Maintenance

Original instructions
BG00710171 en-US B.001.1 2016-04-04
Maintenance Manual
Deutz F6L914/BF6L914
LH203
Maintenance Manual LH203
WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product. Keep this publication for future reference.
Copyright © Sandvik
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Table of Contents
1 Introduction ................................................................... 11
1.1 The purpose of these instructions ......................................................12
1.2 Identification of the product ................................................................ 13
1.2.1 Product type and serial number .................................................. 13
1.2.2 Product manufacturer ..................................................................14
1.2.3 Manuals .......................................................................................14
1.2.4 Location of manuals on the product ............................................ 14
1.2.5 How to identify the correct manual for the product ......................14
1.2.6 Validity of the manuals ................................................................ 15
1.3 Copyright notice ................................................................................... 15
1.4 Definitions ............................................................................................. 15
1.5 Terminology and abbreviations ...........................................................16
2 Safety and Environmental Instructions ...................... 19

2.1 Safety labels, safety messages and signals ...................................... 20
2.1.1 Signal words ................................................................................20
2.1.2 General hazard symbol ............................................................... 20
2.1.3 Mandatory action symbols ...........................................................21
2.1.4 Prohibited action symbols ........................................................... 22
2.1.5 Hazard symbols ...........................................................................23
2.1.6 Labels on the product ..................................................................25
2.1.7 Visual and audible signals ...........................................................39
2.2 User obligations ....................................................................................40
2.2.1 Managing work related hazards .................................................. 41
2.2.2 Scheduled safety inspections and preventive maintenance ........41
2.2.3 Personal Protective Equipment ................................................... 42
2.3 Product limitations ............................................................................... 43
2.3.1 Intended use ................................................................................43
2.3.2 Prohibited use ............................................................................. 44
2.3.3 Center of gravity .......................................................................... 45
2.3.4 Maximum inclination angles ........................................................ 46
2.3.5 Operator visibility .........................................................................49
2.3.6 Modifications ............................................................................... 50
2.4 Hazard zone ...........................................................................................51
2.5 Safeguarding .........................................................................................51
2.5.1 Guards .........................................................................................51
2.5.2 Protective devices ....................................................................... 55
2.6 Complementary protective measures .................................................64
2.6.1 Use of Emergency stop function ................................................. 64
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2.6.2 Emergency exit ............................................................................65

2.6.3 Safe access to machine and three-point support ........................ 65
2.6.4 Isolation and energy dissipation .................................................. 66
2.6.5 Location of the main switch ......................................................... 67
2.6.6 Remote control ............................................................................ 68
2.7 Fire risk control measures ...................................................................68
2.7.1 In case of fire ...............................................................................69
2.7.2 Fire prevention ............................................................................ 70
2.7.3 Fire retardant and flammable materials .......................................70
2.7.4 Fire extinguisher (option) .............................................................71
2.7.5 FS1000 Fire suppression system (optional) ................................72
2.7.6 ANSUL Fire suppression system (optional) ................................ 74
2.7.7 After a fire ....................................................................................77
2.8 Protection against emission hazards ................................................. 78
2.8.1 Noise ........................................................................................... 78
2.8.2 Vibration ...................................................................................... 78
2.8.3 Dust ............................................................................................. 80
2.8.4 Hazardous gases ........................................................................ 80
2.8.5 Diesel particulate matter ..............................................................81
2.9 Emergency procedures ........................................................................82
2.10 Safety considerations for maintenance ..............................................83
2.10.1 Daily inspections and tasks for operators ....................................84
2.10.2 Tasks which require definite technical skills and maintenance
training .........................................................................................85
2.10.3 Tire maintenance .........................................................................86
2.11 Environment ..........................................................................................89
2.11.1 Decommissioning ........................................................................ 89
2.11.2 Dismantling ..................................................................................90
2.11.3 Disposal .......................................................................................92
2.12 Potential product related hazards identified by the user ..................93
2.13 Incident reporting ................................................................................. 94
3 Machine Description ..................................................... 95

3.1 Recommended operating conditions ................................................. 96
3.2 Description of controls and function ..................................................97
3.2.1 Instruments and controls ............................................................. 97
3.3 Circuit breakers .................................................................................... 112
3.3.1 Circuit breaker descriptions .........................................................114
4 Periodic Maintenance ................................................... 115

4.1 Importance of periodic maintenance .................................................. 116
4.2 General notes on maintenance work .................................................. 116
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4.3 Lubricant and coolant recommendations .......................................... 118

4.3.1 Engine ......................................................................................... 118
4.3.2 Transmission ............................................................................... 119
4.3.3 Hydraulics ....................................................................................120
4.3.4 Axles ............................................................................................121
4.3.5 Grease .........................................................................................121
4.4 Filling capacities ...................................................................................121
4.5 Special notes .........................................................................................122
4.6 First service ...........................................................................................122
5 Maintenance Instructions .............................................125

5.1 General .................................................................................................. 126
5.1.1 Check danger, warning, safety note and symbol labels condition
.................................................................................................... 126
5.1.2 Check that all controls are functioning correctly ..........................126
5.1.3 Check major components for oil leaks and mounting ..................127
5.1.4 Test service and parking brake functions (if equipped with
Kessler axles, SAHR brakes) ...................................................... 128
5.1.5 Checking the neutral brake function ............................................132
5.1.6 Check the emergency steering system (optional) ....................... 133
5.1.7 Check arm rest (safety switch) condition .....................................134
5.1.8 General cleaning ......................................................................... 135
5.1.9 Test transmission and the bucket and steering hydraulics .......... 136
5.2 Frame structures .................................................................................. 136
5.2.1 Check hand portable fire extinguisher .........................................136
5.2.2 Check Ansul fire suppression system (option) ............................ 137
5.2.3 Fill fuel tank ................................................................................. 138
5.2.4 Retightening the GET shrouds (optional) cap screws ................. 139
5.2.5 Checking the GET shrouds (optional) fastening visually .............140
5.2.6 Check Sandvik FS1000 fire suppression system (option) ...........142
5.2.7 Check center articulation .............................................................143
5.2.8 Check center articulation with dial gauge ....................................144
5.2.9 Drain water from fuel tank ........................................................... 145
5.2.10 Service the fire suppression system ............................................145
5.2.11 Service the hand extinguisher (option) ........................................145
5.3 Lubrication ............................................................................................ 146
5.3.1 Check automatic central lubrication system (option) ...................146
5.3.2 Grease drive shaft universal joint at centre articulation ...............146
5.3.3 Grease lift cylinder pins, tilt cylinder pins and lift arm pins .......... 147
5.3.4 Grease the center articulation pins ..............................................147
5.3.5 Grease the steering cylinder pins ................................................148
5.3.6 Grease the oscillating axle .......................................................... 148
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5.3.7 Grease the ejector cylinder pins (option) .....................................149

5.3.8 Grease drive shafts and shaft bearing ........................................ 149
5.3.9 Check automatic central lubrication system and fill the grease
tank ..............................................................................................150
5.3.10 Grease the stationary ends of boom / bucket pins ...................... 151
5.3.11 Clean and lubricate operator seat linkages, brake and throttle
pedal linkages ............................................................................. 151
5.3.12 Lubricate the gear selector linkages ............................................152
5.3.13 Lubricate door and hatch hinges ................................................. 153
5.3.14 Lubricate the bearing of the engine throttle linkage .................... 153
5.4 Powerpack .............................................................................................154
5.4.1 Check engine additional equipment ............................................ 154
5.4.2 Check engine oil ..........................................................................155
5.4.3 Check drive belts .........................................................................155
5.4.4 Check air filter assembly condition ..............................................156
5.4.5 Check intake and exhaust ducting and connections for leaks .....157
5.4.6 Service the air filter elements ...................................................... 158
5.4.7 Clean engine cooling fins and transmission oil cooler .................159
5.4.8 Change engine oil and filter .........................................................161
5.4.9 Check engine mountings .............................................................163
5.4.10 Check alternator .......................................................................... 163
5.4.11 Check valve clearances .............................................................. 164
5.4.12 Check exhaust system fastenings ...............................................165
5.4.13 Change fuel filter element ........................................................... 166
5.4.14 Visually check exhaust gas purifier ............................................. 167
5.4.15 Clean the fuel strainer ................................................................. 168
5.4.16 Change the V-belts ......................................................................169
5.4.17 Replace injection valves ..............................................................169
5.5 Powertrain ............................................................................................. 170
5.5.1 Check tires, rims and wheel nuts ................................................ 170
5.5.2 Check transmission oil level ........................................................ 171
5.5.3 Check tire pressures ................................................................... 172
5.5.4 Check wheel nuts tightening torques .......................................... 173
5.5.5 Check oil level in planetary hubs and differentials ...................... 174
5.5.6 Change transmission oil filter element ........................................ 176
5.5.7 Check the tightening torques of power train flanges and bolts ....177
5.5.8 Check axle fastenings visually .................................................... 178
5.5.9 Check the tightenings of axle fastening nuts ...............................179
5.5.10 Check the oscillating axle tightenings ......................................... 180
5.5.11 Measuring brake linings wear ......................................................181
5.5.12 Change transmission oil and filter element ................................. 182
5.5.13 Change oil in planetary hubs and differentials ............................ 184
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5.5.14 Adjusting of wheel bearings ........................................................ 187

5.6 Hydraulics ............................................................................................. 187
5.6.1 Check hydraulic oil level and back pressure ............................... 187
5.6.2 Wash hydraulic oil cooler (optional) .............................................189
5.6.3 Change brake flushing return filter .............................................. 189
5.6.4 Change return oil filter element for bucket and steering
hydraulics .................................................................................... 192
5.6.5 Change hydraulic oil ....................................................................194
5.6.6 Pilot pressure test ........................................................................195
5.6.7 Boom / bucket hydraulic system pressure test ............................196
5.6.8 Steering hydraulic pressure test ..................................................197
5.6.9 Check brake accumulator pre-charge pressures ........................ 198
5.7 Electrics .................................................................................................199
5.7.1 Checking emergency stop and shutdown system ....................... 199
5.7.2 Check lights .................................................................................200
5.7.3 Check gauges and indicator lights .............................................. 201
5.7.4 Check remote control system (option) .........................................201
5.7.5 Check batteries ........................................................................... 202
5.7.6 Check the instrument panel .........................................................203
6 Maintenance cards ........................................................205

6.1 Instructions for reading maintenance cards ......................................206
6.2 Maintenance program .......................................................................... 207
6.2.1 Daily checks ................................................................................ 208
6.2.2 Every 50 hours ............................................................................ 210
6.2.3 Every 250 hours .......................................................................... 211
6.2.4 Every 500 hours .......................................................................... 212
6.2.5 Every 1000 hours ........................................................................ 213
6.2.6 Every 2000 hours ........................................................................ 214
6.2.7 Every 4000 hours ........................................................................ 215
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1 Introduction
Copyright © Sandvik 11 (218)

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1.1 The purpose of these instructions

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

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1.2 Identification of the product

1.2.1 Product type and serial number
The model and serial number of the product are shown on the identification
plate.
• European Economic Area (EEA) countries with CE marking (plate
reorder number: 56026777)
• Other countries (plate reorder number: 56026776)
Identification plate location
The identification plate is located inside the operator's compartment.

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1.2.2 Product manufacturer

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

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1.2.6 Validity of the manuals

This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include information
on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.
1.3 Copyright notice

This publication is copyright of Sandvik Mining and Construction Oy - ©
Sandvik Mining and Construction Oy. It must not be copied, reproduced, or
otherwise made available in full or in part to any third party without Sandvik
Mining and Construction Oy´s prior written consent.
All Rights Reserved.
1.4 Definitions
• Product: Machine, machinery, partly completed machinery, component
or tool, including related services
• User: The owner, operator or authorized and trained person involved in
the transportation, installation, operation, maintenance and disposal of
the product
• Information for use: The information in this manual, the safety labels
and signals on the product, and other related information used separately
or in combination to convey information to the user
• Harm: Physical injury or damage to health. This is always in relation to
people, not to equipment or property
• Hazard: Potential source of harm
• Risk: Combination of a probability of occurrence of harm and the severity
of that harm.
• Risk of property damage: Combination of a probability of occurrence of
property damage and the severity of that property damage
• Environmental risk: Combination of a probability of occurrence of
environmental damage and the severity of that environmental damage.
• Hazard zone: Any space within and/or around the product in which a
person is exposed to a hazard.
• Intended use of a product: Use of a product in accordance with the
information provided in the instructions for use.
• Prohibited use: Any use which is not intended use, especially use that is
specifically prohibited in the information for use or use which is plainly
dangerous.

