Operators Manual EJC 245 SANDVIK

7/23/2019 Operators Manual EJC 245 SANDVIK

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EJC 45

SERIAL NO. 3582

OPERATOR’S

MANUAL





Operator’s Manual - English

© 2003 EJC Mining Equipment Inc.Technical Publications Department

4445 Fairview Street

Burlington, Ontario

Canada L7L 2A4

Tel: (905) 632-4940

Fax: (905) 632-2172

E-mail: [email protected]





1

Table of Contents

Introduction .............................................................................1-1Intended Use of Operator’s Manual ...................................................................................... 1-1

Intended Use of Machine ...................................................................................................... 1-1

Machine Identification .......................................................................................................... 1-2

Safety Notations in Operator’s Manual ................................................................................ 1-2

Loader Components .............................................................................................................. 1-3

Loader Orientation ................................................................................................................ 1-4

General Safety Procedures ....................................................2-1Important ............................................................................................................................... 2-1

Typical Work Cycle .............................................................................................................. 2-1

Correct Operation ................................................................................................................. 2-2

Incorrect Operation ............................................................................................................... 2-3

Fire Prevention ...................................................................................................................... 2-4Optional Fire Extinguisher .................................................................................................... 2-4

Optional Fire Suppression System ........................................................................................ 2-4

Optional ROPS/FOPS Canopy ............................................................................................. 2-5

Optional Back Up Alarm ...................................................................................................... 2-5

Controls ....................................................................................3-1Important ............................................................................................................................... 3-1

1. Operator’s Seat ................................................................................................................ 3-2

2. Steer Control Lever.......................................................................................................... 3-3

3. Boom/Bucket Control Lever............................................................................................ 3-3

4. Transmission Control Levers........................................................................................... 3-3

5. Emergency Stop Button ................................................................................................... 3-4 6. Fire Suppression Button (If fitted)................................................................................... 3-5

7. Instrument Panel .............................................................................................................. 3-5

8. Master Disconnect Switch (Not Shown) ......................................................................... 3-5

9. Accelerator Pedal (Not Shown) ....................................................................................... 3-6

10. Service Brakes Pedal (Not Shown)................................................................................ 3-6

Instruments ..............................................................................4-1Important ............................................................................................................................... 4-1

1. Controller Fault Light ...................................................................................................... 4-2

2. Tow Switch ...................................................................................................................... 4-2

3. Brake Impending Light .................................................................................................... 4-2 4. Engine Temperature Gauge ............................................................................................. 4-4

5. Engine Oil Pressure Gauge .............................................................................................. 4-4

6. Voltmeter ......................................................................................................................... 4-4

7. Manual/Radio Switch ...................................................................................................... 4-4

8. Front Lights Switch ......................................................................................................... 4-6

9. Rear Lights Switch........................................................................................................... 4-6

10. Park/Emergency Brake Light/Button............................................................................. 4-6



Table of Contents

2

11. Audible Alarm ............................................................................................................... 4-6

12. Dimmer Switch .............................................................................................................. 4-8

13. Brake Fault Light/Button ............................................................................................... 4-8

14. Converter Oil Temperature Gauge .............................................................................. 4-10

15. Converter Oil Pressure Gauge ..................................................................................... 4-10

16. Hour Meter................................................................................................................... 4-10

17. Remote Control Transmitter On Light......................................................................... 4-12

18. Remote Control Receiver On Light ............................................................................. 4-12

19. Stop Engine Light/Button ............................................................................................ 4-12

20. Check Engine Light ..................................................................................................... 4-14

21. Horn Button ................................................................................................................. 4-14

22. Ignition Switch............................................................................................................. 4-14

23. Diagnostic Port ............................................................................................................ 4-14

Starting the Engine/Motor ......................................................5-1

Stopping the Engine/Motor ....................................................6-1

Brake Tests ..............................................................................7-1Service Brakes Test .............................................................................................................. 7-1

Park Brake Test ..................................................................................................................... 7-2

Operating the Bucket/Dump Box ...........................................8-1Important ............................................................................................................................... 8-1

Boom/Bucket Control Lever ................................................................................................. 8-1

Typical Work Cycle .................................................................9-1Important ............................................................................................................................... 9-1

Work Cycle ........................................................................................................................... 9-1

Tramming the Machine .........................................................10-1

Operating Hints .....................................................................11-1Towing the Machine ..............................................................12-1

Maintenance and Check Points ...........................................13-1Introduction ......................................................................................................................... 13-1

Engine Off ........................................................................................................................... 13-1

Greasing the Machine ...........................................................14-1Automatic Greasing System ............................................................................................... 14-1

Troubleshooting ....................................................................15-1Important ............................................................................................................................. 15-1

Engine Will Not Crank Over .............................................................................................. 15-1Engine Will Crank Over But Not Start ............................................................................... 15-2

Engine Stalls During Operation .......................................................................................... 15-2

Excessive Exhaust Smoke .................................................................................................. 15-2

Engine Misfiring ................................................................................................................. 15-3

Engine Knocking ................................................................................................................ 15-3

Engine Oil Pressure Low .................................................................................................... 15-3

Engine Overheats ................................................................................................................ 15-3



Table of Contents

3

Hydraulic Oil Foams ........................................................................................................... 15-4

Torque Converter/Transmission Overheats ........................................................................ 15-4

Machine Will Not Move ..................................................................................................... 15-4

Loss of Power ..................................................................................................................... 15-4

Machine Will Not Turn ....................................................................................................... 15-5

Little or No Dump Box/Bucket Action ............................................................................... 15-5

Defective Lighting System ................................................................................................. 15-5

Air Venting the Fuel System .............................................................................................. 15-6

Option: Radio Remote Control .............................................16-1Introduction ......................................................................................................................... 16-1

Instrument Panel - Radio Remote Control .......................................................................... 16-1

Manual Control to Radio Remote Control .......................................................................... 16-2

Radio Remote Control to Manual Control .......................................................................... 16-3



Table of Contents

4



S01001/07/00-A 1-1

Introduction

Intended Use of Operator’s Manual 1. Only trained, authorized personnel shall operate and service this machine.

2. The Operator’s Manual is intended as a guide for the correct use and daily maintenance of

this machine. For periodical maintenance, see Service Manual. For parts, see Parts Manual.

3. The Operator’s Manual is an important part of the machine, and should be available to the

operator at all times.

4. The Operator’s Manual shall be read carefully before starting and operating the machine, or

before carrying out any preventive maintenance.

5. The Operator’s Manual should be replaced immediately if lost or unreadable.

6. If any part of this manual is not clearly understood, contact the original equipmentmanufacturer. Always quote model number and serial number to request information. Each

individual machine is custom built to satisfy requirements of the mine site, and to comply

with the laws of the country in which the mine site is located.

EJC Loaders

Technical Publications Department

4445 Fairview Street

Burlington, Ontario

Canada L7L 2A4

Tel: (905) 632-4940

Fax: (905) 632-2172

E-mail: [email protected]

Intended Use of Machine

1. EJC loaders are designed to load, haul, and dump rock material exclusively. EJC trucks are

designed to transport and dump rock material exclusively. Intended use also includes

following all operating, inspection, and maintenance instructions in this manual.

2. This machine shall only be used:

• for its intended use

• when it is in proper technical condition• by an operator aware of safe operating procedures and possible danger

• in strict notice and use of the operator’s manual.

3. Unintended and careless use of this machine may adversely affect the health of the operator

or third persons, or prejudice the machine and other properties. The operator must exercise

care and common sense when operating this machine.

4. Always obey local safety rules related to accident prevention and environmental protection.



Introduction

S01001/07/00-A 1-2

Machine Identification

Each machine is identified by model number and serial number. The machine model and serial

number are displayed on the name plate, and on the front cover of all manuals.

The name plate is located in the operator’s compartment.

Figure 1: Name Plate

Safety Notations in Operator’s Manual

1. Throughout the Operator's Manual, the following safety notations appear. Follow these

notations, and local government regulations at all times.

2. NOTES will always appear in italics.

NOTE: Indicates a procedure or condition that is essential for the operator to know.

3. CAUTIONS will always appear in bold italics.

CAUTION: Indicates an action or condition that, if not followed, could cause damage to the

machine or other equipment.

4. WARNINGS will always appear in bold preceded by a warning triangle. This symbol, with

a warning statement, means “Warning, be alert! Your safety is involved!” Carefully read the

message that follows.

This indicates an action or procedure that, if not followed, could cause personal injury

or death.



