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Service

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100% found this document useful (1 vote)

997 views1,146 pages

Service

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Emanuel Nicolas Villarruel

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Original instructions

BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual

Deutz BF4M2012C
LH204
Service and Repair Manual LH204

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.

This page is intentionally left blank

Table of Contents

1 Introduction ................................................................... 15
1.1 The purpose of these instructions ......................................................16
1.2 Identification of the product ................................................................ 17
1.2.1 Product type and serial number .................................................. 17
1.2.2 Product manufacturer ..................................................................17
1.2.3 Manuals .......................................................................................18
1.2.4 Location of manuals on the product ............................................ 18
1.2.5 How to identify the correct manual for the product ......................18
1.2.6 Validity of the manuals ................................................................ 18
1.3 Copyright notice ................................................................................... 19
1.4 Definitions ............................................................................................. 19
1.5 Terminology and abbreviations ...........................................................20

2 Safety and environmental instructions .......................21

2.1 Safety labels, safety messages and signals ...................................... 22
2.1.1 Signal words ................................................................................22
2.1.2 General hazard symbol ............................................................... 22
2.1.3 Mandatory action symbols ...........................................................23
2.1.4 Prohibited action symbols ........................................................... 24
2.1.5 Hazard symbols ...........................................................................25
2.1.6 Labels on the product ..................................................................27
2.1.7 Visual and audible signals ...........................................................35
2.2 User obligations ....................................................................................35
2.2.1 Managing work related hazards .................................................. 36
2.2.2 Scheduled safety inspections and preventive maintenance ........37
2.2.3 Personal Protective Equipment ................................................... 37
2.3 Product limitations ............................................................................... 38
2.3.1 Intended use ................................................................................38
2.3.2 Prohibited use ............................................................................. 39
2.3.3 Center of gravity .......................................................................... 40
2.3.4 Maximum inclination angles ........................................................ 41
2.3.5 Operator visibility .........................................................................43
2.3.6 Modifications ............................................................................... 44
2.4 Hazard zone ...........................................................................................45
2.5 Safeguarding .........................................................................................45
2.5.1 Guards .........................................................................................45
2.5.2 Protective devices ....................................................................... 50
2.6 Complementary protective measures .................................................59
2.6.1 Use of Emergency stop function ................................................. 59

2.6.2 Emergency exit ............................................................................59

2.6.3 Safe access to machine and three-point support ........................ 60
2.6.4 Isolation and energy dissipation .................................................. 61
2.6.5 Location of the main switch ......................................................... 62
2.6.6 Remote control ............................................................................ 63
2.7 Fire risk control measures ...................................................................64
2.7.1 In case of fire ...............................................................................65
2.7.2 Fire prevention ............................................................................ 66
2.7.3 Fire retardant and flammable materials .......................................66
2.7.4 Fire extinguisher(s) ......................................................................66
2.7.5 ANSUL Fire suppression system (optional) ................................ 68
2.7.6 After a fire ....................................................................................71
2.8 Protection against emission hazards ................................................. 72
2.8.1 Noise ........................................................................................... 72
2.8.2 Vibration ...................................................................................... 72
2.8.3 Dust ............................................................................................. 73
2.9 Emergency procedures ........................................................................73
2.10 Safety considerations for maintenance ..............................................75
2.10.1 Daily inspections and tasks for operators ....................................76
2.10.2 Tasks which require definite technical skills and maintenance
training .........................................................................................77
2.10.3 Supporting the machine for repair procedures ............................ 78
2.10.4 Tire maintenance .........................................................................79
2.11 Environment ..........................................................................................82
2.11.1 Decommissioning ........................................................................ 82
2.11.2 Dismantling ..................................................................................83
2.11.3 Disposal .......................................................................................85
2.12 Potential product related hazards identified by the user ..................86
2.13 Incident reporting ................................................................................. 87

3 General Repair Instructions ......................................... 89

3.1 Hydraulics maintenance ...................................................................... 90
3.2 Pressure accumulators ........................................................................ 91
3.3 Electric system maintenance .............................................................. 92
3.4 Battery maintenance ............................................................................ 93
3.5 Welding ..................................................................................................96
3.6 Lifting methods and lifting points .......................................................96
3.7 Lifting the boom using a hoist ............................................................ 99
3.8 Lowering the boom using a hoist ....................................................... 99

4 Frame Structures .......................................................... 101

4.1 Section safety messages ..................................................................... 102

4.2 Main components ................................................................................. 105

4.3 Middle hinge joint ................................................................................. 106
4.3.1 Design features of upper hinge ................................................... 106
4.3.2 Design features of lower hinge ....................................................108
4.3.3 Disassembly of middle hinge joint ............................................... 109
4.3.4 Assembly of middle hinge joint ....................................................113
4.4 Oscillating axle ..................................................................................... 115
4.4.1 Disassembly of the oscillating axle ..............................................117
4.4.2 Assembly of oscillating axle ........................................................ 119
4.5 Pins ........................................................................................................ 121
4.5.1 Design features of the pins ..........................................................121
4.5.2 Pin removal prepatory steps ........................................................122
4.5.3 Pin removal with a puller ............................................................. 123
4.5.4 Pin removal without special tools ................................................ 124
4.5.5 Pin installation ............................................................................. 125
4.6 Lift arm ...................................................................................................125
4.6.1 Design features of the lift arm ..................................................... 125
4.6.2 Bushing replacement ...................................................................126
4.6.3 Bucket stopper adjustment ..........................................................127
4.6.4 Removing the bucket ...................................................................128
4.6.5 Installing the bucket .....................................................................131
4.7 Welding ..................................................................................................133
4.7.1 Precautions before welding ......................................................... 134
4.7.2 Basic quality requirements .......................................................... 134
4.7.3 Frame welding .............................................................................135
4.7.4 Bucket welding ............................................................................ 135
4.7.5 Edge preparation .........................................................................136
4.7.6 Working temperature and pre-heating .........................................137
4.7.7 Heat-input - number of welding passes .......................................138
4.7.8 Welding to other steels ................................................................139
4.7.9 Gas cutting .................................................................................. 142

5 Lubrication System .......................................................145

5.1 Manual central lubrication ................................................................... 146
5.2 Automatic central lubrication .............................................................. 148
5.2.1 Automatic central lubrication control ........................................... 151
5.2.2 Lubrication lines and targets ....................................................... 157
5.2.3 Functional description of the components ...................................159
5.2.4 Filling the central lube reservoir .................................................. 162
5.2.5 Bleeding the pump ...................................................................... 163
5.2.6 Main piping .................................................................................. 164
5.2.7 Doser adjustments ...................................................................... 165

5.2.8 General troubleshooting .............................................................. 167

6 Fire Suppression System ............................................. 169

6.1 Ansul ......................................................................................................170
6.1.1 Main components ........................................................................ 170
6.1.2 System description ...................................................................... 171
6.1.3 Ansul system operation ............................................................... 172
6.1.4 Ansul Checkfire system (optional) ...............................................173
6.1.5 System Specifications ................................................................. 175
6.1.6 Location of nozzles and actuators ...............................................176
6.2 Fire suppression system control ........................................................ 177
6.2.1 System notifications and troubleshooting (Fire suppression
system control) ............................................................................ 177

7 Cabin .............................................................................. 179

7.1 Main components (Machines with canopy) ........................................180
7.2 Functional description of components .............................................. 182
7.2.1 Seat controls ............................................................................... 182
7.2.2 Steering joystick .......................................................................... 183
7.2.3 Boom and bucket joystick ............................................................183
7.2.4 Door switch ..................................................................................184
7.2.5 Speed pedal ................................................................................ 189
7.2.6 Brake pedal valve ........................................................................190
7.2.7 Vehicle Control and Management system user interface ............ 190
7.3 Removing the operator's compartment ..............................................207
7.4 Installing the operator's compartment ............................................... 209
7.5 Removing the seat ................................................................................211
7.6 Installing the seat ................................................................................. 211
7.7 Parking, braking and blinker lights control ........................................212
7.7.1 System notifications and troubleshooting (Parking, braking and
blinker lights control) ................................................................... 216
7.8 Driving lights control ............................................................................219
7.9 Sound and reversing signal .................................................................219
7.9.1 System notifications and troubleshooting (Sound and reversing
signal) ..........................................................................................223

8 Powerpack ..................................................................... 225

8.1 Engine ....................................................................................................226
8.1.1 Technical data ............................................................................. 226
8.1.2 Engine control ............................................................................. 228
8.1.3 Starting the engine ...................................................................... 239
8.1.4 Turning off the engine ..................................................................240
8.1.5 Jump-starting ...............................................................................240

8.1.6 Restarting an out of fuel engine .................................................. 241

8.1.7 Changing engine oil and filter ......................................................242
8.1.8 Engine mounts inspection ........................................................... 245
8.1.9 Changing the engine drive belt ....................................................247
8.1.10 Removing the engine .................................................................. 249
8.1.11 Installing the engine .................................................................... 256
8.2 Pump drive unit .....................................................................................263
8.2.1 Changing pump drive unit lubricant .............................................264
8.2.2 Removing the pump drive unit .....................................................265
8.2.3 Installing the pump drive unit .......................................................267
8.2.4 Steering, Boom and Bucket pump ...............................................270
8.2.5 Brake charging pump .................................................................. 277
8.2.6 Drive pump .................................................................................. 282
8.3 Fuel system ........................................................................................... 286
8.3.1 Fuel filters ....................................................................................287
8.3.2 Changing the fuel filter elements .................................................290
8.3.3 Fuel lines ..................................................................................... 294
8.3.4 Fuel level monitoring ................................................................... 295
8.4 Air filtering .............................................................................................299
8.4.1 Air filter ........................................................................................ 300
8.5 Exhaust system .................................................................................... 301
8.5.1 Exhaust piping .............................................................................302
8.5.2 Exhaust purifier ........................................................................... 303
8.5.3 Servicing the exhaust purifier ...................................................... 304
8.5.4 Removing the exhaust purifier .....................................................305
8.5.5 Installing the exhaust purifier .......................................................306
8.6 Cooling system ..................................................................................... 307
8.6.1 Cleaning the cooler cores ............................................................307
8.6.2 Removing the cooler ................................................................... 308
8.6.3 Installing the cooler ..................................................................... 316
8.6.4 Cooler tube and sealing removal .................................................324

9 Power Train ....................................................................327

9.1 System description ...............................................................................328
9.2 Transmission control ........................................................................... 329
9.2.1 System notifications and troubleshooting (Transmission control)
.................................................................................................... 334
9.3 Transmission hydraulics ......................................................................338
9.3.1 Transmission oil pressure monitoring ..........................................338
9.4 Drive motor ............................................................................................342
9.4.1 Removing the drive motor ........................................................... 344
9.4.2 Installing the drive motor ............................................................. 347

9.4.3 Checking the drive motor pressures ............................................349

9.5 Dropbox ................................................................................................. 350
9.5.1 Changing the dropbox oil ............................................................ 352
9.5.2 Removing the dropbox ................................................................ 353
9.5.3 Installing the dropbox .................................................................. 357
9.6 Cardan shafts ........................................................................................361
9.6.1 General maintenance and inspection ..........................................362
9.6.2 Removing a cardan shaft ............................................................ 363
9.6.3 Installing a cardan shaft .............................................................. 364
9.6.4 Tightening torques of power train flange bolts ............................ 365
9.7 Axles ...................................................................................................... 366
9.7.1 Changing the axle oil ...................................................................369
9.7.2 Measuring brake linings wear ......................................................371
9.7.3 Brake slack adjuster adjustment ................................................. 372
9.7.4 Removing the rear axle ............................................................... 373
9.7.5 Installing the rear axle ................................................................. 376
9.7.6 Removing the front axle .............................................................. 378
9.7.7 Installing the front axle ................................................................ 382
9.8 Wheels ................................................................................................... 384
9.8.1 Removal of the rear tires ............................................................. 386
9.8.2 Removal of the front tires ............................................................ 388
9.8.3 Installing the tires ........................................................................ 390
9.8.4 Rim .............................................................................................. 391
9.8.5 Structures and functions of the off-road tire components ............392
9.8.6 Tire mounting and dismounting on rim ........................................ 394

10 General Hydraulics ....................................................... 403

10.1 Hydraulic oil .......................................................................................... 404
10.2 Hydraulic diagram ................................................................................ 405
10.3 General hydraulic maintenance .......................................................... 406
10.3.1 General troubleshooting .............................................................. 408
10.3.2 Basic causes of hydraulic system failures ...................................409
10.3.3 Checking hydraulic system for leaks ........................................... 410
10.3.4 Low temperature starting .............................................................410
10.3.5 Prevent of cavitation formation ....................................................411
10.3.6 Oil filters ...................................................................................... 411
10.3.7 Servicing filters and strainers ...................................................... 411
10.3.8 Level of oil in tank ........................................................................412
10.3.9 Oil storage and handling ............................................................. 413
10.4 Hydraulic pressure test points ............................................................ 414
10.5 Hydraulic oil tank ..................................................................................416
10.5.1 Hydraulic oil level monitoring .......................................................418

10.5.2 Changing the hydraulic oil ........................................................... 422

10.5.3 Reasealing the hydraulic oil tank .................................................424
10.5.4 Repairing the tank ....................................................................... 426
10.6 Oil temperature monitoring ................................................................. 426
10.6.1 System notifications and troubleshooting (Oil temperature
monitoring) .................................................................................. 429
10.7 Filter monitoring ................................................................................... 431
10.7.1 System notifications and troubleshooting (Filter monitoring) .......435
10.8 Suction lines ......................................................................................... 436
10.8.1 Bleeding the suction lines ............................................................438
10.9 Pilot pressure control unit ................................................................... 439
10.10 Hoses and tubing ..................................................................................440
10.10.1 Marking of hydraulic hoses ..........................................................445
10.11 Hydraulic component symbols ........................................................... 447

11 Steering ..........................................................................453
11.1 Steering hydraulic diagram ................................................................. 454
11.2 Steering system description ................................................................455
11.3 Steering main valve .............................................................................. 456
11.3.1 Checking and adjusting the steering main relief valve ................ 457
11.3.2 Removing the steering main valve .............................................. 459
11.3.3 Installing the steering main valve ................................................ 461
11.4 Emergency steering (option) ............................................................... 462
11.4.1 Emergency steering control .........................................................463
11.5 Steering cylinder ...................................................................................469
11.5.1 Removing the steering cylinder hoses ........................................ 471
11.5.2 Removing the steering cylinder ................................................... 473
11.5.3 Steering cylinder disassembly .....................................................476
11.5.4 Steering cylinder reassembly and installation ............................. 477
11.5.5 Inspection and repair ...................................................................477
11.5.6 Installing the steering cylinder hoses .......................................... 478
11.5.7 Installing the steering cylinder ..................................................... 480
11.5.8 Steering cylinder bypass test ...................................................... 483

12 Boom / Bucket Hydraulics ............................................491

12.1 Boom and bucket hydraulic diagram ..................................................492
12.2 Boom and bucket system description ................................................493
12.2.1 Ejector bucket (option) control .....................................................494
12.2.2 Boom floating (option) ................................................................. 495
12.3 Bucket main valve ................................................................................ 496
12.3.1 Removing the bucket main valve ................................................ 498
12.3.2 Installing the bucket main valve .................................................. 499

12.3.3 Checking and adjusting the bucket main relief valve .................. 500
12.4 Tilt cylinder ............................................................................................501
12.4.1 Tilt cylinder leakage test .............................................................. 502
12.4.2 Removing the tilt cylinder hoses ..................................................504
12.4.3 Removing the tilt cylinder ............................................................ 505
12.4.4 Tilt cylinder disassembly ..............................................................507
12.4.5 Inspection and repair ...................................................................508
12.4.6 Reassembly and installation ........................................................509
12.4.7 Installing the tilt cylinder hoses ....................................................510
12.4.8 Installing the tilt cylinder .............................................................. 511
12.5 Lift cylinders ......................................................................................... 512
12.5.1 Lift cylinder leakage test ..............................................................514
12.5.2 Removing the lift cylinder hoses ..................................................516
12.5.3 Removing the lift cylinders .......................................................... 517
12.5.4 Lift cylinder disassembly ............................................................. 519
12.5.5 Inspection and repair ...................................................................520
12.5.6 Reassembly and installation ........................................................521
12.5.7 Installing the lift cylinder hoses ....................................................522
12.5.8 Installing the lift cylinders ............................................................ 523

13 Brake System ................................................................ 525

13.1 Brake system hydraulic diagram ........................................................ 526
13.2 Brake system description .................................................................... 527
13.2.1 Park brake block ..........................................................................528
13.2.2 Brake pedal valve ........................................................................528
13.2.3 Pressure accumulators ................................................................528
13.2.4 Brakes control ............................................................................. 532
13.2.5 Brake pressure monitoring .......................................................... 555

14 General Electric System ............................................... 563

14.1 System description ...............................................................................564
14.1.1 Voltage monitoring .......................................................................564
14.2 Circuit breakers .................................................................................... 565
14.3 Batteries ................................................................................................ 568
14.3.1 Removing the batteries ............................................................... 570
14.3.2 Installing the batteries ................................................................. 571
14.4 Emergency stop control .......................................................................572
14.4.1 System notifications and troubleshooting (Emergency stop
control) ........................................................................................ 575
14.5 Remote drive control ............................................................................576
14.5.1 System notifications and troubleshooting (Remote drive control)
.................................................................................................... 579
14.6 Warning and alarm state ...................................................................... 580

14.6.1 System notifications and troubleshooting (Warning and alarm

state) ........................................................................................... 585
14.7 Control system start-up diagnostics .................................................. 586
14.8 Alarm log ............................................................................................... 589
14.8.1 System notifications and troubleshooting (Alarm log) ................. 591
14.9 Controling additional functions .......................................................... 592
14.10 Parameter control ................................................................................. 595
14.11 Password management ........................................................................596
14.11.1 System notifications and troubleshooting (Password
management) .............................................................................. 598
14.12 System implementation ....................................................................... 599
14.13 Changing the control modules ............................................................600
14.14 Modules program updating ................................................................. 604
14.15 CANbus status data ..............................................................................607
14.16 Output preconditions ........................................................................... 609
14.16.1 Introductions ................................................................................609
14.16.2 General conditions ...................................................................... 610
14.16.3 Machine functions ....................................................................... 610
14.16.4 Chair module outputs .................................................................. 611
14.16.5 Middle module outputs ................................................................ 613

15 VCM System Error Codes .............................................619

15.1 Chair module alarm index ....................................................................620
15.2 Display module alarm index ................................................................ 622
15.3 Middle module alarm index ..................................................................622

16 Technical Specification ................................................ 631

16.1 Technical data ....................................................................................... 632
16.2 Machine weights ................................................................................... 633
16.3 Main components weights ...................................................................633
16.4 Brake system ........................................................................................ 633
16.5 Engine ....................................................................................................634
16.6 Default pressure settings .....................................................................634

17 Appendices ....................................................................637
17.1 The tightening torques for screws and nuts ......................................639
17.2 SGH-50 Hydraulic pumping unit ..........................................................641
17.3 Function of lubrication system ........................................................... 653
17.4 Doser groups ........................................................................................ 659
17.5 ANSUL fire suppression system Installation, Recharge, Inspection
and Maintenance manual (option) .......................................................667
17.6 Donaldson air filter manual ................................................................. 783
17.7 Pump drive unit and Drop Box Operating Instructions .................... 791

17.8 Drive Pump Operating and Service Instructions ............................... 815

17.9 Drive Motor Operating Instructions .................................................... 931
17.10 Axle Service Manual ............................................................................. 983
17.11 Dana cardan shafts ...............................................................................1075
17.12 Tank breather filter ............................................................................... 1097
17.13 Emergency radio Tele Radio Panther Operating Instructions
(option) .................................................................................................. 1103
17.14 Emergency Radio Installation and User Instructions (optional) ...... 1121

1 Introduction

Copyright © Sandvik 15 (1146)

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Service and Repair Manual LH204

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.

16 (1146) Copyright © Sandvik

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Service and Repair Manual LH204

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 compartment next to
the bucket joystick.

1.2.2 Product manufacturer

Sandvik Mining and Construction (China) Co.,Ltd
No.1200, Xingrong Rd, Jiading district, Sanghai China
http://www.miningandconstruction.sandvik.com/

Copyright © Sandvik 17 (1146)

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

18 (1146) Copyright © Sandvik

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1.3 Copyright notice

This publication is copyright of Sandvik Mining and Construction Oy - ©
Sandvik Mining and Construction Oy. It must not be copied, reproduced, or
otherwise made available in full or in part to any third party without Sandvik
Mining and Construction Oy´s prior written consent.
All Rights Reserved.

1.4 Definitions
• Product: Machine, machinery, partly completed machinery, component
or tool, including related services
• User: The owner, operator or authorized and trained person involved in
the transportation, installation, operation, maintenance and disposal of
the product
• Information for use: The information in this manual, the safety labels
and signals on the product, and other related information used separately
or in combination to convey information to the user
• Harm: Physical injury or damage to health. This is always in relation to
people, not to equipment or property
• Hazard: Potential source of harm
• Risk: Combination of a probability of occurrence of harm and the severity
of that harm.
• Risk of property damage: Combination of a probability of occurrence of
property damage and the severity of that property damage
• Environmental risk: Combination of a probability of occurrence of
environmental damage and the severity of that environmental damage.
• Hazard zone: Any space within and/or around the product in which a
person is exposed to a hazard.
• Intended use of a product: Use of a product in accordance with the
information provided in the instructions for use.
• Prohibited use: Any use which is not intended use, especially use that is
specifically prohibited in the information for use or use which is plainly
dangerous.
• Safe working procedures: Practices and methods developed for users
by their employer for work to be performed. These detail how specific
risks in the workplace will be managed, taking into account information
for use supplied with the product as well as local acts, laws and
regulations.
• Safeguard: Guard or protective device.
• Guard: Physical barrier, designed as part of the product, to provide
protection.
• Protective device: Safeguard other than a guard, which reduces the risk
either alone or in conjunction with a guard; e.g., interlocking device, hold-
to-run control, limiting device.

Copyright © Sandvik 19 (1146)

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

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

1.5 Terminology and abbreviations

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

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2 Safety and environmental instructions

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2.1 Safety labels, safety messages and signals

This section includes explanations of safety symbols, signs, signals and
labels used on the product and in the information for use.

2.1.1 Signal words

The following signal words and symbols are used to identify safety
messages in these instructions:

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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Location of the safety and information labels

2 42 1 6 21 24 36 25 10 9 8 27 35

22 4

22 23

20 1
7
42
4
35
3

5 22 26 29 22 6 2

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Labels inside the cabin

27 11

13 12

41 29

33 30

34 31

40 32

14 20

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Safety and information labels

1 2 3

4 5 6

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7 8 9

10 11

12 13

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14 20

56026777 EU area (CE marking)

56026776 outside EU area

29 30 31

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32 35

33 34

1,2,3...

40 41

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Symbol labels

21 22 23

Jacking point
Centre of gravity
56037927 Engine oil filling
56004224
4 pieces

24 25 26

Transmission / hydraulic oil fill-

Hydraulic oil level Fuel filling
ing

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2.1.7 Visual and audible signals

The machine is equipped with the following visual and audible safety
signals:
• Reverse alarm: The reverse alarm switches on when the drive selector
is set to reverse position. The alarm sound is frequent beeping.
• Warning and function signals: The warning and function signals give
important information on the machine operating status, functions,
warnings and alarms. Warning and function signals inform the operator,
for example, of oil levels, brake pressures and engine functions.
• Horn: The horn releases a loud sound and can be used to warn others in
dangerous situations. The horn push button is located in the right hand
joystick.
• Beacon (optional): The beacon is located at the top of the safety cabin/
canopy. The beacon flashes a yellow light when ignition is in POWER ON
position or the machine running.
• Fire suppression system signals (with fire suppression system
option): Visual alarm will be seen when the fire suppression system is
activated.

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:

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• 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.
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:
• Provide training and orientation
• Validate training methods
• Verify competence and skills
• Monitor and evaluate user performance regularly

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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.
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.

A. 800 mm
B. 800 mm
C. 3500 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°

Angle loaded max 10°

Angle unloaded max 15°

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Angle loaded max 2°

Angle unloaded max 7°

2.3.5 Operator visibility

When operating the machine, always remember that visibility is limited.
Ensure that unauthorized persons are not present in the vicinity of the
machine.
The following visibility drawing has been prepared by means of computer
simulation based on the standard ISO 5006:2006 Earth-moving machinery -
Operator's field of view - Test method and performance criteria. The
drawings show the visibility from the operator compartment when the
machine is in tramming position.

Straight

Blind area Visible area

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

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Location of the guards

The diagram below indicates where the guards are located.

11 13 15 6 1 7 3

14 6 4 5 6 10 8 9 16

1. Safety cabin or canopy

2. Machine covers

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3. Bucket tilt cylinder cover

4. Automatic lubrication unit cover

5. Center articulation guard 5

6. Mudguards
7. Boom pin cover
7

8. Fuse box cover

9. Battery box cover 10
10. Hydraulic tank filler guard
11. Cooler cover 11

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12. Fan guards

13. Exhaust purifier/Muffler cover 15
14. Coolant expansion chamber cover (water-
cooled)
13

15. Alternator belt cover

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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(s)
• Fire Suppression System (optional)
• Wheel chocks
• Emergency stop buttons
• Pressure relief valves for pressure accumulators
• Main circuit breaker release button
• Preventative functions for machine movements
• Emergency steering (optional)
• Neutral brake
• Frame articulation locking device
• Boom support device
• Reverse alarm
• Flashing beacon (optional)
• Directional lights
• Locking main switch
• Locking pressure release cap with coolant expansion tank
• 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.

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Frame articulation locking device

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

The frame articulation locking device is located at the articulation area of

the machine.

The locking device is provided to prevent unplanned movement of the

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

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Installing the articulation locking device

1. Make sure the machine is in straight position. Remove the frame
articulation locking pin from its bracket on the frame.

2. Insert the pin into the hole on the frame.

3. Climb into the cabin and start the engine. Slowly move the steering a bit
from left to right, until the pin drops into place.
It's necessary to have a second person helping the operator by giving
signs of pin movement from safe distance, because observing the locking
pin from the cabin is difficult.
Note! To avoid damaging the machine, the locking pin must be carefully
observed during the installation. When the pin drops down, stop
turning the machine.

4. Shut down the engine, climb out from the cabin and make sure that the
pin is correctly in place.

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Removing the articulation locking device

1. Climb into the cabin. Start the engine and slowly move the steering a bit
to the left or to the right to release pressure against the pin.
2. Shut down the engine, climb out from the cabin and remove the pin.

3. Place the pin back to the bracket

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Boom support device

DANGER
CRUSHING HAZARD!
Unexpected movement of boom will cause death or severe injury.
Never enter under the boom under any circumstances.

The boom support pins are located on the front mud guards.

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

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Installing the boom support device

1. Make sure the bucket is empty.
2. Climb into the cabin, turn the machine on and raise the boom.
3. Shut down the unit and step out of the cabin.
4. Remove the locking devices from their holders.

5. Place the locking devices into their holes in the boom as seen in the
picture.
• NOTE! Make sure you do not walk under the boom in any
circumstances.
• NOTE! Always use both support devices when supporting the boom.

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6. Lower the boom slowly against the support devices.

• NOTE! Pressing the boom too strongly against the support devices
damages both the boom and the frame.

7. Turn the bucket to fully tilted position.

8. Shut down the unit.

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Removing the boom support device

1. Walk around the unit and make sure that no-one is working on the unit or
under the boom.
2. Sound the horn and have a look around. When it is safe, turn the
machine on.
3. Raise the boom and shut down the unit.
4. Remove the support devices.
• NOTE! Do not walk under the boom in any circumstances.

5. Climb back into the cabin, sound the horn again, turn the machine on,
lower the boom slowly against the stops and the bucket to the ground.
6. Place the boom support devices back to their holders.

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2.6 Complementary protective measures

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

Emergency stop buttons

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

2.6.2 Emergency exit

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

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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 you turn off the machine, 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 and pilot accumulators
as follows:
• Shut down the engine.
• Turn the ignition switch to the "1" position.
• Review the pressure values in the VCM display to verify that the brake
system has released pressure. Pressures should be 0 bar.
• To be sure that the pressure is released, connect a 400 bar pressure
gauge to the accumulator pressure measuring point with caution.

