directs pump flow to brake flushing
• Check valve (1 bar)
• Maintain a back pressure of 1 bar for brake flushing and cooling
• Limits the brake flishing and cooling pressure to 1 bar, and prevents seal failure
• Now when the system is charged, the pump will run on no load condition
• This prevents pump from overheating
<
<
Training modules
BRAKE HYDRAULICS
Functional description - Brake charging valve
• The charging valve has three positions and is spring loaded
• There is a constant 150 bar spring load on the valve
• When brake charging pump deliver oil flow to the brake system
• The accumulators, start charging and the pressure increases in the brake
charging system (MP503)
• When the brake charging pressure, increases more than 150 bar (MP503)
• Charging valve start shifting against the 150 bar spring force
• The valve shifts to 2nd position
<
<
Training modules
BRAKE HYDRAULICS
• When the charging valve shifts to 2nd position the charging pressure rises
up to 150 bar (MP503)
• To keep the valve in 2nd position, a constant 150 bar hydraulic pressure is
required
• Which shifts the valve against the 150 bar spring force
• At the same time, oil is directed to the relief valve and on top of the
charging valve
• The oil pressure which is directed to the top of the charging valve adds on
to the 150 bar spring force
• The maximum hydraulic pressure which can be added to the spring force is
limited to 40 bar by the relief valve
• Thus the total pressure over the charging valve is (150 + 40 = 190 bar)
• Thus the charging pressure increases up to 190 bar (MP503) till the
charging valve shifts to 3rd position
<
<
Training modules
BRAKE HYDRAULICS
• When the charging valve shifts to 3rd position the charging pressure rises up
to 190 bar (MP503)
• The oil pressure over the charging valve is drained to the tank, via 40 bar
relief valve
• The oil pressure which hold the sequence valve during brake charging,
drain to tank and sequence valve shifts
• The oil from brake pump is now directed to the brake flushing and cooling
• The accumulators are fully charged and the brake charging pressure waits
behind the solenoid valves (Y3001 & Y3048)
<
<
Training modules
BRAKE HYDRAULICS
• When the park brake switch is pulled, parking brake solenoids activates
• Accumulator pressure waiting at solenoids is directed to the brake
housing through J1 & J2 lines
• Brakes are released
<
<
Training modules
BRAKE HYDRAULICS
• During normal operation parking solenoids are energized
121 bar
• Brake pedal is used to apply brakes or slow down the unit
• Pressing the brake pedal 121 bar


• Maintain pressure difference between pedal-in and pedal-out pressure
• Drains brake lines oil to tank when the engine is shut down
<
<
Training modules
BRAKE HYDRAULICS
Recovery hook
• Recovery hook is used to recover the break down loader
• Pulling the hook releases the brakes
• 9.2 liter accumulator provides necessary oil for brake

release (only for 3 pulls)
• Accumulator is pre-charged with nitrogen up to 90 bar

• Accumulator always remains pressurized even if the
power supply is cut
• Safety valve prevents brake releasing when engine is
running and hook is pulled
• Accumulator (30 bar) prevents releasing of brakes by

shifting the drain valve
<
<
Training modules
BRAKE HYDRAULICS
Recovery hook
• The system is designed to release the brakes only if
the engine is not running, provided all the system
settings are correct
Conditions for brake release:
1. Engine is running and hook is not pulled
• Brakes will not release
2. Engine is running and hook is pulled

3. Engine is running and hook is pulled, the hook is

kept pulled and the engine is shut down
4. Engine is not running and hook is pulled

• Brakes will release
<
<
Training modules
BRAKE HYDRAULICS
Recovery hook
1. Engine is running and hook is pulled
<
<
Training modules
BRAKE HYDRAULICS
Recovery hook
1. Engine is running and hook is pulled, the hook is
kept pulled and the engine is shut down
<
<
Training modules
BRAKE HYDRAULICS
Recovery hook
1. Engine is not running and hook is pulled
• Brakes will release
<
<
Training modules
ELECTRICAL SYSTEM
<
<
Training modules
ELECTRICAL SYSTEM
Electrical system description
• Powered up by 2x12V batteries, placed in the rear frame
• Lockable, main/master switch to engage or dis-engage the electrical system with the batteries power supply
• Main circuit breaker in the dash board to isolate power supply in case of an emergency
• Fuses prevents component failure in case of any malfunction or short circuit in the electrical system
• All the input/output devices are connected to the control system and are controlled by the control system
<
<
Training modules
ELECTRICAL SYSTEM
Electrical system control
• Control system monitor the machine operating condition and pops up alarm in case of any error
• Controls machine functions by using I/O of the modules
CAN High
• Communicates through CAN bus and SAE J1939
120Ω
120Ω
• Main components
• Control system display – Cabin CAN Low
• Chair module – Dash board

• Middle module – Dash board
• Dash module – Dash board
• Front module – Top od hydraulic tank
• Rear Module – Rear frame
• Engine control module (part of the engine) Module Module Module Display
Module Module <

<
Training modules
ELECTRICAL SYSTEM
Sensors - Temperature sensor PT1000
• Two wired circuit
• Sensor B3001 – Hydraulic oil temperature B3001
• Output signal is measured as resistance and converted as temperature
• 0° = 1000 Ω & 10° = 1038,7 Ω
GND AI
XM3:11 XM2:12
Note! 3,87 Ω change with 1° change in temperature <
MIDDLE MODULE
<
Training modules
ELECTRICAL SYSTEM
Sensors - Pressure sensor
• Three wire electrical circuit + 24V GND
• Sensor B3056 – Brake pressure front
XM2:23 XM3:11
• Sensor B3057 - Brake pressure rear
• Sensor B3034 – Brake charging pressure
• Output signal is measured in milliamps and converted as a pressure
B3056 B3057 B3034
DI DI DI
XM3:5 XM3:6 XM3:13
C Sensor signal high error
MIDDLE MODULE
<
<
Training modules
ELECTRICAL SYSTEM
Sensors - Level sensor (fuel tank)
• Three wire electrical circuit
• Output signal changes according to the fluid level in the tank
• Output signal is measured in milliamps and converted as a level
<
<
Training modules
ELECTRICAL SYSTEM
Solenoid valves Valve Application
• Electrically controlled, direction valve Y3001 Front brake control

• When activated directs oil flow Y3048 Rear brake control
• 2 position ON/OFF type valve Y3067 Pilot accumulator drain valve
• Signal types
Y2003 Lubrication system
• 24 V / 0 V (ON/OFF solenoid valves)
Y3052 Brake accumulator drain valve
<
<
Training modules
ELECTRICAL SYSTEM
Proportional solenoid valves Valve Application
• Electronically controlled direction valves Y3028 Boom up