Introduction

S01001/07/00-A 1-3

Loader Components

Figure 2 : Loader Components (Side View)

No. Item Purpose

1. Bucket Loads, contains, and dumps broken rock.

2. Lift Arms Raise and lower the bucket.

3. Front Frame Supports the bucket, lift arms, and components

required to run the machine.

4. Rear Frame Supports engine, transmission, and other components

required to run the machine.5. Center Hinge Connects the front and rear frames. The front and rear

frames pivot around the center hinge to steer the

machine right and left.

6. Outrigger Contains engine components. The outrigger is also

known as skirt.

7. Tires Tires carry the weight of the machine and its load.

8. Operator’s Compartment

(standard location)

The operator sits in the operator’s compartment to

control the machine.

9. Operator’s Compartment

(EJC 115 LP location)

4 5 3 1

76

28 9



Introduction

S01001/07/00-A 1-4

Loader Orientation

1. The front end of the loader is the bucket end.

2. The rear end of the loader is the engine end.

3. Left and right of the machine are referred to by standing at the rear of the machine andlooking towards the bucket.

4. The operator’s compartment where the operator sits, is on the left side of the machine.

Figure 3 : Loader Orientation

LEFT

RIGHT

REAR FRONT



S02001/07/01 2-1

General Safety Procedures

ImportantThis section contains safety procedures which apply to all trucks and loaders.

WARNING!!

Each machine is custom built. Read entire manual for safety instructions specific to the

individual machine.

WARNING!!

Only trained authorized personnel shall operate this machine.

To operate this machine safely:

1. Carefully review and understand the contents of this manual before operating this machine.

2. Know all of the machine's capabilities and functions.

3. Follow all safety and operational procedures contained in this manual.

4. Keep the machine in a clean, well maintained condition.

5. Immediately report any faults for immediate corrective action.

Typical Work Cycle

1. Inspect the machine and perform any required maintenance the operator is authorized to do

while the engine is off.

2. Start the engine.

3. Inspect the machine and perform any required maintenance the operator is authorized to do

while the engine is on.

4. Raise and lower the main implement.

5. Test the park and service brakes according to the brake test procedures in this manual.6. If the machine is functioning normally, begin operating the machine.

7. If the machine is not functioning normally, shut it down and report the faults immediately.

8. Do not operate the machine again until the faults have been corrected.




S02001/07/01 2-2

Correct Operation

1. ALWAYS keep all decals on the machine in legible condition. Observe and follow them at

all times.

2. ALWAYS make sure that all gauges, the horn, and indicator lights function properly.3. ALWAYS report any damage or faulty operation immediately. DO NOT operate the

machine until the faults are corrected.

4. ALWAYS tag the steer control lever to alert other personnel when any machine component

has been disconnected.

5. ALWAYS disconnect the frame lock in the center hinge area before operating the machine.

6. ALWAYS be seated and wear the seat belt (if fitted) when operating the machine.

7. ALWAYS make sure that the transmission is in neutral before starting the engine. During

idle periods, shift the transmission to neutral and apply the park brake.

8. ALWAYS sound the horn for a few seconds before starting the engine/motor to alert other

personnel in the area. Sound the horn frequently during the shift if visibility is reduced.

9. ALWAYS start the engine while sitting in the operator’s seat.

10. ALWAYS test all brakes before starting the shift, and before operating the machine on

grades.

11. ALWAYS keep hands, arms, head, etc. inside the operator's compartment.

12. ALWAYS drive carefully, observe traffic rules and be in full control of the machine.

13. ALWAYS use extreme caution when moving the machine with the main implement (bucket

or dump box) raised. Whenever possible, lower the main implement to the “carry” position

before driving.

14. ALWAYS park on level ground, if possible. 15. ALWAYS turn the machine into a side wall, or block all wheels on both sides of each wheel

if parking on a grade.

16. Except in case of emergency, ALWAYS shut off the engine before turning the master

disconnect switch to the “OFF” position.

17. ALWAYS turn the master disconnect switch to the “OFF” position before working on or

around electrical connections.

18. ALWAYS install the frame lock before working in the centre hinge area or transporting the

machine.

19. ALWAYS stop the engine before filling the fuel tank!

20. ALWAYS refill the fuel tank at the end of each operating period to prevent condensationfrom contaminating the fuel.

21. ALWAYS maintain three points of contact when climbing on the machine. For example, one

hand and both feet, or both hands and one foot.




S02001/07/01 2-3

Incorrect Operation

1. NEVER use the machine for anything other than its intended purpose. EJC trucks are

designed to transport and dump rock material exclusively. EJC loaders are designed to load,

haul and dump rock material exclusively. 2. NEVER use the steer control lever as a hand hold when mounting or dismounting the

machine. The machine may turn even when the engine/motor is stopped.

3. NEVER operate the machine unless all required preventive maintenance has been

performed.

4. NEVER operate the machine unless all electrical boxes are closed tight.

5. NEVER start the machine unless:

• area near the machine is clear

• all covers are installed

• park brake is applied

• transmission control lever is in the NEUTRAL position.

6. NEVER attempt to start the machine by towing.

7. NEVER allow riders in the operator's compartment, in the main implement (bucket or dump

box), or on any other part of the machine.

8. NEVER raise the dump box on a dump truck, if the dump truck is on a slope and the dump

truck is turned.

9. NEVER allow the machine to roll backward with the transmission in forward while working

on steep grades.

10. NEVER drive near or beside a walking person.

11. NEVER leave the machine unattended unless:

• main implement (bucket or dump box) is fully lowered

• transmission control lever is in the NEUTRAL position

• park brake is applied

• engine/motor is switched off and has stopped.

12. NEVER service or adjust the machine when it is in motion. NEVER service or adjust

hydraulic components under pressure.

13. NEVER stand or allow other personnel to stand in the centre articulation area unless the

frame lock is installed and the steer pressure has been bled off to zero.

14. NEVER service electrical parts on an electric-powered machine, unless the trailing cablehas been disconnected. It must not be connected again unless all parts are properly

connected. Use only EJC service parts to ensure that they are identical to parts originally

fitted.




S02001/07/01 2-4

Fire Prevention

1. Keep the machine clean.

2. Keep all electrical wiring and components in good working order.

3. Ensure that the engine air intake, fuel and exhaust systems in diesel machines aremaintained properly.

4. Keep fire fighting equipment in working order. Know where it is located, and how to use it.

This may require training beyond the scope of this manual.

Optional Fire Extinguisher

NOTE: The location of the optional fire extinguisher is determined by the customer.

In case of fire, do the following.

1. Stop the machine and shut the engine off.

2. Move to a safe distance away from the fire. Determine the location and size of the fire.

3. Remove fire extinguisher from the machine.

4. Hold fire extinguisher upright.

5. Follow instructions on fire extinguisher for correct use.

6. Aim the spray of the fire fighting chemical at the base of the fire until the fire is out.

7. Make sure the fire is out and can not start again.

8. Report the fire immediately.

9. The fire extinguisher must be refilled by trained authorized personnel.

10. The machine must be cleaned and serviced by trained authorized personnel before it is put towork again.

Optional Fire Suppression System

The optional fire suppression system is activated by two large red buttons. One button is located

in the operator’s compartment. The other button is located on the frame of the machine. Each

button is fitted with a safety lockout ring to prevent accidental activation of the fire suppression

system.

In case of fire, do the following.

1. Stop the machine and shut the engine off.

2. Grasp the ring pull and pull it hard away from the button. This removes the safety lockout

device.

3. Strike the top of the red button, hard. This causes fire suppressing chemicals to be expelled

into various areas of the machine to suppress the fire.




S02001/07/01 2-5

WARNING!!

The fire suppression system is designed to suppress fires in their early stages. Do not

hesitate-if you detect a fire on the machine, activate the fire suppression system

immediately. The earlier you do this, the more effective the system will be.

4. Move to a safe distance away from the fire. Report the fire immediately.

5. The machine must be cleaned and serviced by trained authorized personnel before it is put to

work again.

Optional ROPS/FOPS Canopy

Description

Roll Over Protective Structures (ROPS) are overhead structures designed to reduce the possibility

of operators from being crushed if the machine they are operating should roll over.

Fall Over Protective Structures (FOPS) are overhead structures that protect operators from falling

objects such as loose rock.

WARNING!!

Always wear seat belt.

Certification

Each new ROPS/FOPS has a certification plate that lists the standards to which it was certified.The certification plate should be displayed on the ROPS/FOPS at all times.