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.

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Follow the local regulations and guidelines set by your employer and the
authorities.
2.6.5 Location of the main switch

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

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Battery isolation switch

The battery isolation switch turns on/off the current from the battery to the
machine electric circuit.

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.

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2.7 Fire risk control measures

WARNING
FIRE AND EXPLOSION HAZARD!
An explosion hazard could exist in addition to the fire hazard.
Ignition sources like smoking, open flames, welding work and sparks
together with combustible materials like fuel, can cause fire and if
not avoided, could lead to death or severe injury.
Ignition sources are prohibited in the vicinity of the machine ready
for operation or in operation.
During maintenance appropriate fire prevention and protection
measures must be followed including but not limited to trained
personnel, proper fire extinguishing equipment and agents. Before
any maintenance or repairs requiring ignition sources like welding or
flame cutting, a proper risk assessment must be carried out prior to
the start of the work to control the risk.

Smoking and open fire are prohibited in the vicinity of the product. Access
to all fire-fighting equipment must be granted at all times, especially during
maintenance and repair works.
All fire-fighting equipment must be inspected and serviced regularly,
according to local regulations. Damaged fire-fighting equipment and used
fire extinguishers must be replaced immediately.
Know the various types of fires and the appropriate fire-fighting methods.
Be aware that various fires must not be extinguished with water. In most
cases special extinguishing agents, dry powders or deoxygenating are
required.
All personnel must be trained regularly in fire-fighting methods, in
cooperation with local authorities and rescue organizations. In case of fire,
the fire alarm must be activated and all available personnel must contribute
in the fire-fighting according to the predetermined fire plan of the workplace.

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2.7.1 In case of fire

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

4. Activate the fire suppression system (if fitted).

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

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2.7.2 Fire prevention

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

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Location of the fire extinguisher

The hand-held fire extinguisher is located on the right rear mudguard.

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 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.
The locations of the fire suppression nozzles and manual actuators are
represented in the figure(s) below.

2
9

1. Rear left 6. Exhaust

2. Pump drive 7. Rear frame actuator
3. Dropbox 8. ANSUL tank assembly
4. Fuel lines 9.. Operator compartment
actuator
5. Intake/Turbo 10. Checkfire unit (option)

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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.

2.7.6 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 sound pressure level and volume measurements in the operator
station have been performed according to the ISO 4871.

Measured A-weighted emission sound pressure (At high idle 2410

level at operator's position rpm)
LpA [dB re 20 μPa] 94 dB
Uncertainty, KpA [dB] 3 dB
(At high idle 2410
Measured A-weighted sound power level
rpm)
LWA [dB re 1 p W] 114 dB
Uncertainty, KWA [dB (A)] 3 dB

The values were determined applying test codes given in ISO 6393 and
ISO 6394
Note! The sum measured noise emission value and its associated
uncertainty represents an upper boundary of range of values which
is likely to occur in measurements.

2.8.2 Vibration

WARNING
VIBRATION HAZARD!
Exposure to vibration could cause severe health effects.
Follow the maintenance schedule and keep the machine on good
operating condition. Participate in the health surveillance and
training programs offered by your employer.

Measured vibration level

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

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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.

2.9 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".

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• 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 Supporting the machine for repair procedures

1. Ensure that the machine is on an even surface and movement in the
driving direction is prevented by, for example, wheel chocks.
Install the frame locking pin before lifting machine and removing the
tire.

2. Install the frame articulation locking device.

• See chapter “Frame articulation device”.
3. Raise the front of the machine until the front tires are just off the ground
by using machine hydraulics hoist or jack.
• Note! This can be done also with bucket using machine hydraulics.
Ensure that the stands used for support have sufficient loadbearing
capacity.

4. Place the stand under the front of the machine.

• Lower the weight of the machine on to the stand.
5. Ensure that the bucket is lowered and the boom is resting on stops.
• If required, raise the boom and install the boom support devices.
• See chapter “Boom support device”.
6. Raise the rear of the machine until the rear tires are just off the ground by
using hoist or jack.
Ensure that the stands used for support have sufficient loadbearing
capacity.

7. Place stands under the rear of the machine.

• Lower the weight of the machine on to the stands.

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2.10.4 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 General Repair Instructions

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3.1 Hydraulics maintenance

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.

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.

Maintenance, repair, and installation of hydraulic equipment must

only be carried out by experienced hydraulics experts.

• Do not attempt any such repairs that you do not fully understand.
• Never do any repair work on the hydraulic circuit if the system is
pressurized.
• Always shut down the machine before tightening or repairing a leaking
hose connection.
• Do not try to locate a leak from a hose or a connection by feeling with
your hand. The high-pressure oil spray from the leak can penetrate the
skin and cause a serious injury. A high-pressure oil spray can also start a
fire.
• Avoid direct skin contact with oil. Prevent oil from getting into your eyes;
use eye protection.
• Do not work under a device or component that is held up only by the
hydraulics. Use separate supports in conjunction with maintenance and
repair.
• Do not remove cylinders or their valves unless the components held by
them are properly supported and system non-pressurised.
• Pipe connections, hose lengths, and hose types must correspond with
the specifications. When replacing or repairing hoses, use original
Sandvik Mining and Construction spare parts or hoses and fittings
recommended by the manufacturer. Ensure that the pressure ratings of
the hoses and connecting fittings correspond with the working pressures.
• Any alterations require a written authorization from the
manufacturer.

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Pressure tests
General
• Make sure that the hydraulic oil is at operating temperature!
• Connect and disconnect the pressure gauge(s) only when the circuit is
non pressurized. For more information refer to Service and repair
manual.
• Use only special couplings for pressure testing
• Do not overtighten couplings. When special couplings are used, finger
tight is adequate. Overtightening causes harmful leakage.
• Use hose(s) long enough to read the gauge(s) while sitting in the cabin.
• Attach all measuring point protection caps after the checking procedure.
For more information refer to the Service and Repair manual.

3.2 Pressure accumulators

Only perform maintenance work when the machine is parked on a

WARNING
EXPLOSION HAZARD!
Explosion of an accumulator could cause death or severe injury.
Under no circumstances may any machining, welding or soldering
work be done on the accumulator shell.
Work on systems incorporating accumulators (repairs, connection of
pressure gauges, etc.) may be carried out only after the fluid
pressure has been released.

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WARNING
EXPLOSION HAZARD!
Use of oxygen or air in pre-charging the accumulators could cause
an explosion which could cause death or severe injury.
Only use Oxygen Free Nitrogen (N2) in pre-charging the
accumulators.
It is recommended that a regulating valve is fitted in the gas line
when charging accumulators with rating of less than gas supply
pressure.

New or reconditioned accumulators are delivered with a nitrogen charge of

10 bar (145 psi) to prevent damage during transit. Before being put into
operation they must be charged with nitrogen to the pre-charge pressure
p0. See correct pre-charge pressure form machine hydraulic schematic.
Under no circumstances should oxygen or air be used.
Having connected the hydraulic line, it should be bled of all air by means of
bleeder screw on the accumulator. Use only original spare parts to replace
damaged gas valve elements.

3.3 Electric system maintenance

• Work on electric equipment or materials is only to be carried out by
qualified electricians or other professionals, or assistants under their
supervision and control, observing electrotechnical regulations.
• The local electrotechnical and electric safety regulations must always be
observed.
• Use only original electric components.
• If disturbances in electric supply occur, stop the vehicle at once.
• Voltage must be cut off from the parts of the equipment or device that are
to be checked, serviced, or repaired, if the regulations so require. Check
that the disconnected parts are dead, and then lock the main switch or
arrange a work earthing if necessary.
• Do not touch battery terminals, alternator terminals, or wiring cables
while the engine is operating. Severe electrical shock, which may lead to
personal injury, can result from improper shielding of electrical
components.
• Check the electric devices of the equipment regularly. Faults, such as
loose wires and damaged insulation, must be repaired at once.
• When handling high-voltage components, remember that capacitors may
have an electric charge, even if the voltage is cut off. Short the capacitors
with an earthing rod.
• Before making any changes to the electric devices, Sandvik Mining
and Construction’s electric engineering department must be
consulted and a written authorization received to ensure the
operation of the device does not change.

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Working on live components

DANGER
DANGEROUS ELECTRICAL VOLTAGE HAZARD!
High voltage electrical shock will cause death or severe injury.
Ensure use of personal protective equipment such as safety glasses,
high voltage gloves and arc flash shield and suit where necessary.
Observe special caution to the hazard of live work.
When handling high voltage components, always have at least one
person present who is trained in emergency response procedures.
Do not work alone.

• If the component been tested must be live, a fellow worker must be

standing by to cut off voltage with the emergency or main switch in an
emergency situation. Follow the electric safety regulations.
• Use a red-and-white safety chain and warning signs to encircle the
working area.
• Use only insulated tools and test equipment rated for the voltage and
application.
• Observe special caution.

3.4 Battery maintenance

Only perform maintenance work when the machine is parked on a

DANGER
DANGEROUS ELECTRICAL VOLTAGE HAZARD!
High-voltage electric shock will cause death or serious injury.
Before starting any work on the motor or other equipment,
particularly before opening covers over live or moving parts, ensure
the main switches of the machine and gate end panel (electric
loaders) are in OFF position.

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DANGER
EXPLOSION HAZARD
Batteries generate explosive gases. It only takes a small spark, flame
or a burning cigarette to set off a dangerous explosion which will
cause death or severe injury if a person is near the battery.
Keep all ignition sources well away from the batteries.

WARNING
CHEMICAL HAZARD!
The acid in the battery burns skin, eats holes in clothing, and can
cause blindness if it gets in the eyes.
Always wear eye protection, protective overalls, and protective
gloves when working with batteries.

Always wear eye protection, protective overalls, and protective gloves when
servicing batteries.
• Always disconnect the negative (-) pole first, and then the positive (+)
pole. Always reconnect the positive pole (+) first, and then the negative
(-) pole.
• Reversing battery polarity can result in personal injury caused by a
sudden discharge of electrolyte from the battery vents and/or the sudden
rupture of the battery case caused by an explosion of internal hydrogen
gas.
• To prevent sparking when connecting a battery charger, pull the charger
supply cord or switch the charger off before connecting the charging
wires to the battery terminals. Open the battery cell caps slightly during
charging to allow the generating gases to escape.

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• The acid in the battery burns skin, eats holes in clothing, and can cause
blindness if it gets in the eyes. If you get battery acid on your skin, flush
the spot at once with clean water. Flush the eyes with plenty of clean
water, and call a doctor.
• When servicing batteries, remember that lead-acid batteries generate
(during charging and discharging) oxygen and hydrogen which form a
highly explosive mixture. A spark or an open flame can cause an
explosion. If necessary, ventilate the battery compartment properly
before disconnecting or connecting the cables.
• To prevent explosion, the electrolyte level must be maintained and
checked regularly. Add distilled water, if required, before starting, never
immediately after use. With a high enough electrolyte level, the cells
have less space for gases.
• Use a flashlight when checking electrolyte levels, never an open flame.
• The battery terminals should never be shorted as sparks can cause the
battery to explode.
• Do not test electric devices by making contact with the battery terminal.
• Do not carry battery by terminals. Do not drop battery, puncture or
attempt to open battery case. Do not subject product to open flame or fire
and avoid situations that could cause arcing between terminals.
• Sealed lead acid battery electrolyte is a clear to cloudy liquid with slight
acidic odor. Acid saturated lead oxide is a dark reddish-brown to gray
solid with slight acidic odor.
• Lead and Lead Dioxide are not soluble. Battery Electrolyte (acid) is 100%
soluble in water.
• Protective Measures to be taken if material is released or spilled
• Remove combustible materials and all sources of ignition. Avoid contact
with acid materials. Use soda ash, baking soda or lime to neutralize any
acid that may be released.
• Store batteries at ambient temperature.
ENVIRONMENT POLLUTION HAZARD!
Unneutralized or lead-contaminated acid will cause severe
environmental damage.
Do not release unneutralized acid. Neutralize as above for a spill,
collect residue, and place in a drum or suitable container. Dispose of
as a hazardous waste.
Do not flush lead-contaminated acid into sewer or nature.
Always obey local laws and environmental regulations when
recycling or disposing a battery.

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3.5 Welding
Welding, drilling, cutting or any addition of attachments voids
certification.
To assure the safety of the operator, the ROPS/FOPS must not be
repaired by welding. ROPS/FOPS must always be overhauled if it has
been damaged or altered in any way.

Before starting to weld, determine the material to be welded, and the

welding method and fillers. Contact Sandvik Mining and
Construction’s Service, if necessary.

• Do not repair steering equipment by welding.

• Never repair ROPS/FOPS by welding.
• Welding must be left to qualified personnel.
• Before electric welding, the main switch must be disconnected. Also,
Remote Control equipment (optional) must be disconnected.
• If welding must be done close to any of the control modules, disconnect
the module wiring before welding.
• The ground cable of the welding machine must be connected as close to
the weld as possible. The ground cable must not be connected so that
the current can flow through a bearing, joint coupling, sealing surface,
lever, or control cable.
• When welding painted area, paint must be removed from the adequate
area to avoid the fumes from the paint.
• Use a protective mask and other personal protective devices when
welding.
• Arrange adequate ventilation.
• Arrange protection against fire.

3.6 Lifting methods and lifting points

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DANGER
LIFTING AND CRUSHING HAZARD!
Faulty lifting practice will cause death or severe injury.
The objects being lifted are heavy. Assistance may be required when
lifting the object.
Make sure that lifting equipment is in good condition and correctly
rated.
Always obey local rules and safety regulations.
Always make sure that the lifting device is properly fastened before
lifting.
Make sure there is no one in the hazard zone when attaching, testing
or detaching the lifting device. Never perform any kind of work or
pass underneath a hanging load.

1. Lower the safety rails (optional) and lock them in the down position.
2. Install the frame articulation locking device.
3. Rollback the bucket to transport position.
4. Shut down the engine and turn the main switch to OFF position.
5. The lifting points (four) are marked with hook symbols.
On some loader models the rear frame lifting lugs must be lifted up from
the frame before hooking.

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6. The lifting device used must be of the correct type and have sufficient
lifting capacity. The loader or parts of it must not be lifted with any
devices that are not specifically designed for lifting purposes.
• Check the correct weight of the loader from the type plate or the
technical specification sheet.
• Never exceed the lifting capacity specified by the manufacturer of the
lifting device.

7. Make sure that the lifting equipment is in proper condition.

8. Wire ropes and chains used for lifting must be checked regularly.
• Damaged wire ropes and chains must be marked clearly and
discarded at once.
9. Never wind the wire ropes or the chains around the hook of the hoist.

10. The wire ropes must be fastened according to the manufacturer’s

instructions.
11. The lifting routes must be planned so that the load is not moved over
persons or such places where persons may be present.

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12. Lift the loader only a few centimeters at first to make sure that it is
properly fastened and in balance. Do not continue lifting until you are
sure of proper fastening and balance.
13. If control lines must be used, make sure that they are long and strong
enough

3.7 Lifting the boom using a hoist

The recommended method to lift the boom is to use the machine's own
hydraulics.
If it is not possible to use the hydraulic system for lifting, use a hoist.
1. Make sure that the machine is on an even surface, the parking brake
applied and movement is prevented with wheel chocks.
2. Install the frame articulation locking device
• To install the frame articulation locking device see chapter Safety and
environmental instructions
3. Remove the ignition key.
4. Turn the main switch off and padlock it.
5. Place a DANGER - DO NOT START warning sign on the main switch.
• The sign may only be removed by a person who is fully aware of the
current status of the work.
6. Remove the bucket.
• Removing the bucket is presented in chapter Frame structures
7. Install a suitable lifting bar through the lift arm bushing.
8. Attach lift chains to the lift bar.
9. Bleed hydraulic pressure from the tilt cylinder by connecting a capillary
test hose into the test points
10. Bleed hydraulic pressure from lift cylinders by connecting a capillary test
hose into the test points
11. Disconnect tilt cylinder hoses.
12. Plug the open valve ports.
13. Disconnect lift cylinder hoses.
14. Lift the boom slowly to the up position.
15. Install the boom locking pins.
16. Lower the boom slowly against the stops.

3.8 Lowering the boom using a hoist

The recommended method to lower the boom is to use the machine's own
hydraulics.
If the boom hydraulics do not work, the boom must be lowered using a
hoist.
1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented with wheel chocks.

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2. Make sure that the frame articulation locking device is installed.

• Installation is presented in chapter Safety and environmental
instructions.
3. Remove the ignition key.
4. Turn the main switch off and padlock it.
5. Place a DANGER - DO NOT START warning sign on the main switch
6. Install a suitable lifting bar through the lift arm bushing.
7. Attach chains to the lifting bar
8. Raise the boom slightly using a hoist.
9. Climb up to the wheel guard and remove the boom locking device.
10. Put the boom locking device into the holder and secure it.
11. Repeat steps 9 and 10 for the other side.
• NOTE! Do not walk under the boom under any circumstances.
12. Lower the boom slowly against the boom stops using a hoist.

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4 Frame Structures

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4.1 Section safety messages

WARNING
IGNORING INSTRUCTIONS HAZARD!
If you do not understand any information related to your duties in the
service and repair 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.

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DANGER
CRUSHING HAZARD!
Unexpected movement of boom will cause death or severe injury.
Never go under the boom until it is supported accordingly with the
boom support device.

WARNING
SLIPPING, TIPPING 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.
Always wear required personal protection, such as safety helmet,
safety gloves, safety boots, etc. Keep ladders, steps, handrails,
handles, and working platforms clean of oil, dirt, and ice. Obey local,
site and mine regulations concerning working on places where there
is a risk of falling. Always wear safety belts and lines when required.

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

WARNING
LIFTING HAZARD!
Incorrect lifting methods could cause death or severe injuries.
Make sure that correctly rated lifting equipment is used when lifting
heavy components.

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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.

4.2 Main components

1 2 3 4 5 6

1 Rear frame 2 Oscillating axle

3 Middle hinge joint 4 Front frame
5 Boom 6 Bucket

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4.3 Middle hinge joint

4.3.1 Design features of upper hinge
The upper middle hinge is adjustable and equipped with a self-centering
ball-joint. The hinge pin (12) is fastened with a flange (9) from its upper end
to the fixed bushing of the rear frame. The ball joint bearing (4) and the pin
are pressed together with help of a sleeve and the upper flange. The sleeve
made of special steel has been fitted to the fixed bushings of the rear
frame.

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9
1

12
2

10 3

13
11

15
5

16
7

1 Screw M16x30 12.9 2 Screw M16x30 12.9

3 Screw M12x30 8.8 4 Ball joint bearing
5 Lower bearing seal 6 M12x40 12.9
7 O-ring 8 Screw M10x20 8.8
9 Upper flange 10 V-seal
11 Bearing upper flange 12 Hinge pin
13 Upper bearing seal 14 Bearing lower flange
15 V-seal 16 Cover

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4.3.2 Design features of lower hinge

The lower middle hinge is adjustable and equipped with a self-centering
ball-joint. The pin is fastened with a flange from it's upper end to the fixed
bushing of the front frame. The bearing and the pin are pressed together
with the help of a sleeve and the upper flange. The sleeveis made of a
special steel and is fitted to a fixed bushing on the rear frame.

17 30

21
25
28

27 19

18 20

31 23

32 24

17 Screw M12x45 12.9 18 Screw M12x40 12.9

19 Shim 0.2 mm 20 Shim 0.5 mm
21 Center ring 22 Ball joint bearing
23 Upper flange 24 Lower flange
25 Cover 26 Lower flange
27 Sleeve 28 Seal
29 Seal 30 Hinge pin
31 Screw M12x40 12.9 32 Screw M16x50 12.9

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4.3.3 Disassembly of middle hinge joint

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.

Be careful when handling hot oil. Wear suitable protective gloves,

protective clothing and safety goggles when handling oil.

WARNING
HIGH-PRESSURE OIL SPRAY HAZARD!
High-pressure oil spray could cause death or serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening any plugs or connectors.

WARNING
FIRE HAZARD!
Fuel or oil leaks can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

1. Make sure that the machine is on an level surface, the parking brake is
applied and movement is prevented by wheel chocks.
2. Make sure that the bucket is lowered and the boom is resting on the
stops.
3. Install the frame articulation locking device.
4. Before performing any maintenance work on the hydraulic system, the
hydraulic oil tank must be depressurized.
• Pressure is released by using the directional valve on top of the
hydraulic oil tank.
• Make sure that the valve closes fully once all of the pressure is
relieved.
5. Position safety stands under the front and rear frame.
• Position under the front of the machine on either side as close as
practical to the articulation point, with the wheels still on the ground.
6. Remove the drive shaft from the middle hinge joint.

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7. Position an oil drain container under the machine before removing

hosing.
• Cap all hose connections.
• Ensure that the brake flushing circuit (optional) is looped.
8. Disconnect and remove the wiring from the center articulation.
9. Remove the steering cylinder pin from the front frame end of the cylinder.
• The cylinder can be retracted out of the way once the pin has been
removed using a hydraulic power pack.
• Use a hydraulic power pack to release the parking brake.
10. Remove frame articulation locking device.
11. Support the front frame with an overhead hoist.
• Note! Make sure that lifting equipment is in good condition and
correctly rated.
• Make sure that both sides of the machine are slung to prevent the
machine from leaning once the machine is split.
• Note! Do not remove safety stands until the machine is ready to
split!

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12. Remove the pin retaining flanges (9 and 16) from the upper hinge pin by
removing the cap screws (1,2, and 8).

A B
17
1
9 25
2
18
26
10

11 19

3
19
19

20
20
12
20
27

28
21
4

13 29

5 22

6 30
15
7
23 31
16
8
32
24
32

13. Remove the upper hinge pin (12) by pressing it down (it can be
removed to both directions).
14. Remove the lower hinge pin screws (17 and 32) and flanges (25 and
24).
15. Remove the lower hinge pin (30) from the underside. The pin cannot be
removed from the upside.
16. Take the weight off the front frame with the overhead hoist and remove
the safety stands.
17. Remove the wheel wedges from the front axle.
18. Use the overhead hoist to carefully move the front frame forward away
from rear frame.

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19. Once the front frame is far enough forward, place safety stands and
wheel wedges under front section and release power pack applying
park brake.
20. Remove the rest of the parts from frame and inspect them carefully and
replace if they have been damaged.

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4.3.4 Assembly of middle hinge joint

Remove, inspect and clean all the bearings and bushes from the clevices.
Replace any damaged or worn parts.
Install the hinge pins properly lubricated.
1. Install the ball-joint bearing of the lower hinge-pin into the front frame.
a) Install the lower flange (23.) with the seal (29.) to the front frame
and tighten the flange screws (31.)
• Make sure that the seal lip is pointing downwards.
b) Install the lubricated ball-joint bearing (22.) to it's housing in the
front frame.
c) Install 4 stacks of shims (19. and 20.), evenly spaced.
• An axial play of 0,1-0,3 mm should be adjusted, using shims
between the lower flange and front frame. This can be checked
by temporarily installing hinge pin to the bearing and recording
the play with a dial gauge attached to a magnetic stand.

d) Install the upper flange (26.) with the seal (28.). The seal lip should
face upwards.
e) Tighten the screws and recheck the axial play.

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2. Install the ball joint bearing of the upper hinge pin to the rear frame.
a) Install the lower flange (14.) with the seal (5.) to the rear frame.
Tighten the flange screws (6.).
• Make sure that the seal lip is pointing downwards.
b) Install the upper pin ball-joint bearing to it's housing in the front
frame with the help of some grease.
c) Install the upper flange (11.) with the seal facing upwards and
tighten the screws (3.).
d) Install the V-seals (10. and 15.) to the upper and lower flange. (11.
and 14.).
• Make sure that the seal lips are pointing outwards.
• Use tape to tie down the lip. This stops the lips from bending in
or breaking when joining the front and rear frames.
3. Take the weight off the front frame with a hoist and remove the safety
stands and wheels chocks from the front axle.
Move the front frame back towards the rear frame making sure the pin
holes line up.
4. Install the lower hinge pin (30. ).
• The pin can only be installed from the underside.
5. Mount the lower flange (24.) to the lower pin (30.).
6. Screw two long guide grub screws trough the flange into the hole of the
pin.
7. Use a plastic hammer and knock the lower pin into the correct position.
8. Remove the guide screws and install and tighten the screws.
9. Push the sleeve (22.) into the upper bushing in the rear frame and install
the cover (25) to the upper pin (30.).
10. Center and align the ball joint, using a guide tool.
11. Install the upper hinge pin (12.).
a) Push the pin in.
b) Install the upper flange (9.) and tighten the screws (1.).
c) Install the lower flange (16.) with the O-ring (7.).
d) Tighten the screws (8.).
e) Install and tighten the upper flange screws (2.).
12. Install the hydraulic hoses and wiring across the middle hinge.
13. Install the cardan shaft
14. Install the steering cylinder pins.
15. Remove the safety stands from underneath the machine.
16. Check the hydraulic oil level and refill if needed.
17. Start the machine and make sure that all the functions work.
18. Check the steering hyraulics for any hydraulic leaks

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4.4 Oscillating axle

The oscillating axle has been designed to be extremely strong yet easy to
remove. The assembly consists of two bearing housings which attach
directly to the axle and enable the oscillating movement. The bearing
housings are bolted directly to the rear frame.

1 2 3 4

1 Rear frame 2 Oscillating bearing (rear)

3 Oscillating bearing (front) 4 Front frame

1 2 3 4 5 6 7 8

Front bearing housing assembly

1 Oil seal 2 Housing
3 Grease nipple 4 Bearing housing
5 Bearing 6 Cover plate
7 Oil seal 8 Support plate

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1 2 3 4 5 6 7 8 9 10

Rear bearing housing assembly

1 Grease nipple 2 Cover plate
3 Plate 4 Cover plate
5 Plate 6 Support plate
7 Bearing 8 Grease nipple
9 Bearing housing 10 Oil seal

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4.4.1 Disassembly of the oscillating axle

Only perform maintenance work when the machine is parked on a

Preparatory steps:
1. Make sure that the machine is on an level surface, the parking brake is
applied and movement is prevented by, for example, wheel chocks.
2. Make sure that the bucket is lowered and the boom is resting on it's
stops.
3. Install the frame articulation locking device.
4. Support the rear frame with jacks and/or blocks.
5. Remove the rear wheels.
• For detailed information see chapter Power train, section removing
the tires.
6. Disconnect the cardan shaft from the rear axle.
7. Disconnect the lubrication lines.
8. Disconnect the brake hydraulic hoses from the rear axle.
9. Remove the rear axle.
• For detailed information see chapter Power train, section removing
the rear axle.
10. Support the weight of the axle with a hoist or hydraulic jacks
11. Remove the cover plate screws (8 pcs).
• Remove the cover plate

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12. Open the screws (12 pcs) holding the rear bearing housing to the axle.

13. Remove the rear bearing housing from the axle

14. Open the support plate screws (12 pcs) and remove the front bearing
housing.
15.

• Inspect the seals, bearings and other parts carefully and replace if
they have been damaged.
• Pay particular attention to axle and pin mating surfaces.

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4.4.2 Assembly of oscillating axle

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8
A

A Rear B Front

All parts must be thoroughly cleaned and lubricated before assembly. Install
new bearings and seals to the oscillating axle housings if needed.
1. Install the bearing housing (4) into the front housing (2).
2. Install the cover plate (6) and oil seal (7).
3. Assemble the front housing onto the axle.
4. Install the support plate (8) and tighten the screws.

5. Install the bearing (7) into the rear housing (9).

6. Install the support plate (6) into the bearing (7).

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7. Assemble the rear housing onto the axle.

8. Install the cover plate (4) and tighten the screws.

• Fill the housing with grease before installing the cover plate.

9. Install the plate and cover plate. Tighten the screws.

10. Install rear axle, See detailed information from chapterPower train,
sectioninstalling the rear axle.
11. Connect lubrication lines and check for proper lubrication.
12. Install brake hoses, cardan shaft and wheels

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4.5 Pins

4.5.1 Design features of the pins

The pins are made of CrMo-steel and case hardened to the depth of 0.8–
1.4 mm. All the larger pins have channels drilled to feed grease between
the pin and the frame bushings. This is not a surface where rotation occurs,
but greasing will prevent water from seeping into the gap. This reduces the
chance of corrosion.
All pins have a large diameter which lowers the pressure born by the pin
surface. This guarantees a long service life.
Most pins have a slight press-fit which makes removal easy. For removal,
see instructions below.