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• Safe working procedures: Practices and methods developed for users

by their employer for work to be performed. These detail how specific
risks in the workplace will be managed, taking into account information
for use supplied with the product as well as local acts, laws and
regulations.
• Safeguard: Guard or protective device.
• Guard: Physical barrier, designed as part of the product, to provide
protection.
• Protective device: Safeguard other than a guard, which reduces the risk
either alone or in conjunction with a guard; e.g., interlocking device, hold-
to-run control, limiting device.
• Emergency stop: Function which is intended to 1) avoid dangerous
situations or to reduce existing hazards to persons and damage to
product or work in progress 2) To be initiated by a single human action
• Emission value: Numerical value quantifying an emission generated by
a product (e.g., noise, vibration, hazardous substances, radiation).
• Exposure value: Quantifies the exposure of persons to emissions when
the product is in use. Exposure values can be estimated using the
emission values.
• Respirator: Approved respiratory protective device
• ROPS: Roll-Over Protective Structure. Structure that has been designed
and constructed to reduce the possibility of a seat-belted operator being
injured should the machine rollover.
• FOPS: Falling Object Protective Structure. Structure that has been
designed and constructed to provide operators with reasonable
protection from falling objects.
1.5 Terminology and abbreviations

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

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• SCA = Supplemental Coolant Additive

• SCR = Selective Catalytic Reduction
• VCM = Vehicle Control and Management system
• VEB = Volvo Engine Brake
• VIH = Vehicle Interface Harness
• Vodia = Volvo Diagnostics

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2 Safety and Environmental Instructions

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2.1 Safety labels, safety messages and signals

This section includes explanations of safety symbols, signs, signals and
labels used on the product and in the information for use.
2.1.1 Signal words
The following signal words and symbols are used to identify safety
messages in these instructions:
The signal word, "DANGER", indicates a hazardous situation which, if not

avoided, will result in death or severe injury.
The signal word, "WARNING", indicates a hazardous situation which, if not

avoided, could result in death or severe injury.
The signal word, "NOTICE", indicates a situation which, if not avoided,

could result in damage to property or environment.
2.1.2 General hazard symbol
This general hazard symbol identifies important safety messages in this

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

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2.1.3 Mandatory action symbols

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

Wear safety harness Wear safety footwear
tors
Wear high visibility

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

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

symbol

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2.1.4 Prohibited action symbols

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

Do not modify
guard symbol

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2.1.5 Hazard symbols

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

Falling hazard Skin injection hazard
tion hazard
Sideways tipping haz-

Hanging load hazard Run over hazard
ard

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

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

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

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

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

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Material/substance hazard symbols
Hazardous/poisonous material haz-

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

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

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Danger, warning, safety note and symbol label locations
Rear frame (left side)
104 219 101 117
102
218
121
122
Rear frame (right side)
104
102
101 18
117 37
122
Articulation area (right side)
120 102
105
106
104
101
103 122
20

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Rear end
108 20 44
Cabin
1/2
220
106
122 216
18 102
20
Brake pressure gauges: Top image: with Dana axles, bottom image: with
Kessler axles (SAHR)

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216
220
216
6 111 7
116 9 222
3 223 18
37
38
115 113 114 221

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Boom
105 5
Upper side (front frame)
104 105 19

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Upper side (rear frame)
109 102 217

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Labels
1/2 3
56026777 EU area (CE marking)

56026776 outside EU area
4 5
VAHDONT
IE 19, FI - 20360 TURKUFINLAND
This SAFETY CABIN is certified:
Rock Slide Protective Structure

RSPS PN-92 G-59001
(test report number: __________, by MTT )
Model:
Maximum machine mass M

kg
56027792
RSPS part numbers:

56040554
Optional
56040554

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5.1 5.2
Mechanic gear selector Electric gear selector

6 7
8 23
56024640
56035975
9 111

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217 219
15 16 17
Optional Optional Optional

18 19 20
Optional 56004224
00003850

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37 38
101 102 103

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104 105 106
107 108 109

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43 112
113 114 115

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116 44
BG00374618
117 118 119
120 121 122
Jacking point
56037927

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212 216
02783050
00822810
220 221
00822590

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222 223
00822810
56042852
2.1.7 Visual and audible signals

The machine is equipped with the following visual and audible safety
signals:
• Sound signal: the sound signal sounds when the machine is reversing.
• Warning and function signals: the warning and function signals give
important information on the machine operating status, functions and
inform the operator, for example, of oil levels, brake pressures and
engine functions.
• Horn: the horn releases a loud sound and can be used to warn others in
dangerous situations. The horn button is located above the steering
lever.
• Beacon: the warning light (beacon) is the amber, rotating light on the
machine. The beacon starts to flash when the engine starts.
• Fire suppression system signals (with fire suppression system
option): visual and audible signals will be set when the fire suppression
system is activated.
In addition to the provided signal and alert lights, the machine driving lights
can be used for signaling, according to site specific procedures.

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

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2.2.1 Managing work related hazards

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

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

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2.2.3 Personal Protective Equipment

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

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2.3 Product limitations

2.3.1 Intended use
This SANDVIK loader is intended to load, haul and dump rock material
exclusively in underground mines. Any other use different from this is not
considered as intended. The intended use also includes following the
instruction manual and to observe inspection and maintenance rules.
The manufacturer or supplier will not be liable for any damage resulting
from the product misuse.
When we refer to the front of the unit, this is the end of the unit where the
bucket is attached to. The right and left sides of the unit are designed in
reference to the operators position, looking toward the front of the unit.
This machine is designed and constructed according to state of the art
technology and the recognized safety rules. Nevertheless, unintended and
careless use may cause damage to health of the user or third persons, or
prejudice the machine and other properties.
This loader shall be used only
• for its intended use
• in underground mines only
• when it is in proper mechanical and operational condition
• conscious of safety and possible danger
• in strict notice and use of the instruction manual

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2.3.2 Prohibited use

The following uses are prohibited:
• Use which is not in accordance with the intended use as described
above.
• Use of product for any other purposes than those instructed in the
operator's and maintenance manuals.
• Use of product without required and approved training.
• Use of product without required and approved personal protective
equipment.
• Use of product when unauthorized personnel are in the working area.
• Bypassing or overriding machine safeguards for any reason.
• Use of product when safety systems are deficient or out of order.
• Use of product when the area where you are operating has being
charged with explosives
• Use of product in environment containing explosive gases or explosive
dust.
• Use of product for personnel transport.
• Use of product when there is insufficient ventilation or too high water
level in working area
• Use of product when a fault is detected.
• Use of product as a person lifting device.

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2.3.3 Center of gravity

The center of gravity varies depending on the optional devices, boom and
bucket position as well tank and bucket filling.
The position of the center of gravity for transportation of the machine is
presented in the figure below.
∆z
z
x
∆x
∆x
∆y y
x
Coordinate system is located in center hinge, joint shaft height in the

middle of the unit.
∆x –135 mm
∆y 2 mm
∆z 690 mm

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

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Maximum allowed inclination angles
Angle max 10°

Angle max 15°
Angle max 20°
Angle loaded max 5°

Angle unloaded max 10°


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2.3.5 Operator visibility
DANGER
MOBILE MACHINERY HAZARD!
Being run over by a mobile machine will cause death or severe
crushing injury.
Make sure that there are no unauthorized people in the hazard zone.
When operating the machine, always remember that visibility is limited.

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

ters) ters)

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

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

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

operation. The best way to avoid the hazard is to avoid entering the area
where the loader is being operated. Unauthorized access to the area must
be prevented. Before operating the machine, the operator must make sure
there are no persons in the hazard zone.
Visibility from the operator station is limited, as shown in the visibility chart.
If you must bypass the machine, bypass from the operator station side so
that the operator could see you better. Always wear approved high visibility
clothing.
To further increase safety, the users are required to implement site specific
procedures to ensure proper communication and signaling. This can be
done e.g. by means of a communication radio and/or signaling with vehicle
lights or lamps, according to the procedures defined by the mine.
2.5 Safeguarding
2.5.1 Guards
WARNING
DO NOT REMOVE OR MODIFY GUARDS!
Operation without the guards in place is dangerous and could cause
death or severe injury.
Removing or modifying the guards is strictly prohibited! Before
operation, always make sure that the guards are undamaged and in
place.

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

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Location of guards
The diagram below indicates the location of the machine's guards.
6 5 3
1
2 4 8
1 Safety canopy
3 Bucket tilt cylinder cover 4 Machine covers
2 Front guard
1
3

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5 Engine room guard

7 Cooler cover 8 Reaction bar
6 Reaction bar
5 8
7
6

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

designed to reduce risks to the users. Do not modify the protective devices;
they must always be operable and in place. Remember that regular
preventive maintenance is required. Follow all the instructions for
scheduled maintenance provided in the maintenance manual. In addition to
the maintenance manual, section "Description of controls and functions" in
the operator's manual, as well as these safety and environmental
instructions give information on the protective devices.
The protective devices in the machine include but are not limited to the
following:
• Fire extinguisher
• Fire Suppression System (optional)
• Wheel chocks
• Emergency stop buttons
• Main circuit breaker release button
• Preventative functions for machine movements
• Emergency steering (optional)
• Neutral brake
• Frame articulation locking device
• Boom locking pin
• Reverse alarm
• Flashing beacon
• Directional lights (optional)
• Lockable main switch
• Safety belt
• Anti-slip strips
• Warning signs
Note that some of the protective devices are delivered as optional
equipment and must be ordered by the purchaser.

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Seat belt
The seat belt is a two-point lap belt with an adjustable strap. Its purpose is
to secure the operator of a machine against harmful movement that may
result from a collision, loss of balance or a sudden stop.
You must always fasten the seatbelt when you operate the machine.
Frame articulation locking device
DANGER
CRUSHING HAZARD!
Unexpected articulation movement of the machine will cause death
or severe crushing injuries, if a person is at the center articulation
area.
Make sure that there are no unauthorized persons in the hazard
zone.
Never enter the center articulation area when the engine is running.
The frame articulation locking device is located at the articulation area of

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

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How to install the frame articulation locking device
DANGER
CRUSHING HAZARD!
An unexpected articulation movement of the machine will cause
death or severe crushing injuries, if a person is at the center
articulation area.
zone.
1. Make sure that the machine is in straight position.
2. Remove the frame articulation locking device from its bracket on the rear
frame.
3. Remove the front and rear pins from the frame lugs.

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4. Insert the locking device into the middle of the frame lugs and insert the
rear frame pin into the lug holes and lock it.
5. Insert the front frame pin into the upper lug hole.
6. Climb into the cabin and start the engine. Slowly move the steering a bit
from left to right until the front frame pin drops down into the lower lug
hole.
• Note! To avoid damaging the machine the locking pin must be
carefully observed during installation. When the pin drops down to its
lug hole, stop turning the machine.
• It’s necessary to have a second person helping the operator by
giving signs of device movement from safe distance, because
observing the locking device from the cabin is difficult.
7. Shut down the engine, climb out from the cabin and make sure that the
device is properly fixed and lock the front frame pin.

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How to remove the frame articulation locking device
DANGER
CRUSHING HAZARD!
An unexpected articulation movement of the machine will cause
death or severe crushing injuries, if a person is at the center
articulation area.
zone.
1. Climb into the cabin. Start the engine and slowly move the steering a bit
to left or right to release pressure against the pins.
2. Shut down the engine.

3. Climb out from the cabin and remove the pins and the frame articulation
locking device.
4. Install the locking device back to its bracket and place the pins back to
the frame lugs.

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Boom locking pin
DANGER
CRUSHING HAZARD!
Unexpected movement of the machine will cause death or severe
injury.
zone.
Always use mechanical supports when working under the boom.

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How to install the boom locking pin
DANGER
CRUSHING HAZARD!
It may be possible to lower the boom if the start switch is turned on
even if the motor is not running. An unexpected boom movement
creates a crushing hazard which will cause death or severe injury.
To stop the motor, turn the start switch off. Make sure the start
switch is left to off position.
The boom locking pin is a safety device designed to prevent lowering the
boom while people are working under the boom or bucket.
1. Ensure that the bucket is empty and there are no people in the danger
area.
2. Start the motor.
3. Release the parking brake.
4. Raise the boom and tilt down the bucket.
5. Engage the parking brake.
6. Stop the motor and leave the start switch to off position.
7. Open the screw (A).

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8. Turn the locking pin half a turn, push it in and lock with screw (A).
9. Get into the cabin and start the motor.

10. Lower the boom carefully against the locking pin.
• NOTE! Do not press the boom with excessive force against the
boom locking pin. Excessive force damages the boom and the
machine frame.
11. Stop the motor.

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How to remove the boom locking pin
DANGER
CRUSHING HAZARD!
It may be possible to lower the boom if the start switch is turned on
even if the motor is not running. An unexpected boom movement
creates a crushing hazard which will cause death or severe injury.
1. Ensure that there are no people in the danger area.

2. Start the motor.
4. Raise the boom so that the locking pin can be removed.
5. Engage the parking brake.
6. Stop the motor and leave the start switch to off position.
7. Open the screw (A). Turn the locking pin half a turn, push it in and lock
with screw (A).
8. Lock the pin with the screw.

• NOTE! Lubricate the screw and locking pin if they are dry.
9. Get into the cabin and start the motor.
10. Lower the boom slowly against the stops and the bucket to the ground.
11. Stop the motor.

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2.6 Complementary protective measures

2.6.1 Use of Emergency stop function
The machine is equipped with one or as an option several emergency stop
devices. To stop the machine immediately in an emergency, use the
nearest emergency stop device.
When one of the emergency stop devices is activated, all ongoing functions
are stopped. The emergency stop remains engaged until it is manually
reset. This manual resetting does not restart the machine. It only permits
restarting the machine.
Note! Check the functioning of the emergency stop devices daily. Make
sure that the emergency stop devices can be accessed at all times.
Emergency stops and stopping devices

If the emergency stop button, located in the cabin as shown in attached
picture, is pressed the emergency- and parking brake will engage and
engine will stop. Machines with Remote Control system have two extra
emergency stop buttons on either side of the machine. The engine cannot
be started until the emergency stop button has been released.
Always ensure free access to the emergency stops.
Check the operation of the emergency stops daily.