NOTE: Replace the certification plate as soon as possible if it is missing or illegible. Contact the

original equipment manufacturer if a replacement is required.

WARNING!!

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

brackets, voids certification. To assure the safety of the operator, the ROPS/FOPS must be

replaced if it has been damaged or altered in any way.

Optional Back Up Alarm

If the machine is equipped with an optional back up alarm, an audible alarm sounds when the

transmission is engaged in reverse direction.




S02001/07/01 2-6

Notes



S03008/05/03 3-1

Controls

ImportantThis section contains a description, the location, and the function of the various controls used to

operate the machine The operator must know the location and function of all of them.

NOTE: The numbers on the illustration refer specifically to the item described in each paragraph.

Figure 1: Operator’s Compartment

1

3

5

4

2

7

6



Controls

S03008/05/03 3-2

1. Operator’s Seat

The operator’s seat is adjustable for comfort.

1. To adjust the lower back support, turn dial (1) to the desired position.

2. To adjust suspension, turn dial (2) until the operator’s approximate weight appears in the redzone.

3. To adjust the position of the back rest, pull the lever (3) up.

4. To slide the entire seat backwards or forwards, pull up and hold lever (4).

5. Lower arm rests (if fitted) until they are horizontal. To tilt the arm rests up, turn knob

underneath the arm rest towards you. To tilt the arm rest down, turn the knob away from

you.

6. When the entire seat isin the desired position, fasten the seat belt. Adjust length through

plastic slide so that it fits low around the waist and snug across the lap.

NOTE: The seat belt is available only on machines equipped with ROPS or FOPS canopy.

WARNING!!

Always wear the seat belt while operating a machine equipped with an optional ROPS or

FOPS canopy.

Figure 2 : Operator’s Seat - ISRI6000 Model



Controls

S03008/05/03 3-3

2. Steer Control Lever

The steer control lever controls the direction of the machine as it travels. When the lever is moved

to the left or right, the steer cylinder extends or retracts causing the machine to turn on the center

pivot.

To steer the machine, move the lever in the direction you want the machine to turn.

1. To turn the machine right while the machine is moving forward, push the steer control lever

away from you.

2. To turn the machine left, pull the steer control lever toward you.

3. Boom/Bucket Control Lever

Moving the boom/bucket control lever causes the lift cylinders or the dump cylinders to extend or

retract. The lever moves in four directions as seen from the operator’s seat: right, left, forward and

backward.

1. To raise the lift arms, move the lever to the right.

2. To lower the lift arms, move the lever to the left.

3. To dump (tip) the bucket, move the lever forward, away from the operator’s seat.

4. To roll back the bucket, move the lever backward, toward the operator’s seat.

Figure 3 : Boom/Bucket Control Lever

4. Transmission Control Levers

Direction Control Lever (A)

The right lever is the direction control lever, and has three positions: forward (F), neutral (N), and

reverse (R).

1. To select forward direction, move the direction control lever to the “F” position.

2. To select reverse direction, move the direction control lever to the “R” position.



Controls

S03008/05/03 3-4

3. To select neutral, move the direction control lever to the “N” position.

CAUTION: Stop the machine before changing direction.

WARNING!!

Although the machine is fitted with a safety device to prevent start up of the engine while

forward or reverse direction is selected, always physically check that the direction control

lever is in the neutral (N) position before starting the engine.

Gear Selection Lever (B)

The left lever is the gear selection lever and will have 1 to 4 positions: first gear (1) at the bottom,

then up to second gear (2), then up to third gear (3), and fourth gear (4) at the top of the gate.

Figure 4 : Transmission Control Levers

5. Emergency Stop Button

The emergency stop button disconnects power to the engine when pressed. This button should be

used if an emergency arises.

WARNING!!

The emergency parking brakes will automatically apply when the emergency stop button is

pressed. Be prepared for a sudden stop.

B

A



Controls

S03008/05/03 3-5

6. Fire Suppression Button (If fitted)

This is a RED button mounted in the operator’s compartment. It has a safety lockout device to

prevent accidental activation of the fire suppression system.

To activate the system in event of a fire on the machine, do the following.

1. Grasp the ring pull and pull it hard away from the button. This will remove the safety

locking ring.

2. Strike hard the top of the red button. This will cause fire suppressing chemicals to be

dumped in various areas of the machine to extinguish the fire.

WARNING!!

The fire suppression system is designed to extinguish fires in their early stages. Do not

hesitate! If you detect a fire on the machine, activate the fire suppression systemimmediately. The earlier you do this, the more effective the system will be.

7. Instrument Panel

Refer to “Instruments” later in this manual for more information.

8. Master Disconnect Switch (Not Shown)

The master disconnect switch has two positions: “ON” and “OFF”.

1. To operate the machine, first turn the master disconnect switch to the “ON” position.

NOTE: Turn the engine off before turning the master disconnect switch to the “OFF” position.

2. Turn the master disconnect switch to the “OFF” position before leaving the machine

unattended or performing electrical repairs.

Figure 5 : Master Disconnect Switch



Controls

S03008/05/03 3-6

9. Accelerator Pedal (Not Shown)

This is the right pedal on the floor of the operator’s compartment.

1. To increase the speed of the engine, press the pedal.

2. To decrease the speed of the engine, release the pedal.

10. Service Brakes Pedal (Not Shown)

This is the left pedal on the floor of the operator’s compartment.

1. Press the service brakes pedal to apply the service brakes during normal operations.The

further down the pedal is pressed, the greater the braking effort.

2. Release the pedal to release the service brakes.

NOTE: Wherever possible, use the deceleration of the engine to slow the machine down, finally

stopping it with the service brakes. Avoid resting your foot on the service brakes pedal, asthis will cause a light application of the brakes, with resulting excessive heat and wear on

brake components.



S04087/05/03 4-1

Instruments

Important

This section contains a description, location and function of the various controls used to operate

the machine. The operator must know the location and function of all of them.

NOTE: The numbers on the illustration refer specifically to the item described in each paragraph.

2019 21181715 16 2322141312

1 2 3 4 5 6 7 8 9 10 11

Figure 1: Instrument Panel

. ontro er Fau t L g t

2. Tow Switch

3. Brake Impending Light

4. Engine Temperature Gauge

5. Engine Oil Pressure Gauge

6. Voltmeter 7. Manual/Radio Switch

8. Front Lights Switch

9. Rear Lights Switch

10. Park/Emergency Brake Light/Button

11. Audible Alarm

12. Dimmer Switch

. Bra e Fau t L g t Button

14. Converter Oil Temperature Gauge

15. Converter Oil Pressure Gauge

16. Hour Meter

17. Remote Control Transmitter On Light

18. Remote Control Receiver On Light 19. Stop Engine Light/Button

20. Check Engine Light

21. Horn Button

22. Ignition Switch

23. Diagnostic Port



Instruments

S04087/05/03 4-2

1. Controller Fault Light

The red controller fault light indicates when lit that the IQAN TOC8 Controller has encountered

an error.

WARNING!!

If this light illuminates during normal operation, bring the machine to a controlled stop and

shut down the engine immediately. Contact your supervisor or maintenance personnel

immediately. Do not operate the machine until corrective action has been taken.

2. Tow Switch

The tow switch is a key operated switch used during the tow procedure to energize the front and

rear solenoids. When the solenoids are energized, maintenance personnel are able to pump oil tothe brakes and release them.

1. After inserting the proper key, turn the key switch to the right to energize the solenoids.


When illuminated, this yellow light indicates that the brakes are about to apply automatically.

The following conditions will cause the light to illuminate:

• clutch oil pressure drops to 150 psi

• engine oil pressure drops below 12 psi

• brake accumulator pressure drops to 1600 psi

NOTE: The brake fault light will also illuminate if brake accumulator pressure drops to 1600 psi.

NOTE: The light will remain on while pressures are low.

WARNING!!

If this light illuminates during normal operations, be prepared for a sudden stop! Observe

the instrument panel frequently.



Instruments

S04087/05/03 4-3

2019 21181715 16 2322141312

1 2 3 4 5 6 7 8 9 10 11

Figure 2 : Instrument Panel

1. Contro er Fau t L g t

2. Tow Switch




6. Voltmeter

7. Manual/Radio Switch




11. Audible Alarm

12. Dimmer Switch

13. Bra e Fau t L g t Button



16. Hour Meter


18. Remote Control Receiver On Light

19. Stop Engine Light/Button


21. Horn Button

22. Ignition Switch

23. Diagnostic Port



Instruments

S04087/05/03 4-4

4. Engine Coolant Temperature Gauge

The engine coolant temperature gauge indicates the operating temperature of the engine coolant.