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4.5.2 Pin removal prepatory steps

Preparatory steps:
• Support the equipment carefully to prevent accidents and damages
caused by heavy parts.
• If the greasing of the pin/frame gaps has been neglected, you can pump
oil or rust-loosening agent through the nipple to ease removing.
• Remove lubrication lines (if installed).
• Remove locking flange (or bolt).

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4.5.3 Pin removal with a puller

B
A

A Install the puller screw here

B Two piece puller flange
C Hollow pin

1. Clean the threaded hole at end of the pin and oil it.
2. Hollow pins clean the hole.
3. Clean the surrounding area where the puller will be fitted.
4. Mount the puller. Oil the puller’s threads.
5. Use a wrench to turn the nut (be sure the wrench fits exactly).
6. Tightening the nut will make the pin to move.
• If the pin is stuck badly, hit the other end of pin with a mallet while pulling
from the other end.
• If you have a hydraulic puller, use it in the same way as described with
mechanical puller.
• You can use a hydraulic jack to remove pins, such as for steering
cylinders.
• The middle hinge pins can also be removed with a hydraulic jack.

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4.5.4 Pin removal without special tools

DANGER
FLYING METAL SPLINTER HAZARD!
The pin surface is made of hardened steel. If the pin is hit with a hard
object, it might crack and result in metal splinter moving at high
velocity. If an eye is hit by splinter, it will cause severe eye injury or
blindness.
Hit the pin with softer materials than the pin itself.

Always wear safety goggles when installing or removing pins.

The most effective loosening can be obtained by using a heavy tool with
high speed.
• Perform all precautions as mentioned before.
• Make sure that the tools you use are clean so they do not slip out of your
hand.
• Remember to support you work.
• If you are able to use a hoist or tackle, attach a heavy steel bar (ca ø 40 -
60 mm, length 3 - 4 m) as shown below. Use the bar as a pendulum to hit
the pin.

• The bar should be supported in the middle.

• The ends of the bar should be straight and cut flat with no buns.
• Use the end of the bar to knock the pin loose.
• Mark the pin to know from where it has been removed.

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4.5.5 Pin installation

DANGER
FLYING METAL SPLINTER HAZARD!
The pin surface is made of hardened steel. If the pin is hit with a hard
object, it might crack and result in metal splinter moving at high
velocity. If an eye is hit by splinter, it will cause severe eye injury or
blindness.
Use a rubber sledge hammer whenever it is possible.

Always wear safety goggles when installing or removing pins.

• Use grease as lubricant when installing pins.

• Install the pin to the same place from where it was removed.

4.6 Lift arm

4.6.1 Design features of the lift arm
Lift arms have been constructed in a box-sectional form to give maximum
torsional strength and durability to the boom assembly. The boom has
bronze bushings for attachment to the frame and for the bucket pin. The
steel spacer ring is used to line up the bronze bushings.

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4.6.2 Bushing replacement

Preparatory steps:
• When replacing the low end bushings remove the bucket.
• To replace the upper end bushings, lay the bucket on the ground.
Remove the upper pins and lift the upper end of the arm by using the
machines own lift cylinder.

Replacement:
• Weld 5-10 turns to the bushing internal circumference. See picture below.

• Hit the bushing loose.

• The easiest way to install new bushings is to cool them down to deep-
freeze temperature as then they will easily slide to correct place. When
they return to normal temperature, they will expand and make a tight fit.
• Use shims to adjust a maximum axial play of 2 mm between the boom
and the front frame or bucket.

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4.6.3 Bucket stopper adjustment

A B

Bucket stopper adjustment should be checked always when bucket or

bucket stopper absorber is changed.
1. Start the machine and rise the boom so that bucket pin is one meter off
the ground (the bucket in haul position)
2. Crowd the bucket fully back and measure the extended cylinder rod of
the tilt cylinder (dimension A).
3. Lower the boom against boom stops (bucket in haul position)
4. Measure the cylinder rod length A again.
5. The dimension should be between 10...15 mm shorter. If not, the bucket
stopper thickness needs to be adjusted accordingly.
6. Stopper adjusting is made by adding or removing spacers of different
thicknesses under the bucket stops.
• If the dimension change is too big the stopper thickness should be
reduced.
• If the dimension change is less than 10 mm the spacers should be
used under the bucket stoppers.

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4.6.4 Removing the bucket

DANGER
CRUSHING HAZARD!
Hazardous bucket movement will cause death or severe injury if
there are people at the danger area.
Make sure that the bucket is supported before performing any
service work on the bucket system

DANGER
CRUSHING HAZARD!
Getting crushed by the machine will cause death or severe injury.
Do not go beneath the machine unless absolutely necessary. Stay
out of the danger areas when the machine is operated. Make sure
that there are no unauthorized persons in the danger area.

Only perform maintenance work when the machine is parked on a

1. Lower the bucket flat on the ground.

2. Install the frame articulation locking device.

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3. Before removing the joint pins, support the lifting arm lightly with a hoist.

4. Remove the joint pin (2.), (1 pcs) from the bucket tilt cylinder by opening
the fastening screws of retaining plates (3.).
5. Remove the joint pins (2.), (2 pcs) from bucket by opening the fastening
screws of retaining plates (3.).

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6. Fasten the lifting chains to the lifting brackets of the bucket. Remove the
bucket from the lift arm assembly by using a hoist.
• Note! The weight of the bucket is approximately 1300kg (2,0m3).

7. Remove the rubber seals.

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4.6.5 Installing the bucket

1. Make sure that the lifting equipment is in good condition and correctly
rated
• The bucket weighs approximately 1300kg.
2. Make sure that all parts and housings are clean and ready for installation.

3. Use new or corresponding parts for installation.

• When installing the pins, use a lubricant that is intended for the task.
4. Fasten a hoist to the bucket and lift it in position on the lift arm assembly.
• Let the bucket remain supported by the chains.

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5. Place the rubber seals between the brackets.

• Make sure that all parts are well lubricated for installation.
• Push the bucket pins (2.) through the brackets.
• Install and tighten the fastening screws of retaining plates (3.).

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6. Place the spacer rings and the rubber seals between the brackets.
• Make sure that all parts are well lubricated for installation.
• Push the dump cylinder pin (2.) through the brackets.
• Tighten the fastening screws of retaining plates (3.).

7. Detach the lifting chains from the lifting brackets of the bucket.
8. Grease all points on bucket pins and boom.
9. Check the bucket stopper adjustment.
• The correct axial play is 2mm. Use shims to adjust accordingly.
• See section Bucket stopper adjustment.
10. Remove the frame articulation locking device.

4.7 Welding
If you must weld the machine, remove the alternator wires and turn
the main switch OFF before welding. Take into consideration the fire
and explosion hazard created by welding. Make sure that the
machine and its surroundings are clean and fireproof.

Note that for electric welding work, the batteries must be

disconnected and both connector leads (”+” and “-”) securely
protected to avoid connection to each other or the frame structure.

Note! Frame material: Raex Multisteel N (S355N (EN 10025-3), S355K2+N

(EN 10025-2))

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4.7.1 Precautions before welding

• Turn the main switch OFF.
• If welding must be done close to any of the control modules, disconnect
all the module wiring before welding.
• The ground cable of the welding machine must be connected as close to
the weld as possible. The ground cable must not be connected so that
the current can flow through a bearing, joint coupling, sealing surface,
lever, or control cable.
• All parts must be supported carefully to avoid flexing and changes in
dimensions caused by heat stresses.
• If welding is performed near pins or in places where flexing may cause
changes in the alignment of bushings you should remove the pins and
check (and correct) the alignment after welding. Additional support of the
welding piece may be needed.
• The object welded must be cleaned thoroughly and the welding seam
must be deep enough.
• A hole must be drilled at the end of a crack to prevent further cracking.
• Welding rods must be completely dry. If necessary use a drier.
• Dampness will cause hair cracks. To prevent the effects of dampness,
the area around the seam must be preheated to 100 - 200 °C and kept
there during the welding. If the material thickness exceeds 40 mm,
preheating must be done. For material with thickness 10 to 39 mm,
preheating is strongly recommended.
• A suitable welding rod recommended is ESAB OK 48.00 or MAGWIRE
ESAB OK 12.51
4.7.2 Basic quality requirements
If nothing else is mentioned in the special instructions further on, at least
the following quality requirements must be met:
• The surface of the weld must be flat.
• No pores or overlaps (ISO 5817) should be left.
• No scars or holes from a chipping hammer or from starting with a new
rod should be left.
• In ordinary cases, ISO 5817 quality level C is good enough.
When welding e.g. tanks to frame, make sure that the weld on the
frame will not end where there is another weld on the other side of
the frame plate.

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4.7.3 Frame welding

In addition to the general instructions, pay attention to the following details:
• The quality of the weld must meet the following requirements:
- contraction cavities and caves must be filled and roughnesses must
be removed
- no scars or holes from clipping hammer may be left
- the surface of the weld must be flat and the weld must join the base
material smoothly
- ISO 5817 quality level C
• A method which guarantees a proper penetration on the underside must
be used.
In addition to the general instructions, quality requirements must be met
when welding in the places mentioned below:
• Welding of fast bushings to frame plates
• Repair and fastening weld of middle hinge plates
• Welding of the crossbeams
• Fastening levels for the axles
• Lugs
• Lift arms
• Swing levers
Special attention must be paid to quality when welding the following places:
• Central hinge joints, plates and their fastening welds
• Beams of the oscillation system and their fastening welds
• Hoisting lugs
4.7.4 Bucket welding
Wear resistant steels like Hardox should be welded using filler metal that
provides low hydrogen content in the weld metal.
Manual metal-arc, gas metal-arc and TIG welding are recommended for the
welding of wear resistant steel plate. When very good mechanical
properties are required in the welded joint, heat input should be restricted to
maximum of 3 kJ/mm.

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4.7.5 Edge preparation

A good fit between the workpieces is essential in order to minimize stresses
and thereby the risk of cracking. This risk is greatest for the initial weld
beads, which are often thinner.

All types impurities on and near the edges - such as mill scale, rust, oil,
paint and moisture - should be removed before the start of welding. They
are hydrogen sources that can jeopardize the welding results, causing
cracking.

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4.7.6 Working temperature and pre-heating

Good welding results require that crack-inducing hydrogen is kept away
from the weld area
The edges of the joint must be clean and dry prior to welding, and only dry
filler metal may be used. Welding should be done at an elevated working
temperature when large plate thicknesses are to be welded. The adjacent
diagram is a guide to the choice of working temperature, which should be
maintained throughout welding. The temperature can be checked, for
example with temperature indicating sticks, on the plate surface opposite
the heated one (see figure). Under special conditions of restraint, in damp
weather and when tack welding, the next higher temperature level is
recommended.
Preheating must be done carefully. The maximum temperature is 220°C.
t1 t2
y
(t3 = 0)

75 m m
75 m m
t3

t1 t2 (= t1 )

40 0 HB 20C° 75C° 10 0C° 17 5C°

1
50 0 HB 10 0C° 12 5C° 15 0C° 17 5C°
0
20 30 40 50 60 70 80 90 10 0 11 0
x
Combined plate thickness = t1 + t2 + t3 i.e. at least double the plate thickness
x Combined plate thickness
y Measure the temperatures here

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4.7.7 Heat-input - number of welding passes

If the impact strength of the welded joint must be equivalent to that of the
parent metal (impact strength at -40 °C), the following rule of thumb used:

Combined plate thickness

(mm) = minimum number of welding passes
5

Example: 20 mm thick plate (butt weld) should be welded with at least 8

passes (beads). If the impact strength requirement is lower, the number of
passes may be reduced.
When these types of steel are welded, a soft zone, whose width varies with
the heat input, forms near the fusion limit. However, if the heat input is kept
to a reasonable level, the soft zone will be so narrow that it will not have
any effect on the strength of the welded joint.

3
+
2
+
1 +

0
0 10 20 30 40 50 60 x
Diagram showing approximately the heat input given by the rule of thumb

x Single plate thickness

y kJ/mm

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4.7.8 Welding to other steels

In terms of alloying content, wear resistance steels like Hardox can be
welded to similar steels and to ordinary structural steels. The filler metal
used for a welded joint should be of the same strength class as the steel
with the lowest strength values.

Filler metals
Filler metals should be selected with regard to the demands that are made
on strength and toughness in the welded joint and for the conditions of
restraint that prevail.
In most cases, ”soft” filler metals can be used. This should be done
wherever possible. There are many advantages with a ”soft” weld metal,
among other things it will undergo plastic deformation more readily when
the weld has cooled. The joint will then be under much less restraint, which
provides greater security against cracking. ”Soft” filler metal should always
be used for fillet welds. ”Soft” filler metal is also used for butt welds, when
the same strength is not required in the filler metal as in the parent metal. In
cases where it is necessary to have a filler metal that is equally strong as
the parent metal (a ”matching” filler metal), a ”soft” filler metal is
recommended in the root beads.
Choose welding processes and filler metals that give the lowest possible
hydrogen level. Covered electrodes shall be well dried so that they give a
maximum hydrogen contest of 5 - 10 ml per 100 g of weld metal (the Hg
method according to the IIW).
Filler metals shall be stored in such a manner that moisture absorption is
prevented. The recommendations of the filler metal manufacturer should be
followed carefully. Always keep opened packages of electrodes dry and
warm. Do not return unconsumed electrodes to dry cabinets if there is the
least risk that they may have absorbed moisture from the air. (Harmful
moisture absorption can take place in 30 to 60 minutes) Instead, throw the
electrodes away or ask the manufacturer for advice on drying. Precautions
that apply to covered electrodes also apply in the main to granular flux and
flux-cored wire.

Choosing filler metal

Use as ”soft” a filler metal as possible in each individual case. In most
cases, it is fully adequate to use a filler metal equivalent to E-7018 and
E-7028 or equivalent grades for gas metal-arch (fluxcored and solid wire)
and submerged metal-arch welding. The filler metals mentioned here are
used for the welding of wear resistant steel plates. Only ”soft” filler metal
may be used for 500 HB wear resistant steels.

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Filler metal Submerged - arc

Manual metal - arc welding Gas metal - arc welding
Manufacturer welding
Flux -cored Granular
Solid wire Wire
E -7018 E -7028 wire flux
E - 70 S - 6 EM 12
E - 70 - T5 F- 72
CODE-ARC EASY-ARC CHEM-
AIRCO Fluxcor 5 S-10
7018 MR 7028 BRITE A681
ARCOS Ductileud 70 70 C
ARC-Weld Easyare 328 Super 28
BOC-MUREX Fortrex 31 Murecor 5 Murex 1313
Fox HL 180
Böhler Fox Ev 50 EML 5 EM S2
K6
Chemetron Atom arc 7018
P48
Maxeta 22 Elgamatic
ELGA P51
MAxeta 23 100
P55
OK 48.00
OK 38.48
OK 48.04 OK Tubrod OK Au-
OK 38.84
OK 48.15 15.00 OK Autrod OK Flux trod 12.20
ESAB OK 38.85
OK 48.68 OK Tubrod 12.51 10.71 OK Au-
OK 38.65
OK 48.30 15.18 trod 12.22
OK 38.95
OK 55.00
Hobart Hobart 718 SR Fabco 85 HB28 H-400 HB-25
Phoenix
ES 50
Ferex 7018 LT Rot BR 160 Corofil E
Norgas Norgas 50 SW 35
Baso 120 Conare L 55
Magsi 14
150
Haftcord
Supercord
Supercord X
Fluxofil 30 OP 121
Oerlikon Tensicord Fabracord Carbofil 1-A OE S 2
Fluxofil 31 TT
Tenacito
Tenacito R
Tenacito 38 R
Philips 35 Philips C 6
Philips 35 C Philips C6 H Philips PZ Philips PZ 860 Lin- Lincoln L
Philips
Philips 35 S Philips C 57 6130 6000 coln 61
Philips 77 H
SH Multifer UV 420
Phoenix-Union SH 120 K Union S2
150 K1 TT

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Filler metal Submerged - arc

Manual metal - arc welding Gas metal - arc welding
Manufacturer welding
Conarc L Cor-O-Fil
SMIT Conarc 54 SW26 P120 SW35
150 B55
Excalibur 7018
Excalibur Excalibur Outershield SuperArc
Lincoln Electric
7018-1 7028 75C L-56
Jet-LH 78

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4.7.9 Gas cutting

When wear resistant plate (e.g. Hardox 400 or 500) is gas cut, the layer
adjacent to the cut edge becomes as hard as or harder than the original
material. Gas cutting may cause micro fractures in this layer. To prevent the
fractures the area near the cut edge must be preheated. 400 HB hardness
needs preheating temperature of 100°C and 500 HB hardness 150°C.
Cold plates must not be gas cut. Let them warm up to room temperature
(+20°C) before starting gas cutting or pre-heating process.
Figure 1 shows the hardness after gas cutting at different distances from
the cut edge. Figure 2 shows where this hardness was measured and
indicates the conformation of the hard layer (light blue area).
In order to expedite the machining of gas-cut edges, the cutting edge
should cut so deep that it penetrates through the hard layer into the softer
underlying material.
Hardness after gas cutting:

HV 10 HV 10
500 600
1

450 1

400
500 2

350 2
HB 400 HB 500
300
400
250
200
150 300
0 2 4 6 8 0 2 4 6 8

Distance from cut edge, mm

The gas-cut edges will be less hard if the plate adjacent to the line of cut is
heated during gas cutting. But in this case, a wider and deeper soft zone
will be created inside the hard layer in comparison to ordinary cutting. Heat
can also be applied after gas cutting to reduce the hardness of the cut
edge.
The curves refer to a plate thickness of 30 mm. It can be assumed that the
soft zone will be somewhat wider for thinner plate. A wider zone will also be
obtained if a lower cutting rate than normal is used.

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Sites of hardness measurement

1 Hardness measured in middle of plate
2 Hardness measured just below plate surface

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5 Lubrication System

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5.1 Manual central lubrication

Front frame lubrication lines, greasing blocks and targets

14 13 11
4 5 12 10
9

3 8
1 7
2 6

Lines layout and greasing blocks, front frame

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11 Boom, lower end, right 12 Boom, lower end, right

13 Boom, lower end, left 14 Lift cylinder, the upper left

E F

8 10

C C

D
9
D

E F
C-C

2 7 F-F

1 5 4

D-D E-E

Lubrication targets, front frame

1 Steering cylinder, front 2 Lift cylinder, the lower left
3 Dump cylinder 4 Boom, lower end, left
5 Lift arm, left 6 Drive shaft bearing
7 Lift cylinder, the lower right 8 Lift cylinder, the upper right
9 Pin group, centre hinge, 10 Lift arm, right
upper
11 Boom, lower end, right 12 Boom, lower end, right
13 Boom, lower end, left 14 Lift cylinder, the upper left

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Rear frame lubrication lines, greasing blocks and targets

2 3
1 8

4 7
5 6

6
3
4

8
2

1 5 7

Lines layout, greasing blocks and lubrication targets, rear frame

1 Axle cradle, rear 2 Axle cradle, rear
3 Axle cradle, rear 4 Axle cradle, front
5 Axle cradle, front 6 Steer cylinder, rear
7 Drive shaft support bearing 8 Pin group, centre hinge,
lower

5.2 Automatic central lubrication

The automatic central lubrication unit pumps grease with the help of dosers
to the unit's joints. By adjusting the stroke of the doser, amount of grease
going to the joints can be controlled. The pump operating time interval can
be adjusted through the parameters of the VCM system.
1 Rear frame doser group
2 Front frame doser group, left
3 Automatic central lubrication unit
4 Front frame doser group, right

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Front frame

7 5

11
12

8
10 1 2 3 9

1 Upper middle hinge joint 2 Cardan shaft support bearing

3 Boom lift cylinder pin, lower 4 Boom hinge pin, right
right
5 Boom hinge pin, left 6 Boom lift cylinder pin, upper
left
7 Bucket tilt cylinder pin 8 Steering cylinder pin, front
9 Right side doser group 10 Boom lift cylinder pin, lower
left
11 Lubrication pump unit 12 Boom lift cylinder pin, upper
right
13 Left side doser group

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Rear frame

7
7 6
8
6
1 8

3 5

4 4

1 3 2 4

1 Oscillation, rear cover 2 Oscillating bearing, rear

3 Oscillating bearing, rear 4 Oscillating bearing, front
5 Oscillating bearing, front 6 Lower hinge joint
7 Cardan shaft support bearing 8 Steering cylinder pin, rear

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5.2.1 Automatic central lubrication control

The automatic central lubrication unit pumps grease with the help of dosers
to the unit’s joints. By adjusting the stroke of the doser, the amount of
grease going to the joints can be controlled. The pump operating time
interval can be adjusted through the parameters of the control system.
Releasing the parking brake activates the lubrication. The automatic central
lubrication control sends alternately 24 V and 0 V signals from the control
system module’s output. Lubrication is performed every time the status of
the automatic central lubrication control changes. The lubrication lines are
divided into two different circuits. One circuit is pressurized when the
control signal is 24 V and the other when the control signal is 0 V.
The control system monitors the pressure in the main grease pressure lines
with pressure sensors 1 and 2, and alerts if the pressure lines are leaking
or clogged. The pressures for the automatic central lubrication greasing
lines are monitored after the pump control signal has changed. Pressure
sensor 1 is monitored after the ascending control signal, and pressure data
sensor 2 is monitored after the descending control signal. The control
system monitors the following parameters:
• The pressure signal must become active after a change in the control
signal.
• The time period that the pressure signal can be active.
• When the central lube reservoir is empty.
• If the above parameters are not fulfilled an alarm is activated.
The central lubrication system is controlled by a valve. Changing the valve
mode changes the servo oil flow to the double acting pump to move the
piston of the lubrication device. Each piston movement alternatively adds
grease to lines 1 and 2. The lubrication interval is set to 10 minutes as
default. When the parking brake is activated the central lubrication unit
stops working. The counter does not reset when the parking brake is
released.
The symbol on the left of the main window shows if the automatic central
lubrication is malfunctioning. When the center of the symbol becomes red it
indicates that the central lube reservoir is empty. The arrows above and
below become darker when there is a pressurizing problem with the two
main grease lines.

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Forced functions (requires service password)

Forced functions windows are used for control the machine’s different
functions by using the display module’s buttons instead of the machine’s
control buttons. A forced functions window can replace a broken control
actuator; for example, if the steering joystick is broken, the machine can be
driven for service using a forced functions window.
NOTE! Test functions may cause unexpected movements of the machine.
Always be sure when test functions are done that there is enough free
space around the machine.

Central Lubrication test

This window is used for testing automatic central lubrication control (even
when the parking brake is on). This function is used to remove air from the
grease network after installation and to test the operation of the mechanical
dosers.
When the test function is on, the greaser’s cycle time is active for 180
seconds, or until you close the test window. Mechanical dosers are
inspected by going from one doser to another and waiting for the next
greasing period, to see if they function properly. The alarms function

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normally during testing and running out of grease will stop the function. The
alarms of the automatic central lubrication are seen as text in the central
lubrication testing window.
Testing automatic central lubrication:
1. Press button Test on/off to initiate 180 second cycle.
2. Test function will remain operating as long as the test window is open.
3. Press button Test on/off or change the display window to end test and
return to normal lube internal.

Forcing the digital outputs of modules

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3. Switch the output (or outputs) to be forced on or off.

• “1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE!SEND

Digital outputs of automatic central lubrication control:

Function Module Connector pin

Lubrication valve Middle XM1.2

Measurement data of the modules (requires service password)

The measurement data windows show the values and statuses of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want on the measurements menu window
and press theOK button. The measurement data window of the connector
opens.
The connector pins for automatic central lubrication are listed in
“Inputs” and “Outputs” tables in section System notifications and
troubleshooting (Automatic central lubrication control)

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System notification and troubleshooting (Automatic central lubrication control)

System Interlocks
The automatic central lubrication is not controlled if:
• The parking brake is engaged.
• There is no grease left in the container.

Inputs
Signal level Connector
Actuator Description Module
pin
Grease pressure
Pressure switch 24 V / Float Middle XM3.20
1
Grease pressure
Pressure switch 24 V / Float Middle XM3.21
2
Sensor Grease end Float / 24 V Middle XM2.19

Outputs
Actuator Description Signal level Module Connector pin
Control valve Lubrication valve 24 V / Float Middle XM1.2

Module No Alarm text Alarm log

Middle 197 Out of grease X

Description: The central lube reservoir is out of grease.

Action: Lubrication unit
• Add grease to the central lube reservoir.

Module No Alarm text Alarm log

Central lubrication valve short to
Middle 198 X
ground
Central lubrication valve signal short
Middle 199 X
to external voltage

Description 1: Short circuit in voltage feed of automatic central lubrication

valve
Action 1: Wire harness
• Disconnect the connector pin XM1.2 of the Middle module.
• Force the output XM1.2 off and then back on in the forcing window (see
Chapter “Automatic central lubrication control”, section ”Forcing the
digital outputs of the modules”).
• Check the alarm log for the number of this kind of alarms. If the number
of alarms did not go up (i.e. the alarm did not go off again), the fault is in
cabling, short circuit to ground.

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• Restart the control system after having checked the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.
Description 2: Voltage in uncontrolled output of voltage feed to the valve of
the automatic central lubrication
Action 1: Wire harness
• If the alarm stopped, the fault is in wiring, short circuit to operating
voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.

Module No Alarm text Alarm log

Middle 204 Central lubrication error X

Description: Leak in automatic central lubrication lines 1 or 2

Action: Test the functioning
• Test the functioning of the automatic central lubrication in the test
window. See chapter “Automatic central lubrication control”, section
“Central lubrication test”.

Module No Alarm text Alarm log

Central lubrication grease line
Middle 205 X
blocked

Description: Clogging in automatic central lubrication line 1 or 2

Action:: Test the functioning
• Test the functioning of the automatic central lubrication in the test
window. See chapter “Automatic central lubrication control”, section
“Central lubrication test”.

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5.2.2 Lubrication lines and targets

Rear frame

1 2 3 8
7
8

5 6
1 4

4 5 6 7
3

1 Axle cradle, rear 2 Axle cradle, rear

3 Axle cradle, rear 4 Axle cradle, front
5 Axle cradle, front 6 center hinge pin, lower
7 Sttering cylinder pin, rear 8 Drive shaft, Pillow block

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Front frame

4 5
9 10

3
7 8

1 2
6

3
10
5
1 2 9 6 7

1 Steering cylinder pin, front 2 Boom lift cylinder pin, lower

left
3 Bucket tilt cylinder pin 4 Boom lift cylinder pin, upper
left
5 Lift arm pin, left 6 Driveshaft bearing
7 Boom lift cylinder pin, lower 8 Boom lift cylinder pin, lower
right left
9 Middle hinge pin 10 Lift arm pin, right
11 Bucket hinge pin (manual
lubr.)

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5.2.3 Functional description of the components

1 Solenoid valve Y2003

2 Low level switch S2008

1. Solenoid valve Y2003

The solenoid valve controls the flow of servo oil (35 bar) to the double
acting grease pump for operation of the lubrication device. When the status
of the valve changes, the lubrication device pushes lubrication grease to
the lubrication line. Lubrication grease is pushed to lubrication lines 1 and 2
alternately. Return oil (approx. 5 bar) is supplied to the top of the lubricant
barrel to give positive feed to the follower plate.

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2. Low level switch S2008

The level switch indicates too low a level in the central lube reservoir. When
the grease level is too low the low level switch closes and the lubrication
function is disabled. The low level switch opens when the tank is filled.

1 Doser group
2 Pressure switches

1. Doser groups

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A doser group consists of a base plate and dosers installed onto the base
plate. The base plate divides the lubricant to the dosers, which feed the
preset amount of lubricant to the lubrication points. The amount of grease
supplied to any given point can be adjusted at the doser.

2. Pressure switches S3009 and S3010

The pressure switches indicates pressure in lubrication lines. When the
pressure in the lubrication line is sufficiently high, the contact closes.
Pressure should be 40 bar.

When changing the dosers, make sure there is no pressure in the

system.

Note! If the doser screws are tightened too tightly, the operation of the
doser might be prevented. The maximum tightening torque for the
screws is 8 Nm.