Y3025 Boom down
• When activated directs oil flow
Y3027 Bucket roll back
• Movement of the valve is proportional to the current value
Y3024 Bucket dump
• Signal types Y3022 Steering right
• PWM 0-100 % (proportional solenoid valves)
Y3023 Steering left
• 0- 1000 mA (valve control feedback)
0….27V
PWM
Module
0….1000mA <
< Current feedback
Training modules
ELECTRICAL SYSTEM
Location & wire colour code
• Location of component can be identified by the component code
• Example: S3059: S + 3 + 059 (rear frame)
Identification number of component
Actuator marking
Location of component
B = Transducers
D = Diode Type of component
E = Miscellaneous (lights)
F = Protective devices
G = Generators, power supplies
H = Signalling devices (horn)
J = Spare
K = Contactors, relays
M = Motors (electrical, engine)
N = Spare
P = Measuring- and testing equipment
R = Resistors
S = Switches
X = Terminals, plugs, socket, electrical boxes <
< Y = Electrically operated mechanical devices
Training modules
ELECTRICAL SYSTEM
Reading electrical schematic
1. Address, to where the wire continues
2. Arrow indicates the direction of

power flow
3. Module and connector name
4. Module connector pins I/O

information
5. Column numbers
6. Options marked with star “*”
7. Drawing number and sheet

information
<
<
Training modules
ELECTRICAL SYSTEM
Main circuit breaker
• Main circuit breaker located on the dash board is a safety
device
• When activated cuts off the power supply to the machine

electrical system
• Pressing main circuit breaker button(S0064) connects 400
Amp fuse (F3035) coil with ground
• 400 Amp fuse activates and open the circuit

• Parallelly contact 4-5 closes and trip 150 Amp fuse (F3064)
• Power supply to the whole electrical system is cut
<
<
Training modules
ELECTRICAL SYSTEM
Emergency stop
• All the emergency stop buttons are connected in series
• Activating the emergency stop button MIDDLE MODULE
• De-energises the safety relay K0203 XC2:2 XC2:14
• All retaled function will stop working DO GND
• Safety relay controls supply for,

• Brake control
S0051
• Boom & bucket control
• Steering control
• Engine ignition
S3021
• Power supply to ignition key switch
• E-stop state signal to control system
S3020
<
<
Training modules
ELECTRICAL SYSTEM
Ignition switch
• Ignition switch gets power supply from fuse F0007 via safety relay K0203
From Fuse F007 via
• Ignition switch control power supply for, safety relay
• Engine start (50a)

• Engine stop (15)
• Main relay K0006 (15)
• Loading light DI (54)
• Ignition parking position (58)
S0004
XC1:8
DI
XD2:18
DI
<
<
Training modules
ELECTRICAL SYSTEM
Parking brake release
• Pulling the parking brake switch (S0006) sends input to the control system PARKING BRAKE ON LIGHT
• XD2:20 – Park brake engage SUPPLY +24V DASH MODULE
• XD2:19 – Park brake release Fuse F0006
DO – XD2:22
• Modules checks all the interlocks before the output is activated
• Brake accumulator pressure is above allowed limit
• Transmission pressure is above alarm limit
• Engine is running
• Hydraulic oil level is above alarm limit (engine shutdown)
• Door is not open
• Gear selector is in neutral
PARKING BRAKE ENGAGE PARKING BRAKE RELEASE

DASH MODULE DASH MODULE
DI – XD2:20 DI – XD2:19
<
<
Training modules
ELECTRICAL SYSTEM
Parking brake release
• Brake activation is controlled by two solenoids Y3001 & Y3048
• Solenoid gets PWM output from Middle & Rear modules
• Front brake control – XM1:7
• Rear brake control – XR1:2
XM1:7 XR1:2 XR1:5 XM1:6
• Solenoid Feedback is also controlled by Middle & Rear modules
• Front brake control – XM1:6 PWM PWM FB- FB-
• Rear brake control – XR1:5
<
<
Training modules
CONTROL SYSTEM
<
<
Training modules
CONTROL SYSTEM
Control system description
• A communication network consisting of control modules connected together and communicates with each other via CAN bus
• The control system:
• Controls machine functions CAN High
120Ω
120Ω
• On-Board diagnostics
• Saving data of service events etc.
CAN Low
• Monitor and show machine operating parameters
• Warning/alarm pops up in case of any malfunction
• One display for all functions

• Operating parametrs, Weighing, TPMS, etc.
• Options can be added or removed easily

Module Module Module Display
<
< Module Module
Training modules
CONTROL SYSTEM
Currently new version modules (EPEC 3724)
are used only in TH663i and TH551i
I/O (Input/output) modules
• I/O (Input/output) modules are the brain for the machine communication system
• Two version of modules are in use
• Epec 2024 (old version)
• Epec 3724 (new version)
• Both modules are NOT directly interchangeable

• Physically both types of I/O module looks same
• All I/O modules have four color coded connectors

• 3 x 23-pin for Input / output
• 1 x 8-pin for power and system CAN
• All connectors are mechanically keyed to mate only with identical colors
<
<
Training modules
CONTROL SYSTEM
I/O (Input/output) modules
• Modules function depends on module ID (Node ID)
• Replacing a module does not necessitate any programming
• Modules get their program from display software
• Incorrect type of I/O modules or software prevents starting of the unit
Node ID:
Chair - 4 Middle - 7
Dash - 5 Rear - 8
Front - 6 Spare - 127
<
<
Training modules
CONTROL SYSTEM
Control system display
• All machine operating parameters can be checked from the display
• Pressure
• Temperature
• Weighing result
• In case of any malfunction, alarm or warning pops up in the display

• Diagnostic window helps to diagnose an issue
• Options can be added or removed from the display
• Alarm logs and weight logs can be dowloaded to the USB
• Programing or updating new software can be done from display
<
<
Training modules
CONTROL SYSTEM
CAN bus
• Controller Area Network (CAN)
• Twisted pair of wire CAN_H and CAN_L
• CAN_H and CAN_L are terminated at each end with a 120 Ω resistor
• All the modules are connected to same CAN bus
• ECM (Engine control module) are connected to the module via J1939 CAN protocol
• Each CAN bus have thier own 120 Ω end resistor
CAN High
3,7
5V
2,5
V
1,2
0 0 1 0 1 0 1 0 0 1 1 0 1 0
5V
CAN Low <
<
Training modules
CONTROL SYSTEM
Traditional wiring
24V
Traditional Vs CAN bus wiring
S1 S3 S5
S2 S4 S6
K1 K2 K3
Y1 Y2 Y3
0V
Y1 Y2 Y3 CAN bus wiring

24V S1 S2 S3 S4 S5 S6
GND
Module GND
CAN bus
24V
<
< GND 24V
Module
Training modules
CONTROL SYSTEM
I/O signal types
• I/O (Input/Output) modules contains I/O pins which provides various types of signals
• The I/O pins are used for input and output signals
• The usage of each I/O pin is determined by the application

• Analogue input (AI)
• Digital input (DI)
• Digital output (DO)
• Pulse input (PI)
• Pulse width modulation (PWM)
• Feed back (FB-)
• Differnent I/O pins are used to connect different devices
• Devices are connected to the module in close circuit
• Close circuit minimizes the risk of module input damage
<
<
Training modules
CONTROL SYSTEM
Principle of closed electrical circuit
• Electrical devices are connected to a module in a closed loop circuit
Example: Solenoid valve:
• DO outputs are connected to the valve and grounded in module GND pin
• This kind of circuit minimize the risk of module input damage which is caused by e.g. earth current during welding
Example: Light switch:

• Power supply for the switch is connected to module’s DO output
• Signal pin for Switch is connected to the module’s DI pin
• DI pin observe the current state of the switch
<
<
Training modules
CONTROL SYSTEM
Analogue input – voltage & current mode
• An analogue input can be used in voltage or current mode
Voltage mode:
• Measure range is 0 to 5 V
• Analog inputs can be used with all voltage sensors which operate in range 0 to 5 volts
• Temperature sensor
• Joystick measuring sensor
Current mode:
• Measure range is 0 to 22,7 mA
• Analog input can be used with all current sensors which operate in range 0 to 22,7 mA
• Temperature sensor
• Pressure sensor
• Steering sensor
• Current measure sensor
<
<
Training modules
CONTROL SYSTEM
PWM output
• Pulse width modulated (PWM) output is used to control hydraulic proportional valves
0….27V
• PWM output is connected such that, the return path is feedback pin
• The current can be controlled
• Frequency of PWM output can be adjusted from 40 to 2550 Hz PWM
• Maximum current is 3 Amp
Module
Feedback
• Feedback pin is normally used as return path for PWM output
0….1000mA
• The pin has an ability to measure the current flowing through it
• Measure the current of electrically controlled hydraulic proportional valves Current feedback
• The maximum input current is 1 Amp
<
<
Training modules
CONTROL SYSTEM
0….27V
Cyclical program execution

• I/O modules gets input from actuators PWM
• Information is sent to CANbus

Module Display Module
• Module reads input and check the pre-condition
• Ones the pre-conditions are met, output is set

0….5 VDC 00101100 0….1000mA
• Execution of function is done
Voltage signal Can message Current feedback
• The process takes approx. 10 ms
Read inputs
CAN Bus
Execute program
set outputs <

< Execution time is 10ms
Training modules
CONTROL SYSTEM - DISPLAY
<
<
Training modules
CONTROL SYSTEM DISPLAY
Control system display
• Display is mounted on the dash board
• Can be used through the five buttons on the display
• Different gauge windows to show temperature, pressure etc.
• Display can be used for,

• Trouble shooting / Diagnostic
• Installing new module or updating the software
• Options can be added or removed from the display
• Alarm and warning informs operator about any error in the control system
<
<
Training modules
Transferring data to USB
• All the alarm and weight logs can be transferred to the USB
• Connect the USB into the USB port in the dash board
• Open the alarm log window and data can be transferred
<
<
Training modules
Checking installed software package
• Current installed software package can be checked from the display
• Checking the installed software version is a 3 step process,
• From main window press button “5” (>>)
• From gauge window press button “4” (?)
• From the limits gage window press button “2” (About)
• If require the new installation package can be installed in the display
• New installation package can be found Sandvik “ST Downloads” database
• Installation the new package into USB and connect to USB port on the display
• Service level password and challenge code is required to install new installation
package
<
<
Training modules
Installing new module
• If required new module can be installed in the machine
• Connecting the module to the programming connector in the dash board
• From display under the service password select “New Module”
• It is recommended to make a new module as “SPARE” module before programming it to the required module
• Programme the module as required i.e. Chair, Dash, Front, Middle, Rear
<
<
Training modules
Diagnostic window – Boom & Bucket
• Diagnostic window can be used to diagnose an error in the control system
• The window shows all the interlocks and the status of input and output
<
<
Training modules
Diagnostic window – Steering
<
<
Training modules
Diagnostic window – Brakes
<
<
Training modules
Diagnostic window – Gear selection
<
<
Training modules
Diagnostic window – Throttle
<
<
Training modules
Diagnostic window – I/O measurement
• Module Input/Output measurment can be done from the display
• Indvisual connector in can be chekced and tested for functionality

• Important tool for diagnostic an elecrical issues
<
<
Training modules
Calibration window
• Replacing a joystick or sensor require calibration
• Calibration can be done under calibration window behind servcie level password
<
<
Training modules
Calibration window – Joystick configuration
• Changing the joytstick configuration can be done from display
• Under caliration window got to ”CONF”

• Configuration needs challange code
• Always change the label corresponding to the change in joystick configuration
<
<
Training modules
Function test window
• Various function can be tested from display
• Function test helps to reduce trouble shooting time and to check the functionality of the system
<
<
Training modules
POWER PACK
<
<
Training modules
POWER PACK
Components
1. Fuel filters
2. Engine oil filter
3. Radiator
4. Engine
5. Charge air cooler (CAC)

6. Coolant tank
7. Exhaust muffler
8. Air filter assembly
<
<
Training modules
POWER PACK
Air filters assembly
• Air filter assembly is mounted in the rear frame
• Cleans the intake air to the engine
• Filter clogging indicator indicates, if the filters are clogged
• Main parts of the air filter are,

• Safety filter
• Primary filter
• Clogging indicator
• Scavenging line outlet
<
<
Training modules
POWER PACK
Fuel filters
• Fuel filters are mounted in right side of rear frame
• Fuel shut-off valve must be closed during maintenance
• Fuel filters assembly have, D

A. Fuel pre-filter
B. Water trap
C. Fuel filter
D. Feed Pump
<
< Note! Never fill the new filter before assembly, use feed pump to fill the filters and to bleed the fuel system
Training modules
POWER PACK
Expansion tank
1. Pressure cap (expansion reservoir)
2. Filling cap (coolant reservoir)
3. Coolant level MIN mark
4. Overflow hose
5. Venting hoses
6. Filling hose (coolant pump)
7. Coolant level indicator
<
<
Table of contents
POWER PACK
Expansion tank
• The expansion tank consists of two chambers,
• Coolant reservoir
• Expansion reservoir
• When the pressure in the coolant reservoir increases,

• The coolant will move to the expansion reservoir
• The expansion reservoir does not usually contain any coolant
• The pressure cap (1) opens when pressure reaches certain level
• Cooling system is filled through the coolant reservoir cap (2)
• Coolant level should be above MIN mark (3) on the expansion tank
• Note! Do not open filler cap when the engine is hot
• Note! Do not open pressure cap
<
<
Table of contents
POWER PACK
Cooling system – Volvo engine
• Engine coolers are mounted to the rear frame
• Engine radiator and CAC (charge air cooler) are mounted together as an assembly
• Upper section - CAC (Charge Air Cooler)
• Lower section - Radiator
• Engine-mounted water pump circulates coolant through the engine and the radiator
• Hydraulically driven fan provides necessary air flow for cooling
<
<
Training modules
POWER PACK
Cooling hydraulic system
• Engine radiator and CAC fan is driven by hydraulic motor
• Electronically controlled engine cooler pump provides necessary oil flow for the cooler motors
• Pump pressure is limited to 350 bar, by the main relief valve
• Engine cooler pump flow is controlled by the control system and varies with,
• Engine coolant temperature
• Current reduces with increase in temperature and vice versa
• The flow increases with reduction in coil current
<
<
Training modules
POWER PACK
Scavenging line check valve
• The scavenge line leads from the air filter to the exhaust pipe
• Make sure that the check valve is in good condition
• If necessary, clean or replace the check valve
• The flow direction should be towards the exhaust pipe
• The check valve must be positioned straight and “TOP” marking pointing up ward
<
<
Training modules
POWER PACK
Pressure adjustment - Engine cooler pump
Stand-by pressure
• Connect a 400-bar pressure gauge to the measurement point MP301
• Disconnect the electric connector 341 from the pump controller
• Connect an external power supply instead, feed 600 mA 24V