Normal operating temperature for the DDEC engine should be 190 to 210° F. The maximum

allowable temperature is 235° F. Should the engine temperature rise above 210° F for an

extended period of time, the engine will shut down automatically.

NOTE: Normal operating ranges may be represented on the gauge dial as a green zone. Unsafe

operating range may be represented as a red zone.


The engine oil pressure gauge monitors the oil pressure in the lube site of the DDEC engine.

Normal oil pressure at operating temperature should be 50 psi (3.45 bar). Minimum

recommended pressure at low idle is 12 psi (0.83 bar).

NOTE: Normal operating range is represented on the gauge dial as a green zone. Unsafeoperating range is represented as a red zone.

CAUTION: If the stop engine light/button illuminates, check the oil pressure gauge. If the oil

pressure is below 7 psi (0.48 bar), shut down the engine immediately to prevent internal

damage. Do not operate the machine until corrective action has been taken.

WARNING!!

The brakes will automatically apply if the engine oil pressure drops below 7 psi (0.48 bar) -

be prepared for a sudden stop!

6. Voltmeter

The voltmeter indicates the system voltage when the electrical system is switched on. The normal

operating range (green zone) is between 26 V and 30 V.

CAUTION: Do not operate the machine if the indicator is in the red zone while the engine is

running. Corrective action must be taken.


Turn the switch to the “MANUAL” position to control the machine from the operator's

compartment.

Turn the switch to the “RADIO” position to operate the machine using radio remote control.



Instruments

S04087/05/03 4-5

2019 21181715 16 2322141312

1 2 3 4 5 6 7 8 9 10 11



2. Tow Switch




6. Voltmeter





11. Audible Alarm

12. Dimmer Switch




16. Hour Meter





21. Horn Button

22. Ignition Switch

23. Diagnostic Port



Instruments

S04087/05/03 4-6


Use this switch to turn the front lights on and off.

1. To turn the front lights on, turn the switch clockwise.

2. To turn the front lights off, turn the switch counter-clockwise.


Use this switch to turn the rear lights on and off.

1. To turn the rear lights on, turn the switch clockwise.

2. To turn the rear lights off, turn the switch counter-clockwise.


The large red park brake light/button is used to apply or release the park brake. The light is on

when the park brake is applied.

1. To apply the park brake, press the button. The light will go on.

2. To release the park brake, pull the button out fully. When the button is released, it will spring

back to the middle position and the light will go out.

WARNING!!

The fact that the light is on is not proof that the park brake is functioning effectively. Testthe park brake at the beginning and end of each operation period, before operating on an

incline, and before leaving the machine unattended. See park brake test procedure.

11. Audible Alarm

The audible alarm sounds if accumulator pressure falls below 1600 psi, or if brake differential

pressure drops below 300 psi.

To acknowledge the alarm and stop the alarm from sounding, press the brake fault light/button.

After a delay of 32 seconds, the alarm will sound again if the fault has not been corrected.

CAUTION: If the audible alarm sounds, bring the machine to a controlled stop and shut down theengine immediately.

CAUTION: Press the brake fault light/button to silence the alarm only if corrective action is being

taken.



Instruments

S04087/05/03 4-7

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1 2 3 4 5 6 7 8 9 10 11



2. Tow Switch




6. Voltmeter





11. Audible Alarm

12. Dimmer Switch




16. Hour Meter





21. Horn Button

22. Ignition Switch

23. Diagnostic Port



Instruments

S04087/05/03 4-8

12. Dimmer Switch

Turn this rotary switch to make the lights on the dash and instrument panel brighter or dimmer.

13. Brake Fault Light/Button

The red brake fault light/button indicates a fault in the brake hydraulic circuit and provides a

means to silence the audible alarm while troubleshooting is being performed.

CAUTION: If this light illuminates, bring the machine to a controlled stop immediately. Do not

operate the machine until the cause of the warning has been determined and corrective

action is being taken.

An alarm will sound shortly after the light illuminates. The alarm will continue to sound until the

fault is corrected or acknowledged.

To acknowledge the fault and silence the alarm, press the light/button in. If the condition that

caused the alarm still exists, the light will remain on and the alarm will sound again.

WARNING!!

The brakes will apply automatically if the brake system accumulator pressure falls below

1400 psi - be prepared for a sudden stop!



Instruments

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1 2 3 4 5 6 7 8 9 10 11



2. Tow Switch




6. Voltmeter





11. Audible Alarm

12. Dimmer Switch




16. Hour Meter





21. Horn Button

22. Ignition Switch

23. Diagnostic Port



Instruments

S04087/05/03 4-10


The converter oil temperature gauge indicates the temperature of the oil in the torque converter

and transmission.

NOTE: Normal temperature range is from 180° F (82.2° C) to 200° F (93.3° C). This may berepresented as a green zone on the gauge dial. Unsafe temperature range is from 225° F

(107.2° C) to 250° F (121.1° C). This may be represented by a red zone on the gauge dial.

If the converter oil temperature rises above 225° F (107.2° C), do the following.

1. Bring the machine to a controlled stop, then apply park brake.

2. Put the transmission in neutral and rev the engine to approximately half throttle (1000 rpm).

3. Observe the converter oil temperature gauge.

CAUTION: Shut down the engine if the temperature does not begin to fall within two minutes.

Corrective action must be taken.

4. Run the engine at half throttle until the gauge needle has fallen well into the green zone, orthe normal operating range of 180° F (82.2° C) to 200° F (93.3° C).

NOTE: An overheating torque converter can be caused by poor maintenance, such as a dirty

cooler, low oil level, or by poor operating habits, such as using too high or too low a gear

during loading or tramming. ENSURE THE FAULT IS NOT POOR OPERATING

HABITS!


The clutch oil pressure gauge indicates the clutch pressure in the transmission. The normal

operating pressure is between 240 psi (16.55 bar) and 300 psi (20.69 bar).

CAUTION: Do not operate the machine with a clutch pressure gauge of 210 psi (14.48 bar) or less.

Corrective action must be taken.

WARNING!!

Brakes will automatically apply if the clutch pressure drops below 60 psi (4.14 bar) - be

prepared for a sudden stop! Check the instrument panel frequently.

16. Hour Meter The hour meter registers the total running hours of the machine. If the hour meter stops working,

inform supervisor.



Instruments

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1 2 3 4 5 6 7 8 9 10 11



2. Tow Switch




6. Voltmeter





11. Audible Alarm

12. Dimmer Switch




16. Hour Meter





21. Horn Button

22. Ignition Switch

23. Diagnostic Port



Instruments

S04087/05/03 4-12


This green light indicates that the radio is transmitting.


This red light indicates that the machine is switched to radio remote control mode.


Light

When the engine starts, this light will come on for 5 seconds.

When this light comes on during normal operations, it indicates that there is a fault in engine fluid

levels, pressures or temperatures. This fault may damage the engine.CAUTION: If the stop engine light remains on, or comes on during operations, shut down the

engine immediately! Do not operate the machine until corrective action has been taken.

The following conditions will trigger the warning light and audible alarm:

• engine oil presure gauge needle in red zone (pressure at 7 psi or lower);

• engine coolant temperature gauge needle in red zone (temperature at or above 210° F);

• level of engine coolant is too low;

• converter and transmisison oil pressure gauge needle in red zone (pressure at 60 psi or

lower).

ButtonTo acknowledge the engine fault warning, press the button.

NOTE: To troubleshoot an engine fault, press in the button. The light will flash a code which

identifies the cause of the engine fault. If everything is normal, the stop engine light will

flash two (2) times slowly, then five (5) times quickly. This code is 25. Other codes are

located in the Detroit Diesel Engine Operator’s Manual and Detroit Diesel

Troubleshooting Manual. To correct the engine fault, consult the Diagnostic Data Link

and the Detroit Diesel Troubleshooting Manual.

WARNING!!

Brakes will automatically apply if engine oil pressure falls below 7 psi (0.48 bar) - be

prepared for a sudden stop!



Instruments

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1 2 3 4 5 6 7 8 9 10 11



2. Tow Switch




6. Voltmeter





11. Audible Alarm

12. Dimmer Switch




16. Hour Meter





21. Horn Button

22. Ignition Switch

23. Diagnostic Port



Instruments

S04087/05/03 4-14


When this light comes on, it indictes that there is a fault in engine fluid levels, pressures, or

temperatures. The engine will automatically adjust fuel injection and timing to compensate. If the

fault persists, the engine will automatically shut down.