Note! When replacing dosers, make sure corresponding parts are used.

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5.2.4 Filling the central lube reservoir

The central lube reservoir is filled through a filling nipple at the high-
pressure filter housing. The central lube reservoir is full when lubricant
overflows from the safety valve of the central lube reservoir. When the
central lube reservoir is full the follower plate is in its upper position. If there
is air in the central lube reservoir it can be removed as follows:
1. Open the hexagonal plug in the cover of the central lube reservoir.

2. The bleeding screw in the follower plate shall be opened for about three
turns and filling of the central lube reservoir with grease continued until
completely airless lubricant comes out of the bleed screw.
3. Close the bleed screw fully.
4. Refit the hexagonal plug.
Bleeding is normally required only on the first initial filling of a new
lubrication unit or after overhaul. During the following fillings the central
lube reservoir does not have to be bled, if it is certain that there is no air in
the central lube reservoir and it has not got there during the filling.

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5.2.5 Bleeding the pump

If there is air in the pump, the pressure of the lubricant in the main piping of
the system may not increase high enough resulting in an alarm. The pump
must be bled as follows:

A Symmetrical Recycler (On First)

B Time Multiplier (Scale 1 To 10)
C Time Range (1 To 60 s)

1. Adjust the lubrication time relay by adjusting the time multiplier knob to
position 3.
2. Operate the system at reduced cycle intervals.
3. Open the bleeding screws in the housing of the non-return valves for
about three turns.
4. The pump is allowed to work until fully airless lubricant comes out of the
holes in the bleed screws during the pressurising period of both lines.
5. Screw down the bleed screws and reset the lubrication time relay to
normal cycle interval by adjusting the time multiplier knob back to
position 10. Check time range is set to 60 seconds.

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5.2.6 Main piping

When filling or bleeding air from the piping, the following measures must be
taken into account:
All closing plugs of the dosing modules and pipe branches must be
removed. The pump is operated until fully airless lubricant comes out of the
closing plugs nearest to the pump and the plugs involved are fastened.
Above mentioned measures are repeated until fully airless lubricant comes
out of the openings. Work from closest to the lubrication unit to the farthest
point.

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5.2.7 Doser adjustments

4 5 9 10

3 7 8

1 2 6

Doser No Target Stroke

1 Steering cylinder front end 10 mm
2 Lift cylinder lower end, left 10 mm
3 Tilt cylinder 5 mm
4 Lift cylinder upper end, left 10 mm
5 Lift arm, left 10 mm
6 Drive shaft support bearing 2 mm
7 Lift cylinder lower end, right 10 mm
8 Lift cylinder upper end, right 10 mm
9 Centre articulation bearing,lower end 10 mm
10 Lift arm, right 10 mm

1 2 3 8

4 5 6 7

Doser No Target Stroke

1,2,3 Oscillation, rear cover 10 mm
4,5 Oscillation bearing, front and rear 10 mm

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Doser No Target Stroke

6 Centre articulation bearing upper end 10 mm
7 Steering cylinder rear end 10 mm
8 Drive shaft, pillow block 10 mm

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5.2.8 General troubleshooting

Funktion disturb- Cause of the function

Way of repairing
ance disturbance
The alarm-signal The level switch in the lu-
Fill the lubricant barrel.
light is illuminating. bricant barrel gives alarm.
The main pipe between
The alarm-signal Locate and repair the
the pump and the dosing
light is illuminating. leakege.
module leaks.
The alarm-signal
Air in the pump. Deaerate the pump.
light is illuminating.
The alarm-signal Deaerate the main pip-
Air in the main piping.
light is illuminating. ing.
Regulate the pressure
at least at 10-12 bar.
Hydraulic pressure is in-
(Note! sometimes oc-
sufficient.
casional changes in
Sometimes occasional
The alarm-signal pressure may give
changes in pressure may
light is illuminating. cause to the lightning of
cause the lub warning
the alarmsignal lamp
symbol to light up even if
even if no visible cause
no visible cause is found.
for the alarm could be
observed later.)
One bearing gets too Increase the amount of
little lubricant or The lub dose is too little. grease. Adjust the dos-
nothing at all. er stroke.
The lubrication pipe be-
One bearing gets too
tween the dosing module
little lubricant or Check and repair.
and the lubrication point is
nothing at all.
damaged.
One bearing gets too A mote in the dosing mod-
Change or clean the
little lubricant or ule prevents the feeding
dosing module.
nothing at all. piston from moving.
The normal working pres-
Increase the working
One bearing gets too sure is insufficient be-
pressure temporarily or
little lubricant or cause of non-return pres-
clean the lubrication
nothing at all. sure caused by blockage
point.
in a bearing.

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Funktion disturb- Cause of the function

Way of repairing
ance disturbance
Change the grease for
Grease has stiffened (e.g. a thinner and more col-
One bearing gets too with cold) in the piping dresistant one. In-
little lubricant or and the dosing module crease the working
nothing at all. does not receive enough pressure temporarily. If
pressure. this does not have any
effect, warm the piping.
A bearing gets too
much lubricant al- The dosing module is Change the dosing
though the dosage damaged. module.
adjustment is small.

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6 Fire Suppression System

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6.1 Ansul
6.1.1 Main components

7
4

2
1

1 Dry chemical tank 2 Pressure switch

3 Nitrogen cartridge 4 Remote actuators
5 Nozzles 6 Detection circuit
7 Checkfire unit (option)

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6.1.2 System description

The A-101/LT-A-101 system consists of three major components: a
container to store the dry chemical extinguisher agent; an actuation system
operated manually or automatically, and an agent distribution system which
delivers the agent from the tank through hydraulic hose and fixed nozzles
to the hazard areas. The system layout is setup so that all the fire hazard
areas are covered by extinguishing spray. The hazardous areas are areas
with oil/fuel lines near hot surfaces and electrical wiring.
Note! Activation of the fire suppression system causes the engine to shut
down automatically (when pressure drops, pressure switch opens).

Pressure switch, location may vary depending on unit equipment

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6.1.3 Ansul system operation

2
1
8
3

The system can be activated manually from a valve inside the driver’s cabin
or from a unit that is fitted externally in an easily accessible location on the
vehicle (back of the machine).
Discharge of the A-101/LT-A-101 system manually is initiated from a remote
actuator (1). Depressing the actuator plunger punctures the seal on the
cartridge. The released pressure is transmitted to the pneumatic actuator/
cartridge receiver (2). A safety relief valve (3) at this point prevents too high
an actuation pressure build-up. The pressure drives a puncture pin through
the seal in the expellant gas cartridge (4). This releases the expellant gas
which is then transmitted to the dry chemical tank (5) where it fluidizes the
dry chemical before carrying it to the fire hazard. A sealed burst disc
assembly (6) prevents the flow of dry chemical until sufficient pressure is
built up within the dry chemical tank. When the proper pressure is reached,
the disc breaks allowing the gas/dry chemical mixture to flow to the
nozzle(s) (7) and discharge onto the hazard. Line to optional pressure
switch (8). Line from automatic detection system (9).

Note! An A-101/LT-A-101 system does not remove the need for a hand
portable fire extinguisher on the equipment.

When recharging the suppression system: Only authorized service

people may remove and refill powder / nitrogen gas tanks or
pressurize the system.

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6.1.4 Ansul Checkfire system (optional)

Checkfire system consists of detection wiring, control module, actuator with
nitrogen cartridge, mounting bracket, and squib.
Checkfire system contains its own internal Lithium batteries as the power
source. The 3.6 VDC internal lithium battery is connected to the control
module by a removable type plug. The battery must be replaced annually or
when the Yellow Battery LED and sounder are pulsing.
See separate Ansul fire suppression system manual for detailed
information of the checkfire system.

6
1
5
2

Checkfire control module front panel indicators

1 Battery (yellow) 2 Alarm (red)
3 Detection (yellow) 4 Release (yellow)
5 Power (green) 6 Sounder

1. Battery (Yellow)
• LED pulses once every 10 seconds when indicating battery trouble
• The yellow battery trouble LED will pulse when a low power condition is
detected in either of the connected supplies (internal or external). If only
one power source is used, the control module will automatically ignore
the unconnected circuit upon resetting the control module. If a power
source is once connected and recognized, a subsequent loss of that
power source will be recognized as a Battery Trouble condition. If a
power source is once connected, recognized, and then disconnected, the
disconnected supply can be ignored by operating the RESET button.

2. Alarm (Red)
• The alarm LED will flash if an alarm condition exists. An alarm condition
is caused by operation of the detection circuit or operation of the manual
pull/pressure switch input circuit. The alarm condition will continue until
the source of the alarm is removed and the control module is reset.

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• DETECTION CIRCUIT ACTIVATION MODE - Upon receipt of an input to

the detection circuit, the Alarm LED and the sounder will pulse at a rate
of 2 times per second and will continue at this rate until the first time
delay period has expired. After the first time delay, a second time delay
mode is initiated. This causes the LED and sounder to pulse at a rate of
4 times per second. After discharge, the LED and sounder will continue
to pulse at a rate of 4 times per second for 30 seconds. After that, it will
switch to the trouble mode and pulse once every 10 seconds.
• ELECTRIC MANUAL RELEASE MODE - The first time delay mode will
be by-passed and the LED will pulse at a rate of 4 pulses per second.
After the time delay setting is reached, it will pulse another 30 seconds at
the same rate. After that, the control module will go into the post-
discharge mode, at which time the Alarm LED and Release LED will
pulse at a rate of one pulse per 10 seconds.
• PRESSURE SWITCH CIRCUIT (FEED BACK) ACTIVATED MODE -
When this mode is actuated, the Alarm LED will pulse a minimum of 30
seconds at 4 pulses per second. The control module will then go into the
post-discharge mode and the Alarm and Release LED will pulse at a rate
of one pulse per 10 seconds.

3. Detection (Yellow)
• The Yellow Detection Trouble LED and the audio pulse once every 10
seconds when the control module detects a trouble in the detection
circuit. The control module will automatically return to normal when the
trouble is cleared.
• The sounder gives the audio indication for all alarm and trouble outputs.
The sounder will pulse at the same rate as the visual corresponding LED.
• The sounder gives the audio indications of the various outputs. The
sounder is rated at 85 Db at 10 feet.
• The pulse rates are as follows:
- Alarm
- Time Delay 1 = 2 pulses per second
- Time Delay 2 = 4 pulses per second
- Trouble
- 1 pulse per 10 seconds
- Loss of Power
- 1 pulse per 10 seconds
- Release Circuit Fired
- 4 pulses per second for 30 seconds, then 1 pulse per 10
seconds
- Low Battery
- 1 pulse per 10 seconds

4. Release (Yellow)
• The Yellow Release LED and the audio will pulse at a rate of once every
10 seconds when a trouble condition is detected in the release circuit.
The control module will return to normal when the trouble condition is
cleared.

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• The Release trouble will also pulse after the system has completed a
discharge cycle or a pressure switch feed back signal has been received.
The trouble signal in this condition is used to indicate a recharge of the
fire suppression system is necessary. A Release trouble under either of
these conditions can only be cleared by resetting the control module.

5. Power (Green)
• LED pulses once every 3 seconds when indicating normal power.
• The green Power Normal LED pulses "on" once every 3 seconds
indicating power is normal from both sources of input power. If the power
drops below an acceptable level from either the internal or external
source of input power, the green Power LED will be extinguished. If only
one source of power is used, the green Power LED will extinguish when
the voltage level drops below an acceptable level.
6.1.5 System Specifications
Ansul

Dry chemical tank capacity 11,3 kg FORAY multi purpose dry chemical
Cartridges 122,5 bar at (+21 °C)
Number of nozzles 6

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6.1.6 Location of nozzles and actuators

2
9

1 Rear corner, left 2 Pump drive unit

3 Dropbox 4 Fuel lines
5 Intake/Turbo 6 Exhaust piping
7 Rear frame actuator 8 ANSUL tank assembly
9 Operator Compartment 10 Checkfire unit
actuator

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6.2 Fire suppression system control

Measurement data of the modules (requires service password)

The measurement data windows show the values and statuses of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want on the measurements menu window
and press theOk button. The measurement data window of the connector
opens.
The connector pins for emergency stop are listed in “Inputs” and
“Outputs” tables in section System notifications and troubleshooting
(Fire suppression system control).
6.2.1 System notifications and troubleshooting (Fire suppression system control)
When “fire suppression released” input comes active, “Emergency stop
enable” output is reset, causing an emergency stop situation.

Inputs
Signal level Connector
Actuator Description Module
pin
Fire suppres- FireSuppression-
24 V / Float Middle XM1.20
sion Released

Outputs
No outputs.

Module No Alarm text Alarm log

Fire suppression alarm acti-
Chair 31 X
vated. E-stop activated.

Description: Fire suppression alarm activated. E-stop activated.

Action: No action

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7 Cabin

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7.1 Main components (Machines with canopy)

K0065 S0051
DISP. H0018 H0035
K0025 


S501
K0113





H0062
K0005 


H0014
K0006



H0027



K0029 


X0286
K0031 S0007
K0255

S0002
S0064
S0006
S0008
S0001 S0004



1111

S0053
G0003 S0056
G0004 X0124

0000 

S0036
X0125 X0126

K0005 Rear light switch K0006 ANSUL

K0025 Bucket counter K0029 Rear lights
K0031 Cabin corner light K0065 Emergency steering pump
K0113 Ejector Bucket (option) K0255 Fire extinguisher (option)
H0014 Alarm light red H0018 Alarm light yellow
H0027 Fuse blown, Front frame H0035 Low charging light
H0062 Fuse blown, Rear frame
S0001 Front lights S0002 Rear lights
Parking brake control but-
S0004 Ignition key S0006
ton
S0007 Blinkers S0008 R-C Mode switch
S0036 Brake test S0051 Emergency stop
Emergency steering (op-
S0053 Brake release pump S0056
tion)

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Main circuit breaker re-

S0064 S501 VCM button panel
lease
X0286 12V output
G0003 Inverter G0004 Inverter
1111 Chair module DISP VCM system display
VCM-display program
X0124 X0125 CAN-Open connector
connector
Engine diagnostic con-
X0126 CAN-BUS connector 0000
nector

5
2 4

1 Ansul actuator 2 Checkfire control box

3 Steering joystick 4 Brake pedal
5 Speed pedal 6 Door switch
7 Bucket and boom joystick

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7.2 Functional description of components

7.2.1 Seat controls
The operator’s seat features several controls that can be adjusted for the
operator’s comfort.

3
4

1 Lower back support

2 Seat belt
3 Back rest
4 Seat suspension
5 Forward and backward position

1. Lower back support

To adjust the lower back support turn the dial clockwise or counter
clockwise.
2. Seat belt
When the entire seat is in the desired position, fasten the seat belt (2) over
your lap. Adjust the length by pulling the loose end of the belt out until the
belt fits firmly over your lap.
3. Back rest
To adjust the position of the back rest, pull down the lever (3) in right side of
the seat. Push back on the back rest or allow the back rest to come forward
to achieve a comfortable position.
4. Seat suspension
To adjust the suspension, turn the suspension dial (4) until it reads your
approximate weight in kilograms (kg).
5. Forward and backward position

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To adjust the forward and backward movement, pull up on the lever (5)
mounted on front of the seat and move the seat to a comfortable position.
Make sure you can press both pedals to the floor.
NOTE! A correctly functioning and individually adjusted operator seat is
essential to your health. Take adequate care of your seat and have it
serviced regularly to ensure that it functions correctly.
NOTE! The operator seat may only be fitted, serviced and repaired by
specialist personnel, in accordance with national regulations and the
machine manufacturer’s fitting instructions. In the event of incorrect
assembly and/or repair, all warranty and liability claims shall be null and
void. The fitting regulations can be obtained from Sandvik Mining and
Construction.
7.2.2 Steering joystick
When moving the steering pilot control lever (V1111), pilot pressure (35 bar)
flows from control valve to main valve (V3102) and moves the main valve
spools. High pressure oil flows through main valve (V3102) to steering
cylinder (A3121) and the machine turns. When the steering control joystick
is returned to the center position the pressure affecting on the main valve
spools is relieved and the centering springs centralize the spool so that the
cylinder ports will be closed.
7.2.3 Boom and bucket joystick
When moving the bucket pilot control joystick, pilot pressure (35 bar) flows
from control valve to bucket main valve (V3201) and moves the main valve
spools. High pressure oil flows through main valve (V3201) to lift (A2221) or
tilt (A2222) cylinders and the bucket moves. When the bucket control
joystick is returned to the center position the pressure affecting on the
bucket main valve spools is relieved and the centering springs centers the
spool so that the cylinder ports will be closed.

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7.2.4 Door switch

The door switch S1147 has three sets of contacts; NO = Normal open and
NC = normal closed. The system interprets the door to be closed only when
the NO-input has no voltage but the NC input has voltage. The system
interprets the door to be open, if the NO-input has voltage but the NC has
no voltage. If both of the door switch inputs are simultaneously energized or
de-energized for more than the time period set with the parameter, it is an
error condition and an alarm will be given. Third contact NO is controlling
voltage direct from battery to cabin lights. When the door is open, cabin
lights will illuminate.

Inputs
Actuator Name Signal level Module Connector pin
Door open
switch (S1147) 24 V / Float,
Door switch Chair XC2.18
normally open 24V = open
(NO)
Door open
24 V / Float,
switch (S1147)
Door switch 24V = Chair XC2.21
normally closed
Closed
(NC)

Outputs
Actuator Name Signal level Module Connector pin
Door switch op-
Door switch 24 V / 0 V Chair XC2.23
erating voltage

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Door status control

The door switch has a safety classification, which has two separate working
outputs opposite of each other. NO= Normal open and NC= Normal closed.
The only state that the system interprets the door to be closed is when the
NO input does not have any voltage and the NC output has voltage. The
system interprets the door to be open if the switch outputs are in the same
state (either open or closed), if the NO inputs have voltage and NC outputs
do not have any voltage. If both of the door switch outputs are open or
closed simultaneously for more than the time period set by a parameter, an
alarm will be given of an error state.
If there is an error in the door switch, this information will be brought to the
alarm log and the monitoring channel.

Testing the door switch

Button test window 1 is used for testing the door switch functions. The two
buttons to the right of the door symbol indicate the status change when the
door is opened or closed.
The info window shows the door switch test symbols.

Forced functions (requires service password)

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NOTE! Test functions may cause unexpected movements of the machine.

Always be sure when test functions is done there is no-one beside the
machine and the machine has enough free space.

Forcing the door switch

Force the door switch status (open/closed) by using the Door switch forcing
window.

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1. Set a forcing value for the door switch control.

• Close = close the door.
• Open = open the door.
2. Start the forcing by pressing the SEND button.
• The forcing function will remain active until leaving the window.
• The forcing function controls the door in all situations.
• Using the door switch forcing function will leave a marking in the
alarm log.
NOTE! Pressing the SEND button forces all the functions that are selected
to be forced. If multiple functions are forced simultaneously, make sure that
the forcing values are logical.

Measurement data of the modules (requires service password)

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System notifications and troubleshooting (Door status control)

Inputs
Actuator Description Signal level Module Connector pin
Door switch Door open NO Float / 0 V Chair XC2.18
Door switch Door open NC Float / 0 V Chair XC2.21

Outputs
Actuator Description Signal level Module Connector pin
Door switch supply
Door switch 24 V / 0 V Chair XC2.23
voltage

Module No Alarm text Alarm log

Module supply pin XC2/23 short to
Chair 37 X
ground
Module supply pin XC2/23 short to
Chair 38 X
external voltage

Description 1: Module supply pin XC2/23 short to ground

Action 1: Wire harness
• Detach the Chair module connector pin XC2.23.
• Turn off the system’s operating voltage and turn it back on again.
• If the alarm does not go on again, the fault is in the cabling, short circuit
to ground.
• Restart the control system after repairing the cabling.
Action 2: Module
• If action 1 does not correct the malfunction, the Chair module may be
broken. Change the module if needed.
Description 2: Module supply pin XC2/23 short to external voltage
Action 1: Wire harness
• Detach the Chair module connector pin XC2.23.
• If the alarm does not go on again, the fault is in the cabling, short circuit
to operating voltage.
• Repair the wiring.
Action 2: Module
• If action 1 does not correct the malfunction, the Chair module may be
broken. Change the module if needed.

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Module No Alarm text Alarm log

Cabin door switch error, both con-
Chair 65 X
tacts open
Cabin door switch error, both con-
Chair 66 X
tacts close

Description: Cabin Door switch error both open (both door switches open)
or Cabin door switch error both close (both door switches closed)
Action 1: Wire harness
• When the door is open, the voltage of connector pin XC2.18 should
measure 24 V.
• When the door is open, the voltage of connector pin XC2.21 should
measure 0 V.
• If the voltage measurements are incorrect, repair the wire harness of the
door switch.
Action 2: Module
• If action 1 did not correct the malfunction, the module may be broken.
Change the Chair module if needed.
7.2.5 Speed pedal
The speed pedal V3782 is single acting hydraulic remote control. When you
press the pedal, it releases proportional pilot pressure from 5 to 21 bar.
The engine RPM is controlled to a fixed RPM figure defined by a
parameter. After starting the engine, the RPM is controlled to “idle RPM”.

Speed pedal control

Engine RPM is controlled to fixed RPM figure defined with parameter. After
starting the engine, engine RPM is controlled to “idle RPM”.
With “Constant engine speed” input the engine RPM can be controlled to
value determined by “constant engine RPM” parameter. With the same
input engine RPM can be controlled back to idle RPM.
The number of revolutions are shown by the tachometer in the main
window. The bars of the tachometer darken as the number of revolutions
increase. (each bar represents 200 RPM) Below the bars of the
tachometer, revolutions are also shown as a number value.

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7.2.6 Brake pedal valve

V1501

138 bar

P A
T

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Using the display module

The system is used with the display module’s five buttons (buttons 1-5). By
pressing the buttons, the user can move from one display window to
another and adjust the system’s functions and setting values.
The functions of the buttons vary depending on the display window. The
symbols at the bottom of the display window show which function is
activated by pressing a button. For example, pressing the buttons on the
main window shown in the picture above opens the following display
windows (the main window opens when the system’s operating voltage is
switched on):

Button Symbol Function

When the button is pressed, the service window opens.

When the button is pressed, the display information change.

(km/h, km, m, kg, h e, h m)

When the button is pressed, the alarm log opens.

When the button is pressed, the information window for the

main window opens.

When the button is pressed, gauge window 1 opens.

External display buttons

An external keyboard is used to control the VCM display in the same way
as the display buttons.

Refer to the chapter "Using the display module".

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

1 2

5
6

7 8 9 10 3

1 Bucket counter 2 Time

3 Forward screen (gauge 4 Fuel gauge
window 1/3)
5 Function status 6 Tachometer
7 Service window 8 Display options
9 Alarm log window 10 Information window

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Symbols on the display windows

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

Moving from one display window to another

Symbol Function
Moving to a previous display window level. For ex-
ample, returning from the gauge windows to the
main window.
Moving to the next window on the same display win-
dow level. For example, moving from gauge window
1 to gauge window 2.
Moving to the previous window on the same display
window level. For example, moving from gauge win-
dow 4 to gauge window 3.

Scrolling down.

Scrolling up.

Moving in the menu windows

Symbol Function

Moving to the next item on the menu.

Moving to the previous item on the menu.

Activating a menu function.

Adjusting the setting values

Entering to system service functions requires service level
password. Entering is allowed only by Sandvik Mining and
Construction's trained technical personnel.

It is very important, that the service password is not given to any

unauthorized persons. Any unauthorized use of the service menus
may result in serious malfunctions. The service password may only
be given to a service person sufficiently trained by Sandvik Mining
and Construction.

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Symbol Function

Moving to the next item on the menu / increasing the

setting value.

Moving to the previous item on the menu / decreas-

ing the setting value.

Activating a menu function / accepting an adjusted

value.

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Display information in the Main window

By pressing the info button (button 2), you can select the measurement
shown in the upper part of the main window and gauge windows. Every
short push of the button changes the measurement shown. After the last
measurement option is shown, the next push of the info button will show
the first measurement again.
Driving speed is the default measurement which will appear everytime the
power is turned on again. The following measurements can be selected:

Speedometer: machine driving speed

Odometer: machine distance travelled in kilometers

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Trip meter: machine distance travelled in meters

• By pressing the info button for three seconds, the Trip meter resets to 0.
• If the button is not pressed for a full three seconds, the measurement
option will change.

Machine hours

Bucket scale

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Tachometer

The tachometer is in the centre of the main window. The arch aligned bars
become green according to the engine rpm. Underneath the bars, rpm is
also shown in numeric value.

Fuel gauge
The fuel gauge is in the main window on the right- hand side of the
tachometer.

The vertically aligned bars become green according to the fuel level (all
bars green= the tank is full).
When the fuel level is low (below or at the warning level), only the lowest
bar is yellow and the symbol of the gauge flashes between black and red.
Refuel immediately.

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Function status

Automatic central lubricationBlinkers (optional)Emergency steering

(optional)Parking brake (wheel brakes)Brake accumulator pressure
low
There are status symbols in the main display which indicate the status of
various functions.

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

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

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

The symbol to the right on the main window tells the status of the parking
brake (wheel brakes). The symbol is grey when the parking brake is
released, and becomes red when the parking brake is engaged.

The symbol to the right on the main window tells the status of the brake
accumulator pressure. The symbol is grey when the accumulator pressure
is ok, and becomes red when the accumulator pressure is too low.

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Gauge displays

Gauge displayGauge display 1/3Gauge display 2/3Gauge display 3/3

Enter the gauge window by pressing next window “>>” button on the Main
window.
There are four gauge windows and they can be seen by using next window
“>>” and previous window “<<” buttons.
▲ Moves back to Main window.
?Opens the gauge information window which gives detailed information of
the measured value.

1 2 3

1 Hydraulic oil temperature

2 Boost pump pressure
3 Drive pump oil temperature

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1 2 3

4 5

1 Engine oil pressure

2 System voltage
3 Engine running temperature
4 Turbo pressure
5 Hourmeter (machine / engine / transmission)

1 2 3

1 Brake circuit charging pressure

2 Brake circuit 1 pressure, front
3 Brake circuit 2 pressure, rear

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

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Warning appears in the display with a blinking yellow warning triangle, an

exclamation mark inside.

Alarm appears in the display with a blinking red warning triangle, an

exclamation mark inside.

If any warning or alarm appears in the display, do not operate with

the loader until the cause has been determined and possible fault
has been repaired. Call a service person.

Display settings

Open the display settings window by pressing the Display settings button
in the service window.
This window is used for adjusting the contrast and brightness of the display
module and selecting the language of the user interface. Select the
language of the user interface from the languages that can be browsed in
theLanguage field.

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Bucket counter

The bucket counter is on the upper left corner of the main window (the
bucket symbol and a number).
The bucket counter value increases one every time you press the bucket
counter button on the dashboard or joystick. The bucket counter can be
reset by pressing the joystick button for more than two seconds.
The bucket counter reading can be set manually in the service menu.
Bucket counter can be reset with the Reset button and increase or
decrease the bucket counter value with the +/- button to its right.

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Time and Date

The current time is shown in the upper right corner of the main display.
To adjust the time, use the following instructions:
• Enter the service menu by pressing service button.
• Enter the service password window by pressing service button again.
• Enter the password and press OK
• Enter the time service window by choosing the Time and service and
pressing OK.
• Press + or- button until hours or minutes field becomes dark.
• Press OK button and after that + or — buttons to increase or decrease
the value.
• Press OK button to accept the value entered.
Date setting:
• Date setting is done in the same way as time setting as described above.

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Neutral brake
The neutral brake is taken into use with an option parameter.
The neutral brake prevents driving the machine downhill in neutral gear.
A window appears on the display that informs that the neutral brake is
activated.
The neutral brake engages the parking brake, when the gear has been on
neutral (Clutch pressure switch) for a time period defined with a parameter
(the default value is 3 seconds).
When the operator releases the parking brake, a gear must be selected
within the time period.