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2.6.2 Emergency exit
Holes of the operator cabin can be used as emergency exit. Go out through
the hole.
2.6.3 Safe access to machine and three-point support
WARNING
SLIPPING, TRIPPING AND FALLING HAZARD!
Slipping, tripping or falling could cause death or severe injury.
Use access ways and maintain three-point support. Keep all access
ways clean.
Use proper working platforms to prevent falling.
Three-point support is feature of an access system that enables a person to

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

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

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

When the machine is switched off, be aware that in a fault situation there
can still be stored pressure in the hydraulic system. The hydraulic system
can store pressure in the accumulator and cylinder lines. All major machine
assemblies should be lowered down or supported to isolate any hydraulic
energy.
Release charging pressure from the brake accumulators as follows:

• Shut down the engine by turning the ignition switch to “0” position. Wait
at least 30 seconds for the brake accumulators to release pressure.
• To be sure that the pressure is released, connect a 400 bar pressure
gauge to the accumulator pressure measuring point with caution.
Release charging pressure from the pilot pressure accumulator as

follows:
• Ensure that the machine is on an even surface and movement is
prevented by wheel chocks.
• Ensure that the boom is resting on stops and the bucket is lowered to the
ground.
• Shut down the engine.
• Wait until pressure is bled from the pilot pressure accumulator.
• To be sure that the pressure is released, connect a 400 bar pressure
gauge to the accumulator pressure measuring point with caution.

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Fuel system disconnection

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

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

Earthing the machine frame reduces the risk of electric shock.
Make sure that the machine front and rear frame are earthed prior to
service and repair work.
Follow the local regulations and guidelines set by your employer and the
authorities.
2.6.5 Location of the main switch
The machine is equipped with a main switch which prevents the electrical
system and the engine from being turned on when the main switch is in off
position.
Note! Do not turn the main switch to off position when the engine is
running. This may damage the alternator, the voltage regulator or
other electronic equipment.
Note! Always turn the main switch to off position before leaving the
machine unattended.

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2.6.6 Remote control

Remote control (option) is a system that improves operator safety, when
used as intended. Remote control allows the operator to control the unit
from a safe distance, without needing to go to a potentially dangerous area.
Typical dangerous areas in this meaning are conditions where a risk of fall
of ground exists, such as open stopes.
Do not drive into an area with a risk of fall of ground. Use remote control.
Read the separate remote control system instructions prior to operation.
2.7 Fire risk control measures
WARNING
FIRE AND EXPLOSION HAZARD!
An explosion hazard could exist in addition to the fire hazard.
Ignition sources like smoking, open flames, welding work and sparks
together with combustible materials like fuel, can cause fire and if
not avoided, could lead to death or severe injury.
Ignition sources are prohibited in the vicinity of the machine ready
for operation or in operation.
During maintenance appropriate fire prevention and protection
measures must be followed including but not limited to trained
personnel, proper fire extinguishing equipment and agents. Before
any maintenance or repairs requiring ignition sources like welding or
flame cutting, a proper risk assessment must be carried out prior to
the start of the work to control the risk.
Smoking and open fire are prohibited in the vicinity of the product. Access
to all fire-fighting equipment must be granted at all times, especially during
maintenance and repair works.
All fire-fighting equipment must be inspected and serviced regularly,
according to local regulations. Damaged fire-fighting equipment and used
fire extinguishers must be replaced immediately.
Know the various types of fires and the appropriate fire-fighting methods.
Be aware that various fires must not be extinguished with water. In most
cases special extinguishing agents, dry powders or deoxygenating are
required.
All personnel must be trained regularly in fire-fighting methods, in
cooperation with local authorities and rescue organizations. In case of fire,
the fire alarm must be activated and all available personnel must contribute
in the fire-fighting according to the predetermined fire plan of the workplace.

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2.7.1 In case of fire

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

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

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2.7.2 Fire prevention

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

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2.7.4 Fire extinguisher (option)
The fire extinguisher is normally mounted to the front frame left mudguard.
Location might vary depending on unit equipment.
Using a fire extinguisher

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

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

distributor.

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2.7.5 FS1000 Fire suppression system (optional)

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

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

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

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Engine switch-off system with FS1000
Engine shutdown kit

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

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

2. Low pressure warning light
3. System fault or discharge warning light
4. Engine shutdown delay timer of 6 seconds with 20 second time extension
button
5. Engine shutdown test button (simulating system discharge)
6. Key operated engine shutdown override (for authorized personnel only)
The twin pressure switch is wired into engine shutdown panel triggering
audio-visual alarm and starting engine shutdown delay timer sequence on
drop of pressure. Timers are factory set to an automatic 6 seconds, with a
20 second manual timer reset. If there is no operator intervention,
automatic engine shutdown will take place 6 seconds after fire suppression
system activation.

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If the button 4 is pressed during the 6 second countdown, it resets the timer
to an extended 20 second delay, allowing the operator to have both hands
free to drive the vehicle for another 20 seconds before the engine shuts
down automatically.
The panel is fitted with a manual override function (6) to allow the
equipment to be moved if necessary. However, to reduce the risk of the
equipment being operated with the fire suppression system discharged, the
override button must be held depressed (spring return button) to maintain
override. As soon as the button is released, the unit will return to the
shutdown mode.
2.7.6 ANSUL Fire suppression system (optional)
The ANSUL fire suppression system is installed in the machine for fire
suppression. The system is a cartridge operated dry chemical system with
fixed nozzle distribution network. The system can be either manual or
automatic.
Note! The system is not designed or intended to extinguish all fires. It
extinguishes mainly fires in the engine compartment. It is extremely
important that alternative fire fighting equipment is available in case the
system does not totally extinguish a fire.
Location of nozzles and actuators
1 2 6 5
4 R 3 D
1 Engine, left side 2 Torque converter

3 Engine, right side 4 Engine cooling air tunnel
5 Transmission 6 Batteries
D Dashboard actuator R Remote actuator

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Manual ANSUL fire suppression system

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

2. Strike the red button (2).

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Automatic ANSUL fire suppression system
WARNING
FIRE HAZARD!
Fire could lead to death or severe injury.
Reconnect the automatic fire suppression system before taking the
machine into use.
Note! Automatic fire suppression system is disconnected during machine

transport and must be reconnected before machine is taken into use. While
disconnected, the automatic fire suppression system can be manually
operated from the manual actuator.
The automatic fire suppression system includes an alarm, automatic fire
detection system and automatic fire extinguishing.
When fire breaks out, the system actuates automatically and releases fire
extinguishing chemicals through the nozzles.
The system is controlled by the control unit. The control unit is represented
below.
2 6
3 5
7 8
1 Battery trouble (yellow LED) 2 Alarm (red LED)

3 Detection trouble (yellow 4 Release trouble (yellow LED)
LED)
5 Power normal (green LED) 6 Sounder
7 Delay button 8 Reset button

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Engine switch-off system with ANSUL (optional)

The engine switches off automatically 5 seconds after the fire extinguishing
system has been actuated. To avoid automatic switch-off, immediately
press and release the delay button on the control unit. Pushing the delay
button will postpone the automatic engine switch-off by 5 seconds. If
necessary, use the button until you have found a suitable parking place.
Reconnecting the automatic ANSUL fire suppression system
2 1
1. Remove the terminal housing cover (1) by opening the two captive
screws.
2. Connect the protracting actuation device connector (2) that is extending
from the actuator body to the connector (3) located inside the terminal
housing.
3. Use the two captive screws to reattach the terminal housing cover.
2.7.7 After a fire

Once the fire is out and the machine has cooled down, open the ventilation
hatches to clear the machine of smoke and gases. Avoid breathing in the
combustion gases. Keep a hand-held fire extinguisher close and ready to
use during ventilation.
Wash the machine with plenty of water as soon as possible after
extinguishing, because the powder used can cause corrosion, especially to
the cables.
Empty tanks and gas cartridges must be replaced before using the
machine. Only authorized service personnel may remove and fit powder
tanks and gas cartridges.
Do not start the machine again until the cause of the fire has been
established and the fault has been repaired.
Report all fires to the supervisor.

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2.8 Protection against emission hazards

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

The measurement of the sound pressure level at the operator’s position
has been measured in accordance of European Directives 98 / 37 / EC and
2000 / 14 / EC.
• Sound pressure level at the operator’s position: 93 dB (A) (at high idle
(2300 rpm))
2.8.2 Vibration
WARNING
VIBRATION HAZARD!
Exposure to vibration could cause severe health effects.
Follow the maintenance schedule and keep the machine on good
operating condition. Participate in the health surveillance and
training programs offered by your employer.

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Measured vibration level

This loader had following vibration values in our tests:
• Hand arm vibration value: a8hw = 1.9 m/s²
• Whole body vibration value: a8hw = 1.0 m/s²
Note that vibration values are highly sensitive to driving speed and terrain
driven. Above values are valid for our testing environment and testing work
cycle.
Note! The vibration emission level given in this manual has been measured
in accordance with a whole body vibration standard ISO 2631-1:1997.
The vibration emission level may vary because of the different ways
in which vehicle can be driven (for example: driving speed and
surface smoothness) and may increase above the level given in this
information sheet. This could lead to significantly higher exposure
values when the vehicle is used regularly in such a way (for example:
very high driving speed in very rough terrain).
Note! To be accurate, an estimation of the level of exposure to vibration

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

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

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

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

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

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

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

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• Electric accidents: If the machine touches an electric power line, the

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

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

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preventive maintenance for the product. The maintenance instructions also

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

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

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

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2.10.3 Tire maintenance
Working with inflated tires and multi-piece wheel rims

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

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

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Safe maintenance procedures

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

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

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

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

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

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

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Refer to the maintenance manual for further information concerning the

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

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

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2.11.3 Disposal
This section gives useful advice to identify which parts of the product are
recoverable, with a view to recycling or reusing the materials or
components for new applications. To ensure environmentally sound
treatment of a product and all of its components, the recovery issues are
already taken into account during the design phase of the product. Correct
handling of waste materials reduces costs and promotes the best use of the
components and materials.
• Machine body: All the steel constructions and the copper and aluminum
in the electrical wiring are recyclable. The metals can be melted and
used as raw material for new products, except for parts that have been in
contact with substances that are regarded as hazardous waste. The
contaminated parts can usually be simply cleaned or rinsed, after which
they can be recycled.
• Plastic: Most plastic parts are recyclable, similarly to the metals. Each
plastic part carries information on the material used and a manufacturing
date, which can be used for determining whether the part can be
recycled.
• Rubber parts and tires: Tires can be recycled, and used as recovered
material. Worn-out tires can be returned to the dealer from whom they
were originally bought. Rubber tubes and hoses must be cleaned before
they are disposed of.
• Glass: Glass can be recycled, as well as laminated glass such as
windshields and windows. Various types of glasses shall be sorted
according to local rules and regulations.
• Electrical and electronic waste: Electrical and electronic components
contain valuable and recyclable materials, and in addition a set of
chemicals and heavy metals. Electrical components that are classified as
hazardous waste (accumulators, batteries, circuit boards) and other
hazardous waste must be delivered to a licensed waste treatment
location or be disposed of according to local regulations. Never dump
hazardous electrical or electronic waste.
• Gas discharge / xenon lamps: Gas discharge lamps contain mercury
and are hazardous waste. They must not be dumped. Lamps must be
taken care of by an authorized hazardous waste disposal company.
• Air conditioning units: Air conditioning units, which contain CFC and
HCFC compounds, must always be delivered for treatment to a licensed
waste disposal facility.

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• Batteries: Batteries are classified as environmentally hazardous material

and require special handling and storing in accordance with applicable
ordinances, rules and regulations. Batteries can cause serious harm to
the ecosystem; lead in the batteries is highly toxic and it accumulates in
the body over time. The disposal shall be taken care of by an authorized
waste disposal company. According to producer responsibility, producers
of batteries and accumulators are also responsible to accomplish the
waste management of batteries that they have placed on the market.
Batteries also contain diluted sulphuric acid. The acid is extremely
corrosive and it burns skin, eats holes in clothing, and can cause
blindness if it gets in the eyes. If you get battery acid on your skin, or
clothes, rinse them immediately with water. Use sodium bicarbonate to
neutralize the acid. If it gets in the eyes, flush the eyes with water, and
call a doctor.
• Oils and fluids: Oil waste must not be disposed of by burning, and
under no circumstances must oil be poured down the drain or into water
systems. Waste oil shall be collected in appropriate containers. The best
containers for collecting oil waste are the original containers for the oils.
The original containers already have the necessary warning labels, are
easy to close, and can be moved around fairly easily. Always strike out
the product name on the label and clearly label the container "oil waste".
Empty oil containers must not be dumped in landfills without having been
cleaned. Cleaned plastic containers can be disposed of as regular waste.
Most countries have arranged a recycling system for metal barrels.
Greases, fuels, solvents, and other substances must not be mixed with
oil waste.
• Solid waste containing oil: Oil filters, oil rags, fuel filters, and oil
absorbents must be collected in a separate container.
• Solvents and oil trap sludge: Solvents and sludge that has collected on
the surface of the oil traps can both be collected in a same container. The
surface layer in the oil traps must be removed regularly, and the entire
trap must be drained at least once a year, including the sludge at the
bottom. Do not mix the oil trap sludge with oil waste.
• Fuel oil: Fuel oil is hazardous waste that must in all cases be processed
by an authorized waste treatment plant.
• Radiator, brake, and clutch fluids: Used radiator, brake, and clutch
fluids contain traces of heavy metals, zinc, and copper, for which reason
they must not be poured down the drain or mixed with oil waste. They are
to be collected in a separate, labeled container and delivered to the same
plants as the oil waste.
2.12 Potential product related hazards identified by the user

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

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2.13 Incident reporting

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

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3 Machine Description

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3.1 Recommended operating conditions

Because the loader normally operates in mine conditions, its engine,
transmission and hydraulic systems are filled with oils suitable for typical
conditions. However, in cold conditions oils may thicken. This makes
starting difficult and the torque converter and hydraulic pumps may be
damaged. For this reason, avoid any temporary parking in frosty weather. If
the machine is to work in very cold or very hot conditions, see the
Maintenance Manual and Engine manufacturer’s Instruction Manual for the
correct oils and the proper fuel selection.