NOTE: Both the check engine light and the stop engine light will come on at start up, indicating

that the system is connected and functioning. Both lights will go out if the DDEC engine’s

Electronic Control Module doesn’t find a fault.

21. Horn Button

Always sound the horn before starting the engine/motor. Sound the horn frequently in areas of

low visibility and/or frequent traffic.

1. Press the horn button to sound the horn.

2. Release the horn button to stop the horn from sounding.

22. Ignition Switch

This rotary switch has three positions: “ON”, “OFF” and “START”. Turned fully clockwise to the

left is the “OFF” position.

1. Turn the switch one position clockwise to switch the electrical system on.

2. Turn and hold the switch to the extreme clockwise position to start the engine/motor.

WARNING!!

Never leave the machine (except in case of emergency) unless the ignition switch is turned to

the “OFF” position, as the steering pressure will not bleed off until the switch is off.

23. Diagnostic Port

The diagnostic port allows certified maintenance personnel to communicate with the IQAN TOC8

Controller.

NOTE: The diagnostic port should only be used by trained and authorized personnel.



DOC ID NO./MONTH/YEAR 5-1

Starting the Engine/Motor

WARNING!!

Never attempt to start the engine/motor without first knowing how to shut it off.

CAUTION: Check the engine for correct oil level before starting the engine.

CAUTION: Check the transmission for presence of oil before starting the engine/motor.

WARNING!!

Before starting the engine/motor, sound the horn and make sure that the area is clear,

especially between the front and rear frames. 1. Make sure that the frame lock is in the storage position.

2. Turn the master disconnect switch to the “ON” position.

3. Sit in the operator's seat. Adjust seat as desired. Wear seat belt if machine is equipped with a

canopy.

4. Make sure that the park brake is applied.

5. Make sure that the transmission is in neutral.

6. If the instrument panel is equipped with a main circuit breaker, turn the main circuit breaker

to the “ON” position.

7. Turn the ignition switch to the “ON” position. NOTE: The check engine warning light and the stop engine warning light will come on. This is

the Electronic Control Module (ECM) diagnosing the system to ensure everything is

functional. If all conditions are normal, the warning lights should go out after

approximately 5 seconds. If the warning lights do not go out, consult Detroit Diesel

Service Manual for diagnostic procedures.

8. After the warning lights go out, and with your foot OFF the accelerator pedal, turn and hold

the ignition switch in the start position and crank the engine. As soon as the engine starts,

release the switch. If it does not start immediately, continue to crank for up to 10 or 15

seconds. If the engine still doesn't start, allow the starter motor to cool for one minute, then

try again. If it still won't start, refer to Operator Troubleshooting or Detroit DieselTroubleshooting Manual for diagnostic procedures.

CAUTION: Do not engage the starter motor when the engine is running.

9. Check all gauges and indicators to make sure that systems are functioning properly.

NOTE: Check the instrument panel frequently during operations.

10. As soon as the engine starts and is running smoothly, increase the engine speed to 1/4

throttle.



Starting the Engine/Motor

DOC ID NO./MONTH/YEAR 5-2

11. Release the park brake only when the check engine light and stop engine light have both

gone out.

12. When the engine is running normally, reduce engine speed to low idle.

13. Reapply the park brake.

WARNING!!

Do not attempt to move the machine unless all warning lights are out and gauges register

normal pressures and temperatures.



S06001/04/01 6-1

Stopping the Engine/Motor

To stop the engine/motor, do the following:

1. Bring the machine to a controlled stop. Apply the brakes if necessary.

2. Lower the boom/bucket until the bucket is in firm contact with the ground.

3. When the machine is completely stopped, put the transmission in neutral.

4. Apply the park brake.

5. Let the engine idle for 2 to 5 minutes. This allows critical components to cool gradually.

6. Turn the ignition switch to the “OFF” position. The engine/motor should stop within 30

seconds of turning the switch.

NOTE: If the machine is fitted with a delayed shut down device, the engine/motor will not stop

immediately.

WARNING!!

Do not leave the operator's compartment until the engine/motor has stopped.

7. If the machine is equipped with a main circuit breaker on the instrument panel, turn the main

circuit breaker to the “OFF” position.

8. Dismount from the machine and turn the master disconnect switch to the “OFF” position.

WARNING!!

Do not leave the operator's compartment unless the park brake is applied and the bucket is

in firm contact with the ground.



Stopping the Engine/Motor

S06001/04/01 6-2

Notes



S07003/02/01 7-1

Brake Tests

Service Brakes Test

WARNING!!

It is essential that the service brakes and park brake be properly maintained at all times.

WARNING!!

You must always be certain that the service brakes and park brake are working properly at

all times. Test the service and park brake at the beginning of each shift.

PERFORM THE SERVICE BRAKE TEST EXACTLY AS SET FORTH BELOW:

1. Start the engine/motor as normal.

2. Roll back the bucket.

3. Release the park brake.

4. Apply the service brakes with the service brakes pedal.

5. Select second (2nd) gear and forward direction. Rev the engine to full power.

CAUTION: The machine must not move at all!

CAUTION: Do not hold the engine at full power for more than five (5) seconds, as the torqueconverter will quickly overheat.

6. Repeat the test in reverse direction.

7. Select neutral and shut down the engine/motor.

WARNING!!

If the machine fails the service brake test, tip the bucket into firm contact with the ground.

Apply the park brake, shut down the engine and dismount from the machine. Block all four

wheels. (If blocks are not available, turn the machine into a sidewall or bank). Do notoperate the machine again until corrective action has been taken!



Brake Tests

S07003/02/01 7-2

Park Brake Test

CAUTION: Maintenance is vital if serious injury is to be avoided. No machine can endure the harsh

conditions present at any mine without maintenance of the machine. Failure to report a

minor problem will often mean a more serious problem later. A problem or suspected

problem which can threaten injury to the operator or others should be given the highest priority.

WARNING!!

It is essential that the park brake and the service brakes be maintained properly at all times.

If one is to go near any part of the machine for refuelling or any other reason, the machine

wheels must be blocked and all brakes must be set as even slight movement of the machine

when a person is in a vulnerable position can cause death or serious injury.

WARNING!!

You must always be certain that the park brake and service brakes are working at all times.

PERFORM THE PARK BRAKE TEST EXACTLY AS SET FORTH BELOW:

1. Start the engine/motor and check all instruments and gauges.

2. Make sure that the park brake is applied.

3. Observe instrument panel to check that park brake light is on.

4. Roll back the bucket to the carry position.

5. Select second (2nd) gear and forward direction. Rev the engine to full power.

CAUTION: The machine must not move!

6. Repeat the test in reverse direction.

CAUTION: If the machine does not move, do not keep the engine at full power for more than five (5)

seconds.

CAUTION: If the machine does move, do not move it more than a few feet. If the machine moves

there is a problem with the brakes and the machine should be immediately shut down

for maintenance.

WARNING!!

If the machine fails any part of the park brake test, push the park brake light/button, shut

down the engine and dismount the machine. Block the front and rear wheels. If blocks are

not available, turn the wheel into sidewall or bank. Do not operate the machine again until

corrective action is taken.



S08001/02/02 8-1

Operating the Bucket/Dump Box

ImportantWith practice and experience the bucket can be rolled back and lowered at the same time by

moving the lever to the left and toward you simultaneously. Moving the lever to the right and

away from you will raise and tip the bucket. The ability to become a more efficient operator will

come with practice and experience.

WARNING!!

Never stand or allow other personnel to stand under a raised bucket, unless the bucket is

safely supported.

WARNING!!

Always use extreme caution when moving the machine with a raised bucket. Where

possible, always lower the lift arms on the stops in the carry position before moving.

Boom/Bucket Control Lever

This machine is equipped with a single boom/bucket control lever which moves in four directions.

NOTE: Right and left refer to the lever, NOT the machine’s right and left.

1. To raise the lift arms, move the lever to the right.

2. To lower the lift arms, move the lever to the left.

3. To dump (tip) the bucket, move the lever forward.

4. To roll back the bucket, move the lever backward.



Operating the Bucket/Dump Box

S08001/02/02 8-2

Notes



S09001/05/01 9-1

Typical Work Cycle

ImportantMaximum loading efficiency is obtained by adjusting the loading cycle to the operating

conditions. The following cycle includes operations common to all load-haul-dump situations.