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Alarm log

The alarm log is a database where the critical warnings from the system
and all alarms are saved. This includes any unusual operation of the
machine or control system.
In the alarm log window, you can browse the alarms and warning sent by
the modules that are saved in the alarm log. Open the alarm log from the
main window or the gauge windows. The alarm log can also be opened by
pressing theAlarmlog button (this requires a factory password).
The alarm log symbol is red if new alarms have been recorded after it was
last browsed. It is light grey if there are no new alarms.
The alarm log is used as help in troubleshooting. It is possible to browse
each module’s error messages in the alarm log. Each error message is
shown on a separate line in the alarm log.
The information shown in an error message line from left to right:
• Status fo the alarm: on = alarm active, off = alarm not active
• New: A new alarm has been recorded after the log was last browsed
• The date and time of the alarm

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• The module or actuator that has sent the alarm

• Alarm number
• Count: the number of times the alarm has occured
• Reason for the alarm

Alarm log window 1

• The All button shows all alarms that have occured.
• The Events button shows all the events that have occured, e.g. entered
codes and alarm log cleared.
• The Active button shows the alarms which are currently active.

Alarm log window 2

• The CLEAR button clears the alarms from the display (does not delete
anything).
• The History button retrieves the alarms that were cleared with the
CLEAR button back to the display.

Alarm log window 3

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• The To File button saves the alarm log as a file named

alarms.XXXXXXX.txt into the disply’s file system (”XXXXXXX” is the
serial number of the machine). If needed, the file can be sent to an
update display or with an update display application on a computer to the
computer’s hard disc. You can also send the log to a computer’s hard
disc with Etools.
• TheTo USB button saves the alarm log to a USB stick, when the USB
stick is connected.
• The Show Log button shows all the alarms that have been recorded into
the alarm log, as separate entries, without the count.

7.3 Removing the operator's compartment

1. Shut down the engine.
2. Make sure that the machine is on a level surface, the parking brake is
applied and movement is prevented with wheel chocks.
3. Make sure that the bucket is lowered and the boom is resting on the
stops.
4. Install the frame locking device.
Installing the frame articulation locking device is presented in chapter
Safety and Environmental Instructions.
5. Remove the electric cables connected to cabin’s bulkhead panel, and
protect the connectors.
6. Disconnect all hydraulic hoses and piping from the cabin.
• Plug open ends.
7. Connect the lifting chains securely to the cabin.
• Then take the weight of the cabin on the hoist.

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8. Remove the right side screws of the cabin

• You must remove the cover plate to remove the right-rear cabin
screw.

9. Remove the left-side cabin screws.

• You must remove the steering cylinder cover to gain access to the
left-side cabin screw

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10. Slowly lift the canopy from the frame.

• Make sure that all the hydraulic hoses and electrical cables going to
the cabin are detached.

7.4 Installing the operator's compartment

1. Make sure that the machine is on a level surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Make sure that the bucket is lowered and the boom is resting on stops.
3. Install the frame locking device.
• Installation is presented in chapterSafety and Environmental
Instructions.
4. Slowly lift the canopy on to the frame.
• Make sure that none of the hydraulic hoses and electrical cables
going to the cabin are caught between the canopy and frame.

5. Install the left-side cabin screws.

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6. Install the right side screws of the cabin

7. Install the steering cylinder

• Installation is presented in chapter Steering section Installing the
steering cylinder.
8. Install all hydraulic hoses and piping from the cabin.
9. Install the electric cables connected to cabin’s bulkhead panel.
10. Install the fire suppression system cables and hoses.

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11. Install all of the canopy cover plates.

7.5 Removing the seat

WARNING
LIFTING WARNING
The object being lifted is heavy. Assistance may be required when
lifting object.
Make sure that the lifting equipment is in good condition and
correctly rated. Always obey local rules and safety regulations.

1. Read the seat operating instructions from the operators manual.

2. Move the seat forward to access the rear mounting bolts.
3. If an air ride seat is fitted, remove the electrical wiring from the seat
4. Remove the mounting bolts from the seat.
5. Remove the seat from the cabin.
6. Repair the seat if possible or replace it.

7.6 Installing the seat

1. Read the seat operating instructions from the operators manual.
2. Make sure that the seat cover is fitted to the seat.
3. Lift the seat up and into position in the cabin carefully.
4. Refit the mounting bolts to the seat tensioning them once they are all
fitted. Also check the operation of all the functions of the seat.
5. Check that the seat can move forward and back freely on its slides. Also
check the operation of all the functions of the seat.

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6. Where an air ride seat is fitted the following additional steps must be
taken:
• Refit the electrical wiring.
• Turn ignition key on and check that the air bag inflates and deflates
correctly.

7.7 Parking, braking and blinker lights control

Parking lights
Parking lights are on when the parking brake is engaged. The driving
direction of the machine is indicated by switching the parking lights on at
only one end of the machine at a time.
The rear park lights are on when the driving direction is forward, and the
front park lights are on when the machine is being reversed.
Both the front and the rear parking lights are on when the gear is in neutral
or the parking brake is engaged.

Brake lights and blinkers (turning direction lights)

Controlling front and rear brake lights is the same as controlling the
machine‘s brake lights. Blinkers / direction lights indicate which way the
machine is turning (brake light blinking).
Working lights refer in this document to cabin corner lights (and possibly
other lights connected to the same cabin module control) and loading lights.
Brake lights do not function, if the engine is not running.
The front brake lights are on, when the brake pressure is below the defined
parameter value and the gear is in reverse or neutral. Brake pressure
information comes from the brake pressure sensor.
The rear brake lights are on when the brake pressure is below the defined
parameter value and the gear is in forward or in neutral. Brake pressure
information comes from the brake pressure sensor.
Note! For safety reasons there are 2 brake circuits and both have a
pressure sensor. The brake lights are switched on, if the pressure of one or
both the circuits is below the parameter value. If pressure transducer is in
error state, brake lights are controlled, according to working transducer.
Pressure sensors are calibrated from the VCM display.
The blinkers function with a switch in the cabin. Brake lights, which function
the American way, work as blinkers. The blinkers function only, if the power
has been switched on with the ignition key. The on and off periods of the
blinkers can be set with a parameter.
Note! InfraFREE does not control the blinkers in any situation so far.

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Warning light (beacon)

The warning light (beacon) is the amber, rotating light on top of the
machine.
The warning light operation is selected with a parameter, to choose whether
the light is on or off.

Forced functions (requires service password)

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Forcing the digital outputs of modules

This window is used for forcing the digital outputs of each connector of a
module on or off:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• “1” forces the output on,
• “0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

Digital outputs of automatic central lubrication control:

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Function Module Connector pin

Beacon light Chair XC2.7
Brake lights / Blinker Front Left Middle XM1.14
Brake lights / Blinker Front Right Middle XM1.22
Brake lights / Blinker Rear Left Middle XM1.23
Brake lights / Blinker Rear Right Middle XM2.2
Directional light front (parking lights) Middle XM2.17
Directional light rear (parking lights) Middle XM2.23

Measurement data of the modules (requires service password)

The measurement data windows show the values and statuses of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want on the measurements menu window
and press theOK button. The measurement data window of the connector
opens.
The connector pins for parking, braking and blinker lights are listed in
“Inputs” and “Outputs” tables in section System notifications and
troubleshooting (Parking, braking and blinker lights control)

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7.7.1 System notifications and troubleshooting (Parking, braking and blinker lights
control)

System Interlocks
• Machine is in running state
• Ignition key must in “on” position, except parking lights are on in “parking”
position.
• All the lights are off, when the engine starts.
- The lights switch off, when the start-up alarm starts.
- The lights are switched back on two seconds after the start-up has
finished (the ignition key position).
- The parking lights will stay on during the start-up (because the
parking brake is on).

Inputs
Signal level Connector
Actuator Description Module
pin
Panel Blinker right Float / 0 V Chair XC3.16
Panel Blinker left Float / 0 V Chair XC3.17

Outputs
Signal level Connector
Actuator Description Module
pin
Directional light
Led-light rear (parking 24 V / 0 V Middle XM2.23
lights)
Directional light
Led-light rear (parking 24 V / 0 V Middle XM2.17
lights)
Brake lights /
Led-light Blinker Front 24 V / 0 V Middle XM1.14
Left
Brake light /
Led-light Blinker Front 24 V / 0 V Middle XM1.22
Right
Brake light /
Led-light Blinker Rear 24 V / 0 V Middle XM1.23
Left
Brake light /
Led-light Blinker Rear 24 V / 0 V Middle XM2.2
Right
Beacon Beacon light 24 V / 0 V Chair XC2.7

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Module No Alarm text Alarm log

Both blinker inputs are on simulta-
Chair 117 X
neously

Description: Both blinker inputs are on simultaneously

Action 1: Wire harness
• Detach the Chair module connector pins XC3.16 and XC3.17 and
measure the voltages of inputs (0 V / 27,5 V).
• If blinker inputs are on simultaneously when switching the input, check
cabling and switch.
Action 2: Module
• If action 1 does not correct the malfunction, the Chair module may be
broken. Change the module if needed.

Module No Alarm text Alarm log

Chair 83 Rotation beacon short cut X
Chair 84 Rotation beacon Voltage in pin X
Middle 168 Rear rightside light shortcut X
Middle 169 Rear rightside light Voltage in pin X
Left rear brake and blinker light
Middle 170 X
short to ground
Left rear brake and blinker light
Middle 171 X
short to external voltage
Driving direction reverse light short
Middle 172 X
to ground
Driving direction reverse light short
Middle 173 X
to external voltage
Driving direction forward light short
Middle 184 X
to ground
Driving direction forward light short
Middle 185 X
to external voltage
Middle 193 Front rightside light shortcut X
Middle 194 Front rightside light Voltage in pin X
Left front brake and blinker light
Middle 195 X
short to ground
Left front brake and blinker light
Middle 196 X
short to external voltage

Description 1: Shortcut on light pins connected in Chair- and Middle

module.
Action 1: Wire harness

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• Disconnect connector from Chair- or Middle-module that has caused

alarm:

Alarm no Connector Function

168 XM2.2 Brake blinker light RR
170 XM1.23 Brake blinker light RL
193 XM1.22 Brake blinker light FR
195 XM1.14 Brake blinker light FL
83 XC2.7 Warning light (beacon)
172 XM2.17 Directional light front
184 XM2.23 Directional light rear
• Check if alarm disappears when forcing corresponding output on (see
chapter ” Lights control”, section “Forcing the digital outputs of the
module”).
• If alarm disappears fault is in the wiring short to ground.
• Repair wiring.
Action 2: Module
• If action 1 does not correct the malfunction, the Chair or Middle module
may be broken. Change the module if needed.
Description 2: Voltage on light output when voltage is not controlled
Action 1: Wire harness
• Disconnect connector from Chair- or Middle-module that has caused
alarm:

Alarm no Connector Function

Brake blinker light RR Voltage in
169 XM2.2
pin
171 XM1.23 Brake blinker light RL
Brake blinker light FR Voltage in
194 XM1.22
pin
196 XM1.14 Brake blinker light FL
84 XC2.7 Rotation beacon Voltage in pin
Directional light front Voltage in
173 XM2.17
pin
Directional light rear Voltage in
185 XM2.23
pin
• Check if alarm disappears when forcing corresponding output on (see
chapter ”Lights control”, section “Forcing the digital outputs of the
module”).
• If alarm disappears fault is in the wiring short circuit to supply voltage.
• Repair wiring.

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Action 2: Module
• If action 1 does not correct the malfunction, the Chair- or Middle-module
may be broken. Change the module if needed.

7.8 Driving lights control

The driving lights include front and rear lights that are switched on with the
buttons on the dashboard. The driving lights are switched off when you
start the engine.There are seperate buttons for switching on the front and
rear lights.

Switch Relay Target

S0001 K0005 Front right and left light
K0006 Cabin corner light
S0002 K0029 Rear right and left light
K0031 Rear corner light

7.9 Sound and reversing signal

Sound signal
Every time the machine is started, the horn signal sounds for three
seconds. The horn signal also sounds by pressing the button in the cabin.

Reversing signal and light

The alarm signal for reversing indicates that the reverse gear is selected.
The sound signal warns that the machine is reversing, and at the same
time, the reverse light is on.
The sound signal’s pulse duration parameter is adjusts the sound signal
type. If the pulse duration parameter of the sound signal is set to zero, the
sound signal is continuous.

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Forced functions (requires service password)

Forced functions windows are used to control the machine’s different

functions by using the display module’s buttons instead of the machine’s
control buttons. A forced functions window can replace a broken control
actuator; for example, if the steering joystick is broken, the machine can be
driven for service using a forced functions window.
NOTE! Test functions may cause unexpected movements of the machine.
Always be sure when test functions are done that there is no-one beside
the machine and the machine has enough free space around it.

Measurement data of the Modules (requires service password)

The measurement data windows show the values and status of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want in the measurements menu window
and press theOK button. The measurement data window of the connector
opens.
The connector pins for Sound signal and reversing signal are listed in
the ”Inputs” and ”Outputs” in the section ”System notifications and
troubleshooting (Sound and reversing signal)”.

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Forcing digital outputs of the modules

This window is used for forcing the digital outputs of each connector of a
module on or off.
NOTE! The Dashboard and Rear modules’ connectors can be selected
only if there are five modules in the machine:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• “1” forces the output on,
• “0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

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The digital outputs of the sound signal and reversing signal:

Function Module Connector pin

Signal horn Middle XM 1.15
Reverse warning horn / light Middle XM 2.16

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7.9.1 System notifications and troubleshooting (Sound and reversing signal)

Inputs
Signal level Connector
Actuator Description Module
pin
Switch Horn 24/Float Chair XC3.18

Outputs
Connector
Actuator Description Signal level Module
pin
Sound signal Signal horn 24/0 V Middle XM1.15
Reverse warn-
Sound signal 24/Float Middle XM2.16
ing horn / light

Module No Alarm text Alarm log

Middle 91 Horn signal short to ground X
Middle 92 Horn signal short to external voltage X
Reverse warning buzzer/light signal
Middle 176 X
short to ground
Reverse warning buzzer/light signal
Middle 177 X
short to ext. voltage

Description 1: A short circuit to ground

Action 1: Wire harness
• Detach the connector pin that caused the alarm from the module:
Connector
Alarm No Function
pin
91 XM1.5 Horn signal
176 XM2.16 Reverse warning horn / light
• Check whether the alarm stops when you force the output in question on
the I/O Forcing window( see section “Sound and reversing signal",
section “Forcing digital outputs of the modules”).
• If the alarm stops, the fault is in wire harness, short circuit to ground.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the module may be broken.
Change the module if needed.
Description 2: Short to ext. voltage.
Action 1: Wire harness

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• Detach the connector pin that caused the alarm from the module:
Connector
Alarm No Function
pin
92 XM1.5 Horn signal
177 XM2.16 Reverse warning horn / light
• Check whether the alarm stops when you force the output in question on
the I/O Forcing window ( see section “Sound and reversing signal",
section “Forcing digital outputs of the modules”).
• If the alarm stopped, the fault is in wire harness, short circuit to ground.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the module may be broken.
Change the module if needed.

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8 Powerpack

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8.1 Engine
8.1.1 Technical data

Engine model Deutz BF4M2012C

Output capacity 93 kW (126 hp) @ 2500 RPM
Torque 445 Nm (330 lb.-ft.) @ 1500 RPM
Dry 390 kg
Weight
Wet 420 kg
Coolant filling capacity 13 L
Oil filling capacity 11 L
API-specification, CF-4, CG-4, CH-4, CI-4
Oil classification
ACEA-specification, E2-96, E3-96, E4-99
above -25 °C SAE 5W-40 / SAE 5W-30
Oil viscosity +5 °C... +30 °C SAE 10W-30 / SAE 10W-40
above +20 °C SAE 15W-40 / SAE 15W-50

Engine oil classification

The use of engine oil brands which have not been approved may lead to
increased wear or engine damage. Do not use any fuel additives.

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Only engine oils of the same grade and SAE class should be used when
topping up.
The SAE class (viscosity) of the engine oil must be selected according to
the average air temperature for the time of year. The exact use of SAE
classes according to the air temperature would result in regular engine oil
changes. For this reason, the temperature limits for SAE classes should be
taken as a guideline which can be exceeded or undershot temporarily.

Lube oil quality class Turbocharged engine

API-specification CF-4, CG-4, CH-4, CI-4
ACEA-specification E2-96, E3-96, E4-99

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. Do not use any fuel additives.
The use of engine oil brands which have not been approved may lead to
increased wear or engine damage. Refer to the Deutz Operation Manual for
further details.
See separate engine manufacturer's Operator Guide for further
information.

Valve clearance
• Inlet valve 0.3 mm ± 0.05 mm
• Exhaust valve 0.5 mm ± 0.05 mm

Starter motor
• Voltage 24 V
• Output 4,0 kW

Alternator
• Voltage 28 V
• Current rating 80 A

Tightening torques of the engine components are presented in the

Deutz operating instructions manual.

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8.1.2 Engine control

Use the ignition switch to start the engine. Every time the engine is started,
a warning signal sounds for 3 seconds, after this the engine starts.
When starting takes longer than a time period set with a parameter, the
starting is stopped. After this, the ignition switch must be turned to the “0”
position before restarting. When the engine is running, starting the engine
is disabled.
The system interprets that the engine is running when engine revolutions
and the engine’s oil pressure are above values set with parameters.
The emergency stop function prevents the engine from starting and the
engine shuts down.
The parking lights are on when the ignition switch is in the parking position.
(for more information, refer to chapter ”Lights”).
The system has an engine stop delay function in case a serious
malfunction occurs. This way, when you press the SEO (Stop Engine
Override) button, the engine keeps running for a time period set with a
parameter, during which the machine can be moved. If this function is used,
it will be recorded in the alarm log.
If the engine stops in an unusual way (not switched off with the ignition key,
but switched off with the DDEC system), the emergency steering pump will
be controlled.

Controlling engine revolutions

Engine revoutions are controlled by the Chair module’s throttle pedal.
Revolutions request are sent through the SAE J1939 bus to the engine.
The actual revolutions of the engine are read from the SAE J1939 bus.
Engine RPM is controlled to fixed RPM figure defined with parameter. After
starting the engine, engine RPM is controlled to “idle RPM”.
With “Constant engine speed” input the engine RPM can be controlled to
value determined by “constant engine RPM” parameter. With the same
input engine RPM can be controlled back to idle RPM.
The number of revolutions are shown by the tachometer in the main
window. The bars of the tachometer darken as the number of revolutions
increase. (each bar represents 200 RPM) Below the bars of the
tachometer, revolutions are also shown as a number value.

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Delayed engine shutdown

Delayed engine shutdown is an option, which can be activated by an option
parameter. Delayed engine shutdown activates, if boost pressure is too
high and engine is not allowed to shutdown, before pressure lowers
enough.
When delayed engine shutdown is activated, operator is informed with a
pop-up display. Pop-up display informs operator about the amount of time,
left to engine shutdown and that opening the door causes immediate
shutdown. Bypassing delayed engine shut-down causes alarm log entry,
which contains information about the reason, why the function is bypassed
(Open door or emergency stop).

Stop Engine Overdrive

The system has an engine stop delay function in case a serious
malfunction occurs. This way, when you press the SEO (Stop Engine
Override) button, the engine keeps running for a time period set with a
parameter, during which the machine can be moved. If this function is used,
it will be recorded in the alarm log.
If the engine stops in an unusual way (not switched off with the ignition key,
but switched off with the DDEC system), the emergency steering pump will
be controlled if the machine has the emergency stop function (for more
information, see chapter ”Emergency steering”)

Diagnostics window for engine

The sensor data for motor control is shown in gauge window 2:

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• Engine oil pressure: bar

• Battery voltage: V
• Engine cooling water temperature: °C
• Turbo boost pressure: °C
• Machine hours: h
Active alarms and warnings are shown with the following symbols in the
gauge window. The alarm symbol appears on the left hand side of the
sensor symbol that the alarm or warning applies to.
The alarm and warning limits of sensors are shown in the information
window.
The top of the gauge window, from left to right, shows the box counter
reading, the chosen measurement from the info button, for example, motor
operational hours, and the time.
Pressing the ? button in gauge window opens the info window. Info
windows give detailed information about the symbol meanings and the
alarm or warning limits set by the parameters.

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Testing the buttons

This window is used for testing the position data of the ignition switch.
When the function is activated, the picture of a button on the right side of
the symbol becomes black.

Ignition switch positions:

• P = Parking

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• I = Electric power on
• III = Starting the engine

Forced functions (requires service password)

NOTE! Test functions may cause unexpected movements of the machine.

Always be sure when test functions is done there is no-one beside the
machine and the machine has enough free space.

Controlling the engine

The window is used for forcing the following functions: inching, gearing,
starting/stopping the engine, and braking.

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The functions to be forced are chosen on the right-hand side column:

• Off = function not forced
• On = function forced
On the left-hand side column, the value can be set according to which
function is to be forced.
Forcing the motor to start/stop:
1. Select Start motor on/off as the function to be forced.
2. Set the forcing values for the control. Set the status of motor starting in
the left-hand side field:
• 0 = motor not started.
• 1 = motor started.
3. Set the status of the motor running in the middle field:
• 0 = motor not running.
• 1 = motor running.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
• All forcing is deactivated also when you leave the window.
5. Stop the motor by setting the value “0” in the middle field and pressing
the SEND button.
A forced function controls the motor regardless of the situation. Only
emergency stop prevents the controlling.
NOTE! Pressing the SEND button forces all the functions that are selected
to be forced. If you force multiple functions simultaneously, make sure that
the forcing values are logical.

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Forcing the digital outputs of modules

Digital outputs of engine:

Connector
Function Module
pin
Engine stop Middle XM 1.3
Engine start Middle XM 1.16

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Measurement data of the modules (requires service password)

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System notifications and troubleshooting (Engine control)

Inputs
Signal level Connector
Actuator Description Module
pin
Ignition
Engine start 24 V / Float Chair XC1.8
switch
Ignition
Engine stop 24 V / Float Chair XC1.14
switch
Ignition Ignition parking
24 V / Float Chair XC1.15
switch position
Engine bypass
Engine 24 V / Float Chair XC1.21
SEO
Constant en-
Engine 24 V / Float Chair XC2.5
gine speed

Outputs
Signal level Connector
Actuator Description Module
pin
Engine EngineStop 24 V / Float Middle XM1.3
Engine EngineStart 24 V / Float Middle XM1.16

Module No Alarm text Alarm log

No data received in SAE J 1939
Chair 64 X
from ECM

Description: No data received in SAEJ 1939 from ECM (Contact failure

between J1939 and CAN bus.)
Action 1: Wire harness
• Disconnect connectors XC4.7 and XC4.8. Measure the voltage of both
connectors against ground.
• The voltage should be around 2-3 V. The machine’s power must be
turned on and ignition key turned to position 1 (power on).
• If there is no voltage in the connector pin, repair the wiring.
Action 2: Cabling
• Turn the ignition key to position 0.
• Measure resistance between connector pins XC4.7 and XC4.8.
Resistance should be around 55 - 65 Ohm.
• If the resistance differs from the above, check the terminal resistor and
wiring.
Action 3:
• Contact Sandvik Mining and Construction services.

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Module No Alarm text Alarm log

Chair 67 Engine bypass SEO used X

Description: Engine bypass SEO used

Action: Engine bypass
• No action needed. This will be recorded in the alarm log.

Module No Alarm text Alarm log

Starting not allowed! Press brake
Chair 88
button down
Engine is tried to start while gear
Chair 98
button is not in neutral position
Engine starting not allowed. E-stop
Middle 126
state active!

Description 1:Starting not allowed! Press brake button down

Action 1: Wire harness
• Turn the key to the I position
• Check the status of the parking brake engage switch XC1.17 (see
chapter “Brakes control” section “Testing the buttons”. )
Action 2: Module
• If action 1 does not correct the malfunction, the Chair module may be
broken. Change the module if needed.
Description 2: Engine is tried to start while gear button is not in neutral
position.
Action: Set gear button is into neutral position.
Description 3: Engine starting not allowed. E-stop state active!
Action:See chapter ”Emergency stop control”.

Module No Alarm text Alarm log

Chair 85 Delayed engine stop popup
Door opened during delayed engine
Chair 86 X
stop
E-stop activated during delayed en-
Chair 87 X
gine stop

Description 1: Delayed engine stop popup

Action: No action
Description 2: Door opened during delayed engine stop
Action: Delayed shutdown bypassed, immediately shutdown

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Description 3: E-stop activated during delayed engine stop

Action: Delayed shutdown bypassed, immediately shutdown

Module No Alarm text Alarm log

Middle 67 Engine stop signal short to ground X
Engine stop signal short to external
Middle 68 X
voltage

Description 1: Engine stop signal short to ground

Action 1: Wire harness
• Detach the Middle module connector pin XM1.3.
• Check whether the alarm stops when you force the output in question in
the forcing digital outputs window(see chapter ”Engine control”,
section ”Forcing digital output of the modules”).
• If the alarm stopped, the fault is in the wire harness, short circuit to
ground.
• Repair the wiring.
Action 2: Module
• If action 1 did not correct the malfunction, the Chair module may be
broken. Change the module if needed.
Description 2: Engine stop signal short to external voltage
Action 1: Wire harness
• Detach the Middle module connector pin XM1.3.
• Turn off the systems operating voltage and then turn it back on again.
• If the alarm stops, the fault is in the cabling, short circuit to operating
voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 did not correct the malfunction, the Middle module may be
broken. Change the module if needed.

Module No Alarm text Alarm log

Middle 103 Engine start signal short to ground X
Engine start signal short to external
Middle 105 X
voltage

Description 1: Engine start signal short to ground.

Action 1: Wire harness
• Detach the Middle module connector pin XM1.16.
• Check whether the alarm stops when you force the output in question on
the I/O Forcing window (see chapter ”Engine control”, section ”Forcing
digital output of the modules”).

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• If the alarm stopped, the fault is in wire harness, short circuit to ground.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.
Description 2: Engine start signal short to external voltage
Action 1: Wire harness
• Detach the Middle module connector pin XM1.16.
• Check whether the alarm stops when you force the output in question on
the I/O Forcing window (see chapter ”Engine control”, section ”Forcing
digital output of the modules”).
• If the alarm stopped, the fault is in wire harness, short circuit to operating
voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.
8.1.3 Starting the engine
Note! Do not run the starter motor for longer than 20 seconds at a time.
Allow the starter motor to cool down for one minute before a new
starting attempt. If the engine does not start after two attempts, trace
the cause with the aid of the diagnosis chart found in separate Deutz
Daliaengine Operation manual.

Note! Only start the engine with securely connected batteries.

Use the ignition switch to start the engine. Every time the engine is started,
a warning signal sounds for a time period, after this the engine starts.
The emergency stop function prevents the engine from starting and
running.
The parking lights are on when the ignition switch is in the “0” position
Conditions that prevent starting:
1. The emergency stop mode is on
2. The gear is selected
3. Ignition key is in position “0”
4. Main circuit breaker is remote tripped from the cabin
Note! Activation of the fire suppression system causes the engine to shut
down automatically (When pressure drops, pressure switch S345
opens).

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8.1.4 Turning off the engine

Use the ignition switch to stop the engine.
Conditions that result in the engine being turned off:
1. The emergency stop mode is on
2. Ignition key is turned to position “0”
If the engine stops in an unusual way (the engine stops even though it has
not been switched off with the ignition key) the emergency steering pump
will be controlled if the machine has the emergency steering function (for
more information, see chapter Steering).
8.1.5 Jump-starting
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.

Only perform maintenance work when the machine is parked on a

If the battery is discharged, the engine can be started using jump leads and
a donor battery.
• Connect the positive terminals first and then the negative battery
terminals.
• Wait 5 minutes.
• Start the engine and allow to run for a short while.
• Remove the jump leads in the reverse order.
Note! Do not use rapid charger / welding machine to start the engine. This
may cause damage to the VCM-System.

Note! Only perform jump-starting with separate batteries. Make sure that
the donor battery and the starter battery has the same nominal
voltage. Otherwise a battery could be irreparably damaged.

Note! Only use insulated jump leads (cable cross section approximately 70
mm²) and insulated terminal clamps. There is a risk of short circuit.

Note! A discharged battery can freeze at about -10 °C; it must have thawed
out before jump-starting.

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8.1.6 Restarting an out of fuel engine

The system does not need to be bled unless it has been run completely dry.
Bleeding is then done by using the hand pump located on the fuel filters to
prime the system. Under normal operating conditions the systems bleeds
automatically.