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3.2 Description of controls and function

3.2.1 Instruments and controls
Machines with Dana axles
2 4 5
14
11
7 6
10 3
12
15
13
8
9
1 Instrument panel 2 Steering lever

3 Gear selector 4 Bucket control lever
5 Boom control lever 6 Accelerator pedal
7 Brake pedal 8 Seat
9 Arm rest / safety switch 10 Main switch
11 Parking brake control button 12 Brake pressure gauges
13 Fire suppression system 14 Transmission oil dipstick
button (option)
15 Light switches and horn

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Machines with Kessler (SAHR) axles
14 1
2
4 5
11
10
7
6
12
3
15
13
8 9
1 Instrument panel 2 Steering lever

3 Gear selector 4 Bucket control lever
5 Boom control lever 6 Accelerator pedal
7 Brake pedal 8 Seat
9 Arm rest / safety switch 10 Main switch
11 Parking brake control button 12 Brake pressure gauges
13 Fire suppression system 14 Transmission oil dipstick
button (option)
15 Light switches and horn

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Gauges
1 2 3 4
5 6 7
1 Tachometer / Hourmeter 2 Engine oil temperature

3 Transmission oil temperature 4 Hydraulic oil temperature
5 Fuel level 6 Engine oil pressure
7 Transmission oil pressure
1. Tachometer / Hourmeter
Idling speed 700 r/min, max. rpm 2300 r/min.
The hour meter functions when the engine is running. It shows the total
operating hours of the engine.
2. Engine oil temperature

Engine oil temperature is normal, when the pointer is in the green sector.
If the pointer moves to the red sector the engine is getting too hot.
Stop the engine and trace the trouble.
3. Transmission oil temperature

The transmission oil temperature should be below 100 °C.
4. Hydraulic oil temperature

Oil temperature should be below 100 °C.
5. Fuel level
This gauge shows the fuel level.

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6. Engine oil pressure

Oil pressure at idle should be at least 50 kPa (0,5 bar).
7. Transmission oil pressure

This gauge shows the transmission clutch pressure.
It should be between 1,65 MPa (16,5 bar) and 1,93 MPa (19,3 bar).
8. Return oil filter back pressure
Measure the filter back pressure with engine running at max. rpm.
If the pointer moves to the red sector (in normal working temperature) the
filter element must be changed.

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Brake pressure gauges
1 2
Machines with Dana axles (LCB) are equipped with Front brake circuit
pressure gauge (1) and Rear brake circuit pressure gauge (2).
1
3
Machines with Kessler axles (SAHR) are equipped with Front brake-circuit
release-pressure gauge (1), Brake-accumulator charging-pressure gauge
(2) and Rear brake-circuit release-pressure gauge (3).

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Start switch and light etc. switches
1 Start switch
2 Emergency stop
7 8 9
3 4 5 6
3 Front light switch

4 Rear light switch
5 Parking light switch
6 Horn
7 Blinker switch (opt.)
8 Brake test button or Brake release pump button (opt. for Dana/
Kessler axles)
9 Circuit breakers

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10
10 Remote Control switch (opt.)
1. Start switch
• Position 0. power off
• Position 1. power on
• Position 2. no use
• Position 3. engine starting
2. Emergency stop
Pushing the button engages the service- and parking brakes and shuts
down the engine. Button must be pulled out before starting the engine.
Signal light illuminates when emergency brake is on.
3. Front light switch
4. Rear light switch
5. Parking light switch
6. Horn
7. Blinker switch (opt.)

• If the machine has blinkers, the parking light switch is in the instrument
panel.
8. Brake test button or Brake release pump button (opt. for Dana/
Kessler axles)
Description of Brake test button function for machines equipped with
Dana (LCB) axles:

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Pushing the button down engages the emergency / parking brake. Brake is
released by pulling the three position button fully up and released to center
position. Brakes engages automatically, if
• Electric current is cut off.
• Engine stops.
• Brake system oil pressure is too low.
• Transmission oil pressure is too low.
• Engine oil pressure is too low.
Description of Brake release pump button function for machines
equipped with Kessler (SAHR) axles:
If the engine shuts down unexpectedly or the torque converter driven pump
breaks down, the pressure needed for releasing the brakes can be
produced with a special brake release pump. After that the unit can be
towed to a safe location. Refer to the Towing section for more information.
9. Circuit breakers
10. Remote Control switch (option)

Read the Remote-Control System Operators Manual carefully before
operating with RC-system. Check remote control system functioning
according to remote control system instruction before operation. The RC-
switch must be turned off before starting / operating the machine from the
cabin.

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Indicator- and signal lights
1 3 5 7 9
2 4 6 8 10
1 Parking brake on
2 Grearse end. (opt)
3 Service brake is on
4 Emergency steering (option)
5 Alternator
6 Low engine oil pressure / Fan belt sensor
7 Low brake pressure
8 Engine over heat
9 Low fuel level
10 Low hydraulic oil level
1. Parking brake on
Signal light is on if parking brake is engaged.
2. Grearse end. (opt)

Signal light is on if grease end.
3. Service brake is on
Signal light illuminates when brake pedal is pressed or when emergency
brake is on.
4. Emergency steering (option)

Light illuminates when the emergency steering pressure is too low.
5. Alternator
When lamp lights up the alternator is not charging the battery.
6. Low Engine oil pressure / Fan belt sensor

The warning light is on when the engine oil pressure drops too low or the
cooling fan v-belt is torn.
7. Low brake pressure

The warning light is on when the accumulator pressure drops too low.

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8. Engine over heat

Signal light illuminates when engine temperature is too high.
9. Low fuel level

Signal light illuminates when the fuel level is low.
10. Low hydraulic oil level

Signal light illuminates when the hydraulic oil level is too low.

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Brake & accelerator pedal
2 1
Equipped with Dana (LCB) axles
Equipped with Kessler (SAHR) axles

The Brake pedal (2) is foot operated and is used to stop the loader.
Pressing the pedal applies the brakes and stops the loader and vice versa.
The Accelerator pedal (1) is also foot operated and is used to increase the
machine speed. The harder you press the accelerator, the higher the
engine revolutions will rise.
Never drive with your foot on the brake pedal. It causes overheating
of the hydraulic system and early wear or brake failure. Use the foot
rest.

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Arm rest
The armrest can be lifted up while going in to the canopy. When the arm
rest is up the steering and bucket controls will not work (safety feature).
• Engage parking brake.
Engine fan belt sensor
When the engine cooling fan V-belt is torn or loose, electrical switch is
actuated by the tension roller.
• Engine stops
• Low engine oil pressure signal light illuminates
• Horn sounds

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Steering control lever
Pushing the lever forward turns the machine to right and pulling the lever
turns the machine left.
Note: The machine does not turn if the arm rest is up.
Gear selector
The three forward and reverse gears (speeds) of the Power-Shift

transmission are selected with gear selector lever. There are three
positions for the selector lever: Forward (on the left), reverse (on the right)
and in the middle is neutral position. Pushing the lever further from the
operator connects higher gear. Closer to the operator are the lower gears.

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Electrical gear selector (option)
There are two lateral shift positions for the selector lever:
Forward (on the left), reverse (on the right). Neutral position is closest to
the operator, regardless of the lever position in forward-reverse direction.
Pushing the lever further from the operator connects higher gear. Closer to
the operator are the lower gears.

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Bucket control levers
1 2
1 2
The bucket control levers are used to raise and lower the boom and to
dump and roll back the bucket.
• To dump the bucket - push the lever (1).
• To roll back the bucket - pull the lever (1).
• To lower the boom - push the lever (2).
• To raise the boom - pull the lever (2).
DANGER
CRUSHING HAZARD!
It may be possible to lower the boom if start switch is turned on even
if the motor is not running. An unexpected boom movement creates
a crushing hazard which will cause death or severe injury.

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Ejector bucket control lever (option)
• To eject the ejector plate out - turn the lever up.

• To retract the ejector plate in - press the lever down.
Remember always to move ejector plate in before loading.
3.3 Circuit breakers
B
A
A Main fuse B Fuses
Right side, rear frame

Fuse ID Description Capacity
F300 Main fuse system 80 A

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Instrument panel
F1 Driving lights 8A
F2 Driving lights 8A
Parking, indicator and brake lights, re-
F3 versing alarm, rotary beacon (opt.), 8A
central lubrication
F4 Start circuit 15 A
F5 Gauges, horn 8A
F6 Brake circuit, engine stop 8A
F7 Remote control (opt.) 8A
F9 Emergency stop 8A
Behind instrument panel

F8 Fire suppression system 5A

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3.3.1 Circuit breaker descriptions

Note! Ensure main electric switch is off when re-setting circuit breakers.
B
A
A Main
B Instrument panel
The circuit breaker are located at the instrument panel in the cabin.
The Circuit breaker fuses F1 - F9 have a push-button that pops up when
the circuit breaker is triggered. After clarification of a fault situation, the
circuit breaker can be reset by pushing the button back down. Main fuse
F300 are ceramic fuse.
Triggering of the circuit breaker can be caused by, for example, temporary
and/or transient disturbance in electricity distribution. In that case, the
circuit breaker is reset and the situation monitored in order to determine
whether the disturbance is recurring. An actual fault in wiring or some
component, for example a short circuit, can also trigger the circuit breaker.
In that case the electrical wiring and components of the circuit breaker in
question must be examined.

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4 Periodic Maintenance

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4.1 Importance of periodic maintenance

This machine is designed for hard work in difficult and demanding mine
conditions. To ensure trouble-free and economical operation, it is extremely
important to adhere to the schedule for regular maintenance. By following
this schedule closely, you can easily detect possible defects in the machine
which can be repaired before they become serious. This will ensure low
repair costs and minimize production disturbances.
The pages that follow give information on servicing various machine
components and the corresponding service intervals. We urge all end users
to review the engine manufacturers engine operators guide for additional
information regarding servicing.
All of the machine´s subsystems must be maintained and serviced
periodically according to the manufacturers service and maintenance
instructions, even if the subsystem or option is not currently in use. The
personnel should also be aware of the intended use of these subsystems/
options and check that they are functioning and serviced as if they were in
constant use.
All unused subsystems must be maintained.
4.2 General notes on maintenance work

We recommend that records be kept on servicing and wearing part
replacements. Regular maintenance procedures at the correct intervals
increase productivity, reliability, economy and the safety of the equipment.
Even maintenance work can be dangerous, unless caution is observed.
Everybody involved in maintenance work should understand the possible
hazards and use safe working methods. Before starting any maintenance
or repair work, read the manufacturer’s instructions. Be sure to follow them.
Before any maintenance or service work, make sure the machine is
isolated and stored energy is released.
Make sure the machine is parked on level surface and the frame
articulation locking device is installed.
Notify the location and use of fire extinguishers!
Never attempt to clean, adjust, repair or lubricate the machine while it
is in motion or the engine is running.
Personnel must not wear long, loose hair or loose clothing, nor should they
wear jewelry, including rings, because of the risk of injury.
Use personal protection suits and other protective equipment as far as is
necessary or mandatory.
Do not perform any modifications, extensions or rebuilding of the machine
that would affect safety. Consult the supplier or manufacturer. This also
includes the built-in and adjustment of safety devices and valves, as well as
the welding of frame structures.

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Spare parts must meet the manufacturer’s technical specifications.

Conformity to these standards is guaranteed only when genuine spare
parts are used.
It is absolutely necessary to have suitable specialized workshop equipment
to ensure high-quality maintenance work.
Any maintenance or repair work on the SANDVIK machine must be
performed by properly trained or instructed personnel only. Work must be
performed on electrical appliances by electricians and on hydraulic
appliances by mechanical technicians with knowledge and experience
particular to the work to be done.
Carry out any activity specified in this manual with respect to adjustment,
maintenance and inspection times, in addition to heeding any indications
for replacement of parts.
Clean and wash the equipment regularly and always before and after
maintenance and repair work. Before cleaning the machine with water or by
steam jet or with other cleansers, cover the alternator, connection boxes
and major connections. Remove the covers after cleaning!

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4.3 Lubricant and coolant recommendations

4.3.1 Engine
Oil classification
Naturally aspirated engine DEUTZ F6L 914 API CD/SF / CF-4 / CH-4
Turbocharged engine DEUTZ BF6L 914 API CE/SG / CG-4 / CH-4
Naturally aspirated engine: oil API CC/SF can be used when halving the oil
change interval.
Turbocharged engine: oil API CF-4 can be used when halving the oil
change interval.
Viscosity -30°C - +30°C SAE 0W-40

-20°C - +30°C SAE 10W-40
-5°C - +30°C SAE 20W-50
Diesel fuel sulphur content max 0.5% (by weight). In case of sulphur
content is higher than 0.5% or prevailing ambient temperature below -10°C
the oil change intervals must be halved.
Factory filling oil:

• Shell Rimula R4L 15W-40
Factory filling oil selection is based on the location of the factory.
Choose the lubricant which meets the classification requirement and
is suitable under your local production circumstance when changing
or adding oils.
See the separate DEUTZ Operation Manual for further information.