WARNING!!

Always travel up and down grades with the bucket facing downhill. It could be used to stop

the machine in an emergency.

Work Cycle

1. Lower the lift arms on the stop blocks and tip the bucket to the desired digging angle.

2. Drive the machine in first (1st) gear, forward direction and full power, forcing the bucket

cutting lip into the muck pile. Alternate dump and roll back movements will assist in good

penetration.

3. As the bucket achieves maximum penetration, gradually roll back the bucket to fill it

completely.

4. Select reverse direction and slowly withdraw from the muck pile. Keep the bucket low and

rolled back. Drive to the dumping area.

CAUTION: Always carry a loaded bucket with the lift arms on the stop blocks, not on the cylinders.

5. When approaching the dumping area, release the accelerator pedal and stop the machine

with the service brakes. Shift the direction control lever to the neutral position.

6. Apply the park brake. If the machine is diesel powered, rev the engine to full speed.

7. Raise the bucket to the maximum height required and tip the bucket to dump the load.

8. Roll back the bucket and lower it to the carry position. Release the park brake to return to

the loading point.



Typical Work Cycle

S09001/05/01 9-2

Notes



S10001/05/01 10-1

Tramming the Machine

This machine is designed to travel in either direction with the full range of gears being available

in both directions.

WARNING!!

Never move the gear shift lever into Neutral while tramming, especially when travelling on

an incline. This could result in complete loss of control of the machine because there are no

gears engaged in the transmission.

1. Start the engine/motor.

2. Make sure the park brake is applied.

3. Select forward (F) or reverse (R) direction of travel.

NOTE: Always start out in first (1st) gear.

4. Roll back the bucket to the carry position.

5. Place the gear shift lever into first (1st) gear.

6. Release the park brake.

7. Increase engine speed. The machine should move at a controlled speed.

8. Shifting from one gear to another can be done any time conditions permit. When shifting

down, slightly rev the engine. When shifting up, momentarily release the accelerator pedal.

9. Do not shift down unless the machine is travelling at a speed low enough to permit this.

10. Use the transmission to slow the machine down, finally stopping it with the brake pedal.

This will reduce wear and extend the life of the brake components.

11. Always stop the machine to engage low speed gear range before descending or ascending a

steep incline.

12. Follow all safety procedures and local traffic rules and regulations while operating the

machine.

13. On reaching the dump site:

• Bring the machine to a controlled stop.

• Move the direction control lever to neutral and apply the park brake.

• Raise the lift arms to the required height and dump the load.

• Lower the lift arms and roll back the bucket on the respective stops.

• Select the required gear range. Release the park brake and return to the loading point.



Tramming the Machine

S10001/05/01 10-2

Notes



S11001/02/02 11-1

Operating Hints

NOTE: Always report and faults or problems with your machine as soon as possible. Minor

malfunctions can quickly grow to major faults if ignored.

1. ALWAYS sound the horn before starting the engine/motor. Sound the horn frequently,

especially in areas of limited visibility and congestion.

2. ALWAYS keep the loading and dumping areas as clean and level as possible to ensure equal

distribution of weight and improve stability.

3. If possible, work the outer edges of the muck pile first and then the centre. This will prevent

spreading of loose material in the loading area.

4. When loading the bucket, shake any excess load off the bucket before moving to the dump

area. This will assist in keeping roadways clean and prevent spillage.

5. Avoid spinning or lifting the wheels off the ground while loading the bucket. This will

accelerate tire wear and cause premature structural problems.6. ALWAYS carry a loaded bucket as low as possible to ensure good stability and visibility.

7. ALWAYS test the park brake before operating on an incline.

8. ALWAYS travel in first (1st) gear and avoid excessive use of the brakes when carrying a

loaded bucket down an incline.

9. When dumping, only lift the bucket high enough to clear the object being loaded.

CAUTION: Never contact the roof with the bucket.

NOTE: On machines equipped with a catalytic exhaust purifier, avoid running the engine at idle

for long periods. This can cause “masking” of the catalyst and reduce the efficiency of the

purifier.



Operating Hints

S11001/02/02 11-2

Notes



S12001/02/01 12-1

Towing the Machine

At times it may be necessary to tow the machine. This can be done safely using the following

procedure.

CAUTION: If the park brake cannot be released with the park/emergency light/button, or if the

machine is a “dead” machine, do not attempt to tow it. Inform maintenance.

WARNING!!

Carry out steps 1 and 2 before connecting the towing machine.

1. Lower the boom arms and bucket on the stops.


3. Place wheel blocks on both sides of all four wheels.

4. Connect the two machines with a rigid tow bar or “A” frame. Also install a secondary safety

chain or wire ropes to both machines. See illustration.

WARNING!!

The towing machine must have ample power and braking capacity to move, stop, and hold

both machines.

5. Authorized maintenance personnel stand by to release the brakes.

WARNING!!

Only release the brakes under the strict supervision of the mechanical supervisor. The

machine will be rendered completely without means of braking once the brake lines have

been manually pressurized. It will remain in this state until the pressure is manually

released. Ensure that the machine is securely blocked with wheel chocks or is securely

connected to a tow vehicle before releasing the brakes.



Towing the Machine

S12001/02/01 12-2

Figure 1: Towing the Machine

WARNING!!

Do not release the brakes on the towed machine unless it is properly connected to the towing

machine, and the towing machine has an operator in the operator’s compartment in control

of the machine. At no time allow anyone to ride on the towed machine.

6. Authorized maintenance personnel release the brakes. Only pump sufficient pressure to

release the brakes (approximately 1500 psi). Excess pressure will damage the brake seals.

7. Remove the wheel blocks using extreme caution. Always be aware of hazards.

8. Place the towing machine into first (1st) gear and direction of travel.

9. Guide personnel assist in travel navigation.

1. SAFETY CHAIN MUST BE FITTED.

2. BLOCK BOTH SIDES OF ALL FOUR WHEELS BEFORE LINKING BOTH MACHINES.

1

2



S13005/04/02 13-1

Maintenance and Check Points

IntroductionThis section contains a checklist of items to be checked and/or serviced before the machine is put

to work. For more information regarding these procedures, or for maintenance other than required

on a daily basis, refer to the Service Manual.

NOTE: The correct type and quantities of various lubricants used in the different systems on this

machine are specified in the Service Manual.

WARNING!!

Report all damage and faulty operations immediately. Do not operate a faulty machine.

Ensure the frame lock is fitted before working in the central articulation area. Never service

or adjust the machine while it is motion. Do not work around the loader end of the machine

with the lift arms and bucket raised, unless the lift arms are properly supported.

Engine Off

NOTE: Inspect the following points before starting the engine/motor.

General Inspection

1. Walk around the entire machine to make sure it is in good condition.

2. Report any damage or faults immediately.

Operator’s Compartment

1. Make sure the operator’s compartment is clean.

2. Remove all debris which could interfere with the correct operation of the pedals.

Batteries

1. Check the condition of the battery cable, terminals, and connections.

2. Check that the batteries are clean and secure.

WARNING!!

Batteries emit toxic hydrogen gas when charging. Do not smoke and keep area well

ventilated when inspecting the batteries.




S13005/04/02 13-2

Fire Extinguisher (If Fitted)

1. Verify that pressure is in the safe zone.

2. Check condition of trigger handle and hose. Ensure that the fire extinguisher is securely

mounted, but easily removable.

.

Figure 1: Fire Extinguisher

Fire Suppression System (If Fitted)

1. Check that the dry chemical tank and gas expellant tanks are installed, hoses and fittings are

in good condition, and that both actuators are fitted with safety lockout rings.

NOTE: One actuator is located in the operator’s compartment; the other is located on the rear

frame.

Figure 2 : Fire Suppression System

Bucket Cutting Lip and Dump Stops

1. Check the condition of the bucket cutting lip (1), corners and sidesheet welds for cracks.

Check condition of dump stops (2) and lift arm stops (3).

CAUTION: Poor lip condition can greatly reduce loading efficiency.




S13005/04/02 13-3

Figure 3 : Bucket Cutting Lip and Dump Stops

Fuel Tank

1. Check fuel level in the tank and refill it if necessary.2. Check for cracks and leaks.

NOTE: Do not allow the machine to run out of fuel. Fill up the machine as often as possible to

prevent condensation inside the tank(s). If the machine is equipped with two fuel tanks, the

fuel level in both tanks should be the same. If the fuel level in both tanks is not the same,

the crossover pipe is probably blocked. Report this to your supervisor.