1. The fuel system is bled when the engine is started after refueling if the
system was previously allowed to run dry.
2. Fill the fuel tank with recommended grade of fuel. If only partial filling is
possible, add a minimum of 40 liters of fuel in to the tank.
3. Start the engine and check for leaks. Shut down the engine before
correcting leaks.

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8.1.7 Changing engine oil and filter

Only perform maintenance work when the machine is parked on a

When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer’s requirements.

1. Ensure that the machine is on an level surface, the parking brake is

applied and movement is prevented by, for example, with wheel chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Install the frame locking pin.
Be careful when handling hot oil. Wear suitable protective gloves,
protective clothing and safety goggles when handling oil.

4. Run the engine until operating temperature is reached; then shut down
5. Position container under the drain plug to catch oil from engine.
6. Remove the drain plug and emptying oil to the container.

7. Reinstall drain plug, using a new gasket.

8. Check drained oil for excessive contamination eg. metal, aluminium or
rubber particles.

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9. Remove the oil filter.

10. Clean the mating surface of the oil filter housing.

Make sure that no pieces of old oil seal are left behind
11. Put a thin layer of engine oil on the seal rings of the new oil filters
12. Tighten the oil filters by hand.
Note! Oil filter must be changed with every oil change.
13. Fill engine with correct quantity (max. 11 l with filters) and type of oil to
bring the oil level to the FULL mark on the dipstick.
• Check right oil viscosity for different ambient temperatures from
section Technical data.

14. Start engine and run at low idle for 20-30 seconds.
• Check lube oil pressure reading.
15. Shut the engine down.
• Wait 5 min.
16. Recheck oil level and add oil if needed, bringing oil level to FULL mark
on the dipstick.
17. For further information, check Deutz Operation Manual.

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See separate engine manufacturer's Operator Guide for further

information.

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

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8.1.8 Engine mounts inspection

WARNING
HIGH TEMPERATURE WARNING.
A hot surface can cause injury
Wait for the engine to cool down before performing work on it.

1. Make sure that the machine is on an level surface, the parking brake is
applied and movement is prevented by, for example, wheel chocks.
2. Make that the bucket is lowered and the boom is resting on stops.
3. Install the frame articulation locking device.
4. Open engine covers to gain access to the engine.
5. Visually inspect the mounts looking out for:
• Condition of rubbers (deteriorated).
• Cracks.
• Bent or damaged components.
• Broken / loose bolts.

6. Check the tension of the engine mounting bolts, both on the engine and
the frame.
• Engine mounts, M16x120 8.8: 160 -180Nm
• Frame bracket, M16x55 8.8: 160 - 180Nm
• Frame bracket, M16x60 8.8: 160 - 180Nm
• Engine bracket, M12x15 8.8: 72 - 82Nm
7. Where accessible check the deflection of the mounts using a bar to lever
the engine mounts.
8. If the rubber isolators are worn, cracked, oil/heat effected, they will
require replacement.

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9. To replace isolators it will be necessary to raise the engine slightly to

allow removal.
• Use caution when raising the engine. Raise the engine just enough
to replace the isolator. Make sure that the engine/torque converter/
hydraulics pumps or wiring are not damaged.
10. Remove the engine mounting bolts.
• Lift the engine by using appropriate lifting tools. Raise just sufficient
to replace isolators.
• Disconnect hydraulic hoses and wiring if required.

11. Install new rubber isolators.

12. Replace engine mounting bolts and lower the power pack into position.
• Make sure that there are no hoses, wiring etc. between the engine
and frame when lowering the engine.
• Remove the lifting tools.
13. Tighten the engine mounting bolts.

See separate engine manufacturer's Operator Guide for further

information.

WARNING
FIRE WARNING
Leaks from damaged fuel and oil lines, tubes or hoses can cause
fires.
Tighten any loose connections and replace damaged oil lines, tubes
or hoses.

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8.1.9 Changing the engine drive belt

1. Remove the drive belt guard.
• Remove the 21 bolts holding the belt guards.
• Remove the 4 bolts from the radiator fan.

2. Remove the radiator fan

3. Insert a wrench into the belt tensioner (1) .
• Turn the tensioner and pull the drive belt off the pulleys.

2
1

4. Remove the drive belt (2).

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5. Install a new drive belt and re-adjust the tensioner.

6. Install the radiator fan.
7. Install the drive belt covers
8. Start the engine and observe that the belt is functioning correctly.

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8.1.10 Removing the engine

Only perform maintenance work when the machine is parked on a

See separate engine manufacturer's Operator Guide for further

information.

WARNING
HIGH TEMPERATURE WARNING
A hot surface can cause injury.
Only perform work on a cooled down engine.

DANGER
HIGH-PRESSURE OIL SPRAY HAZARD
The high pressure oil spray can cause serious personal injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

Be careful when draining hot coolant. Wear suitable protective

gloves, protective clothing and safety goggles when handling
coolant.

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Be careful when handling hot oil. Wear suitable protective gloves,

protective clothing and safety goggles when handling oil.

1. Make sure that the machine is on an level surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Make sure that the bucket is lowered and the boom is resting on it's
stops.
3. Install the frame articulation locking device.
• Installing of the frame articulation locking device is presented in
chapter Frame structures section Frame articulation locking device.
4. Before removing the power pack, drain the oil from the gearbox and the
engine.
5. Disconnect all fuel lines from the engine. Plug and clearly mark all open
hose ends.
• Remove auxiliary prefilter before engine cover lifting.

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6. Open the radiator cap.

• Expansion tank is equipped with a locking pressure release cap.

7. Open the tap on the radiator drain hose and empty the entire contents
into a container.
8. Close the tap on the radiator drain hose and clamp it back to the storage
position.
9. Disconnect coolant hoses from the expansion tank.

10. Disconnect low coolant level sensor wiring.

11. Disconnect the wiring P-clamps and fire suppression hosing from the
engine cover.
• Remove the fire suppression tank assembly if necessary.
• Note! Do not open fire suppression line connections if machine is
equipped with FS1000 fire suppression system. System must be
de-pressurized if line connections needs to be opened.

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12. Attach the lifting device to the engine cover assembly to support it.
• Make sure that the lifting device is in good condition and correctly
rated.

13. Detach the engine cover assembly by opening the fastening screws.
14. Lift out the engine cover using the hoist

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15. Remove inlet and outlet pipes from turbo charger.

• Remove the turbo charger cover plates.
• Open the clamps from inlet rubbers on the turbo and air cleaner
assembly.
• Remove the main intake pipe and air cleaner assembly from the
machine.
• Open the clamp which is holding the exhaust pipe in position.
• Open the clamps from exhaust side of the turbo charger and
muffler.
• Remove the exhaust section from the machine.
• Cover the turbo inlet and outlet to prevent the entry of foreign
matter.

16. Remove the engine cooler assembly.

• Removal of engine cooler is presented in Chapter Powerpack,
section Removing the engine cooler.
• Clearly label any hosing to the cooler assembly before
disconnecting them.
• Disconnect any other equipment attached to cooler assembly.
• Remove any straps that may be holding hoses etc. to the engine
and equipment.
17. Disconnect the oil sight gauge hose from the bottom of the gearbox.
• Beware oil will spill from the gearbox.
• Plug the open ends of the gearbox.

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18. Remove the hydraulic piping and hosing from the driving pump mounted
on the gearbox.

• Beware oil will spill from the hoses when disconnected.

• Plug the open ends of the hoses and the pump.
19. Disconnect the other lines from the pressure regulator, etc. Plug the
open ends.
20. Remove the hydraulic hosing from the pumps mounted below the
gearbox.

• Beware oil will spill from the hoses when disconnected.

• Plug the open ends of the hoses and the pump.
21. Disconnect the wiring from the starter motor, piston pump and ECM
(Engine Control Module).
• Clearly label all the engine wirings before disconnecting them.
• The engine control unit is located on the right-hand side of the
engine.
• It is only necessary to remove the wirings that are connected to the
frame.

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22. Loosen all engine mounting screws (6 pcs) going through the mounting
rubbers.

23. Set the engine stand near the machine ready to sit the engine in once it
has been removed.
24. Connect a suitable engine lifting device to the engine lifting points. Take
the weight off the engine with a hoist.
• Make sure the lifting device is in good working order and correctly
rated.

25. Remove the engine mounting screws and carefully lift the engine and
gearbox from the machine making sure nothing gets fouled as the
engine is removed.

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8.1.11 Installing the engine

Only perform maintenance work when the machine is parked on a

See separate engine manufacturer's Operator Guide for further

information.

Ensure that lifting equipment is in good condition and correctly

rated.

Tighten any loose connections and replace damaged fuel and

hydraulic oil lines, tubes and hoses. Leaks can cause fires.

When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer’s requirements.

1. Change over components from the old engine to the new one cleaning
and inspecting them for damage or wear as you proceed. i.e.. starter
motor, alternator etc.
2. Check the condition of the engine mounts and rubbers. Replace as
required.

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3. Replace engine mounting screws and lift the engine into position.
• Ensure no persons or equipment gets caught as the engine is
lowered into position.

4. Remove the lifting device.

5. Carefully tighten all engine mounting screws (6 pcs).
• Tightening torque: 180 Nm (lubricated)

6. Connect the wiring to the engine ECM (Engine Control Module) and
starter motor etc.
• The engine control unit is located on the right-hand side of the
engine.
• Use the labels and electrical drawings as a guide.
7. Connect the oil sight glass hose to the dropbox.

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8. Connect the hydraulic piping and hosing to the driving pump mounted on
the dropbox.

9. Connect the hydraulic hosing to the pumps mounted below to the

dropbox.

10. Install the engine cooler assembly.

• Installation of engine cooler is presented in chapter Powerpack,
section Installing the engine cooler.
11. Connect the cooler hoses and pipes to the engine.
• Tighten all cooler hose clamps and pipe retaining clamps.
• Connect the wire harness to mask assembly.

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12. Install the inlet and exhaust pipes to the turbo charger.
• Check that the turbo has no foreign objects in it.
• Check the general condition of the turbo, check blades and bearing
etc.
• Lift the exhaust pipe and the inlet pipe back to their positions.
• Tighten the clamps on both ends of the pipes.
• Install the turbo charger cover plates.

13. Connect fuel lines to the engine

• Renew old fuel filters.
• Prime the fuel system using the lift pump.

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14. Install engine covers using a hoist. Fit and tension fastening the screws.

15. Connect coolant hoses to the expansion tank.

16. Connect low coolant sensor wiring.

17. Connect all wiring and hosing to the engine cover.
18. If fire suppression tank was removed, install the fire suppression tank to
its position.
• See the fire suppression system manufacturers instructions.

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19. Ensure the radiators emptying tap is closed. Fill the radiator until the
tank is full.

20. Fill engine with oil trough the filling point on engine.
• Filling the engine with oil, is presented in chapter Powerpack,
section Changing engine oil and filter.

21. Fill the hydraulic oil tank.

• Oil level should be between the sight glass.
22. Fill the dropbox with oil.
• Filling the dropbox with oil is presented in chapter Dropbox, section
Chancing the dropbox oil..
23. Bleed the air from the suction lines.
• Bleeding the suction lines is presented in chapter General
hydraulics, sectionSuction lines.

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24. Start the engine and keep the engine running at idling speed until oil
pressure reading is displayed.
If no oil pressure is displayed after approx. 10 seconds, switch off
the engine and determine the cause. See engine manufacturers
instructions for more information about starting the engine.

25. Once the oil pressure has come up check that the oil pressure reading
in display is correct for both engine and transmission. Shut down the
engine after approx. 1 minute.
26. Check the engine, transmission, hydraulics and cooling system for
evidence of any leaks.
27. Check all fluid levels. Engine, transmission, hydraulics and coolant. Fill
if necessary.
28. Remove the frame articulation locking device.
29. Restart the engine.
30. Check from the display that there are no active alarms.
31. Operate the bucket and steering hydraulics through their complete
cycles a few times.
• Repeat this step until the machine movements are functioning
smoothly.
32. Recheck the hydraulic oil levels. Fill if necessary.
• Oil level should be between the sight gauge.

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

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8.2 Pump drive unit

4
6 5

Pump drive unit components

1 Pump drive unit 2 Drive pump
3 Boom and bucket pump 4 Steering pump
5 Brake pump 6 Pump drive unit draining
point
7 Pump drive unit dipstick 8 Pump drive unit breather and
filling

Functional description
The pump drive unit distributes energy from the engine to the brake pump,
drive pump and steering,bucket and boom pumps.

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8.2.1 Changing pump drive unit lubricant

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 pump drive oil drain point.
• NOTE! Be careful when handling hot oil. Wear suitable protective
gear.
2. Open the drive pump filler cap(2.) and remove the dipstick (3.).

3 2

3. Open the oil drain plug (1.) at the bottom of the pump drive.

4. Drain the oil.

5. Re-install the drain plug. Inspect the plug for the dirt or debris. Replace
the gasket.
6. Fill pump drive (2.).
• See chapter Filling capacities for correct oil amount.
Do a check of the pump drive oil level from the dipstick (3.).
7. Install the filler cap and dipstick (.
8. Run the engine two minutes at idle to prime the hydraulic lines.
9. Recheck the oil level with engine running at idle.
10. Add quantity necessary to bring oil level to LOW mark on dipstick.
11. Recheck the oil level with warm oil.
12. Bring the oil level to FULL mark on dipstick.
13. Check drain plugs, oil filter and oil lines for leaks and tighten if
necessary.

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8.2.2 Removing the pump drive unit

WARNING
HIGH TEMPERATURE WARNING.
A hot surface can cause injury
Wait for the engine to cool down before performing work on it.

1. Make sure that the machine is on an level surface, the parking brake is
applied and movement is prevented by, for example, wheel chocks.
2. Make that the bucket is lowered and the boom is resting on stops.
3. Install the frame articulation locking device.
• Installing of the frame articulation locking device is presented in
chapter Frame structures section Frame articulation locking device.
4. Place an oil drain container under the machine and drain the gearbox
and engine oil, or use an oil recovery system to remove the oil from the
gearbox and engine.
5. Removing the engine and pump drive gearbox assembly. Engine
removing is presented in chapter Powerpack section Engine section
Removing the engine.
6. Open screws (A, B, 16 pcs.) and remove engine and pump drive gearbox
mounts (2 pcs.)

7. Connect a suitable lifting device to the pump drive gearbox. Take the
weight off the gearbox with a hoist.
• Make sure the lifting device is in good working order and correctly
rated.

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8. Open pump drive gearbox fastening screws (C, 8 pcs).

9. Carefully slide the gearbox unit apart from the engine and lift it to the
place.
• Make sure it is well balanced before lifting operation. Gear box unit
with hydraulic pumps weights app. 270 kg.
• The rubber disc (A) is free to float axially in the outer ring (B).

See separate engine manufacturer's Operator Guide for further

information.

WARNING
FIRE WARNING
Leaks from damaged fuel and oil lines, tubes or hoses can cause
fires.
Tighten any loose connections and replace damaged oil lines, tubes
or hoses.

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8.2.3 Installing the pump drive unit

Only perform maintenance work when the machine is parked on a

1. Connect an overhead hoist to pump driver gearbox unit to support it.

• Make sure the pump driver gearbox unit is well balanced.
2. Carefully wash the mounting and control surfaces of the inner/flywheel
and dry thoroughly.
3. Align the rubber disc grooves (A) with the outer ring cogs (B).
• It may be necessary to slightly rotate the crankshaft back and forth
when installing the pump drive gearbox.

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4. Carefully slew the pump drive gearbox unit in the inner/flywheel housing
(B).

• Ensure the rubber disc (A) will not bend.

5. Fasten the pump drive gearbox mounting screws ( A, 12 pcs) to the
engine.

• Do not try to force the screws into threads.

• When all screws are in place tighten the screws.

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6. Install the engine and pump drive gearbox unit mounts ( 2 pcs). Fasten
the screws ( A,B 16 pcs).

7. Remove pump drive gearbox lifting equipment.

8. Install the engine.
• Engine installation is presented in chapter Powerpack and Engine
and Installing the engine.

See the separate manufacturer's service manual for correct torque

settings.

Check the correct tightening torques from the appendice The

tightening torques for screws and nuts

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8.2.4 Steering, Boom and Bucket pump

Double gear type pump P3124 produces hydraulic oil flow needed in the
hydraulic systems. The pump has two blocks on the same shaft. The shaft
speed is approximately 2400 rpm when the engine is running at 2500 rpm.
The shaft rotates counter clockwise.

1 2

Block 1
Block 1 (gear pump P3111) produces the hydraulic oil flow needed for
steering, pilot control, boom and bucket. If steering function is not in use the
flow is available for boom and bucket functions. Maximum pressure is
limited to 220 bars by a pressure relief valve. The volume flow is
proportional to the engine rpm and the maximum flow is 70 l/min. The pump
block outlet is equipped with a non-return valve, which prevents the
hydraulic flow from returning to the pressure side of the pump block.
Block 2
Block 2 (gear pump P3111) produces the hydraulic oil flow needed for
boom and bucket hydraulics. Maximum pressure is limited to 230 bars by a
pressure relief valve. The volume flow is proportional to the engine rpm and
the maximum flow is 56 l/min.

See the separate service instructions manual for dismantling,

assembly and inspection information.

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Removing the Steering, Boom and Bucket pump

1. Make sure that the machine is on a level surface, the parking brake is
applied and the movement is prevented with wheel chocks.
2. Make sure that the boom and bucket are lowered and the boom is resting
on the stops.
3. Make sure that the main switch is in the OFF-position
4. Connect a capillary test hose to pressure measuring points MP201 and
MP101 and release the pressure.

11 13

12 14

10 7

7 MP701 Boost pump pressure

9 MP704 Drive pump pressure (F)*
10 MP703 Drive pump pressure (R)*
11 MP201 Bucket pump pressure
12 MP101 Steering pump pressure
13 MP405 Pilot pressure
14 MP501 Brake charging pressure
*) F = Driving direction Forward
*) R=Driving direction reverse
5. Remove the pump assembly cover from the bottom of the machine.

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6. Open the hydraulic hose connections from the pump.

• Plug the open ends and move the hoses aside.

7. Open the pump retaining screws.

8. Carefully remove the steering, boom and bucket pump

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Installing the Steering, Boom and Bucket pump

1. Install the steering, boom and bucket pump to the pump drive unit.

2. Install the pump retaining screws.

• Replace the O-ring seal of the pump fastening flange.
• Replace the O-ring seals of the pump hydraulic hose flange joints.

3. Install the steering, boom and bucket pump hydraulic lines.

4. Check the hydraulic oil level and fill if needed.

5. Bleed the suction lines.
• Bleeding the suction lines is presented in chapter General hydraulics.
6. Start the machine and check the pump and hoses for leaks.

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Checking the steering circuit pressure

The hydraulic oil temperature should be 60...80°C.
Connect and disconnect pressure gauge(s) only when the circuit is not
pressurized.
Use only special couplings for pressure testing
Do not overtighten couplings. When special couplings are used, finger tight
is adequate.Overtightening causes harmful leakage.
The pressure checking must be done with the engine running. It is
necessary to have a second person reading the gauges from a safe
distance.

11 13

12 14

10 7

7 MP701 Boost pump

1. Install the frame articulation locking device.

• For installation see chapter Safety and environmental instructions .
2. Install a 400 bar pressure gauge to the measuring point.
3. Start the engine and run at low idle.
4. Move the bucket against the stops.
5. Record the gauge reading.
• The correct pressure is 220 ±5 bar.
6. Shut down the engine.

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7. Remove the pressure gauge from the measuring point and refit the
measuring point cap.

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Checking the boom and bucket circuit pressure

11 13

12 14

10 7

7 MP701 Boost pump pressure

1. Install the frame articulation locking device.

• For installation see chapter Protective devices.
2. Install the pressure gauge to the measuring point.
3. Start the engine and run at low idle.
4. Move the bucket against the bucket stops.
5. Record the gauge reading.
• The correct pressure is 230 ±5 bar.
6. Shut down the engine.

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7. Remove the pressure gauge from the measuring point and refit the
measuring point cap.
8.2.5 Brake charging pump
Pump P3521 produces hydraulic oil flow needed in the brake and oil cooler
(optional) hydraulic systems. The pump shaft speed is approximately 2400
rpm when the engine is running at 2150 rpm. The shaft rotates counter
clockwise.

1 2

Block 1
Pump P3513 is a piston type pump. Block 1 produces the hydraulic
pressure and flow needed for the brake system. The volume flow ( max 40
l /min 2400 rpm ) produced by the pump block is hydraulically adjusted
according to the needs of the machine braking capacity. Maximum pressure
is limited to 190 bars by a pressure relief valve.
Block 2 (optional)
Pump P3801 is a gear type pump. Block 2 produces the hydraulic pressure
needed for an optional oil cooler. Maximum pressure is limited to 210 bars
by a pressure relief valve. The volume flow is proportional to the engine
rpm and the maximum flow is 47 l/min.
See the separate service instructions manual for dismantling,
assembly and inspection information.

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Removing the Brake charging pump

11 13

12 14

10 7

7 MP701 Boost pump pressure

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6. Open the hydraulic hose connections from the pump.

• Plug the open ends and move the hoses aside.
• Clearly mark all hoses.

7. Open the pump retaining screws (2pcs).

8. Carefully remove the brake charging pump.

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Installing the Brake charging pump

1. Install the brake chargning pump to the pump drive unit.

2. Install the pump retaining screws.

• Replace the O-ring seal of the pump fastening flange.
• Replace the O-ring seals of the pump hydraulic hose flange joints.
3. Install the charging pump lines.

4. Check the hydraulic oil level and fill if needed.

5. Start the machine and check the pump and hoses for leaks.

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Chekcing and adjusting the Brake charging pump pressure

11 13

12 14

10 7

7 MP701 Boost pump pressure

1. Install the frame articulation locking device.

• For installation see chapter Protective devices.
2. Check chapter Technical Specifications section Default pressure settings
for the correct pressure and choose a suitable pressure gauge.
3. Install the pressure gauge to the measuring point.
4. Start the engine and run at low idle.
5. Move the steering joystick forward and backward for correct pressure
reading.

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6. Record the gauge reading.

7. If the pressure is not within the specified range, adjust the pressure with
the pressure adjustment screw.

8. Shut down the engine.

9. Remove the pressure gauge from the measuring point and refit the
measuring point cap.
8.2.6 Drive pump

Hydrostatic transmission on is closed loop hydraulic system. It contains

hydraulically controlled pump P3701 which is mounted on pump drive unit.
Pump flow allows the hydraulic motor A3741 to drive cardan shafts through
drop box unit where it is mounted.

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Removing the Drive pump

1. Make sure that the machine is on a level surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Make sure that the boom and bucket are lowered and that the boom is
resting on the stops.
3. Make sure that the main switch is in OFF-position.
4. Connect a capillary test hose to pressure measuring points MP703 (10)
and MP704 (9).

11 13

12 14

10 7

7 MP701 Boost pump pressure

9 MP704 Drive pump pressure (F)*
10 MP703 Drive pump pressure (R)*
11 MP201 Bucket pump pressure
12 MP101 Steering pump pressure
13 MP405 Pilot pressure
14 MP501 Brake charging pressure
*) F = Driving direction Forward
*) R=Driving direction reverse
5. Open the hydraulic hose connections from the pump.
• clearly mark all hoses and plug the ends.

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6. Remove the drive pump mounting screws (4 pcs.).

7. Remove the drive pump using a hoist.

• Make sure that the lifting device is in good condition and correctly
rated.

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Installing the Drive pump

1. Replace the seal between the drive pump and drive pump unit.
2. Replace the O-rings of the drive pump hydraulic hose flange joints.
3. Install the drive pump to the drive pump unit.
• Make sure that the lifting equipment is in good working order and
correctly rated.

4. Install the drive pump mounting screws (4 pcs.).

5. Install the hydraulic hose connections to the pump.

6. Check the hydraulic oil level and fill if needed.

7. Bleed the air from the suction lines.
• Bleeding the suction lines is presented in the chapter Bleeding the
suction lines.

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Checking and adjusting the drive pump pressures

8.3 Fuel system

A Fuel prefilter B Fuel filter

C Fuel return line D Fuel pump

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8.3.1 Fuel filters

Fuel filters are essential in protecting fuel system components against
contaminants that may be in the fuel. These contaminants can block fuel
injectors causing engine malfunctions and deterioration. Dirt, rust, scale
and water are the major impurities present in fuel. These impurities can
originate from dirty and rusty storage tanks and, as the vehicle ages, from
corrosion within the fuel system components.
Note! Replacing of the fuel filter elements is presented in the Deutz
Operation Manual.

Fuel prefilter and fuel filter

Fuel prefilter and fuel filter remove fine particles from the fuel before it
passes through the fuel injection system.

1 Prefilter
2 Fuel filters

Fuel prefilter with water separator

In the fuel filter equipped with a water separator, the fine particles remain
trapped in the filter media while the water condensate and drop to the
bottom of the filter. Water separator is equipped with a drain valve at the
bottom of the filter to drain water from the filter.

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1 Vent Screw
2 Seal Ring
3 Filter Element
4 Drain Plug

Fuel filter
Fuel filter consists of two filters: one with coarse filter element and one with
fine filter element. The filter removes the fine particles from fuel before it
passes trough the fuel injection system. Fine particles remain trapped in the
filter media.

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1 Vent Plug
2 Seal Ring
3 Filter Element

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8.3.2 Changing the fuel filter elements

WARNING
WARNING! FLAMMABLE MATERIAL!
Risk of fire due to spilled fuel on hot surfaces.
The fuel cleaner element must be changed when the engine is cold.

WARNING
WARNING! FLAMMABLE MATERIAL!
Failure to eliminate leaks could cause fire.
Tighten any loose connections and replace damaged components.

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

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.

1. Clean the outside of the fuel prefilter (A) and fuel filters (B).

• Cover any hoses / lines under the filters.

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2. Remove the fuel filter with a suitable filter removal tool.

• Collect any spilled fuel in a collection vessel.
• Clean any dirt from the filter carrier (1).
• Turn the filter cartridge (2) anticlockwise and remove it.
• Fuel filter bleeding screw (3).

3 1 3

3. Install the fuel filter in accordance with the instructions on the fuel filter.
• Clean any dirt from the filter carrier sealing surfaces with diesel oil.
• Lubricate the filter cartridge sealing surfaces slightly with clean diesel
fuel.
• Install the filter cartridge clockwise.
• Screw the filter onto the filter bracket by hand until the rubber seal
just touches the mating surface.
• Tighten a further half turn, no more.

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4. Bleeding the fuel system.

• Open slightly the bleeding screw (C) top of the fuel filter carrier.
• Open slightly the pressure control valve (B).
• First use the auxiliary prefilter hand pump (A) to pump fuel.
• Turn the engine with starter max 20 s until fuel free from air bubbles
escapes from control valve (B) and bleeding screw (C).
• Tighten pressure control valve (B) and bleeding screw (C) (tightening
torque 15 Nm).
• Check the fuel system for any leaks.
5. Run the engine at idle about for a few minutes.
• Check the fuel system for any leaks.
6. Shut down the engine and correct leaks if any.

Cleaning the auxiliary fuel prefilter

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1 5

6
2

1. Clean the outside of the auxiliary prefilter (A) and cover any hoses / lines
under the cleaner.
2. Collect any spilled fuel in a collection vessel.
3. Drain water from the filter by unscrewing the drain plug (4).
4. Clean the any dirt from the filter carrier (1) sealing surface (6).
5. Open the filter cartridge (2) and dirt trap (3) anti clockwise and remove.
6. Open dirt trap (3) anti clockwise and remove.
7. Emptying emulsion into the fuel collection container and clean the dirt
trap (3).
8. Install the filter cartridge (2) and dirt trap (3) together. Wet the filter
cartridge with fuel, wet the sealing surfaces (6) slightly with oil.
9. Check the fuel system for any leaks and vent the system after starting
the engine.
Changing the auxiliary fuel prefilter
1. Clean the outside of the auxiliary prefilter (A) and cover any hoses / lines
under the cleaner.
2. Collect any spilled fuel in a collection vessel.
3. Clean the any dirt from the filter carrier (1) sealing surface (6).
4. Changing the clogged filter cartridge (2).
5. Lubricate the filter cartridge (2) with fuel, lubricate the sealing surfaces
(6) slightly with oil.
6. Install the filter cartridge (2) and dirt trap (3) clockwise.
7. Check the fuel system for any leaks and bleed the system after starting
the engine.
Bleed the auxiliary fuel prefilter
1. Open the bleed screw (7) slightly.