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4.3.2 Transmission
Operation temperature Oil viscosity Oil classification

Caterpillar TO-4
Below 0 °C SAE 10W
John Deere J20 C, D
Caterpillar TO-4
Above 0 °C SAE 30
John Deere J20 C, D
Recommended Viscosity Grade Based on Prevailing Ambient Temperature
Factory filling oil

• Shell Spirax S4CX SAE 10W (Former product name: Shell Donax TC
SAE 10W)
or adding oils.
Recommended oils for severe applications

Severe applications for transmissions include:
• Vehicles which cycle forward to reverse under full power for a majority of
the vehicle duty cycle.
• Vehicles which operate in average ambient temperatures of over +40 °C.
• Vehicles operating in heavy dust or in environments where components
may be partly submerged or where there is reduced radiant cooling from
the component.
• Vehicles having continuous "high productivity" duty cycles under full
power for a majority of the duty cycle.
Vehicles with duty cycles meeting one or more of the above criteria are
considered a severe application and these guideline should be followed.
Where ambient temperature variation do not allow the use of high viscosity
lubricants in transmission, follow the lubricant recommendations on the
"operation temperature - oil viscosity - oil classification" table. Always use
the highest viscosity lubricant, where overlapping grades exist for the
prevailing ambient temperature.

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Use SAE 40 or SAE 50 lubricant that meets CAT TO-4 requirements. In

cases where vehicles must be cold-started in ambient temperatures below
+5 °C, vehicle warm-up procedures must be followed before moving vehicle
or damage to the drivetrain components could occur.
See the separate DANA Maintenance and Service Manual for further
information.
4.3.3 Hydraulics
Hydraulic oils meeting DIN 51524 HVLP or ISO 6743-4 HV can be used.
Factory filling oil

• Shell Tellus S2 V 46 (Former product name: Shell Tellus T46)
or adding oils.
Recommended viscosity grade based on prevailing ambient

temperature and system's operating temperature
System’s operating tem-
Ambient temperature ISO viscosity
perature range (normal
(cold start) grade
operation)
above - 15 °C 40 - 50 °C ISO VG 32
above + 0 °C 50 - 60 °C ISO VG 46
above + 5 °C 60 - 80 °C ISO VG 68
above + 15 °C 70 - 90 °C ISO VG 100
Use of Lubrizol additive with Kessler axles

If the original factory recommended oil Shell Tellus S2 V 46 is used, no
additive in the brake oil is needed.
If another brand is used, it is recommended to use Lubrizol 9900 additive
(part number 56010389, available from SMC Logistics; sold in 5 liter cans)
to reduce vibration and/or noise in the brakes.
Recommended amount of additive:
• The recommended quantity is 0.5% of the hydraulic oil volume. If
vibration and/or noise still exist, the amount of additive can be increased
to 1%.
• Recommended Lubrizol amount in liters:
- 0.6 L

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4.3.4 Axles
Operation tem-
Oil viscosity Oil classification
perature
SAE 75W-90; SAE API GL-5 + LS (Limited Slip)
Below -10°C
75W-85 MIL-PRF-2105E
SAE 90 or multi grade API GL-5 + LS (Limited Slip)
-10°C - +30°C
oils MIL-PRF-2105E
SAE 140 or multigrade API GL-5 + LS (Limited Slip)
Over +30°C
oils MIL-PRF-2105E
Factory filling oil:

• Shell Spirax S3 AX 85W/140
• Lubrizol 6178LZ oil additive (0.5 l / axle)
- Sandvik Mining and Construction p/n: 04696527
or adding oils.
See the separate axle manufacturer's manual for further information.
4.3.5 Grease
Lithium based greases with penetration 265/295 (NLGI 2) and dropping
point 180 °C should be used.
Factory filling grease:

• Shell Gadus S2 V100 2 (Former product name: Shell Alvania Grease G2)
Factory filling grease selection is based on the location of the factory.
is suitable under your local production circumstance when adding
grease.
4.4 Filling capacities

Engine oil F6L914 14.5 l without filter
16.0 l with filter
BF6L914 16.0 l without filter
17.5 l with filter
Transmission 22 l

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2 x 13.6 l (1.3 l per hub assem-

Axles bly, drive assembly: 11 l) + 0.5 l /
axle oil additive
Hydraulic oil tank appr. 120 l
Fuel tank appr. 130 l
Cooling system Air cooled engine
4.5 Special notes

If the machine is fitted with optional equipment, please read the instructions
for that equipment carefully and follow the service schedule given in the
maintenance instructions.
4.6 First service

Check that the lubricants being used meet site-specific operating
requirements as per Sandvik Mining and Construction Lubricant
Specifications.
The following steps should be carried out during the first week of use (in
addition to the normal, scheduled services ) :
After the first 50 hours
1. Change the transmission oil filter element.
2. Change engine oil and the filter element.
3. Change the fuel filter.
4. Check and tighten the bolts of the exhaust manifold.
5. Check that the air filter and the air pipes are tight.
6. Check the valve clearance (readjust if necessary).
7. Check and tighten the bolts of the oil sump and the engine mountings.
8. Check/tighten the GET shrouds cap screws after each of the first three
shifts (if equipped).
9. Check/tighten bolts of the axles.
• Tighten the axle fastening nuts (inner nuts) to torque of 980 Nm.
• Tighten the axle fastening lock nuts (outer nuts) to torque of 490 Nm
10. Check and tighten wheel bolts.
• See Installing the tires.
11. Check and tighten gearbox bolts.
• UNC 3/4 X 2 1/2 bolts to 340 Nm
12. Tighten the screws of the oscillating axle.
• M12 bolts to 80 Nm
• M24 bolts to 200 Nm

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13. Tighten the screws of drive shafts.

• 1/2 UNF X 1 1/2 GRADE 5 bolts to 110 Nm
• M10X30 - 8.8 bolts to 49 Nm
• M12X35 - 8.8 bolts to 85 Nm
• M16X55 - 8.8 bolts to 210 Nm
14. Check and tighten bolts of other major components.
15. Check V-belts.
16. Make a visual overall check for leaks and possible damages.
The following steps must be carried out during the second week of use (in
addition to the normal scheduled services).
1. Change oil in planetary hubs and differentials.
1. Adjust the wheel bearings.

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5 Maintenance Instructions

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5.1 General
5.1.1 Check danger, warning, safety note and symbol labels condition
1. Check that all note and symbol labels are in place.
• For locations refer to the section Safety and Environmental
Instructions section Labels on the product.
2. Clean all dirt off the labels.
3. Replace all torn off labels with new ones.
5.1.2 Check that all controls are functioning correctly
1. Raise the boom
Operate engine at 1000-1500 rpm
2. Dump the bucket

Engine rpm 1000-1500
3. Roll back the bucket
4. Lower the boom
5. Articulate the machine from left to right.

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5.1.3 Check major components for oil leaks and mounting

1. Make a general visual inspection around and under the machine.
2. Check for oil leaks and loose hoses, frayed wires or bent hydraulic
hoses.
• NOTE! Pay extra attention to hydraulic hoses next to the canopy. If

they burst, hot hydraulic fluid may spray to the canopy and cause
severe injury. Also check the condition of tilt cylinder hose protective
sleeves and chain connected to the cylinder.
3. Check the fuel system for leaks.
4. Check visually the mounting of the engine, the hydraulic cylinders and
the air cleaner.
If anything looks anomalous or is in apparent need of repair, inform the

service personnel.
Do not start the engine, if you are uncertain of the condition of the
machine. Inform the service personnel immediately, if you detect a
leak or any other kind of malfunction or difference in normal use.

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5.1.4 Test service and parking brake functions (if equipped with Kessler axles, SAHR
brakes)
DANGER
CRUSHING HAZARD!
It is possible that the machine moves during brake tests. Getting
crushed under the machine will cause death or severe injury.
Be sure that there are no people in the hazard zone when performing
brake tests.
The following instructions are presenting the service brake test and the
parking brake test. The service brake and the parking brake are tested in
the same way regardless of what options the machine is equipped with.

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Service brake test (SAHR brakes)

1. Ensure that the machine is parked on level ground and the bucket tip is
lifted up.
2. Start the engine and allow the brake system to charge.
3. Check that the pressure in the brake system is at correct operating level
before testing.
• Left gauge (Front brake-circuit release-pressure) should show zero

reading when brakes are engaged and maximum of 110 bar when
brake pedal is released.
• Middle gauge (Brake-accumulator charging-pressure) should show a
reading of 145 - 190 bar.
• Right gauge (Rear brake-circuit release-pressure) should show zero
4. Select 1st gear forward.
5. Release all brakes.
• Take your foot off from the brake pedal.

• Release parking brake (1).
• Parking brake and service brake indicator lights should not
illuminate.
6. Press the brake pedal fully down.

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7. Operate the engine at 1900 rpm.

• The machine should not move and service brake (1) and parking
brake (2) indicator lights should illuminate.
8. Shift gear to neutral.

9. If brake test failed, repair brakes before using the machine.

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Parking brake test (SAHR brakes)

1. Ensure that the machine is parked on level ground and the bucket tip is
lifted up.
2. Start the engine and allow the brake system to charge.
3. Check that the pressure in the brake system is at correct operating level
before testing.
• Left gauge (Front brake-circuit release-pressure) should show zero

• Middle gauge (Brake-accumulator charging-pressure) should show a
reading of 145 - 190 bar.
• Right gauge (Rear brake-circuit release-pressure) should show zero
4. Select 1st gear forward.
5. Take your foot off from the brake pedal and push down the park button
(1).

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6. Operate the engine at 1900 rpm.

• The machine should not move and service brake (1) and parking
brake (2) indicator lights should illuminate.
7. Shift gear to neutral.

8. If brake test failed, repair brakes before using the machine.
5.1.5 Checking the neutral brake function
1. Ensure that the machine is on level ground.
2. Ensure that the gear is in neutral position.
3. Release parking and service brakes.
• NOTE! The machine may begin to move.
4. Check that the neutral brake engages the parking brake when the gear
has been on neutral and brake pedal not been pressed for a time period
defined with a parameter (the default value is 3 seconds).
• A parking brake indicator light informs that the neutral brake is
activated.
5. If neutral brake function does not engage the parking brake, immediately
press the parking brake button, shut down the engine and place wheel
chocks.
• Do not operate the machine before the faulty neutral brake function
has been repaired and tested.

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5.1.6 Check the emergency steering system (optional)

1. Turn the ignition key to the “0” position to shut down the engine.
2. When the engine has stopped, turn the ignition key to the “1” position.
3. Turn the steering lever, the machine should turn on.
• Emergency steering signal light on the instrument panel illuminates.
• NOTE! The machine cannot be turned, if the cabin arm rest is in the
upper position.

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5.1.7 Check arm rest (safety switch) condition
WARNING
SQUASHING HAZARD!
A faulty arm rest (safety switch) could couse death or severe injury.
Make sure there are no unauthorized persons in the working area.
If any malfunction is evident the arm rest (safety swich) must be
repaired before operating the machine.
When the arm rest is up, the steering and bucket controls will not work and
the brakes will engage (safety feature). The arm rest (safety swich) must be
checked at the beginning of every shift.
1. Make sure there are no unauthorized persons in the working area.
2. Make sure the engine is not running and the parking brake is applied.
3. Carefully check the mechanical condition and cleanliness of the switch.
• Pay a special attention to the free movement of the switch arm.
• If any damages (jammed or bent switch arm etc.) are found replace
the switch.
4. Get in to the canopy and lower the arm rest.
5. Start the engine.


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7. Lift the arm rest.

8. Carefully move the steering lever.
9. If the machine starts turning, immediately release the lever, shut down
the engine and apply the brakes.
Do not operate the unit before the faulty interlock has been repaired
and tested.
5.1.8 General cleaning

1. Machines with a cabin.
• Clean the inside of the cabin with a vacuum cleaner.

• Use clean, soft and non-flock cloth to wipe the instrument panel and
the display unit.
• Do not use high-pressure water cleaner or compressed air.
2. Machines with a canopy.
• Protect the instrument panel with cover before cleaning the canopy.
3. Engine bay.
• Cover the exhaust pipe end, alternator, connection boxes, and major
connections before cleaning the machine with water, by steam jet or
other cleanser.
• Do not apply steam or solvent directly to the alternator, starting
motor, or other electronic components.
4. Outside cleaning.
• Clean the machine outside with a high- pressure water cleaner.
• Apply solvent to dirty surfaces and let it affect before washing.
• Be careful when using high-pressure water cleaner.
• Remove any stones, debris, or other loose material that might be
accumulated on the equipment.
Do not apply solvent to hot or delicate surfaces.

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5.1.9 Test transmission and the bucket and steering hydraulics

The transmission and hydraulics should be at operating temperature
during measurement.
1. Test transmission hydraulics.

a) Press brake pedal, engage highest gear, and accelerate.
• DEUTZ F6L 914: The engine should achieve about a 2330 -
2430 rpm stalling speed.
• DEUTZ BF6L 914: The engine should achieve about a 2300 -
2. Test bucket hydraulics.
a) Lower the boom against the stops, keep the control valve in ”boom
down” position, and accelerate.
3. Test steering hydraulics.
a) Turn the loader against the stops, keep the control valve in the
selected position, and accelerate.
5.2 Frame structures

5.2.1 Check hand portable fire extinguisher
1. Check that the gauge pointer is in the green sector.
2. Check that there is no corrosion on the fire extinguisher.

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

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

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

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

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

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

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5.2.4 Retightening the GET shrouds (optional) cap screws

Daily (after each of the first three work shifts after mounting new GET
shrouds or a new bucket equipped with GET shrouds):
1. Make sure that the machine is on a level surface and movement is
2. Make sure that the boom is resting on stops and the bucket lip is lowered
to the ground.
3. If the engine is running, stop the engine.
4. Wash the back side of the shrouds with a pressure washer.
5. Remove the cap screw plugs.