WARNING!!

Avoid overfilling the fuel tank. Use extreme caution when filling the fuel tank and avoid

splashing fuel on the exhaust manifold. Fire Hazard.

Dry Type Air Cleaner(s)

WARNING!!

Do not attempt to service the air cleaner(s) while the engine is running.

CAUTION: It is vitally important that the air cleaner(s) be properly maintained at all times. A

defective air cleaner can dramatically reduce the life on the engine.

1. Check all joints for loose, missing, or damaged clamps. Check rubber connectors forfraying and cracks.

2. Empty and clean the pre-cleaner (if equipped).

3. Check the service indicator. When the red flag appears in the window, the primary element

is dirty and must be cleaned or replaced.

4. Empty and clean the dust cup if the air cleaner is not equipped with a vacuator valve.

2

3




S13005/04/02 13-4

Exhaust System

1. Check the condition of the exhaust pipes, manifolds, joints and purifiers. The exhaust must

be in good condition at all times.

WARNING!!

Do not operate a machine with a defective exhaust system.




S13005/04/02 13-5

(DDEC) Engine Oil

1. New engines usually have a slightly higher oil consumption during the first 200 hours of

operation. Check the engine oil level twice per day; once per day is sufficient after this

period. Always check the oil while the machine is parked on level ground.

2. To allow the oil level to be accurately checked at low idle as well as stopped, the oil dipstick

is provided with marks on both sides.

3. When the engine is at low idle, the dipstick should be coated with oil between the FULL (F)

and LOW (L) marks on the “running” side of the dipstick.

4. When the engine is stopped, the dipstick should be coated with oil up to the FULL (F) mark

on the “stopped” side of the dipstick.

5. Add oil as necessary to maintain oil level.

CAUTION: Do not operate the machine unless the oil level is correct. Severe engine damage could

result.

Figure 4 : DDEC Engine




S13005/04/02 13-6

Engine Coolant Level

1. Remove the cap slowly when it is cool.

2. Add coolant slowly (to prevent air pockets from forming) to a level within 1/2 inch (1 cm)

of the bottom of the fill pipe.

3. Start the engine with the expansion tank cap off and add coolant when the level stabilizes.Allow for the expansion of coolant as it heats up.

4. Stop the engine and re-install the cap. Check the condition of the cap seal. If it is damaged,

replace it.

CAUTION: Never add coolant to an overheated engine. Allow the engine to cool first.

Wheels, Tires, and Wheel Nuts

1. Check the condition and pressure of all four tires. The tire pressure for all four tires must be

80 psi (552 kPa).

WARNING!!

Operators and service personnel must be alerted to the risk involved when working on

multi-piece rim wheels. Refer to Occupational Safety and Health Administration (OSHA)

Regulation 29 CFR Part 1910.177.

NOTE: OSHA is affiliated with the U.S. government.

2. Check wheel nuts for proper torque setting. On a new machine or a machine that has had a

wheel replaced, check the wheel nuts every 10 hours for the first 50 hours of operation, and

thereafter every 50 hours. The setting for all wheel nuts is 400 pounds feet (542 Nm).

Greasing 1. Apply grease to points described in “Section 14: Greasing the Machine”.

Frame Lock

1. Make sure that the frame lock is NOT installed in the center hinge area.

Engine On

NOTE: Inspect the following items after inspecting the engine/motor.

Operator’s Compartment

1. Operate levers and pedals to make sure they are working properly.2. Make sure gauge needles rise to normal levels.

3. Make sure warning lights go out.

Hourmeter

1. Make sure hourmeter is working. If the hourmeter stops working, inform supervisor or

mechanic.




S13005/04/02 13-7

2. Make sure that the preventive maintenance schedule is performed according to the

Preventive Maintenance Schedule in the Service Manual.

Figure 5 : Hourmeter

Lights

1. Check for damage to wiring and mountings.

2. Switch all lights on and verify that they are working.

Figure 6 : Lights




S13005/04/02 13-8

Hydraulic Oil Level

1. Run the engine at half throttle until hydraulic oil reaches normal working temperature.

2. Make sure the main implement is fully lowered.

3. The level must be at the top of the lower sight glass.

WARNING!!

Open the filler cap slowly to release pressure in the tank.

CAUTION: Make sure that the strainer is installed in the filler neck before adding clean oil to the

tank.

Figure 7 : Hydraulic Tank

Transmission Oil Level

1. Run the engine at half throttle until the transmission reaches normal operating temperature.

2. With the engine running at low idle, remove the dipstick and wipe it clean with a clean shop

cloth.

3. Insert the dipstick into the tube fully. Remove it again and read the level.

4. Add oil as necessary to bring the oil level to the full mark on the dipstick.

Hydraulics and Steering 1. With the engine running at half speed, raise the lift arms, roll back the bucket and lower the

lift arms. This ensure that the bucket controls are working correctly.

2. Sound the horn and articulate the machine from left to right.

3. Have an assistant look for oil leaks from the steer, hoist and dump cylinders while they are

being operated.

CHECK LEVEL

DIRTY FILTER INDICATORFILL




S13005/04/02 13-9

Figure 8 : Bucket Hydraulics

Brakes

1. Test all brakes according to procedures in Section 7: Brake Tests.




S13005/04/02 13-10

Notes



S14005/09/00 14-1

Greasing the Machine

Automatic Greasing System




S14005/09/00 14-2

WARNING!!

DO NOT WORK BETWEEN THE FRONT AND REAR FRAMES UNLESS THE

MACHINE IS SHUT DOWN, STEER PRESSURE HAS BLED OFF AND THE FRAME

LOCK IS INSTALLED.

CAUTION: CORRECT AND REGULAR GREASING IS ONE OF THE MOST IMPORTANT ASPECTS

OF SERVICING THIS AND ANY OTHER MACHINE WORKING IN THE MINING

ENVIRONMENT. POOR GREASING WILL LEAD TO PREMATURE FAILURE OF VITAL

BEARINGS, BUSHINGS AND PINS. THIS WILL RESULT IN POOR PERFORMANCE OF

THE MACHINE AND INCREASED MAINTENANCE COSTS.

NOTE: This machine is equipped with a twenty--one point automatic greasing system.

1. Check the grease pump for correct operation at least twice a shift.

2. The following locations are serviced by the automatic greasing system.

3. Grease all drivelines every 50 operating hours. Check hourmeter.

CAUTION: WHEN GREASING DRIVELINE JOINTS, USE A HAND GREASE PUMP TO PREVENT

DAMAGE TO THE SEALS.

QUANTITY DESCRIPTION

1 STEER CYLINDER BASE END

1 TOP HINGE PIN

1 STEER CYLINDER ROD END

1 BOTTOM END HINGE PIN

2 BOOM TO BUCKET LEFT SIDE

2 BOOM TO BUCKET RIGHT SIDE

1 HOIST CYLINDER TO BOOM RIGHT SIDE

1 HOIST CYLINDER TO BOOM LEFT SIDE

1 DUMP CYLINDER PIN AT BASE END

1 BEARING AT FRONT OF CRADLE WELDMENT

1 PILLOW BLOCK DRIVE TRAIN REAR FRAME

1 HOIST CYLINDER/FRAME RIGHT SIDE

1 HOIST CYLINDER/FRAME LEFT SIDE

2 BOOM PIVOT RIGHT SIDE

2 BOOM PIVOT LEFT SIDE

1 PILLOW BLOCK DRIVE TRAIN FRONT FRAME




S14005/09/00 14-3

4. Inspect all grease nipples for damage. Inspect all grease hoses for damage, leaking

andfraying. Ensure that grease is actually reaching the bearings and bushings. Have an

assistant look for grease coming out between bearings and bushings while grease is being

applied.




S14005/09/00 14-4

Notes



S15005/01/01 15-1

Troubleshooting

ImportantThe following tables identify common machine problems and their suggested remedies. If the

operator cannot correct the problem, inform supervisor as soon as possible. Most of the following

problems can be avoided by following operating procedures correctly and carrying out scheduled

maintenance on time.

WARNING!!

Do not operate the machine until any malfunction or problem has been corrected.

NOTE: The following tables are only guides to the simple remedies within the scope of an

operator. Any doubt as to the fault must be referred to maintenance personnel.

Engine Will Not Crank Over

Cause Remedy

Master disconnect switch off Turn master disconnect switch on.