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2. Actuate the pump (5) until fuel free from air bubbles emerges.
3. Tighten the bleed screw.
8.3.3 Fuel lines
Steel lines and flexible hoses carry the fuel from the tank to the engine.
When servicing or replacing the steel lines, copper or aluminum must never
be used. Steel lines must be replaced with steel. When replacing flexible
rubber hoses, proper hose must be used. Ordinary rubber such as used in
vacuum or water hose will soften and deteriorate. Be careful to route all
hoses away from the exhaust system.

WARNING
FIRE WARNING
Oil or fuel leaks can cause fires
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses

See the separate engine supplier operation manual for detailed

information.

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8.3.4 Fuel level monitoring

Fuel gauge
The amount of fuel is measured by the analog sensor connected to the
Middle module.
The fuel gauge is shown in the main window, to the right of the revolution
meter.

The vertically aligned bars become green according to the fuel level (all
bars green = tank is full).
The symbol of the gauge flashes red if the fuel level is low.

Forced functions (requires service password)

Forced functions windows are used to control the machine’s different

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Forcing digital outputs of the modules

This window is used for forcing the digital outputs of each connector of a
module on or off. NOTE! The Dashboard and Rear modules’ connectors
can be selected only if there are five modules in the machine:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.
The digital output of the operating voltage of the oil level sensors:
Connector
Function Module
pin
Fuel level supply sensor, supply voltage
Middle XM 2.1
(B311)

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Measurement data of the modules (requires service password)

The measurement data windows shows the values and status of the
connector pins. The windows are used for help in troubleshooting. From the
module measurement window, select the Middle module connector pins
XM1, XM2 and XM3, then press theOK button. The measurement windows
corresponding to the connector pins will open.
The connector pins for fuel level monitoring are listed in the ”Inputs”
and ”Outputs” tables in the section, ”System notifications and
troubleshooting (Fuel level monitoring)”.

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System notifications and troubleshooting (Fuel level monitoring)

Inputs
Signal level Connector
Actuator Description Module
pin
Fuel level
Sensor 4…20 mA Middle XM3.8
(B311)

Outputs
Connector
Actuator Description Signal level Module
pin
Fuel level sup-
ply sensor, sup-
Sensor 24 V / 0 V Middle XM2.1
ply voltage
(B311)

Module No Alarm text Alarm log

Middle 85 Fuel level low warning
Middle 86 Fuel level low alarm
Middle 128 Fuel level high alarm X
Middle 129 Fuel level high warning X

Description 1: Fuel level out of limits

Action 1: Check the fuel level

Module No Alarm text Alarm log

Middle 87 Fuel level sensor (B311) high error X
Middle 88 Fuel level sensor (B311) low error X

Description 1: Fuel level sensor (B211) high error (the sensor current
value is too high)
Action 1: Sensor
• Measure and check the sensor’s voltage value from ”The measurement
data windows”(refer to chapter ”Fuel level monitoring”, section
“Measurement data of the modules”).
• Change the sensor if broken.
Action 2: Cabling
• Measure the voltage from sensor pole 1, which must be the same as the
machine’s operating voltage
• Fault is in the cabling or the Middle module connector pin XM3.8 (this will
be given by a separate alarm).

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Action 3: Cabling
• Measure the connection from sensor pole 2 to GND. This cable is
connected to the Middle module connector pin XM2.15.
Action 4: Cabling
• Detach the cable for Middle module connector pin XM3.8 and measure
the current to ground.
• With a full tank, should be approx. 20 mA and with an empty fuel tank
should be approx. 4 mA.
Description 2: Fuel level sensor (B311) high error (the sensor current
value it too low)
Action: Sensor
• Measure and check the sensor’s voltage value from ”The measurement
data windows”(refer to chapter ”Fuel level monitoring”, section
“Measurement data of the modules”).

8.4 Air filtering

1 2

3 4 5 6

1 Pipe 2 Air cleaner housing

3 Restriction indicator 4 Filter straps
5 Scavenge line inlet 6 Ejector hose

The outside air drawn into the engine passes through the air filter and is
pulled into the turbocharger. Compressed air from turbocharger is pushed
through the charge air cooler (heat exchanger) to intake manifold and into
the cylinders, where it mixes with atomized fuel from the injectors.
For optimum protection against dust and other airborne contaminants
service the air cleaner system when the maximum allowable air restriction
has been reached, or every 250 hours, whichever occurs first.

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8.4.1 Air filter

1
5

4
3

1 Housing service cover 2 Cleaner housing

3 Outlet end 4 Inlet end (pre-cleaner)
5 Safety element 6 Main element
7 Scavenging hose connection 8 Restriction indicator
(ejector connection)
The air cleaner is a two-stage air cleaner with a built-in high efficiency pre-
cleaner that works according to the to the scavenging principle which is
also known as aspiration. Scavenging is accomplished by a secondary
airflow from the pre-cleaner to the exhaust system tailpipe.

Pre-cleaner
The pre-cleaner removes between 75-98% of the contaminate from the
intake air before the air reaches the main element.

Main element
The main element removes around 99.9% of the remaining contaminant in
the intake air.

Safety element
The safety element stops contaminant from entering the engine during the
service of the main element and in case of leakage in the main element.

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Scavenging hose
The system works according to the ejector principle, where the exhaust
gases suck part of the contaminants from the pre-cleaner to the exhaust
gas stream in the tailpipe.
Note! If the scavenging hose is removed or leaks, the air cleaner system
will not work properly. This hose needs to be checked regularly.

Servicing the air cleaner

Cleaning and/or reusing dry paper type air cleaner elements is not
recommended. Inspection and cleaning of the elements must be done in
accordance with the air cleaner manufacturer’s recommendations.
See separate Donaldson Maintenance and Servicing instructions in
the Appendices chapter.

8.5 Exhaust system

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Hot exhaust gas flowing from the exhaust manifold is used to drive the
turbocharger. From the turbocharger the exhaust gases flow through the
exhaust piping to the catalytic converter and the muffler. Continuous
particle burning and spark reduction take place in the catalytic converter.
The treated exhaust fumes exit through the exhaust piping.
8.5.1 Exhaust piping

5
3

1 Catalytic converter and 2 Clamps

muffler
3 Engine exhaust pipe 4 Tail pipe
5 Ejector line 6 Scavenging line inlet
7 Pipe clamps

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8.5.2 Exhaust purifier

The exhaust purifier does not need maintenance cleaning under normal
operating conditions.
If back pressure problems are suspected (back pressure at full load stall
conditions > 150 mbar), then relatively heavy load driving is recommended
for 20 minutes and then engine shutdown (after normal turbo cool down
run) for 20 min. The purpose of this procedure is to clean off possible soot
accumulators from catalyst surfaces.
Note! If fuel or oil has entered into catalyst (eq. turbo failure), catalyst
should be replaced with a new one.

Maintenance / replacement interval

Emission based maintenance.
1. If it is possible to make reqular and frequent CO and NO2 exhaust
emission measurements, and creating a history since new, the
measurements should run in 500-1000h intervals. If two consecutive
measurements are below a specified machine limit, the purifier should be
changed. (Latest after 10 000h running hours).
2. Fuel sulfur content <500 ppm: If the fuel sulfur content is known and it is
below <500 ppm (<0.05%), the purifier maximum change interval should
be limited to 7000h.
Fuel sulfur content not known or >500 ppm: If the fuel sulfur content is not
known or it is above >500 ppm (>0.05%), the purifier maximum change
interval should be limited down to 5000h.

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8.5.3 Servicing the exhaust purifier

Exhaust purifier is basically maintenance free, no cleaning under normal
operating conditions is needed.
If back pressure problems are suspected (back pressure at full load stall
conditions > 150 mbar), then relative heavy load driving is recommended
for 20 minutes and then engine shutdown (after normal turbo cool down
run) for 20 min. The purpose of this procedure is to clean off possible soot
accumulators from catalyst surfaces.
Note! If fuel or oil has entered into catalyst (e.g. turbo failure), catalyst
should be replaced with a new one.

Maintenance / replacement interval

Emission based maintenance.
1. If it is possible to make regular and frequent CO and NO2 exhaust
emission measurements, and creating a history since new, the
measurements should run in 500–1000 h intervals. If two consecutive
measurements are below a specified machine limit, the purifier should be
changed. (Latest after 10 000 h running hours).
2. Fuel sulfur content < 500 ppm: if the fuel sulfur content is known and it is
below < 500 ppm (< 0.05%), the purifier maximum change interval should
be limited to 7000 h.
Fuel sulfur content not known or > 500 ppm: If the fuel sulfur content is not
known or it is above > 500 ppm (> 0.05%), the purifier maximum change
interval should be limited down to 5000 h.

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8.5.4 Removing the exhaust purifier

1. Let the exhaust cool before you work on it.
2. Remove the exhaust purifier cover (1) to access the purifier/silencer
assembly.

3. Remove the clamp (2).

4. Remove the exhaust pipe (2) from the turbo (1).

+
5. Remove the purifier clamps ( 2) and the ejector pipe clamps (1 and 3).

1
2

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6. Remove the exhaust purifier.

8.5.5 Installing the exhaust purifier

High temperature warning. A hot surface can cause injury.

1. Install the exhaust purifier into the frame

• Tighten the straps and install the ejector pipe
2. Install the exhaust purifier cover.
3. Install the exhaust pipe to the turbo and exhaust purifier..
• Inspect thermal insulation to ensure serviceable, replace if required.

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8.6 Cooling system

8.6.1 Cleaning the cooler cores

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.

1. Open the cooler hatches for proper cleaning.

2. Start the power washer and slowly move up and down the core
concentrating on a small area until the exit water is free from dirt.
• Make sure you have a min. gap of half meter between core and
nozzle.
• HOT WATER CLEANING WITH SOAP (biodegradable detergent)
CAN BE USED, MAX. PRESSURE 82 bar (1200 psi).
3. Continue this until the whole radiator is clean from one side then start
cleaning from the opposite side.
4. Blow off excess water with air.

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8.6.2 Removing the cooler

Only perform maintenance work when the machine is parked on a

WARNING
HOT COOLANT SPLASHING HAZARD!
Hot coolant can cause injury.
Avoid draining hot liquids. Be careful if you have to drain hot liquids.
Wear suitable protective gloves, protective clothing and safety
goggles when handling coolant, whether it is hot or cold.

Read the Fire suppression system instructions when connecting the

system: Only authorized service people may install the system.

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4. Remove cover on the radiator expansion tank and open the radiator cap.
• The expansion tank is equipped with a lockable pressure release
cap.
• When removing the cap, first lift the lever to unlock the cap and wait
for complete pressure evacuation before removing the cap.

5. Open the tap on the radiator drain hose and empty the entire contents
into a container.
6. Close the tap on the radiator drain hose and clamp it back to the storage
position.
7. Disconnect low coolant level sensor wiring.
8. Disconnect wiring P-clamps and fire suppression hosing from the engine
cover.
• NOTE! Do not open fire suppression line connections if machine is
equipped with FS1000 fire suppression system. System must be
depressurized if line connections need to be opened.

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9. Attach the lifting device to the engine cover assembly to support it.
• Make sure that the lifting equipment is in good working condition and
rated correctly.

10. Detach the engine cover assembly by opening the fastening screws.
11. Lift out the engine cover using a hoist
12. Disconnect coolant hoses from the expansion tank.

13. Disconnect the rear light’s wiring harness from mask assembly, and
protect the connectors.

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14. Attach the lifting device to the cooler shroud and remove it.
• open the mounting screws (10 x M20)
• Use shroud lifting points (4 x M16)

15. Lower the cooler shroud carefully onto the supporting blocks

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16. Disconnect the radiator pipes.

• Loosen clamps and brackets then pull the connector hose off.
• Disconnect the turbo charger air hoses from the cooler.
• Disconnect the transmission cooler cell hoses from the cooler.
• Plug the open ends of the turbo charger and the cooler.
• Plug both side open ends of the pipes and hoses to the cooler.

17. Disconnect the hose coming from the expansion tank to the top of the
cooler.
18. Disconnect the fan grill from cooler before remove the radiator.
• Open the nuts (8 pcs).

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19. Attach the lifting device (A) to the radiator to support it.
• Use radiator lifting points (2 x M16).
• Open the bracket screws (B), ( 8 pcs)

A
A

B B

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20. Lift the radiator out carefully using a hoist.

• Be carefully with fan assembly.
• Do not lower the radiator assembly to ground without using a
supporting blocks.

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21. Position the distance blocks under the radiator. Lower the radiator
carefully onto the supporting blocks to prevent damaging.

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8.6.3 Installing the cooler

Only perform maintenance work when the machine is parked on a

Ensure that lifting equipment is in good condition and correctly

rated.

WARNING
FIRE HAZARD!
Leaking fuel or hydraulic oil lines can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer’s requirements.

Read the Fire suppression system instructions when connecting the

system. Only authorized service people may install the system.

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1. Attach the lifting device to the radiator.

• Use radiator lifting points (2 x M16).

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2. Lift the radiator on to machine frame.

• Keep lifting device connected to radiator to support it.

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3. Install the radiator to the place.

• Carefully lift radiator on to place.
• Install and tighten the bracket mounting screws (B), ( 8 pcs)
• Remove lifting device (A) after mounting.

A
A

B B

4. Connect the fan grill to cooler before install the hoses.

• Install and tighten the fan grill nuts (8 pcs).

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5. Connect the radiator pipes to engine.

• Connect the transmission hydraulic hoses to the cooler.
• Connect the emptying tap hose to the cooler.
• Connect the hydraulic hoses to the cooler.
• Connect the engine liquid hoses to the cooler.
• Connect the turbo charger air hoses to the cooler.
• Tighten all radiator hose clamps and brackets.

6. Connect the hose coming from the expansion tank to the top of the
cooler.

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7. Attach the lifting device to the cooler shroud and lift it to the place.
• Use shroud lifting points (4 x M16)
• Install and tighten the mounting screws (10 x M20)

8. Connect coolant hoses to the expansion tank.

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9. Lift the engine covers back into place using a hoist. Tighten the mounting
screws.

10. Connect coolant sensor wiring.

11. Connect all wiring and hosing to the engine cover.
12. If fire suppression tank was removed, install the fire suppression tank to
its position.
• See the fire suppression system manufacturers instructions.

13. Connect the rear light wiring harness to mask assembly.

14. Install wiring P-clamps, fire suppression hosing and any other hosing to
the engine cover.

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15. Ensure the radiators emptying tap is closed.

• Fill the radiator until the tank is full.

16. Pressure test the cooling system to check for leaks.

• To pressure test the radiator, use pressurized air to slowly increase
air pressure in system to a maximum of 1,03 bar (15 psi).
• Check for signs of any leaks around seals and gaskets.
• Test for a minimum of 30 minutes.
17. Start the engine.
• Run until operating temperature is reached.
• Check the cooler system visually for any leaks.
18. Stop the engine.
19. Check coolant level.
• Fill if required.
• Install coolant expansion tank cover.
20. Check hydraulic oil level.
• Fill if required.

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8.6.4 Cooler tube and sealing removal

Only perform maintenance work when the machine is parked on a

Be careful when draining hot coolant. Wear suitable protective

gloves, protective clothing and safety goggles when handling
coolant.

See the separate manufacturers service manual for further

information.

Only carry out work on the cooling system at coolant temperatures

below 50 °C. Wear approved protective gloves, protective clothing
and safety goggles when handling coolant.

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Refer to the separate manufacturers service manual for the

specifications for radiator overhaul.

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9 Power Train

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9.1 System description

1 2 3 4 5 6 7

1 Front axle 2 Drive shaft

3 Transmission 4 Drive Motor
5 Rear axle 6 Pump drive
7 Hydraulic pump

Power from the engine is transmitted to the driveline hydraulically. The

pump drive produces volume flow to the drive motor (4) which convertes
the hydraulic energy into mechanical energy for the drop box .
The drop box output shafts transmit power via drive lines to the front and
rear differentials. The bevel gear and bevel pinion of each differential
transmits power through the differential to the free floating axles. The
planetary final drive sun gears are splined to the axles.
As the axles rotate, planet gears, mounted in the carrier, are forced to walk
around the stationary ring gear, imparting rotation to the planetary carrier
and the wheel to which it is fastened.
The drop box , drive motor and drive pump function together and operate
through a common hydraulic system.

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9.2 Transmission control

Forward and reverse control in manual mode
The transmission is controlled with the FNR (Forward Neutral Reverse)
switch on the steering joystick. Use the FNR switch to choose the driving
direction forward or backward. When the switch is in middle position, the
gear is on neutral.
The following conditions must be met before controlling the transmission is
possible:
• The modules must be operational
• Emergency stop must not be active
• Parking brake must be released
• The engine must be running
• The door must be closed
When these conditions are met, the FNR switch must be switched into
middle position (neutral) before gear control is possible. This is a safety
feature.

Brake test
In case of brake test forward and reverse valves can be controlled on, even
when the parking brake is engaged.
See more detail in chapter “Brake hydraulics” section “Parking brake
test”.

Transmission charging pressure

Pressure is measured and shown on the display.
See more detail in section “Transmission oil pressure monitoring”.

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Forced functions (requires service password)

The functions to be forced are chosen on the right-hand side column:

• Off = function not forced
• On = function forced
On the left-hand side column, the value can be set according to which the
function is forced.
Forcing transmission:
1. Select Gear Control as the function to be forced.

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2. Set a forcing value for the gear.

• The forcing values range between -1...+1.
• A negative value forces transmission reverse and positive forward.
• The number stands for the gear to be forced.
3. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
A forced function controls transmission regardless of the situation, only
emergency stop prevents the controlling.
NOTE! Pressing the SEND button forces all the functions that are selected
to be forced. If you force multiple functions simultaneously, make sure that
the forcing values are logical.

Forcing the digital outputs of modules

This window is used for forcing the digital outputs of each connector of a
module on or off:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE!SEND

Digital outputs of transmission:

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Connector
Function Module
pin
Forward valve Middle XM 2.5
Reverse valve Middle XM 2.6

Diagnostics window for transmission

The top of the window shows the status of the lockings that affect functions.

If the symbol is black, the locking is activated. In other words, the function
is allowed when all the symbols are grey. Lockings from left to right:
• Parking brake must be released
• Door must be closed
• Emergency stop must not be active
• Engine must be running
This window shows the status of gear box control signals and valve control,
and the status changes when the status of the control signals change.
When the value in the field is”0”, the input or output is off. When the value
is ”1”, the input or output is on.
The diagnostics window also shows the following information:
• The status of the FNR switch (for forward and backward inputs
separately).
• Driving direction valve forward
• Driving direction valve backward

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Measurement data of the modules (requires service password)

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9.2.1 System notifications and troubleshooting (Transmission control)

Inputs
Signal level Connector
Actuator Description Module
pin
FNR switch Gear forward 24 V / Float Chair XC1.3
FNR switch Gear reverse 24 V / Float Chair XC1.2
Cardan speed
Pulse sensor 24 V / Float Middle XM3.16
A
Cardan speed
Pulse sensor 24 V / Float Middle XM3.17
B

Outputs
Connector
Actuator Description Signal level Module
pin
Valve Forward valve 24 V / 0 V Middle XM2.5
Valve Reverse valve 24 V / 0 V Middle XM2.6

Module No Alarm text Alarm log

Transmission solenoid F short to
Middle 40 X
ground
Transmission solenoid F short to ex-
Middle 41 X
ternal voltage

Description 1: Short circuit in output

Action 1: Wire harness
• Detach the Middle module connector pin XM2.5.
• Check whether the alarm stops when the output in question is forced on
the I/O Forcing window (see section “Forced functions”).
• If the alarm stops, the fault is in wire harness, short circuit to ground.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.
Description 2: Voltage in uncontrolled output
Action 1: Wire harness
• Detach the Middle module connector pin XM2.5.
• If the alarm stops, the fault is in wire harness, short circuit to operating
voltage.
• Repair the wire harness.
Action 2: Module

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• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.

Module No Alarm text Alarm log

Transmission solenoid R short to
Middle 42 X
ground
Transmission solenoid R short to
Middle 43 X
external voltage

Description 1: Short circuit in output

Action 1: Wire harness
• Detach the Middle module connector pin XM2.6.
• Check whether the alarm stops when the output in question is forced on
the I/O Forcing window (see chapter “ Transmission control” section
“Forced functions”).
• If the alarm stops, the fault is in wire harness, short circuit to ground.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.
Description 2: Voltage in uncontrolled output
Action 1: Wire harness
• Detach the Middle module connector pin XM2.6.
• If the alarm stops, the fault is in wire harness, short circuit to operating
voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.

Module No Alarm text Alarm log

Middle 69 Cardan speed sensor A failure X
Middle 70 Cardan speed sensor B failure X
Module ref 12V out of limits (pins
Middle 90 X
XM3/1 of XM3/9)

Description 1: Drive shaft speed sensor A failure

Action 1: Wire harness
• Check the cable XM3.16.
• Repair the cabling if broken.
Action 2: Sensor current supply
• Measure that the current is adequate.

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• Repair the cabling if the current is not 12V.

Action 3: Sensor
• Change the sensor.
Description 2: Drive shaft speed sensor B failure
Action 1: Wire harness
• Check the cable XM3.17.
• Repair the cabling if broken.
Action 2: Sensor current supply
• Measure that the current is adequate.
• Repair the cabling if the current is not 12V.
Action 3: Sensor
• Change the sensor.
Description 3: Module ref 12V out of limits (pins XM3/1 or XM3/9)
Action 1: Wire harness
• Detach the connector pin that caused the alarm from the module.
• Check if the alarm is still active.
• If the alarm is not active anymore, check the wiring. Power consumption
may be too heavy.
Action 2: Module
• If action 1 did not correct the malfunction, the module may be broken.
Change the module if needed.

Module No Alarm text Alarm log

Gear box control forbidden. TheEn-
Middle 159
able missing

Description: The Enable is missing

Action:
• Refer to chapter ”Control system startup diagnostics”.

Module No Alarm text Alarm log

Gear box control forbidden. E-Stop
Middle 163
active

Description: E-Stop active

Action:
• Refer to chapter ”Emergency stop control”.

Module No Alarm text Alarm log

Gear box control forbidden. Engine
Middle 164
not running.

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Description: Motor is not running

Action:
• Start the motor with the ignition key

Module No Alarm text Alarm log

Gear box control forbidden. Door
Middle 165
open.

Description: The door is open

Action 1:
• Close the door
Action 2:
• Refer to chapter ”Door status control”.

Module No Alarm text Alarm log

Gear box control forbidden. Parking
Middle 166
brake not released.

Description: Parking brake is engaged

Action 1:
• Release the parking brake
Action 2:
• Refer to chapter ”Brakes control”

Module No Alarm text Alarm log

Gear box control forbidden. FNR-Switch
Middle 167
broken

Description: FNR switch broken

Action 1:
• Check the FNR switch power supply
• Check the FNR switch cabling
Action 2:
• Replace the control joystick

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9.3 Transmission hydraulics

9.3.1 Transmission oil pressure monitoring
Transmission pressure is measured with an analog sensor. Alarm and
warning limits are set in the sensor calibration window. The alarms have a
delay time set by parameters. The motor must be running for at least ten
seconds before the alarm delay countdown starts.

Pressure monitoring window

The measurement data of the transmission pressure sensor is shown in

gauge window 1 (Transmission oil pressure).
Active alarms and warning are shown by the following symbols in the
gauge window. The symbol appears on the left side of the sensor symbol
that the alarm or warning applies to.
The alarm and warning limits for the sensor are shown in the information
window.

Forcing the digital output of measuring transmission pressure

This window is used for focing the digital outpus of each connector of a
module on or off:

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1. In the module menu (I/O Force), select the connector Middle XM2 .
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0””0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

The digital output for measuring transmission pressure

Function Module Connector pin
Transmission pressure sensor supply voltage Middle XM 2.1

Measurement data of the transmission pressure sensor (requires

service password)

The measurement window shows the values and status of the connector
pins. The windows are used in troubleshooting. Select connector XM3 of
the Middle module and press theOK button. The measurement data
window of the connector opens.
The connector pins for transmission oil pressure monitoring are listed
in the ”Inputs” and ”Outputs” tables in the section ”System
notifications and troubleshooting (Transmission oil pressure
monitoring)”.

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System notifications and troubleshooting (Transmision oil pressure monitoring)

System interlocks:
• Motor must be running

Inputs
Signal level Connector
Actuator Description Module
pin
Pressure Transmission
4…20 mA Middle XM3.7
sensor oil pressure

Outputs
Connector
Actuator Description Signal level Module
pin
Pressure sen-
Sensor sor supply volt- 24 V / 0 V Middle XM2.1
age

Module No Alarm text Alarm log

Transmission oil pressure high
Middle 75 X
alarm
Middle 76 Transmission oil press. high warning X
Transmission oil pressure low warn-
Middle 77 X
ing
Middle 78 Transmission oil pressure low alarm X

Description: Transmission oil pressure out of limits

Action: Check the machine transmission oil pressure.

Module No Alarm text Alarm log

Transmission oil pressure sensor
Middle 79 X
(B305) high error
Transmission oil pressure sensor
Middle 80 X
(B305) low error

Description 1: Transmission oil pressure sensor (B305) high error and low
error.
Action 1: Sensor
• Measure and check the sensor’s current value from ”The measurement
data windows”(refer to chapter ”Transmission oil pressure monitoring”,
section “Measurement data of the modules”)
• Change the sensor if it is broken.

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Action 2: Cabling
• Measure the voltage from sensor pole A, which must be the same as the
machine’s operating voltage.
• Fault is in the cabling or the Middle module connector pin XM2.1.
Action 3: Cabling
• Measure the connection from sensor pole B to GND.
Action 4: Cabling
• Detach the cable for Middle module connector pin XM3.7 and measure
the current to ground. 0 bar pressure should be approx. 4 mA.
Description 2: Module broken
Action: Module
• If the actions of Description 1 did not correct the malfunction, the Middle
module may be broken. Change the module if needed.

Module No Alarm text Alarm log

Module supply pin XM2.1 short to
Middle 110 X
ground
Module supply pin XM2.1 short to
Middle 111 X
external voltage

Description 1: Module supply pin XM2.1 short to ground

Action 1: Wire harness
• Detach the Middle module connector pin XM2.1.
• Use forcing functions to force output to ON state.
• If the alarm does not anymore active, the fault is in the wire harness,
short circuit to ground.
• After repairing the wiring, turn off the system main power and turn it back
again.
Action 2: Module
• If action 1 did not correct the malfunction, the Middle module may be
broken. Change the module if needed.
Description 2: Module supply pin XM2.1 short to external voltage
Action 1: Wire harness
• Detatch the Middle module connector pin XM2.1.
• Turn off the systems operating voltage and then turn it back on again.
• If the alarm stops, the fault is in the wire harness, short circuit to supply
voltage.
• Repair the wire harness.
Action 2: Module

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• If action 1 did not correct the malfunction, the Middle module may be
broken. Change the module if needed.

9.4 Drive motor

2
1

3
7

5 4

1 Drive shaft 2 Control piston

3 Stroke piston 4 Port plate
5 Lens plate 6 Cylinder
7 Piston
The pump drive produces volume flow which the drive motor converts into
mechanical energy. Hydraulic fluid is directed through the port plate (4) and
the lens plate (5) to the cylinder bores.
The pistons (7) in the cylinder bores execute a stroke that is converted into
a rotary movement by the piston on the drive shaft flange. This movement
forces the pistons to move the cylinder (6) and generate an output torque at
the drive shaft (1)
The output torque depends on the pressure difference between the high-
and low-pressure sides and displacement. The output speed is proportional
to the inward flow and inversely proportional to the displacement of the
hydraulic motor

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For further information refer to the pump manufacturer's manual.

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9.4.1 Removing the drive motor

WARNING
HIGH-PRESSURE OIL SPRAY HAZARD.
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

Only perform maintenance work when the machine is parked on a

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

1. Make sure that the machine is on a level surface and movement is

prevented by wheel chocks.
2. Make sure that the main switch is in OFF-position.
3. Install the frame articulation locking device.
4. Make sure that the bucket is lowered and the boom is resting on it's
stops.
5. Place an oil drain container under the center of the machine and drain
the drive motor oil, or use an oil recovery system to remove the oil from
the drive motor.
6. Lift the covers on the top of the machine and secure them back or
completely remove them from the machine.