6. Retighten the cap screws with a torque wrench and in-hex driver:
• 50 mm shrouds, in-hex driver 19 mm or 3/4", to 475 Nm (350 ft.lb)
• 32 mm shrouds, in-hex driver 5/8", to 339 Nm (250 ft.lb)
7. Insert the cap screw plugs.

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5.2.5 Checking the GET shrouds (optional) fastening visually

Daily (after the first three shifts):
1. Make sure that the machine is on a level surface and movement is
3. Make sure that the boom is resting on stops.
4. Place the bucket lip to the proper height to see the shrouds all around.
5. Stop the engine.
6. Check that the shrouds are not loose. If necessary, retighten with a
torque wrench and in-hex driver:
• 50 mm shrouds, in-hex driver 19 mm or 3/4", to 475 Nm (350 ft.lb)
• 32 mm shrouds, in-hex driver 5/8", to 339 Nm (250 ft.lb)

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7. Check that the wear indicators on the base of the shrouds are not visible.
• When the wear indicators become visible, replace the shrouds.
NOTE! Corner shrouds usually wear out faster than straight shrouds.
For more information of replacing the shrouds, see the Service and Repair
Manual appendice Ground engaging tools in Action.

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5.2.6 Check Sandvik FS1000 fire suppression system (option)

1. Check that pressure indicators are in the green operating zone.
2. Check that the anti-tamper ties on module handles are in place and
secured.
3. Check that activation modules are clean, secure, undamaged and readily
accessible.
4. Check that engine shutdown panel is clean, secure, undamaged and
readily accessible. Check fire system status lights.
5. Check that vent valve caps are in place. If not, then clean valve and fit
new replacement cap.
6. Check hoses and fittings for signs of damage where possible.
7. Check cylinder assembly and head assembly for signs of damage.
8. Check that cylinder and cylinder mounting bracket are secure.
9. For more information refer to the Service and Repair Manual.

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5.2.7 Check center articulation

1. Check for visual signs of wear.
2. Check that the lubrication works.


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5.2.8 Check center articulation with dial gauge
1
2
1 Front frame
2 Rear frame
3 Pointer
4 Magnetic stand
1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented by wheel chocks.
2. Place a dial gauge with a magnetic stand on the upper hinge plate of the
front frame.
3. Press the bucket against the ground so that the front frame rises from the
ground and you can check the readings of the dial gauge.
• The reading should be 0.2–0.4 mm.
4. If the gap is smaller or bigger, adjust it with shims.

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5.2.9 Drain water from fuel tank

1. Close the fuel shut-off valves.
2. Open the drain plug and bleed the condensed water out.
3. Catch any escaping fuel.
4. Close the drain plug.
5.2.10 Service the fire suppression system
1. The fire suppression system and associated equipment shall be
thoroughly examined and checked for proper operation by the fire
suppression system manufacturer, an authorized distributor or their
designee in accordance with FS1000 or Ansul Maintenance Manual.
If your system is other than FS1000 or Ansul, have the system
serviced by an authorized system supplier or dealer.
Always follow the local regulations.
5.2.11 Service the hand extinguisher (option)
1. Have the extinguisher serviced by an authorized supplier or dealer.
2. Always follow the local regulations.

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5.3 Lubrication
5.3.1 Check automatic central lubrication system (option)
1. Check the system visually and fill if necessary
2. Check that all the lubrications points and lines are undamaged and well
greased
5.3.2 Grease drive shaft universal joint at centre articulation
1. Make sure that the machine is on a level surface and positioned straight,
the parking brake is applied and movement is prevented with wheel
chocks.
2. Install the frame articulation locking device.
3. Grease the drive shaft universal joint at the center articulation.
• Use a hand grease gun.

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5.3.3 Grease lift cylinder pins, tilt cylinder pins and lift arm pins
(If automatic central lubrication is not installed)
Note! Due to different operation conditions, this maintenance task may
need to be carried out more often than scheduled.
1. Grease the lift cylinder pins, tilt cylinder pins and lift arm pins through the
lubrication manifold on the front frame.
5.3.4 Grease the center articulation pins

1. Grease the center articulation pins through the grease nipples.

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5.3.5 Grease the steering cylinder pins

1. Grease steering cylinder front end pin through the grease nipple.
• Use hand grease gun.
2. Grease steering cylinder rear end pin through the grease nipple.
• Use hand grease gun.
5.3.6 Grease the oscillating axle

1. Grease the oscillating axle through the lubrication manifold.

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5.3.7 Grease the ejector cylinder pins (option)

1. Grease all four pins directly through the nipples (6 pcs).
5.3.8 Grease drive shafts and shaft bearing

1. Grease all drive shaft U-joints
2. Grease drive shaft support bearings

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5.3.9 Check automatic central lubrication system and fill the grease tank
1. Clean high-pressure grease filter twice a year.

a) Remove pressure from the high-pressure grease filter before
opening it with the help of a venting screw (1) located in the filter
plug (2).
b) Clean the filter element (5). Replace the filter element and required
seals when necessary.
2. Fill the lubricant barrel through the grease filter's filling connection (3).
• Pump until excessive grease flows out from the pressure relief valve
(4).The pressure relief valve can be relocated to the end of an
overflow pipe.
4
5
3. Check all the grease points individually.

• Lubricating pipes are undamaged.
• Lubricant reaches the lubrication points.

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5.3.10 Grease the stationary ends of boom / bucket pins

1. Make sure that the machine is on a level surface and positioned straight,
the parking brake is applied and movement is prevented with wheel
chocks.
2. Make sure that the bucket is on ground and the boom is resting on stops.
4. Grease the pins directly through the nipples.
5.3.11 Clean and lubricate operator seat linkages, brake and throttle pedal linkages
1. Clean operator seat linkages, brake and throttle pedal linkages.
2. Lubricate the seat linkages.

3. Lubricate pedal linkages if equipped with grease point.

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5.3.12 Lubricate the gear selector linkages

1. Lubricate the gear selector linkages through the grease nipple.

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5.3.13 Lubricate door and hatch hinges
WARNING
TRIPPING, SLIPPING OR FALLING HAZARD!
Tripping, slipping or falling could cause death or severe injury.
Use extreme caution when working on the machine.
Always wear a safety helmet when climbing onto the machine.
Keep stairs, steps, handrails, handles, and working platforms clean
of oil, dirt, and ice.
1. Lubricate the door hinges.

• Check that the cabin door and the lock (or latch) work properly.
• Use antifreeze in the lock cylinder during the cold temperature
periods.
2. Lubricate the cover hinges and hatch hinges that are equipped with a
grease point.
Keep stairs, steps, handrails, handles, and working platforms clean

of oil, dirt, and ice.
5.3.14 Lubricate the bearing of the engine throttle linkage

1. Lubricate the bearing of the engine throttle linkage.

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5.4 Powerpack
5.4.1 Check engine additional equipment
1. Check that the fuel hoses and their connections do not leak.
Note! Failure to eliminate fuel leaks could cause a fire. Tighten loose
connections and replace the damaged components if found.
2. Check the fuel filters visually.
3. Check the engine oil filters visually.
4. Check the starter motor visually.
5. Check the alternator visually.
6. Check the wiring harness connected to the engine.

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5.4.2 Check engine oil

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

• After shutting down the engine allow the oil drain to crankcase for
about 5 minutes before checking the oil level.
3. Check oil level.
• The oil level must be between the LOW and FULL marks on the
dipstick.
4. Add oil if needed.
• When adding oil, do not overfill.
5.4.3 Check drive belts
1. Check condition visually, and adjust if necessary.
2. Check the belt for worn, grease-coated, oil-soaked, and missing material.
• Replace as necessary.

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5.4.4 Check air filter assembly condition

1. Check the air cleaner restriction indicator.
• Change the filter elements if the indicator shows red.
• The indicator automatically resets itself after the filters have been
changed.
2. Check the entire air cleaning system for leaks.
3. Check the air cleaner fastenings.

4. Check the air cleaner protective cover(s).
5. Check the dust discharge valve(s).
Tighten and replace parts if needed.

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5.4.5 Check intake and exhaust ducting and connections for leaks
High temperature warning. A hot surface can cause injury.
1. Check intake ducking and connections for leaks.
2. Check exhaust ducking and connections for leaks.

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5.4.6 Service the air filter elements
The air filter element must be replaced when the optical service indicator
shows red.
1. Clean the sealing surface of the outlet tube and make sure that all
contaminant is removed before the new filter is inserted.
2. Clean the inside of the outlet tube carefully.

• When the filter element is changed, the safety element must be kept
in place.
• The safety element must be changed every third time the air filter
main element is replaced.
3. Ensure all clamps, flange joints and mounting bolts are tight and
undamaged.
• Seal any leaks to prevent dirt entering to the engine.
See separate engine manufacturer's Operator Guide for further

information.

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5.4.7 Clean engine cooling fins and transmission oil cooler

Engine must be stopped when cleaning cooling fins and
transmission oil cooler.
Be careful when using high-pressure cleaning units. Make sure you

have a min. gap of half meter between target and nozzle.
Always wear required personal protection, such as safety helmet,

protective clothing, safety boots, hearing protectors, safety goggles,
etc., as dictated by company policy or local regulations.
1. Remove cooling air cowling.
2. Clean with compressed air, cleaning agent and water, or high pressure
steam.
3. Blow air from exhaust air side.
• Be careful not to damage the cooler and cooling fins.

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4. Spray with cleaning agent and wash with water jet, or clean with steam
jet.
• Max spray pressure of 60 bar
• Max. steam temperature of 90 °C
5. Refit cooling air cowling, run engine up to service temperature.

information.

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5.4.8 Change engine oil and filter

Be careful when handling hot oil. Wear suitable protective gloves,
protective clothing and safety goggles when handling oil.
When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer's requirements.
Note! Do not fill the new filter before assembly. There is a risk that
contamination could get into the system and cause malfunctions or
damage.

information.
1. Run the engine until operating temperature is reached; then shut down
the engine.
2. Drain oil pan and reinstall drain plug, using a new gasket if required.
3. Clean the filter adapter and unscrew the oil filter.
• Catch any escaping oil.

• Clean any dirt from the filter adapter sealing surface.
4. Lightly coat the new filter seal with clean lubricating oil and screw in the
new filter until the seal flush.
• Tighten the filter with another half-turn.

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5. Add oil as required to bring the oil level to the MAX mark on the dipstick.
6. Start engine and run at low idle.

• Check lube oil pressure gauge reading and filter seal for leaks.
7. Shut engine down.
• Wait 5 min.
8. Recheck oil level and add oil if needed, bringing oil level to MAX mark on
the dipstick.
Ensure safe and environmentally protective disposal of process

materials and exchange parts.

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5.4.9 Check engine mountings

1. Check the condition of the mountings.
• Tighten and/or repair if necessary.
• For more information refer to the Service and repair manual.
2. Check condition of the rubber pads.

• Deterioration
• Cracks
3. Check condition of the brackets.
• Broken bolts
• Loose bolts
• Bent or damaged components
5.4.10 Check alternator
1. Check the tension and condition of the drive belt.
• Adjust or replace if necessary.
2. Check the alternator terminals for loose connections and corrosion.

• Replace if necessary.
3. Ensure the terminals have contact grease.

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5.4.11 Check valve clearances

Only people who have been given specialized operation and service
training are allowed to perform operations, service, and adjustment
procedures. Read and ensure you understand the following
instructions before servicing the equipment. To avoid potential
damage and injuries, carefully plan your work beforehand.
See Engine Operation and Workshop Manual, or contact your

nearest Deutz dealer.
Check with engine cold.

1. Check inlet valve clearance (1).
• Clearance should be 0,15 mm
• Adjust if necessary
1 2
2. Check outlet valve clearance (2).

• Clearance should be 0,15 mm
• Adjust if necessary

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5.4.12 Check exhaust system fastenings

1. Check exhaust manifold fastening nuts, exhaust flange, and other
connections for tightness.
• Engine DEUTZ F6L 914

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5.4.13 Change fuel filter element

2. Clean the outside of the fuel filter and the filter adapter.
3. Unscrew the filter and catch any escaping fuel.

4. Clean any dirt from the filter adapter sealing surface.
5. Coat the new filter’s seal lightly with fuel.
6. Manually screw in the new empty filter until the seal is flush.
Note! Do not fill the new fuel filter with fuel before assembly. There is a risk
that contamination could get into the system and cause malfunctions
or damage.
7. Tighten the filter with another half-turn.
8. Open the fuel shut-off valves.
• The fuel system does not need to be bled.
9. Start the engine and check for leaks.

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5.4.14 Visually check exhaust gas purifier

• Exhaust purifier is maintenance free under normal operating conditions.
• Excessive smoke or high levels of odor or irritation during operation of

the machine indicate that the purifier is not functioning optimally
• Change interval: Refer to the Service & Repair Manual.
For more information refer to Service and Repair Manual.

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5.4.15 Clean the fuel strainer

2. Screw out and remove filter cap, catch any escaping fuel.
3. Remove strainer and clean with fuel, renew strainer if necessary.
4. Remove seal ring and clean strainer casing with fuel.
5. Screw on filter cap and strainer with new seal.
6. Open fuel shut-off valves.
7. Bleed the fuel system.

information.

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5.4.16 Change the V-belts

1. When replacing, always inspect the fan bearings.
5.4.17 Replace injection valves

1. Replace injection valves

information.