• The correct pressure is 25 bar (±5 bar)
• If required adjust the stand-by pressure with the adjustment screw 302
• Recheck the pressure and readjust if required
<
<
Training modules
POWER PACK
Maximum pressure
• Connect a 400-bar pressure gauge to the measurement point MP301
• Disconnect the electric connector 341 from the pump controller
• Start the engine and increase the speed to the maximum

• The correct pressure is 180 bar (±5 bar)
• If necessary, adjust the pressure via the adjustment screw 301
• Connect the electric connector 341 to the pump controller
• Recheck and repeat the above steps until both pressures (stand-by and maximum)
are correctly set
Notes!
• Never adjust the pressure when engine is running
• Adjust pump pressure based on rpm, the maximum pressure is just a guideline
<
<
Training modules
POWER PACK
Engine cooler blower rpm
• Attach a reflector to the blower fan (as close to the hub as possible)
• Start the engine and operate it at full RPM
• Record the fan RPM from an external speed gun

• The fan rpm must be 2300 rpm
• If required adjust the fan RPM with the adjustment screw 301
• Recheck the pressure and readjust if required
Notes!
• Never adjust the pressure when engine is running
<
<
Training modules
POWER TRAIN
CONVERTER AND TRANSMISSION
<
<
Training modules
POWER TRAIN
Power train
• Power train system is a group of components assembled together to power up the unit
• Power train needs to be robust enough to cater the machine application
• All components are placed together logically and serve a specific purpose
• Though engine provides power to the power train but is not considered as a component of power train
• In case of loaders engine is the rear most component in the powertrain line
<
<
Training modules
POWER TRAIN
Power train - Component
6
1. Front axle (Kessler D91)
2. Drive shafts
2
3. Transmission (Dana RT32421) 5
4. Rear Axle (Kessler D91) 3
5. Torque converter (Dana C273.1)

2
6. Engine
7. Support bearings
1 7
<
<
Training modules
POWER TRAIN
Theory of Converter (video)
<
<
Training modules
POWER TRAIN
Torque Converter
• Torques converter multiplies engine torque
• Provides power output and facilitate mounting for the hydraulic pumps
• Speed sensor S3051 (1) 1

• Measure output speed of the converter and sends information to the control-system
• Used to determine converter slippage
• Effect on converter lock-up function and automatic gear selection function
• Spring loaded regulator valve (2)

• Provides system pressure
3
• Temperature sensor (3)
• Monitor converter outlet oil temperature
• Transmission charging pump (4)

• Provides oil flow for converter & transmission hydraulics
2
4
<
<
Training modules
POWER TRAIN
Torque Converter
Charging pump section (1)
• Provides oil flow for converter & transmission hydraulics
• Driven by a splined shaft which is driven by a gear bolted to the torque converter impeller
Scavenge pump section (2)
• Draws converter leakage oil flow back it back to tansmission sump 1
• Maximum allowed leakage at 2000 rpm is 7.57 LPM or 2 GPM
1 3
4
<
<
Training modules
POWER TRAIN
Pump – location & application (Mercedes Engine) 1
• Engine fan cooler pump (1)




3
4 <
<
Training modules
POWER TRAIN
Drive shafts
• Transmit power from torque converter to final drive
• Two of the drive shafts are supported by support bearing
• Support bearings are connected to the central lubrication system
• Support bearing alignment is critical and to be checked during maintenance
<
<
Training modules
POWER TRAIN
Drive shafts - Maintenance
• Universal joint are permanently lubricated
• All joints must be in same phase
• Misalignment of joints increases vibration and stress on the drive shafts Note!
These yokes have to be together in the same
• Vibration may result in component failure phase
Note!
Note! phase
phase
Note!
phase <
<
Training modules
POWER TRAIN
Transmission
• Transmission, transmit power to the axles through the drive shafts
• Controls the driving direction and with modulation
• Control valve on the transmission consists of a valve body with selector valve spools
• Electric gearshift control with four forward and four reverse

• The gears can be selected by a FNR switch on the steering joystick
• Control system controls the gear selection, by energizing the respective solenoids
• Each gear have individual, hydraulically operated clutch pack

• Transmission and the torque converter operate through a common hydraulic system
• To obtain maximum serviceability they built as separate units
<
<
Training modules
POWER TRAIN
Transmission - Modulation
• The load on the drive train components can become very high, if the driving directions are changed too abruptly
• The transmission has a built—in protection (clutch modulation) against this form of damage
• The pistons that force the clutch plates together and the control valve are,
• Designed to apply lower force when the plates first engage and gradually increase the force until full engagement is made
• This provides a cushioning effect which prevents “shift shock” or sudden high torque surges to the drive line
• All clutches are modulated
<
<
Training modules
POWER TRAIN
Transmission – Modulation valve
• Valve assembly
1. 1 st clutch spool
2. 2nd clutch sool
3. 3rd clutch spool
4. 4th clutch spool
5. Reverse clutch spool
6. Forward clutch spool
<
<
Training modules
POWER TRAIN
Transmission - Solenoid valve block
• The gears can be selected by a FNR switch on the steering joystick
• Control system controls the supply voltage for activation of solenoid valves,
1. Y3004 – Forward gear
2. Y3005 – Reverse gear
3. Y3007 – 2nd gear
4. Y3008 – 3rd gear
5. Y3009 – 4th gear
• Respective solenoids will energies, based on gear selection
<
<
Training modules
POWER TRAIN
Transmission - Solenoid valve block
• Solenoid activation chart based on gear selection
Signal/ Valve Forward – Y3004 Reverse – Y3005 Valve 2 – Y3007 Valve 3 – Y3008 Valve 4 – Y3009
Forward 4 X
Forward 3 X X
Forward 2 X X X
Forward 1 X X X X
Neutral - - X X X
Reverse 1 X X X X
Reverse 2 X X X
Reverse 3 X X
Reverse 4 X
<
<
Training modules
POWER TRAIN
Transmission - Cooling
• Transmission oil is cooled inside the transmission cooler section of the cooler assembly
• Hydraulically driven fan provides necessary air flow for the cooling
• The hot oil is supplied by the converter regulator valve 1

• The cool oil returns back to the transmission
1. Cooler inlet from converter down stream valve
2. Cooler outlet to transmission sump
<
<
Training modules
POWER TRAIN
Transmission Hydraulics Suction/Drain/Return line
1. Transmission pump suction Regulated pressure
Pressure line
2. Pump delivery to filter
3. Filter to spring loaded regulator valve
4. Spring loaded regulator valve to transmission control valve 4
5. Converter drain to scavenging pump 7 3

6. Scavenging pump to transmission sump
7. Common breather 8
2
8. Cooler outlet to tranmission
1
6 <
5
< 2
Training modules
POWER TRAIN Suction/Drain/Return line
Regulated pressure
Transmission Hydraulics Pressure line
<
<
Training modules
POWER TRAIN
Transmission - Oil level sight glass
• Transmission oil level can be checked from ground level through the sight glass
• The marking “MAX & MIN” on the sight glass indicates the limits of oil level
• Oil level can also be checked from the dip stick