Ignition switch in off position Turn to start position.

Loose or dirty battery terminals Clean and/or tighten terminals.

Weak or dead battery Recharge or replace battery.

Transmission directional control lever not in neutral

position.

Shift to neutral.

Any other problem Report to maintenance.



Troubleshooting

S15005/01/01 15-2

Engine Will Crank Over But Not Start

Engine Stalls During Operation

Excessive Exhaust Smoke

Cause Remedy

Fuel tank empty Fill fuel tank and vent fuel system.

Air in fuel system Air vent the fuel system.

Severe cold conditions Longer pre-heat.

Fuel tap closed Open fuel tap.

Loose fuel lines Tighten fuel lines and vent fuel system.

Water in fuel Drain, clean, and refill fuel tank.


Cause Remedy

Fuel tank empty Refill and vent fuel system.

Loose fuel lines Tighten and air vent the fuel system.

Air in the fuel system Air vent the fuel system.

Sudden air intake restriction Remove cause of restriction.

Water in the fuel Drain, clean, and refill fuel tanks.


Cause Remedy

Hot working conditions No remedy on machine.

Machine overloaded Reduce load.

Excessive idling time Switch off when not working or vary engine speed.

Engine oil level excessively high Drain to correct level.

Contaminated fuel Drain, clean, and refill fuel tank.

Air intake restriction Remove source of restriction.



Troubleshooting

S15005/01/01 15-3

Engine Misfiring

Engine Knocking

CAUTION: Shut down engine immediately!

Engine Oil Pressure Low

Engine Overheats

Cause Remedy

Excessive idling time Switch engine off when not working or vary enginespeed.

Air in fuel system Air vent the fuel system.

Water in fuel or contamination Drain, clean, and refill fuel tank.

Cause Remedy

Insufficient oil Refill to correct level. Report to maintenance.

Cause Remedy

Incorrect type/amount of oil Check type/level.

Severe engine oil leaks Check engine oil level while engine is running.


Cause Remedy


Clogged radiator core Clean radiator.

Incorrect type/amount of oil Check type/top up.

Restricted air intake Remove restriction.

Broken belts Replace belts.

Dirty cooler fins Clean cooler fins.

Operating in wrong gear Shift to correct gear.



Troubleshooting

S15005/01/01 15-4

Hydraulic Oil Foams

Torque Converter/Transmission Overheats

Machine Will Not Move

Loss of Power

NOTE: See Engine Misfiring, Torque Converter/Transmission Overheating.

Cause Remedy

Incorrect type of hydraulic oil Check for correct type and amount of fluid. See“Fluid and Lubricant Specifications” in the Service

Manual.

Cause Remedy


Transmission oil level low Check oil level and top up.

Low oil pressure Report to maintenance.

Incorrect type Check type, drain, and refill.

Severe oil leaks Check oil level with engine running.

Clogged cooler core. Clean cooler core.

Cause Remedy

Park or service brake applied Release brakes.

Low clutch oil pressure Report to maintenance.

Transmission in neutral Shift into gear.

Engine/motor stopped Start engine/motor.



Troubleshooting

S15005/01/01 15-5

Machine Will Not Turn

Little or No Dump Box/Bucket Action

Defective Lighting System

Cause Remedy

Frame lock installed Move frame lock to storage position.

Obstruction (i.e. rock) between frames Remove obstruction.


Cause Remedy


Bucket/dump box overloaded Reduce load.

Low hydraulic oil level Check and top up.

Severe leakages Report to maintenance.

Cause Remedy

Defective light bulb Replace bulb.Light assembly wiring loose or broken Tighten or replace ground wire.

Defective light control switch Report to maintenance.

Circuit breaker tripped Report to maintenance.



Troubleshooting

S15005/01/01 15-6

Air Venting the Fuel System

The DDEC engine fuel system is designed to be constantly circulating. This allows air and

contaminants to be purged from the system. If the fuel tank is allowed to run dry, use the

following procedure to restart the engine.To remove all the air from the fuel circuit, do the following:

NOTE: Never use the starting motor and fuel pump to prime the fuel filter and strainer. Prolonged

use of the starting motor and fuel pump to prime the fuel system can result in damage to

the starting motor, fuel pump, and injectors. It can also cause the engine to run erratically

due to the amount of air in the lines and filters.

1. Fill the fuel tank with the recommended grade of fuel. If only partial filling is available, add

a minimum of 10 gallons (38 liters) of clean fuel to the tank.

2. Remove the fuel filter from its cover, fill it with fuel, and reinstall it.

3. Start the engine. Check fuel filter and strainer for leaks.

4. If the engine fails to start after replacement of the fuel strainer and/or filter, the fuel system

will require priming. See Detroit Diesel manuals.



OPT-009/05/03 14-1

Option: Radio Remote Control

IntroductionUse Radio Remote Control (RRC) to operate the machine from a distance when it is too

dangerous for an operator to control the machine directly.

WARNING!!

Observe all warnings and instructions for operating the machine using Radio Remote

Control. See documentation provided by the vendor of the Radio Remote Control System.

Failure to comply may result in personal injury or even death.

Instrument Panel - Radio Remote Control

NOTE: Refer to the Instruments section for a description of RRC control locations on the

instrument panel.

A. Manual/Radio Switch

Turn the switch to the “MANUAL” position to control the machine from the operator's

compartment.

Turn the switch to the “RADIO” position to operate the machine using radio remote control.

B. Transmitter On Light

This green light indicates that the radio is transmitting.

C. Receiver On Light

This red light indicates that the machine is switched to radio remote control mode.




OPT-009/05/03 14-2

Manual Control to Radio Remote Control

The following procedure describes how to change from manual control to radio remote control.

NOTE: Mine procedures regarding RRC should be followed. This procedure is not intended to

replace mine procedures regarding RRC.

1. The operator is controlling the machine from the operator’s compartment.

2. The transmitter and the radio remote controller should also be in the operator’s

compartment.

3. Stop the machine in a safe area. The machine should be in a straight line on level ground.

4. Press in the Park/Emergency Brake Light/Button. The Park/Emergency Brake Light/Button

should be illuminated.

5. Put the transmission in neutral (N).

6. Lower the bucket until it is resting on the ground.

7. Turn the Manual/Radio Switch on the instrument panel to the “RADIO” position. 8. Pull the Park/Emergency Brake Light/Button out to the first position.

NOTE: Do not release the brakes. The red Park/Emergency Brake Light/Button should remain

illuminated.

WARNING!!

Do not leave the machine unattended with the brakes released.

9. Observe the instrument panel. The red Receiver On Light should be illuminated.

WARNING!!

If the light is not illuminated, do not attempt to operate the machine using Radio Remote

Control. Corrective action must be taken.

10. Exit the operator’s compartment. Remove the transmitter and the radio remote controller

from the operator’s compartment.

11. Move to a safe area.

12. Turn on the transmitter.

NOTE: The engine will shut down automatically if the transmitter is not turned on within 30

seconds. (Some Radio Receivers may be programmed for an additional delay. See radio

manufacturers’ documentation for details.)

NOTE: The Transmitter On Light should be illuminated while the transmitter is on. The

Transmitter On Light may or not be visible from the safe area.

13. Use the radio remote controller to control the machine.




OPT-009/05/03 14-3

Radio Remote Control to Manual Control

The following procedure describes how to change from radio remote control to manual control.

NOTE: Mine procedures regarding RRC should be followed. This procedure is not intended to

replace mine procedures regarding RRC.

1. The operator is using the radio remote controller to control the machine.

2. Stop the machine in a safe area. The machine should be in a straight line, on level ground.


4. Lower the bucket until it is resting on the ground.

5. Turn off the transmitter.

NOTE: The engine will shut down automatically if the Manual/Radio Switch is not turned to the

“MANUAL” position within 30 seconds. (Some Radio Receivers may be programmed for

an additional delay. See radio manufacturers’ documentation for details.)

6. Enter the operator’s compartment and sit down in the operator’s seat. Adjust the seat, and

fasten the seat belt, if fitted.

7. Turn the Manual/Radio Switch on the instrument panel to the “MANUAL” position.

8. Observe the instrument panel. The green Transmitter On Light and the red Receiver On

Light should be out.

WARNING!!

If the lights remain illuminated, do not operate the machine. Corrective action must be

taken.

9. Use the controls in the operator’s compartment to operate the machine.




OPT-009/05/03 14-4

Notes



Documents

Operators Manual EJC 245 SANDVIK