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5.5 Powertrain
5.5.1 Check tires, rims and wheel nuts
DANGER
TIRE BURST HAZARD!
Tire burst will cause death or severe injury.
If you notice something abnormal with the rim, contact service
personnel, warn others and do not stand in front of the rim or touch
it under any circumstances.
1. Check tires.
• Check for wear and damage.
• Check inflation pressure visually.
2. Check rim components.

• Check visually that all rim components are in place.
• Check that there are no cracking, wear, deformations etc. on the rim
components.
3. Check visually for loose wheel nuts.

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5.5.2 Check transmission oil level

Ensure that the following conditions are met before checking the
transmission oil level:
• Machine on level ground
• Brakes engaged
• The engine at low idle
• The gear in neutral position
• Transmission oil in operating temperature
1. Check transmission oil level from the dipstick.
• The oil level must be between the MIN and MAX marks on the
dipstick.

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5.5.3 Check tire pressures

Note! Tire pressures must be measured when tires are cold.
Current standard tire fitment:

• Nokian 12.00-20 L5S
1. Check the pressure of all tires.
• Nokian 12.00-20 L5S
- Front: 600 kPa (6.0 bar)
- Rear: 350 kPa (3.5 bar)
Note! Other types of tires are available for the user’s choice. Consult tire
supplier to evaluate conditions and to find out the best solution for
application.
Note! If equivalent tires from other suppliers are used always check
manufacturers specification for correct inflation pressure.

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5.5.4 Check wheel nuts tightening torques

Use always torque wrench for checking the tightness.
1. Check wheel nuts tightening torques.
Hexagonal nut:
• M22 * 1.5
Tightening torque, lubricated:
• Do not lubricate mounting face
• 650 Nm
2. Retighten when necessary.

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5.5.5 Check oil level in planetary hubs and differentials
WARNING
HOT OIL HAZARD!
Hot oil could cause severe burn injury.
Let the machine cool down before servicing it. Wear appropriate
personal protective equipment when servicing the machine.
Checking of the oil level is to be accomplished only in warm condition.

1. Drive the machine on an even surface.
• Position the wheel so that lubricant drain hole is down and the oil
level mark (A) is in horizontal position.
2. Apply the parking brake and prevent machine movement by the wheel
chocks.
3. Clean the wheel end.
4. Open the plug (A).
5. Check oil level.
• Oil level should be at level of the plug hole.
6. Refill if necessary.
7. Clean the plug from contaminants, e.g. metal.
8. Reinstall the plug.

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9. Clean the area of the oil level control plug (B).
10. Open the plug (B).

11. Check oil level.
• Oil level should be at level of the plug hole.
12. Refill if necessary.
13. Clean the plug from contaminants, e.g. metal.
14. Reinstall the plug (B).
15. See the Axle Service manual for further information.

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5.5.6 Change transmission oil filter element

WARNING! HOT OIL HAZARD!
protective clothing and eye-protector when handling oil.

and oil meeting manufacturer’s requirements.
1. Place a large enough oil container under the machine.

2. Clean the filter adapter.
3. Remove the filter bowl from the adapter.

4. Remove the filter element from the bowl and place it to the oil container.
• Discard both element and its o-rings.
5. Check that the o-ring on the filter adapter is not damaged.
• Replace if necessary.
6. Clean the filter bowl interior.
7. Lubricate the new filter element thread with a clean transmission fluid.
8. Lubricate the o-rings with clean transmission fluid.
9. Slide the new filter element down around the core of the filter bowl until
the o-ring on the filter element seals at the bottom of the metal core.
• Fill the new filter element with the transmission oil.
10. Install the filter bowl to the adapter.

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12. Check transmission oil level.
13. Add the quantity necessary to bring the transmission oil level to the
upper mark on the transmission dipstick.

5.5.7 Check the tightening torques of power train flanges and bolts
1. Tightening torques (dry).
Equipped with Kessler (SAHR) axles
Equipped with Dana (LCB) axles

• UNF 3/8: 45 Nm
• UNF 1/2: 110 Nm
• M10: 49 Nm
• M12: 85 Nm
• U-shaft bearing M20: 410 Nm

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5.5.8 Check axle fastenings visually

1. Check the fastenings of front and rear axle visually.
• No loose or damaged parts.

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5.5.9 Check the tightenings of axle fastening nuts

1. Check tightening of axle fastening nuts.

• Tightening torque 980 Nm.
2. Check tightening of axle fastening lock nuts.

• Tightening torque 490 Nm.

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5.5.10 Check the oscillating axle tightenings

1. Check tightening of screws (A).

• Tightening torque 180 Nm (lubricated).
A A
B B
2. Check tightening of screws (B).

• Tightening torque 670 Nm (lubricated).

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5.5.11 Measuring brake linings wear

1. Clean thoroughly the area around the wear indicator.
2. Detach the cap nut.

3. Push the indicator pin inside.
4. The distance (X) of the indicator pin shows the maximum allowed
residual lining wear.
• The maximum lining wear has been reached and a brake check is
necessary, if the end face of the indicator pin is flush with the end
face of the thread bushing.
See the Axle Service manual for further information.

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5.5.12 Change transmission oil and filter element

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

oils meeting manufacturer’s requirements.
Draining is best accomplished immediately after the vehicle has been

operating. The lubricant is then warm and will flow freely allowing full
drainage in minimum time. This is particularly desirable in cold weather.
1. Place a large enough oil container under the transmission oil drain point.
• Container minimum capacity 100 liters.
2. Open the filler cap and remove the dipstick.
3. Open the oil drain plug at the bottom of the transmission.
4. Allow oil to drain completely to the container.
5. Reinstall the drain plug.
• Inspect the plug for the contaminant.
• Replace the gasket if required.
6. Clean the oil filter adapters.

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7. Remove the oil filter element.

8. Place the filter element in the oil container.
9. Install a new oil filter.
10. Fill torque converter and transmission through filler opening until fluid
comes up to LOW mark on transmission dipstick.
11. Install the filler cap and dipstick.

12. Run engine two minutes at idle to prime torque converter and hydraulic
lines.
13. Recheck the oil level with engine running at idle.
14. Add quantity necessary to bring oil level to LOW mark on dipstick.
15. Recheck the oil level with warm oil.
16. Bring the oil level to FULL mark on dipstick.
• Oil level should be seen also on the sight class.
17. Check drain plug, oil filter and oil lines for leaks and tighten if necessary.
See the DANA transmission Maintenance and Service manual for

further information.


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5.5.13 Change oil in planetary hubs and differentials
WARNING
HOT OIL HAZARD!
Wear suitable protective gloves, protective clothing and goggles
when handling oil.
RISK OF PROPERTY DAMAGE

and oil meeting manufacturer’s requirements.
Note! It is recommended to lift the machine and place stands under it. The
wheels can then be rotated to the correct position by hand, after the
brakes have been released with the brake release pump. The axle
must be in horizontal position to the floor when changing the axle
oil. Use blocks to prevent the rear axle from oscillating.
Note! Perform the draining when the oil is warm. The planetary hubs and
the differential have the same oil space, but they have to be drained
and filled from different locations. Inspect the plug magnets and the
drained oil for contaminants. Allow enough time for oil to flow
through the various components when filling the axle oil. Clean the
plugs and replace the plug gaskets.
1. Make sure that the machine is on an even surface.

3. Make sure that the planetary hub drain plug (A) is at 6 o'clock position
and the filler plug (B) with the oil level mark is at 9 o'clock (or at 3 o'clock
in some models) position.
B
A

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4. Open the drain plug (A) and the filler plug (B) on the planetary hub.
5. Drain the oil into an oil drain container.
6. Refit the plugs.
7. Rotate the opposite wheel to the right position.
8. Drain the hub and refit the plugs.
9. Open the differential drain plug and filler plug.
10. Drain the oil into an oil drain container.

11. Refit the differential drain plug.
12. Fill the differential until oil flows out from the filler opening.
13. Refit the differential filler plug.
14. Open the planetary hub filler plug which is at 9 o'clock (or at 3 o'clock in
some models) position.
15. Fill the planetary hub until oil flows out from the filler opening.
16. Refit the planetary hub filler plug.
17. Rotate the opposite hub to the right position and repeat the filling
procedure.

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18. Check the oil level in the differential by opening the differential filler plug
before operating the machine. Refit the differential filler plug.
For further information see Axle manufacturer's manual, in the
Service and Repair Manual, Chapter Appendices.

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5.5.14 Adjusting of wheel bearings
The temperature of the axle parts should be between 0° C and +20° C at

the bearing adjustment.
The readjustment of the wheel bearings is very important for the life time. In
the first 1000 working hours there is a significant setting and wear in of all
parts which lead to a reduction of bearing preload.
Inspect and readjust the wheel bearings after 1000, after 4000 and after
8000 hours, but at least once a year.
1. Follow the Axle Service Manual instructions to do the adjustment. Refer
to Service and Repair manual, Appendices.
a) Lift the machine and block all wheels off the ground. Remove tires.
b) Brakes must be released to turn the wheel hub. Release the wheel
brakes using the brake release pump.
c) Replace the planetary housing O-ring.
d) Tighten the wheel safety nut with special spanner tool.
5.6 Hydraulics
5.6.1 Check hydraulic oil level and back pressure

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1. Check hydraulic oil level.

• Boom in down position and bucket on ground. Oil level should be
between the sight glasses (1).
• Add recommended oil through the filling hole (2) if necessary.
2. Test filter back pressure.

a) Operate the engine at full rpm.
• If the pointer (3) moves to the red sector the hydraulic oil return
filter must be changed.

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5.6.2 Wash hydraulic oil cooler (optional)
WARNING
ENTANGLEMENT HAZARD!
Rotating fan could cause death or severe injury.
Never open the cooling system hatches when the engine is running.
Lock the main switch before opening the hatches.
Use appropriate personal protective equipment when washing the
cooling system.

NOTICE Too high washing pressure may damage the cooler core.
Only wash with pressure below 82 bar.
Note! Due to different mine conditions it may be needed to wash the oil
cooler more than every 50 hours.
1. Wash the cooler cores using a high-pressure water cleaner.

• For general cleaning a high-pressure water cleaner with soap is
sufficient.
• When using a high-pressure water cleaner do not exceed 82 bar
(1200 psi) pressure.
• Make sure that the nozzle of the high-pressure water cleaner is not
too close to the core (min. gap 50 cm).
• Slowly move up and down the core concentrating on a small area
until the exit water is free from dirt.
2. Blow off excess water using a pressure air gun.

3. Start the engine and check that the coolers are functioning normally.
• Check for any leaks.
• Check that the fans are rotating properly.
5.6.3 Change brake flushing return filter


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To change the brake flushing return filter, do the following:

1. Ensure the machine is on a level surface, the parking brake is applied
and movement is prevented with wheel chocks.
3. Open the bolts (1) holding the hose (2) connection brackets.
4. Open the two bolts holding the brake flushing return filter support block to
the machine (3).
2
3
4
2
5. Open the hydraulic line connections attached to the filter (4). Plug the
open ends.
6. Change the filter element inside the filter.
7. Reconnect the hydraulic lines (4) to the filter.
8. Tighten the support block bolts (3).
9. Attach the hose (2) back to the filter support block by tightening the bolts
(1).
10. Start the engine, operate it for a while and check for leaks.

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• Oil level should be between the sight glasses.

• Fill if necessary.


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5.6.4 Change return oil filter element for bucket and steering hydraulics
Change the filter element every 500 hours.

If the pointer of the filter back pressure gauge moves to the red sector (in
normal working temperature with engine running at max. rpm) the filter
element must be changed.
1. Remove filter cover (1).
2. Pull element (2) off adapter.

3. Push new element onto adapter.
4. Refit cover.
5. Operate the engine.
6. Check for leaks.

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• Oil level should be between the sight glasses (1).
• Add recommended oil through the filling hole (2) if necessary.


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5.6.5 Change hydraulic oil

1. Drain the tank to the container.
2. Remove all strainer, breather and filter assemblies from the tank as well
as sediment traps or magnets.
3. Disconnect all hydraulic hoses from top of the tank.
• Plug open ends of the hoses.
4. Clean the inside of the tank. If it is difficult to clean, use a mixture of five
parts of fuel oil to one part of clean lubricating oil.
• Be sure to flush out the bottom. Make sure that all of the flushing
solution is removed from the tank.
5. Thoroughly wash the tank exterior with cleaning solvent.
6. Assemble all of the components removed from the tank.
7. Reconnect all hoses and fittings previously disconnected.
• Replace o-ring seals.
8. Replace all filter elements and breather element with new ones.
9. Make sure that the tank drain tap and all plates and components have
been installed and properly tightened.
10. Refill the hydraulic tank with recommended oil through the filling hole
(1).
• Oil level should be between the sight glasses when bucket is on
ground.
11. Bleed the air from the system.
12. For more information refer to the Service and Repair manual.

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5.6.6 Pilot pressure test

1. Install a 400 bar (40 Mpa) pressure gauge to the quick-disconnect fitting
on the pilot system supply valve (MP405).
2. Run the engine at 1200 rpm.
3. Check the pressure in MP405.

• The pilot pressure should be about 35 bar ± 10bar (3,5 MPa
± 1MPa).

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5.6.7 Boom / bucket hydraulic system pressure test

Note! When testing boom / box functions, ensure sufficient height of the
area.
WARNING
HIGH PRESSURE OIL SPRAY HAZARD
High-pressure oil spray can cause serious injury.
Use extreme caution when checking and adjusting pressures.
1. Connect a 400 bar (40 MPa) gauge to the quick disconnect fitting on the
bucket control valve (MP204).
2. Start the engine and operate it at 1200 rpm.