• Always check the oil level, with engine running and transmission oil at operating temperature
• Oil level checking procedure,
• Add transmission oil until the oil level is at "MAX" mark on the sight glass / sight pipe
• Start the engine and if needed, add oil to bring oil level above the "MIN" mark on the sight glass
• Apply all gears one by one for maximum oil circulation
• Check the transmission oil pressure from control system display in the cabin
• The oil pressure must be between 12.4bar - 15.2bar.
• Add transmission oil until the oil level stays still at "MAX" mark on the sight glass
<
<
Training modules
POWER TRAIN
De-clutch
• When DeClutch is activated, the direction clutches in the transmission are neutralized
• DeClutch does not affect the gear clutches
• The DeClutch can be set to be activated in different ways
• Function modes can be selected from the display
Button:
• DeClutch is activated from the joystick button and released when the button is no longer pressed.
Pedal:
• DeClutch is activated with the brake pedal and released when brake pedal is no longer pressed
Loading:
• DeClutch is activated when driving forward at the same time when pressing the brake pedal and lifting the boom
• It is released when reversing
<
<
Training modules
POWER TRAIN
AXLE
<
<
Training modules
POWER TRAIN
Axles
• Both front and rear axles are Kessler D91
• Rear axle is mounted to the oscillation cradle with +8° oscillation
• Front axle is rigid and is mounted directly to the frame
• This increases stability of the loader during hauling
<
<
Training modules
POWER TRAIN
Axle - Safety
• All mounting connections and safety devices must be checked and serviced at regular interval
• For operational safety, corrosion and cracks on support components (e.g. the axle spindle) are not permissible
• Supporting components with cracks must be replaced immediately
• When replacing the axles, check the mounting bolt torque values
• Mounting bolts torque values are different for front and rear axle
<
<
Training modules
POWER TRAIN
Axle assembly
Axle assembly can be divided into three sections,
• Differential assembly (1)
• Standard differential (Front and Rear)
• Separate oil chamber for differential
• Brake assembly (2)

• SAHR (Spring applied hydraulic released) 3
• Brake discs are paper friction material 2
• Planetary or wheel end assembly (3)

• Two stage planetary wheels 1
• Reduces stress on axle shaft
2
3
<
<
Training modules
POWER TRAIN
Differential assembly
• Based on the application differential assembly can be selected
• Differential assembly can be of different types
• LH307 loader uses Limited Slip differential in both front & rear axle
• Main component in differential assembly are,

• Crown & pinion (always comes in set)
• Side gears
• Bevel gears
• Cross
• Differential housing
• Bearings
• Pinion seal and flange
<
<
Table of contents
POWER TRAIN
Theory of differential (video)
<
<
Training modules
POWER TRAIN
Theory of NO-Spin differential (video)
<
<
Training modules
POWER TRAIN
Differential assembly
<
<
Table of contents
POWER TRAIN
Brake assembly
• Brake assembly consist of set of clutch plates, spring and pistons
• Brakes are Spring Applied Hydraulic Release (SAHR)
• Hydraulic pressure required to release the brakes
• Pressure is applied on the brake piston inside the brake housing
• Piston compresses the spring and brakes are released

• Cutting the hydraulic oil pressure supply, engages the brakes
<
<
Training modules
POWER TRAIN
Brake assembly – Rear cover
• Brake hydraulic hoses are connected to the brake assembly rear cover
• Slack adjustment screw, bleeding screw and brake lining wear indicator are placed in the rear cover
• Bleeding must be carried out, when any service is done on the brake housing
1. Bleed screw 1
2. Slack adjustment screws (3 nos. placed at 120 degree)
3. Brake wear indicator 2
3
<
<
Training modules
POWER TRAIN
Brake housing – Brake wear indicator
• Worn out brake disc may reduce the braking efficiency
• Disc wear can be checked from the brake wear indicator pin
• Checking procedure
• Make sure the brakes are engaged
• Push the indicator pin in as far as it goes
• If the wear indicator stays visible Brakes are good
• If the wear indicator goes all the way in Brake disc replacement is necessary
<
<
Training modules
POWER TRAIN
Brake housing – Brake wear indicator
• If wear indicator shows worn out disc, perform brake test from control system display
• Brake test can be done from control system display window
• Test result OK - brake disc replacement can be done at next scheduled periodic maintenance
• Test result FAIL – brake disc need to be replaced immediately
<
<
Training modules
POWER TRAIN
Brake housing – Slack adjustment
• Piston movement length can be adjusted with the slack adjustment
• Three slack adjustment screws on each brake housing
• Follow all the safety regulations while working on the machine

• Make sure the brakes are engaged
• Screw in the slack adjustment screws until it make contact with the piston
• Screw out the screws 2 rounds (720°)
2
• Slack adjustment on all the four brake housing must be same
<
<
Training modules
POWER TRAIN
Hoses connections – Front axle 4
1. Brake pressure port
2. Brake cooling oil inlet
3. Brake cooling oil outlet
4. Breather
2 3
1
1
2
3
<
<
Training modules
POWER TRAIN
Axle - Hub assembly
• Hub assembly holds the planetary assembly in place
• Hub assembly is mounted directly on axle spindle
• Hub seal on each hub assembly prevents, brake cooling and planetary oil getting mixed with each other
• In case of hub seal failure brake cooling oil mixes with planetary and finally enters into the differential housing
• This result is excess oil in the differential housing
<
<
Table of contents
POWER TRAIN
Axle - Planetary assembly
• Double planetary provides more torque and less stress on the axle shaft
• Both side axle shaft length is different
• L1 – 690 mm
• L2 – 720 mm
• The main component in planetary assembly,

• Planetary assembly
• Gears
• Sun gear
• Correct oil level must be maintained in planetary assembly
• Low or contaminated oil will result in low life of planetary assembly
<
<
Table of contents
POWER TRAIN
Power transmission
• Differential transmit power to the axle shaft
• Power is tranmitted to the planetary assembly and to the wheel end
<
<
Table of contents
POWER TRAIN
Oil level check - Differential
• Ensure that the machine is on a level ground
• Apply the parking brake and prevent machine movement by wheel chocks
• Clean the surface around the plug, Open it to check oil level
• Oil level must be at level of the plug hole
• Clean the plug from contaminants, e.g. metal

• Reinstall the plug
<
<
Training modules
POWER TRAIN
Oil level check - Hub/Planetary
• Ensure that the machine is on a level ground
• Position the wheel so that the oil level mark (1) is in horizontal position and oil drain hole (2) is down position
• Apply the parking brake and prevent machine movement by wheel chocks
• Clean the surface around the plug, open it to check oil level
• Oil level must be at level of the plug hole

• Clean the plug from contaminants, e.g. metal
• Reinstall the plug

1
2
<
<
Training modules
POWER TRAIN
Oil level check – Drain plug
• During checking the oil level or changing the oil, check for contamination on the magnetic plugs
• The contaminations rating on the magnetic plug after 3rd oil change can be rated as,
<
<
Training modules
POWER TRAIN
Axle - wheel bearing adjustment
• Wheel end have taper roller bearings
• Bearing adjustment or preloading to be carried out as per the schedule
• Use correct Kessler hub nut socket for bearing adjustment
• Check the brass spacers for wear and replace if necessary
<
<
Training modules
POWER TRAIN
Tires
• To avoid extra stress to the driveline
• Tires on same axle must have same radius or as close to each other as possible
• Max. radius difference between tires

• On same axle 1.5%
• On front and rear axles 3%
• Radius is measured from upper edge of tire to axle center (without load)
• Maintain correct tire pressure during operation

• Front tires – 6 bar
• Rear tires – 4 bar
• Air pressure during transporting/storing wheels 0,7 bar
<
<
Training modules
LUBRICATION SYSTEM
<
<
Training modules
LUBRICATION SYSTEM
Lubrication system description
• Lubrication system is designed to lubricate all moving joints in the machine
• Lubrication unit assembly is mounted on right hand side of the front frame
• Hydraulically operated pump, pushes the grease from the reservoir
• Grease is pushed out alternatively through the two lubrication lines to the doser units
• Lubrication system is controlled by the control system

• In case of any malfunction in the system warning or alarm pops up in the display
<
<
Training modules
LUBRICATION SYSTEM
Lubrication unit assembly - Components
1. Bleeding screw
2. Grease reservoir
3. Hydraulic pump
4. Directional valve
5. Pressure relief valve

6. Filter assembly
7. Filling point
8. Level indicator switch
9. Solenoid valve
<
<
Training modules
LUBRICATION SYSTEM
Grease reservoir - bleeding screw
• Bleeding screw to is provided at the top of the tank
• Screw is used to bleed any trapped air, inside the tank
• It is recommended to bleed air, every time the reservoir is filled with new grease
• Bleeding prevents aeriation in the greasing line
• Open the screw by few turns and wait until clear oil comes out without air
<
<
Training modules
LUBRICATION SYSTEM
Hydraulic pump
• Solenoid valve controls the pilot pressure flow (35Bar) to the double acting pump (3)
• Pilot pressure moves larger piston back and forth accordingly to the solenoid valve status
• The diameter ratio of larger and smaller piston is 8:1
• This difference in surface area creates higher pressure in the grease lines
• Maximum grease pressure depends on the pilot pressure and can go up to 280bar (35x8=280bar)
• Smaller piston pushes out grease to the dosers via direction valve
<
<
Training modules
LUBRICATION SYSTEM
Directional valve
• The direction valve(4) switches over the pressurized grease between line 1 and 2
• With every stroke, grease is switched over between line 1 & 2
• The spool inside the direction valve changes position with each stroke
• Two non-return valve in the direction valve are used to bleed the pump
<
<
Training modules
LUBRICATION SYSTEM
Pressure relief valve
• Pressure relief valve(5) acts as a safety device
• Prevents building of excess pressure inside the tank
• Opens, if the pressure in the tank rises too high
• While filling the tank, opening of relief valve also indicates that the tank is full
• Relief valve can be remote mounted

• It’s a safety device and must not be removed from the system
<
<
Training modules
LUBRICATION SYSTEM
Filter assembly and filling point
• Pressure filter (6) inside the filter assembly prevents entry of any foreign particle in the grease tank
• The system should never be used without the filter
• The grease must always be filled through the filling point (7) on the filter assembly
• The filter must be removed and cleaned during every maintenance
<
<
Training modules
LUBRICATION SYSTEM
Level indicator switch
• Level switch (8) S208 pops up an alarm in the display if the tank runs out of grease
• The lubrication system will stop functioning when the alarm is active
• Alarm goes off when reservoir is filled
XF2:18 XF2:1
DI +24 V
<
<
Training modules
LUBRICATION SYSTEM
Solenoid valve
• The solenoid valve(9) controls the hydraulic flow (35bar) to the double acting pump
• The status (+24V/0V) of the solenoid valve is controlled by the control system
• With change in status of the solenoid valve, the lubrication unit pushes grease to the lubrication lines
• Returning oil max. 5 bar, is supplied on top of the grease reservoir to give positive feed to the follower plate
XF2:15 XF2:17
GND DO
Y2003
<
<
Training modules
LUBRICATION SYSTEM
Doser groups
• The machine have four doser assembly
• Two in articulation area
• One on each side of the front frame
• The main grease lines are connected to the base plate of the doser assembly
• Dosers dispense the grease to the lubrication targets
• The stroke length of the doser can be set manually as per requirement
• The check valve in the base plate prevents back flow of grease from dosing lines
Main components in doser assembly are,
1. Base plate
2. Dosers
3. Main grease lines
4. Target lines
<
<
Training modules
LUBRICATION SYSTEM
Doser group
• Doser with two outlet (SGA - 12)
• Dispense grease to double target point in turns
SGA - 12
• Doser with one outlet (SGA – 11)

• Always dispense grease to same target point in each stroke
SGA - 11
<
<
Training modules
LUBRICATION SYSTEM
Doser components: SGA-12
2
1
1. Piston
3
2. Adjustment screw
3. Spindle (SGA-12)
4. Grease line in 1
5. Grease line in 2
4 5
6. Grease line out 1
7. Check valves
6 7
8
<
<
Training modules
LUBRICATION SYSTEM
Doser block and dosing: SGA-12
• Grease enters the doser through doser block grease line 1 or 2 depending on grease pump cycle
• Grease line in 1 (1) pressurized
• Pressurized grease moves the spindle (2) and piston (3) for set stroke length
• Stroke length can be adjusted from the adjustment screw (4)
• Secondary side of the piston (3) pushes out the set dose of grease to the grease outlet line (5)
<
<
Training modules
LUBRICATION SYSTEM
→ SGA-12 dose grease points on every alternate stroke
<
<
Training modules
LUBRICATION SYSTEM
Doser components: SGA-11
1. Piston
2. Adjustment screw
3. Spindle (SGA-11)
4. Grease line in 1
5. Grease line in 2
7. Check valves
<
<
Training modules
LUBRICATION SYSTEM
<
<
Training modules
LUBRICATION SYSTEM
→ SGA-11 dose grease points on every stroke
<
<
Training modules
LUBRICATION SYSTEM
Doser adjustment
• All the dosers have a dosing stroke indicator (red color ring)
• To adjust the dosing, remove the plastic cover
• Turn the adjustment screw in or out to adjust the dosing stroke
• The marking slots of the indicator, is a indication of the stroke

• Gap between each slot is 10 mm
<
<
Training modules
LUBRICATION SYSTEM
Lubrication control – Electrical
• Solenoid Y2003 control lubrication function
• Solenoid gets the DO from front module (XF2:17) when,
• The option parameter “Central lubrication in use” is active
• Parking brake released
• Grease reservoir is not empty, grease end DI, XF2:18 is active
• Lubrication interval is in active state
• Output state changes every time when lubrication interval time is elapsed (default 10 minutes)
• In case of pressure error, pressure switch will pop up a warning in the display
XF2:15 XF2:17 XF2:18 XF2:1
GND DO DI +24 V
Y2003
<
<
Training modules
LUBRICATION SYSTEM
Pressure switches
• Pressure switches monitor the pressure in the grease lines
• Switches are mounted at the end of the main lines (articulation area, rear frame)
• The pressure switches are set at 70bar
• Drop in pressure in main line will pops up warning in the display
S3010
S3009
XM3:20 XM3:21 XM2:23