3. Press the bucket against the limiter with the control lever and record the
gauge reading.
• Reading should be 210 bar ± 8 bar.
• Adjust if necessary. For more information on pressure adjusting refer
to the Service and Repair manual.
4. Stop the engine.

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5.6.8 Steering hydraulic pressure test

1. Ensure the machine is on a level surface, the parking brake is applied

and movement is prevented with wheel chocks.
3. Install a 40,0 MPa (400 bar) pressure gauge to the quick disconnect
fitting on steering valve (MP101).

5. Operate the engine at 1200 rpm and turn the machine with the steering
lever to a full turn against the frame articulation locking device.
6. Record the gauge reading.
• Pressure reading should be 150 bar (±8 bar)
• Adjust if necessary. For more information on pressure adjusting refer
to the Service and Repair manual.
7. Stop the engine.

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5.6.9 Check brake accumulator pre-charge pressures

1. Attach a measuring hose to brake circuit measurement point MP503 (1).
• Hose is for ensuring that there is no pressure left in the brake

hydraulic system.
• NOTE! Be careful when attaching the hose, because there might still
be pressure left in the accumulators!
2. Attach a gas filling device to pressure accumulators MP521 (2) and
MP522 (3).
3. Check the pressure reading from the gauge.
• The pre-charge pressure should be 90 bar (±5 bar).
4. Adjust the pre-charge pressure in the accumulators if necessary.
5. Remove the measuring hose from MP503.

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5.7 Electrics
5.7.1 Checking emergency stop and shutdown system
Read the general maintenance instructions before starting to work

on the electric components (Electric system maintenance and
Battery maintenance).
1. Check all emergency stop buttons for damage. There is one emergency
stop button inside the cabin and two emergency stop buttons (optional) at
the rear of the machine, one on either side.
2. Check that none of the emergency stop buttons are pushed.
4. First check the emergency stop button in the cabin. Push button in and
engine should stop instantly.
5. Pull the emergency stop button out to release the emergency stop circuit.
6. Restart the engine.
• Wait 30 seconds before restarting - this allows the starting system to
cool down.
7. Push the emergency stop button on the left rear side of the machine, the
engine should stop instantly.
8. Pull the emergency stop button out to release the emergency stop circuit.
9. Restart the engine.
• Wait 30 seconds before restarting - this allows the starting system to
cool down.
10. Push in the remaining emergency stop button on the right hand rear
side of machine, and the engine should stop instantly.
11. If engine does not shut down, locate the fault and repair the fault
according to the wiring diagrams.

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5.7.2 Check lights

1. Check front lights
2. Check rear lights
3. Check optional lights

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5.7.3 Check gauges and indicator lights
1. Check engine oil temperature (1).

• The pointer should be in the green sector.
1 2 3
9
6
7 8
2. Check transmission oil temperature (2).

• The pointer should NOT be in the red sector.
3. Check hydraulic oil temperature (3).
• The pointer should NOT be in the red sector.
4. Check engine oil pressure (4).
• Engine oil pressure at idling should be at least 0.5 bar
5. Check transmission oil pressure (5).
• Transmission oil pressure should be between 16.5 - 19.3 bar.
6. Check parking brake (6).
• Warning light is on if parking brake is engaged.
7. Check service brake (7).
• Warning light is on if service brake is engaged.
8. Check alternator charging voltage (8).
• Warning light is on if the voltage is not right.
9. Check brake system oil pressure (9).
• Warning light is on if the pressure is too low.
5.7.4 Check remote control system (option)
Check the RC-system functioning according to Remote Control system
instructions.

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5.7.5 Check batteries
WARNING
BATTERY HAZARD!
Batteries include corrosive chemicals and stored energy. Careless
handling of batteries could cause death or severe injury.
Handle batteries with extreme caution. Follow instructions. Always
wear appropriate PPE, including eye protection, protective gloves
and protective overall.
WARNING! LIFTING HAZARD!

Batteries are heavy. Lifting them without assistance could cause
injury.
If possible, use a hoist or other assistance when lifting batteries.
1. Turn the main switch to the OFF position.

2. Open the battery inspection cover.
3. Check all vent caps are tightly in place.

4. Check the holding bracket tightness.

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5. Clean if necessary:
a) Disconnect the electric cables from the terminals and protect the
connectors.
• Always disconnect the (-) clamp first.
b) Protect terminals to prevent accidental shorting.
c) Clean the battery top with a cloth or brush and a solution of water
and soda ash, baking soda, or lime.
• When cleaning, do not allow any cleaning solution, or other
foreign matter to get inside the battery.
d) Rinse with water and dry with a clean cloth.
e) Clean battery terminals and cable clamps.
f) Reconnect the clamps to the terminals.
• Always reconnect the (+) clamp first.
g) Thinly coat the terminals with protective grease to prevent
corrosion.
If the battery box or batteries are extremely dirty, remove the batteries from
the bracket and thoroughly wash the bracket.
5.7.6 Check the instrument panel
Open instrument panel and check:
1. Mounting of components.
2. Condition of wiring.

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6 Maintenance cards

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6.1 Instructions for reading maintenance cards
The maintenance cards show what maintenance procedures are to be

performed at what intervals. In addition to the procedures listed in the
maintenance card of a certain hour interval, also the maintenance
procedures of all relevant shorter intervals must be performed at the same
time.
Maintenance cards:
• daily checks
• every 50 hours
• every 250 hours
• every 500 hours
• every 1000 hours
For example, when performing the scheduled maintenance procedures
after 1000 operating hours from the 1000-hour card, also the procedures
listed in the daily, 50-hour, 250-hour and 500-hour cards must be performed
at the same time. But when performing the scheduled maintenance
procedures after for example 1500 operating hours, it is only necessary to
perform the procedures listed in daily, 50-, 250-, 500- and 1500-hour cards.
This is because 1500 is not divisible by 1000 and thus the procedures listed
in the 1000-hour card must not be done at this point.
The maintenance intervals continue for the whole service life of the
machine. For example the procedures listed in the 2000-hour card are to be
performed after 2000, 4000, 6000, 8000 operating hours and so on.

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1 2 3 4 5 6
Maintenance card
1 Hour type and amount
heading
Maintenance proce-
2 Maintenance procedure to be performed
dure column
Symbol representing the maintenance proce-
3 Symbol column
dure
Maintenance manual page for additional infor-
4 Page number column
mation on the maintenance procedure
Enter a cross here when the maintenance pro-
5 Check column
cedure is completed
Enter any notes on the maintenance procedure
6 Notes column
here
Maintenance card symbol descriptions

Adjust Check
Change/Replace Lubricate
Drain Measure
Service Clean
6.2 Maintenance program

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6.2.1 Daily checks
Diesel hours – Daily
Maintenance procedure Notes
GENERAL 126
Check danger, warning, safety note
126
and symbol labels condition
Check that all controls are functioning
126
correctly
Check major components for oil leaks
127
and mounting
Check brake functions (if equipped
128
with Kessler axles, SAHR brakes)
Check the neutral brake function 132
Check the emergency steering system

133
(optional)
Check arm rest (safety switch) condi-
134
tion
FRAME STRUCTURES 136
Check hand portable fire extinguisher 136
Check Ansul fire suppression system

137
(option)
Fill fuel tank 138
Retightening the GET shrouds (op-

tional) cap screws (after each of the 139
first three shift)
Checking the GET shrouds (optional)
fastening visually (after the first three 140
shifts)
LUBRICATION 146
Check automatic central lubrication
146
system (option)
Grease drive shaft Universal joint at
146
centre articulation
Grease lift cylinder pins, tilt cylinder
147
pins and lift arm pins
Grease the center articulation pins 147

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Diesel hours – Daily
Grease the steering cylinder pins 148
Grease the oscillating axle 148
Grease the ejector cylinder pins 149
POWERPACK 154
Check engine additional equipment 154
Check engine oil 155
Check drive belts 155
Check air filter assembly condition 156
Check intake ducting and connections

157
for leaks
POWERTRAIN 170
Check tires, rims and wheel nuts 170
Check transmission oil level 171
HYDRAULICS 187
Check hydraulic oil level and back
187
pressure
ELECTRICS 199
Check emergency stop and shutdown
199
system
Check lights 200
Check gauges and indicator lights 201
Check remote control system (option) 201
When completed:
Date .............................................................. Diesel hours ..................................................
Approved .......................................................

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6.2.2 Every 50 hours
Diesel hours – 50 HOURS
GENERAL 126
General cleaning 135
Test transmission and the bucket and

136
steering hydraulics
LUBRICATION 146
Grease drive shafts and shaft bearing 149
Check automatic central lubrication

150
system and fill the grease tank
Grease the stationary ends of boom /
151
bucket pins
POWERTRAIN 170
Check tire pressures 172
Check wheel nuts tightening torques 173
HYDRAULICS 187
Wash hydraulic oil cooler (optional) 189
ELECTRICS 199
Check batteries 202
When completed:
Approved .......................................................

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Check Sandvik FS1000 fire suppres-
142
sion system (option)
Check center articulation visually 143
LUBRICATION 146
Clean and lubricate operator seat link-
ages, brake and throttle pedal linkag- 151
es
Lubricate the gear selector linkages 152
Lubricate door and hatch hinges 153
Lubricate the bearing of the engine

153
throttle linkage
POWERPACK 154
Service the air filter elements 158
Clean engine cooling fins and trans-

159
mission oil cooler
Change engine oil and filter 161
Check engine mountings 163
Check alternator 163
POWERTRAIN 170
Check oil level in planetary hubs and
174
differentials
HYDRAULICS 187
Change brake flushing return filter 189
ELECTRICS 199
Check the instrument panel 203
When completed:
Approved .......................................................

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Check center articulation with dial
144
gauge
Drain water from fuel tank 145
POWERPACK 154
Check valve clearances 164
Change exhaust system fastenings 165
Change fuel filter element 166
POWERTRAIN 170
Change transmission oil filter element 176
Check the tightening torques of power

177
train flanges and bolts
Check axle fastenings visually 178
Check the tightenings of axle fasten-

179
ing nuts
Check the oscillating axle tightenings 180
Measure brake linings wear 181
HYDRAULICS 187
Change return oil filter element for
192
bucket and steering hydraulics
When completed:
Approved .......................................................

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Service the fire suppression system 145
POWERPACK 154
Visually check exhaust gas purifier 167
Clean the fuel strainer 168
POWERTRAIN 170
Change transmission oil and filter ele-
182
ment
Change oil in planetary hubs and dif-
184
ferentials
HYDRAULICS 187
Change hydraulic oil 194
Pilot pressure test 195
Boom / bucket hydraulic system pres-

196
sure test
Steering hydraulic pressure test 197
Check brake accumulator pre-charge

198
pressures
When completed:
Approved .......................................................

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Service the hand extinguisher (option) 145
POWERPACK 154
Change the V-belts 169
When completed:
Approved .......................................................

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POWERTRAIN 170
Adjust the wheel bearings 187
When completed:
Approved .......................................................

ID: BG00710171 en-US B.001.1 2016-04-04

ID: BG00710171 en-US B.001.1 2016-04-04
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BG00710171 en-US B.001.1 2016-04-04

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

2.6.2 Emergency exit ............................................................................65

3 Machine Description ..................................................... 95

4 Periodic Maintenance ................................................... 115

4.3 Lubricant and coolant recommendations .......................................... 118

5 Maintenance Instructions .............................................125

5.3.7 Grease the ejector cylinder pins (option) .....................................149

5.5.14 Adjusting of wheel bearings ........................................................ 187

6 Maintenance cards ........................................................205

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Copyright © Sandvik 11 (218)

1.1 The purpose of these instructions

12 (218) Copyright © Sandvik

1.2 Identification of the product

Identification plate location

The identification plate is located inside the operator's compartment.

Copyright © Sandvik 13 (218)

1.2.2 Product manufacturer

14 (218) Copyright © Sandvik

1.2.6 Validity of the manuals

1.3 Copyright notice

Copyright © Sandvik 15 (218)

• Safe working procedures: Practices and methods developed for users

1.5 Terminology and abbreviations

16 (218) Copyright © Sandvik

• SCA = Supplemental Coolant Additive

Copyright © Sandvik 17 (218)

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18 (218) Copyright © Sandvik

2 Safety and Environmental Instructions

Copyright © Sandvik 19 (218)

2.1 Safety labels, safety messages and signals

The signal word, "DANGER", indicates a hazardous situation which, if not

The signal word, "WARNING", indicates a hazardous situation which, if not

The signal word, "NOTICE", indicates a situation which, if not avoided,

This general hazard symbol identifies important safety messages in this

20 (218) Copyright © Sandvik

2.1.3 Mandatory action symbols

Wear protective gloves Wear eye-protector Wear safety helmet

Wear hearing protec-

Wear high visibility

Use cardboard for locat-

General mandatory action

Copyright © Sandvik 21 (218)

2.1.4 Prohibited action symbols

No climbing No smoking No open flames

Do not touch Limit or restrict access Do not weld

Do not remove safety General prohibited action

22 (218) Copyright © Sandvik

2.1.5 Hazard symbols

Mechanical hazard symbols

Falling load hazard Crushing hazard Flying material hazard

Crushing hazard - feet Crushing hazard - hands Cutting hazard

Entanglement hazard Entanglement hazard Entanglement hazard

High pressure injec-

Sideways tipping haz-

Copyright © Sandvik 23 (218)

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

Forward/backward tip- Sideways tipping haz-

Electrical hazard symbols

Dangerous electrical volt- Electrical shock / Electrocu-