DI DI + 24V <
<
Training modules
LUBRICATION SYSTEM
Pressure checking
• Pressure in the grease lines can be checked manually by the pressure gauge, at the pressure measuring points
• Connect pressure gauge 0-400 bar at the pressure checking point
• Open the lubrication test window in the display
• Start the test and check the pressure from the gauge the pressure must be minimum 70 bar
• These pressure measuring points can also be used to remove air from the main lines
Note!:
• The grease pressure can go up to 280bar, use pressure gauge of proper range
• Always follow all safety regulations and wear all the required PPE’s
<
<
Training modules
LUBRICATION SYSTEM
Function test window
• Lubrication function can be tested from the display under ”Function test”
• The test can be performed without releasing the parking brakes

• The dosing inverval during testing will be 3 minutes
• In case of any error in the system, warning will pop up in the display
<
<
Training modules
FIRE SUPPRESSION SYSTEM
ANSUL AND ECLIPSE
• This training section is to provide a basic information about the Ansul fire suppression system and Eclipse fire suppression system
• Completing this training does not entitle the participant(s) to service or install the fire suppression system
• Separate certification training is required to carry out any type of service, maintenance or installation of the fire suppression system
<
<
Training modules
ANSUL FIRE SUPPRESSION SYSTEM
Note: This training section is to provide a basic information about the Ansul fire suppression system and does not entitle the <
< participant(s) to service or install the fire suppression system.
Training modules
275

Why fire suppression
• Fire is the most dangerous machine-related incident that can happen underground
• Fire suppression system makes it easier to suppress the fire in the very beginning
• Activating the system is also possible from the machine or remote location (RRC operation)
• Fire suppression is protecting
• People
• Machines
• Production / production facilities
Training modules
276

This is what we are trying to avoid
Training modules
277

Powder (ANSUL FORAY)
• Covers fire classes A (ordinary combustibles), B (Flammable liquids) and C (Electrical equipment)
• Replaces oxygen
• Expellant gas is nitrogen approved for temperature ranges -54°C to 99°C
• Corrosive powder (needs to be cleaned as soon as possible)
• Does not lower temperature

• Ansul fire suppression system have to option,
• Manual system
• Automatic system (check fire)
Training modules
278

Main components – Without CHECK FIRE
1. Remote actuator
2. Expellant gas cartridge
3. Dry chemical tank
4. Dash board actuator
Training modules
279

Main component – With CHECK FIRE
1. CHECKFIRE 210 display module
2. EOL resistor
3. Linear detection wire
4. Interface control module
5. Electric-pneumatic actuator
6. Expellant gas cartridge
7. Remote actuator
8. Dry chemical tank
9. Electric-dash board actuator
Training modules
280

Nozzle locations
• Fire suppression system is use to protect most likely ignition source which should be inside of discharge pattern
• Common heat sources are engine blocks, exhaust systems, turbocharger, retarder, hydraulics and electrical equipment
• Most likely fuel sources are dripping or leaking couplings and hoses
• Location of nozzles and actuation device (check in your machine)

A1. Engine, left side
A2. Torque converter
A3. Engine, right side
A4. Oil cooler
A5. Transmission
A6. Middle hinge
D. Dashboard actuator
R. Remote actuator
Training modules
281

System actuation
• Manual actuation
• Two actuators located in the machine, one in cabin and another in the rear end of the machine
• Fire suppression system can be activated by pressing the strike buttons on any of the actuators
• Automaic
• Automated activation is triggered by the short circuit of the linear detection wire of the Checkfire system
• Short circuit is caused by the heat and this cause alarm condition in the Checkfire system.
• Manual from Check fire module

• Pressing the “Push to activate/Alarm when lit” button in the Checkfire system
• Display module activates the fire suppression system
• Remote actuation
• Can be activated by the remote control fire suppression button on the RRC transmitter
Training modules
282

• Nozzle types F-1/2
• Fan-shaped discharge pattern with 180º pattern
• Maximum range 84cm in length by 38cm in height
• Nozzle types V-1/2

• Fan-shaped discharge pattern with 160º pattern
• Maximum range 122cm in length by 38cm in height
• Nozzle types C-1/2

• Cone-shaped discharge pattern
• Maximum range 183cm with 90cm diameter
Training modules
283

Nozzle installation
• Use lock washers
• After aiming and tightening Nozzle install blow-off cap
• Only use elbows that have radiuses bend
• Use of straight elbows is not allowed
Training modules
284
FIRE SUPPRESSION SYSTEM 1
Tank assembly 3
2
1. Check valves
2. Dry chemical tank 4
3. Pneumatic actuator
4. Safety valve
5
5. Nitrogen expellant gas cartridge

6
6. Pressure switch
7. Bursting disc
7
Training modules
285

Manual actuator
• Pressing the actuator activates the fire suppression system
• Two actuators in the system
• Operator cabin
• Right side of the rear frame
• Manual actuators are connected to the pneumatic actuator
• Check valve prevents, the gas pressure flow towards the another actuator
• When installing, check the direction of arrow marked on the check valves
• The arrow should always be towards the pneumatic actuator
Training modules
286

Checkfire CF210
• Supervised power, detection, release and communication circuits
• System may be powered by internal battery or external power (internal battery in our system)
• Programmable delays (0, 5, 10 or 15s)
• Color-coded plug and play connections
• Isolation switch for detection circuit
Training modules
287

Display unit
• Manual-activation button and LED
• Immediate release
• Indicates alarm with LED
• Delay/reset/silence button
• Restarts time delay
• Silence sounder during fault
• Resets system (press 3s)
• Detection LED
• Yellow LED pulses and sounder every 10s indicates fault in detection circuit
• Red LED pulses and sounder every second indicates alarm
• Red LED pulses and sounder every 10s indicates system has been released
• Isolate LED
• Yellow LED pulses twice every 30s indicates system is in isolate mode
• Shutdown LED
• Not in use (has been done with separate pressure switch)
Training modules
288

Display unit
• Power LED
• Green LED pulses every 3s normal operation
• Yellow LED pulses every 10s low voltage
• Release LED
• Yellow LED pulses and sounder every 10s fault in release circuit
• Discharge LED
• Not in use (pressure switch feedback)
Training modules
289

Interface control module
• Connection point for different circuits
• Battery compartment
• Programming interface
• Isolation switch
• Mini USB port
Training modules
290

Interface control module
• Detection circuit 1
• Detection circuit 2
• Display module
• Release circuit
• Relays 1 & 2 (optional)
• Aux. Output (optional)
• External power (12/24V)
Training modules
291

Cables and fittings
• Modular cable harness preset lengths (0,6/1,5/3,0/6,1m)
• Color coded over molding
• Red - Detection
• Black - Display
• Blue - Release
• Yellow - Relay
• Green - Power
• Threaded connectors
Training modules
292

Replacing battery
• When replacing battery, actuators (PAD) must be disconnected
• Set system to isolate mode with isolate switch on interface control module
• Replace battery
• Press programming button 5 seconds until all LEDS blinks three times
• This will set installation date of battery to the system
• Return system back to normal state from isolate switch
• Mark date (mm/yy) to sticker in battery cover
• Reconnect actuators (PAD)
Training modules
293

Downloading event history log
• Connect USB cable and stick to mini USB port
• Push programming button three times inside one second to begin file downloading
• Programming LEDS pulse to indicate download has started
• When completed LEDS illuminate steady-on for five seconds
Training modules
ECLIPSE FIRE SUPPRESSION SYSTEM
Note: This training section is to provide a basic information about the Eclipse fire suppression system and does not entitle <
< the participant(s) to service or install the fire suppression system.
Training modules
Table of contents
295

Why fire suppression
• Fire is the most dangerous machine-related incident that can happen underground
• Fire suppression system makes it easier to extinguish the fire in the very beginning
• Activating the system is also possible from remote location
• Fire suppression is protecting
• People
• Machines
• Production / production facilities
Training modules
296

This is what we are trying to avoid
Training modules
System overview
• Equipment fire is a big hazard in any mining operation
• Efficient fire suppression system is a need for all machines
• Two types of fire suppression system are offered by Sandvik

• Eclipse fire suppression system
• Eclipse Sustain (0° to 60 °C)
• Eclipse Extreme (-40° to 60 °C)
• Ansul fire suppression system
• Eclipse fire suppression system uses fluorine free foam
• Ansul fire suppression system uses dry chemical powder
Training modules
Eclipse fire suppression system (video)
<
<
Training modules
299

Nozzle locations
• Fire suppression system is use to protect most likely ignition source which should be inside of discharge pattern
• Common heat sources are engine blocks, exhaust systems, turbocharger, retarder, hydraulics and electrical equipment
• Most likely fuel sources are dripping or leaking couplings and hoses
• Location of nozzles and actuation device,

1. Activation module
2. Nozzle, CAC
3. Nozzle, engine top left
4. Nozzle, fuel filters and hydraulic hoses
5. Nozzle, turbo charger
6. Nozzle,starter
7. Nozzle, exhaust pipe
8. Nozzle, pump
9. Nozzle, bbucket valve

<
< 10. Activation module, cabin
Training modules
FIRE SUPPRESSION SYSTEM 5
Foam agent tank

• Stores the extinguishing agent for fire suppression 6
1. Tank, 45 liters
2. Siphon tube
3. Relief valve
4. Bung
5. Control valve
6. Pressure indicator
Training modules
Foam agent tank - control valve
• Ones the system is pressurized the diaphragm inside the control valve closes and maintain the pressure inside the tank
• When the pressure is released, the diaphragm allows the extinguishing agent to flow through the discharge circuit
Main components
1. Charging connection
2. Pressure indicator
3. Activation line
4. Relief valve
5. Diaphragm
6. Discharge connection
Training modules
Foam agent tank - control valve
Pressurised Released
Training modules
Manual activation units
• Used to manually activate the fire suppression system
• Main components:
• Safety tie
• Handle
• Pressure indicator
• Handle is secured with safety tie (1) 1
• Safety tie breaks when the handle(2) is turned

2
• Turning the handle connects pressured activation line to atmosphere
• Drop in pressure in the activation circuit, activates the fire suppression system
• The pressure indicator shows the pressure in the activation circuit
Training modules
Pressure indicators
• The pressure indicators shows the pressure in the activation circuit
• There are three pressure indicators in the circuit
• One on the tank control valve assembly
• One each on both the manual activation units
• The pressure indicators indicates the charged pressure in the system

• The correct charge pressure is 1500 kPa or 15bar
• When the system is pressurized, the gauge needle must always be in green zone
Training modules
Auto detection tube
• Detection tube is connected to the activation line
• In case of fire the tube is designed to melting
• Melting point of tube is 150 °C
• Melting of the tube, causes pressure drop in the activation circuit
• Drop in pressure activates the fire suppression system
Training modules
Twin pressure switch
• Twin pressure switch monitors the activation line pressure
• S3120 - Low pressure switch (1200 KPa)
• S3119 – Discharge switch (900 Kpa)
• The pressure setting of the switches are marked on both switches

• System pressure input is sent to the engine shutdown panel
• Engine shut-down panel, give warning or alarm in case of drop in pressure
• System activate, if pressure drops below 900 Kpa
Training modules
Engine shutdown panel
• Engine shut down panel gives audio-visual alarm
• Green light – Tank pressure OK
• Yellow light – Tank pressure Low (< 1200 Kpa)
• Red light – System fault or discharge (< 900 Kpa)
• In case of fire, engine shutdown automatically after 6 seconds delay
• Pressing the delay extension button adds delays shutdown by 20 sec.
• Manual override key switch allow the engine starting, if the system is discharged
Training modules

LH307V - Technical Training - 100119

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

LH307V - Technical Training - 100119

Uploaded by

Copyright:

Available Formats

LH307 Technical Training

Module 1 Safety and Environment Module 10 Hydraulics system - Brake hydraulics

Module 2 Technical specification Module 11 Electrical system

Module 3 General overview Module 12 Control system

Module 4 Operator environment Module 13 Power pack - Engine

Module 5 Air conditioning system Module 14 Power train – Converter

Module 6 Frame structure Module 15 Power train – Transmission

Module 7 General hydraulic system Module 16 Power train - Axle

Module 9 Hydraulics system – Steering hydraulics Module 18 Fire suppression system

• Nature of the hazard

• Consequence of interaction with the hazard

• How to avoid the hazard

• Replace if needed <

General Hazard Symbol

SAFETY AND ENVIRONMENT

• Avoid sudden up-and-down boom motion, especially when machine is articulated

• Be careful and drive slowly when approaching the dumping station

SAFETY AND ENVIRONMENT

• Visibility area decal can be found on the operator’s cabin

• Visibility area differ from cabin and canopy version

Cabin version Canopy version

SAFETY AND ENVIRONMENT

• Pressing the emergency stop button,

SAFETY AND ENVIRONMENT

• In an emergency situation, use the safest emergency exit

• To use the emergency exit

SAFETY AND ENVIRONMENT

SAFETY AND ENVIRONMENT

SAFETY AND ENVIRONMENT

• Wear approved PPE’s, which includes but is not limited to:

• Never service the vehicle alone

4. Transmission - DANA RT32421 series

Available option (GET) 2,7 m3 3,0 m3 3,3 m3 3,7 m3

Available option (Bare lip) 3,0 m3 3,3 m3 3,7 m3

7. Hand held fire extinguisher

8. Left hand side doser assembly

10. Battery compartment

• Condition of the bucket and related components visually

• Condition of the boom and related components visually

• Condition of the front and rear frame hydraulic components

• Amount of grease in the central lubrication system is correct

• Fill the tank if necessary

• Condition of the cabin and the door lock

Note! Operating the machine without original protective guards is prohibited

3. Rear lights switch

4. Low/high beam switch

7. Torque converter lock (optional)

8. Bucket counter/VCM-integrated scale (optional)

10. Ride control (optional)

11. Front & rear window wiper

12. Side window wiper

13. Side window washer

• Wrong seat adjustment may lead to fatigue

• Do not make adjustment while driving

• Various seat adjustment can be done

1. Weight & height adjustment 7. Armrests

2. Fore/aft adjustment 8. Seat belt

3. Absorber adjustment 9. Head rest

4. Seat pan angle adjustment 10. Lumbar support adjustment

5. Seat depth adjustment 11. Backrest adjustment

6. Armrest adjustment 12. Left/right adjustment

• The air conditioning is switched ON/OFF from the operator compartment

• All the components are placed inside the air-conditioning unit