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7. Open the drive motor hydraulic lines (1,2 and 3).

• Remove any electric wiring and sensors from the drive motor.
• Clearly mark and plug all hoses.

1 2 3

8. Remove all hydraulic hoses required for the removal of the transmission
from the machine.
• Plug the open ends of the hoses and drive motor.
9. Make sure that all the hydraulic hoses, pipes and electric wirings are
detached required for the removal of the drive motor.
10. Connect the lifting chains to the drive motor.
• Then take the weight of the drive motor on the hoist.
• Note! The drive motor weighs appr. 125 kg.

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11. Open and remove the drive motor fastening screws (4 pcs M20 x 60).

12. Using extreme care, slowly lift the drive motor back and up until the
machine transmission bay has cleared.
• Cover the open drive motor place of the dropbox.
• Then place the drive motor on an appropriate stand.

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9.4.2 Installing the drive motor

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

1. Replace the seal between the drive motor and dropbob unit.
2. Replace the O-rings of the drive motor hydraulic hose flange joints.
3. Install the drive motor to the dropbox.
• Make sure that the lifting equipment is in good working order and
correctly rated.

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4. Install the drive motor mounting screws (4 pcs M20 x 60).

5. Install the drive motor hydraulic lines (1,2 and 3).

• Install any electric wiring and sensors from the drive motor.

1 2 3

6. Check the hydraulic oil level and fill if needed.

7. Bleed the air from the suction lines.
• Bleeding the suction lines is presented in the chapter Bleeding the
suction lines.

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9.4.3 Checking the drive motor pressures

The hydraulic oil temperature should be 60...80 °C.
Connect and disconnect pressure gauge(s) only when the circuit is not
pressurized.
Use only special couplings for pressure testing.
Do not overtighten couplings. When special couplings are used, finger tight
is adequate. Over tightening causes harmful leakage.
The pressure checking must be done with the engine running. It is
necessary to have a second person reading the gauges from a safe
distance.

11 13

12 14

10 7

1. Bucket pump pressure

2. Steering pump pressure
3. Drive pump pressure (forward)
4. Drive pump pump pressure (reverse)
5. Pilot pressure
6. Brake charging pressure
7. Boost pump pressure

The drive motor is delivered pre-adjusted. Under normal circumstances

there is no need for adjustment.
1. Install the frame articulation locking device.
• See chapter Protective devices section Installing the articulation
locking device.
2. Check chapter Technical Specifications section Default pressure settings
for the correct pressure and choose a suitable pressure gauge.
3. Install the pressure gauge to the measuring point.
4. Start the engine and run engine at low idle.
5. Raise the engine RPM to working speed and drive the machine forward
against the brakes.

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6. Record the gauge reading. Check the Default Pressure Settings for
correct value.
7. Raise the engine RPM to working speed and drive the machine
backward against the brakes.
8. Record the gauge reading. Check the Default Pressure Settings for
correct value.
9. Shut down the engine.
10. Remove the pressure gauge from the measuring point and refit the
measuring point cap.
11. If the pressure values differ from the values presented in Default
Pressure Settings contact Sandvik Service personnel.

9.5 Dropbox
The drop box is a single speed type gearbox. It is designed to transmit
power from the drive motor down between the front and rear axles of the
vehicle. Power is transmitted via shafts to both axles. The drop box has
three axles inside. A primary axle is attached to the drive motor, middle axle
transmits power to secondary axle and the secondary axle is attached with
flanges to shafts leading to the front and rear axles of the vehicle. The drop
box has an oil level measurement dipstick, which can be reached from
outside of the vehicle.

Model Stiebel 4615.01

Ratio 1:2,48
Oil capacity 2,6 liters
Max. torque at secondary axle 1425 Nm
Max. speed at primary axle n1 (power input) 3600 rpm
Max. speed at secondary axle n2 (power output) 1452 rpm
Nominal power transmission capacity 90 kW at 3600 rpm
Dry weight 143 kg

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8 1

3
6

1 Primary axle 2 Middle axle

3 Secondary axle 4 Oil lever sight tube
5 Draining plug 6 Lifting brackets
7 Dipstick 8 Filling cap
For more information about the drop box, see the manufacturer's manual.

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9.5.1 Changing the dropbox oil

When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer’s requirements.

1. Drain transmission through the drain hole (1).

2 3

2. Fill the dropbox through the opening (2) until fluid reaches the LOW mark
on the dropbox dipstick. (3).
3. Start the engine and let it run for 15 minutes.
4. Recheck oil level and add if necessary.
5. Bring oil level to FULL mark on dipstick.
• Oil level can be seen through the dropbox oil level sight glass (4)

Be careful when handling hot oil. Wear suitable protective gloves,

protective clothing and safety goggles when handling oil.

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

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9.5.2 Removing the dropbox

Be careful when handling the cardan shaft. Freely moving flange

yokes may cause injuries.

1. Make sure that the machine is on a level surface and movement is

prevented by wheel chocks.
2. Install the frame articulation locking device.
3. Make sure that the bucket is lowered and the boom is resting on it's
stops.
4. Place an oil drain container under the center of the machine and drain
the dropbox oil, or use an oil recovery system to remove the oil from the
dropbox.
5. Lift the covers on the top of the machine and secure them back or
completely remove them from the machine.
6. Remove the operator's compartment.
• For instructions on removing the operator's compartment see section
“Removing the operator's compartment”.

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7. Remove the drive motor hydraulic lines (1,2 and 3).

• Remove any electric wiring and sensors from the dropbox or drive
motor.
• Clearly mark and plug all hoses.

1 2 3

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8. Remove the cardan shaft support (1).

2 3 4

9. Remove both of the cardan shafts (2 and 4) by opening the fastening

screws .
• See section “Removing the cardan shaft”.
• Note! Mark the cardan shaft flange position for example drawing a
line across the flange joints.
10. Open the gravity drain line hose (3) connection from the dropbox .
• Plug the open ends of the hose and dropbox.
11. Remove all wiring harnesses required for the removal of the dropbox
from the machine.
12. Disconnect all wiring harnesses from the connection terminal board to
avoid damage when lifting out the dropbox.
13. Remove all hydraulic hoses required for the removal of the transmission
from the machine.
• Plug the open ends of the hoses and gear box.
14. Make sure that all the hydraulic hoses, pipes and electric wirings are
detached required for the removal of the transmission.

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15. Connect the lifting chains to the transmission.

• Then take the weight of the transmission on the hoist.
• Note! The dropbox weighs appr. 400kg.
16. Open the dropbox mounting screws.

17. Using extreme care, slowly lift the dropbox up and back until the
transmission has cleared the machines transmission bay
• Then place the dropbox on an appropriate stand.

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9.5.3 Installing the dropbox

Be careful when handling the cardan shaft. Freely moving flange

yokes may cause injuries.

1. Clean the dropbox bay and associated parts for reuse.

2. Install the operator's compartment.
• For instructions on installing the operator's compartment see
section“Installing the operator's compartment”.
3. Connect the lifting chains to the dropbox and drive pump.
• Then take the weight of the dropbox on the hoist and making sure
that the dropbox is well balanced.
• Note! The dropbox and drive pump weighs appr. 400kg.
4. Lift the dropbox up over the machine in position for fitting.

5. Using extreme care when lower down the dropbox back to the machines
transmission bay.

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6. Place the dropbox and install the dropbox mounting brackets and screws.
• Tighten the dropbox mounting screws (16 pcs , M16 x 35).
• Remove the lifting chains.

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7. Attach the drive pump hydraulic lines (1,2 and 3).

• Attach any electric wiring and sensors to the dropbox and drive
pump.

1 2 3

8. Fit all required hydraulic hoses and pipes that where removed from the
valves.

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9. Install the cardan shaft support (1).

2 3 4

10. Install both of the cardan shafts (2 and 4) by tightening the fastening
screws .
• See section “Installing the cardan shaft”.
• Note! Install the cardan shaft flange grooves on same position than
before removing the cardan shaft.
11. Attach the hose leading (3) to the dropbox dipstick from the bottom of
the dropbox.
12. Make sure that all required hydraulic hoses, pipes and electric wirings
are connected.
13. Fill the hydraulic tank and dropbox with oil. Hydraulic oil level should be
between the sight glasses.
• Do not start the engine before the drive pump is primed. See
section "Bleeding the suction lines".
• Note!The dropbox oil capacity is 2,6 liters. See section“Dropbox”.

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14. Lift the covers on the top of the machine.

15. Start the machine and check for leaks around the dropbox and drive
pump system.
• Rectify leaks if there any.
16. Stop the engine. Check the oil level in the hydraulic tank and dropbox,
top up if necessary.

9.6 Cardan shafts

1. Flange
2. Yokes

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9.6.1 General maintenance and inspection

Whenever people or material might be endangered by rotating
cardan shafts, the user must take for the relevant safety precautions.

The following procedures are required for all cardan shafts:

• When cleaning cardan shafts, do not use aggressive chemical detergents
or pressurized water or steam jets because the seals may be damaged
and dirt or water may penetrate.
• The faces and the centering diameter of the shaft flanges and companion
flanges must be free of dust, grease or paint to ensure a safe connection.
• Check position of yokes of the shaft. Observe the arrow markings. They
must be in alignment. The splines are fitted to one another and must not
be exchanged or distorted.
• Use nuts and bolts of the precised quality (strength). Use new bolts and
full metal lock nuts.
• Check the flange bolts for tighteness and retighten them with the correct
torque.
• Clean the grease nipples before re-lubricating.
• Do not use molycote paste or any other grease on the bolts and
nuts.
• The cardan shaft consists of two heavy parts. Before removing or
installing the cardan shaft, tie the cardan shaft ends with a strap that
secure them (see figure below).

Refer to the separate DANA Cardan Shafts installation and

maintenance manual.

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9.6.2 Removing a cardan shaft

WARNING
GENERAL WARNING
Freely moving flange yokes may cause injuries.
Be careful when handling the cardan shaft

5. Lift out the cardan shaft.

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9.6.3 Installing a cardan shaft

Only perform maintenance work when the machine is parked on a

WARNING
GENERAL WARNING
Freely moving flange yokes may cause injuries
Be careful when handling the cardan shaft.

1. Clean all the flange joint mounting surfaces.

• The faces of the shaft flanges and companion flanges must be free
of dust, grease or paint to quarantee a safe connection.
2. Check the condition of all fastening bolts and screws.
• Replace if necessary.
• Note! Lock nuts must always be replaced if they are detached.
3. Position the cardan shaft by using hoist.
• Check the arrow markings.
• Ensure correct alignment.

4. Attach the flange joint fastening screws.

• The screws should be evenly tightened crosswise with a torque
wrench.
• Apply blue Loctite 242 to all cardanshaft hardware
• All hardware must be grade 8 or higher.
• Use following tightening torques (dry): 1/2" UNF-8 165 Nm

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5. Use the brake releasing pump to release the brakes if necessary.

• Releasing the brakes makes cardan shaft installation easier by
allowing free rotation of the cardan shaft.
• Note! Do not turn the joints of the cardan shafts with crowbar
because this may damage the grease nipples or seal arrangement
on the bearings.

9.6.4 Tightening torques of power train flange bolts

2 2 1

1 1 1

1 Cardan flange bolts 1/2" UNF-8 (dry):165 Nm (122 lbs. ft)

2 Bearing support bolts M16 8.8 (dry): 218 Nm (161 lbs. ft.)

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9.7 Axles
Front axle
• Kessler D71 PL478-NLB-FS
• Axle overall ratio: 22.37
• Dry weight: 1200 kg

7 6 5

2 3

1 Brake pressure 2 Cooling oil inlet

3 Cooling oil outlet 4 Wear indicator
5 Breather 6 Slack adjuster
7 Bleeder 8 Drain plug

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Rear axle
• Kessler D7l PL478-NLB-FS
• Oscillation: ±8°
• Axle overall ratio: 22.37
• Dry weight: 1300 kg (with oscillating cradle)

7 3 4

8
6 2
1

1 Cooling oil inlet 2 Cooling oil outlet

3 Brake pressure 4 Breather
5 Bleeder 6 Wear indicator
7 Slack adjuster 8 Drain plug

Oil classification
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

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Oil capacity (per axle)

Wheel hubs 2 x 1,5 l
Differential (front) 12,5 l
Differential (rear) 19 l
Total (front) 15,5 l
Total (rear) 22 l

Factory filling oil:

• Shell Spirax S3 AX 85W/140
• Lubrizol 6178LZ oil additive (1 l)
- Sandvik Mining and Construction p/n: 04696527
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.

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9.7.1 Changing the axle oil

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

1 2

3 4 5 6 7

Draining is best doneimmediately after the vehicle has been operating. The
lubricant is then warm and will flow freely allowing full drainage in minimum
time. This is very desirable in cold weather.
1. Make sure that the machine is on a flat surface and movement is
prevented by wheel chocks.
2. To drain the planetary wheel hubs, turn the wheel until lubricant drain
hole (3) is down and the oil level mark is in horizontal position .
3. Clean all lubrication points before opening them.
4. Remove both drain (4 and 7) and fill (1) plugs.
5. Allow sufficient time for lubricant to drain into suitable oil container.
6. Examine the drain plug for metal or contamination.
7. To drain differential oil, remove drain plug (5) at bottom of axle housing
and the filling plug (6).
8. Allow sufficient time for lubricant to drain into suitable oil container.
9. Inspect the drain plug for metal or contaminates.
10. Clean all draining plugs and refit them.
11. Refill the wheel ends. Only use new oils meeting manufacturer’s
requirements.
• Be sure planet cover oil level (is in horizontal position when refilling
wheel ends.
• When filling the wheel ends, allow enough time for lubricant to flow
through the various components.

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12. Refill the axle housing. Only use new oils meeting manufacturer’s
requirements.
• When filling the axle housing, allow enough time for lubricant to flow
through the various components.
• Add Lubrizol 6178 additive only to the differential.
13. Refit the filling plugs (6).
14. See the Axle Service manual for further information.

After filling is completed, allow a few minutes for lubricant to attain its level
and recheck each wheel end and the differentials. Add lubricant if
necessary.
Ensure safe and environmentally protective disposal of process
materials and exchange parts.

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9.7.2 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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9.7.3 Brake slack adjuster adjustment

Only perform maintenance work when the machine is parked on a

Releasing the brakes may cause the machine to move (especially on

an inclined surface). Be sure that this does not cause danger to other
people or equipment.

1. Ensure the machine is on an even surface, the parking brake is applied

and movement is prevented by wheel chocks.
2. Ensure the bucket is lowered and resting on stops.
3. Install the frame articulation locking device.
4. Clean areas around the piston adjusting screws.
5. Detach cap nuts (1) and counter nuts (2).

3 2 1

6. Screw in the piston adjustment screws (3) to contact at the piston.

7. Screw out the screws 3 rounds (1080°) and then 3/4 rounds (270°) back
in.
8. Release the brakes.
9. Tighten the counter nuts.
• Note! The piston adjustment screws must not be turned.
10. Fit the o-rings, and tighten the cap nuts to a low torque.

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9.7.4 Removing the rear axle

1. Make sure that the machine is on an even surface and movement is
prevented by wheel chocks.
Install the frame articulation locking device before lifting machine
and removing the rear tire.

2. Install the frame articulation locking device.

• See chapter “Frame structures”.
3. lift the rear of the machine until the rear tires are off the ground by using
hoist or jack.
Ensure that the blocks used for support have sufficient loadbearing
capacity.

The rear axle is made to oscillate. During removal and installation of

the rear tires, the rear axle must be blocked to prevent the machine
from oscillating. Improper blocking of the rear axle can result in
personal injury.
4. Place blocks under the rear of the machine as shown.
• Lower the weight of the machine on to the blocks.

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5. Put wood blocks between the axle and the frame of the machine on both
sides.

6. Remove the rear wheels.

• See section “Wheels”.
Never remove, move or store a tire that is inflated to full
pressurization. They should have only just enough air pressure
(70kPa) to firmly hold the rim parts in place. When you handle the tire
may burst and cause serious injury or material damage. A broken rim
part under pressure can fly apart and cause serious injury.
7. Before removing the cardan shaft, support the cardan shaft against the
frame with a lifting strap.
• Mark the flanges to help you install them later..
Be careful when handling the cardan shaft. Freely moving flange
yokes may cause injuries.

8. Remove the cardan shaft guide (1).

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9. Open the flange joint (2) of the cardan shaft by opening the fastening
screws.
• Use the brake releasing pump to release the brakes if necessary.
• Releasing the brakes makes cardan shaft removal easier by allowing
the cardan shaft to rotate.
10. After you have removed the cardan shaft, turn the ignition switch to “0”-
position to depressurize the brake system.
11. Open the hydraulic hose connections from the manifold.
• Plug the open ends of the hoses and the manifold.

12. Install a lifting device or jack under the axle.

• Support axle lightly by using hoist.
• Notice! The weight of the rear axle assembly is approximately 1350
kg.
Ensure that lifting equipment is in good condition and correctly
rated.

13. Remove the oscillation housing screws (8pcs).

• The nuts (3) can be removed from the underside.

14. Lower the axle and pull it out from the side of the frame with jacks or a
lifting device.

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9.7.5 Installing the rear axle

1. Clean the mounting surfaces of the axle housing, oscillating cradle and
cardan shaft flange.
• Make sure that the surfaces are flat and undamaged.
2. Attach suitable jacks or lifting device to the rear axle assembly to support
the axle weight.
• The rear axle assembly weighs approximately 1350 kg
3. Lift the axle into position under the rear frame.

4. Attach axle fastening bolts .

• Replace all of the fastening bolts and nuts.
• Torque the bolts to 1275Nm with loctite 242.
5. Put wood blocks between the oscillating cradle and the frame of the
machine on both sides.

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6. Attach the brake hydraulic hose connections to the manifold.

7. Attach the oscillation lubrication lines.

8. Attach the rear cardan shaft by tightening the fastening screws.
• Make sure that the yolks are correctly alligned.
• Use the brake releasing pump to release the brakes if necessary.
• Releasing the brakes makes cardan shaft installation easier by
allowing the cardan shaft to freely rotate..
• See section “Cardan shafts”.
9. Bleed the brakes.
• See separate Axle Manufacturer’s Manual for further information.
10. Make sure that the mating surface of the rim assembly is clean.
11. Install the rear wheels.
• See section “Installing the tires”
12. Remove wood blocks between the oscillating cradle and the frame of
the machine on both sides.

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9.7.6 Removing the front axle

Install the frame articulation locking device before lifting the machine
and removing the front tires.

DANGER
CRUSHING HAZARD!
Unexpected machine movement will cause death or severe injury, if a
person is in a hazard zone.
Make sure that the heavy components of the loader are properly
supported before working. Make sure that there are no unauthorized
people in the hazard zone.

1. Install the frame articulation locking device.

• See chapter “Frame structures”.

DANGER
FALLING LOAD HAZARD
Make sure that the bucket is supported before you service the
bucket system.

2. Lift the boom and install the boom support pins.

• See chapter “Frame structures”.
• Tilt the bucket fully forward.
3. Lift the front of the machine with a hoist or jack until the front tires are
20cm off the ground.

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4. Place a block under the front of the machine as shown.

• Lower the weight of the machine on to the block.

Ensure that the blocks used for support have sufficient loadbearing
capacity.

5. Remove the front wheels.

• See section “Wheels”
6. Before you remove the cardan shaft (2), support the cardan shaft against
the frame with a lifting strap.
• Make a mark in the flanges to help you with installation of the front
axle.
Be careful when you handle the cardan shaft. Freely moving flange
yokes may cause injuries.

7. Open the flange joint (2) of the front cardan shaft by opening the
fastening screws.
• Use the brake releasing pump to release the brakes if necessary.
• Releasing the brakes makes cardan shaft removal easier by allowing
free rotation of the cardan shaft.

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8. Open the brake line connections (3).

• Plug the open ends of the pipes and the axle connectors.

3
2

9. Install a jack or a lifting device under the front axle.

10. Remove the axle nut covers (1).
11. Open the axle fastening nuts (1).
• Note! Make sure the front axle is supported.

12. Remove the axle fastening screws.

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13. Pull the front axle out from the side of the frame with a jack or lifting
device.

Ensure that lifting equipment is in good condition and correctly

rated.

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9.7.7 Installing the front axle

Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses. Leaks can cause fires.

1. Clean the mounting surfaces on the front axle housing and front frame.
• Inspect that surfaces are flat and undamaged.
2. Replace all of the fastening bolts and nuts.
3. Put the axle on to a lifting device.
• The front axle weighs approx. 1200 kg.
4. Put the front axle into position under the front frame.

5. Attach axle fastening screws.

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6. Attach the axle fastening nuts.

• First tighten the inner axle fastening nuts to 2050 Nm (lubricated).
• Finally tighten the outer axle fastening lock nuts to torque 880 Nm
(lubricated).

7. Attach the brake line connections.

3
2

8. Attach the front cardan shaft.

• Make sure that the alignment is correct.
• Use the brake releasing pump to release the brakes if necessary.
• Releasing the brakes makes cardan shaft installing easier by
allowing free rotation of the cardan shaft.
• M12: 115 Nm.
• See section “Cardan shafts”.
9. Bleed the brakes.
• See separate Axle Manufacturer’s Manual for further information.
10. Make sure that the mating surface of the rim assembly is clean and
undamaged.
11. Install the front tires.
• See section “Installing the tires”.

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9.8 Wheels
Specification
12.00 x 24NHS L5S T.U.T.R.I.C
12.00 x 24ETSM Tubeless Tire Techking
Other types of tires are available for the user’s choice. In certain
applications, the productive capabilities of the loader may exceed the TKPH
value given by the tire manufacturer.
Sandvik Mining and Construction recommends that the user consult their
tire supplier to evaluate the conditions and to find the best solution for
application.

Tire pressure
• Front: 775 kPa (7.75 bar, 112 psi)
• Rear: 750kPa (7.50 bar, 109 psi)
Note!To avoid extra stress to the drive line, ensure tires on same axle have
similar radius or as close to each other as possible.

• Max. radius difference between tires on same axle (1.5%).

• Max. radius difference between tires on front and rear axles (3%).
• Radius is measured from upper edge of tire to axle centre (without load)

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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. Danger of
serious injury or death. Tire may burst during inflation. Tire inflation
must always be done inside a tire cage.

Never remove, move or store a tire that is inflated to full

pressurization. During handling the tire may burst and cause serious
injury or material damage. If the pressurized wheel has to be
changed, remove the valve and deflate some air out of the tire so that
it just has enough air pressure to hold the rim parts firmly in place
before loosening the wheel nuts. A broken rim part under pressure
can fly apart and cause serious injury.

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9.8.1 Removal of the rear tires

Dangerous machine movement can cause severe injury or death.
Do not go beneath the machine unless absolutely necessary. Stay
out of the danger areas during operating the machine.
Overrun Hazard. Can cause death or serious injury. MAKE SURE
THAT THERE ARE NO UNAUTHORIZED PERSONS IN THE DANGER
AREA.

Ensure that lifting equipment is in good condition and correctly

rated.

1. Make sure that the machine is on a level surface, the parking brake
applied and movement is prevented with wheel chocks.
2. Install the frame articulation locking device.
3. Install the frame locking device.
• For installation see chapter Safety and Environmental instructions.
4. Raise the rear of the machine until the tires are just of the ground by
using hoist or jack.
5. Place blocks under the rear of the machine as shown.
• Lower the weight of the machine on to the blocks.
• Make sure that the lifting equipment and blocks are in good condition
and correctly rated.

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6. Put wood blocks between the oscillating cradle and the frame of the
machine on both sides to prevent the axle from moving.

7. Deflate some air out of the tyre so it just has enough air pressure (70
kPa) to hold the rim parts firmly in place before loosening the wheel nuts.
8. Support the wheel with a tyre sling using a hoist.

9. Remove the nuts of the axle wheel and carefully pull the wheel out.
• Note! Tyre can also be removed by using a fork lift truck: Put the
forks of the lift truck in position under the tire. Fasten the tire to the lift
truck and remove the nuts of the axle wheel.

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9.8.2 Removal of the front tires

Dangerous machine movement can cause severe injury or death.
Do not go beneath the machine unless absolutely necessary. Stay
out of the danger areas during operating the machine.
Run Over Hazard. Can cause death or serious injury. MAKE SURE
THAT THERE ARE NO UNAUTHORIZED PERSONS IN THE DANGER
AREA.

1. Install the frame articulation locking device.

• For installation see chapter Safety and Environmental instructions
2. Use a jack or hoist to lift the front of the machine until the front tires are
just off the ground.
• NOTE! Make sure the blocks and lifting equipment have sufficient
loadbearign capacity.
3. Place blocks under the front of the machine as shown.
• Lower the weight of the machine onto the blocks.

4. Deflate some air out of the tyre so it just has enough air pressure (70
kPa) to hold the rim parts firmly in place before loosening the wheel nuts.

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5. Support the wheel with a tire sling using a hoist.

6. Remove the wheel nuts and carefully pull the wheel out.
• Note! The wheel can also be removed by using a fork lift truck: Put
the forks of the lift truck in position under the wheel. Fasten the tire to
the lift truck and remove the nuts of the axle wheel.

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9.8.3 Installing the tires

Dangerous machine movement can cause severe injury or death.
Do not go beneath the machine unless absolutely necessary. Stay
out of the danger areas during operating the machine.
Run Over Hazard. Can cause death or serious injury. MAKE SURE
THAT THERE ARE NO UNAUTHORIZED PERSONS IN THE DANGER
AREA.

1. Make sure that the surfaces of the rim and axle flanges are clean..
2. Use a hoist or a fork lift truck to put the tire in position.
• Support the wheel with a tire-sling using a hoist.
• NOTE!Make sure that the lifting equipment is in good condition and
correctly rated.
• The tire can also be installed using a fork-lift truck: Put the forks of
the truck in to position under the tire. Fasten the tire to the forks.
3. Install the tire fastening nuts.
• Use tightening torque of 610 Nm lubr. (Kessler axle) or 490Nm lubr.
(Liangyu axle).
Danger of serious injury or death. The tire can burst during inflation.
Tire inflation must always be done inside a tyre cage. Do not stand in
front of the wheel during tyre inflation. Use an extension hose, so
you are able to stand to one side.
4. Inflate the tires to recommended pressure.

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9.8.4 Rim

Designation of rim

1
2
12
3

11
1
4

7
5
10
13 8 7

6
9

1 Rim flange 2 Bead-seat band

3 Lock ring 4 Locking key (part of lock ring)
5 Flange driver 6 Valve stem support
7 Flange seal (not required 8 O-ring
when mounting new tires)
9 Valve hole 10 Bead seat
11 Rim base 12 Rim width
13 Nominal dia.

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9.8.5 Structures and functions of the off-road tire components

A tire consists of the four primary components; carcass plies, beads, belts
and tread, and these four components are primarily responsible for the
fundamental tire characteristics. The functions of the respective
components are described in this section together with the outlines of the
special construction Off-the-Road tires.

3
1

1. Breakers
Extra layers of rubber-coated cord are placed between the outer plies
and the tread to protect the plies, preventing cuts from reaching t he ply
cords and absorbing shock.
2. Thread
Different tread patterns are employed according to the particular usage of
the tire. These patterns feature excellent traction, longer serviceability
and higher resistance to cutting.
3. Sidewalls
Sidewalls are covers made of a flexible rubber compound which protect
the sides of the tyre. They are designed, under ordinary usage, to
cushion the plies from shock and cutting, and to flex and bend without
cracking.
4. Inner liner
The inner liner is a rubber layer covering the inside of a tire from bead to
bead, and corresponds to the tube of an ordinary tire using a tube. It
keeps the inflation pressure constant, while reducing weight and
simplifying maintenance by eliminating the tube.

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5. Plies
A tire is composed of several layers of plies, which are coated on both
sides with a rubber compound. These layers maintain the inflation
pressure of the tire in supporting the load. Composed of high-tensile
nylon cords (H.T.NYLON), it has greater resistance to heat, shock and
cutting, adding to the durability of the tire. The term ”Ply Rating”,
according to the TRA, is defined as follows: ”A given tire with its
maximum recommended load when used in a specific type of service. It
is an index of tire strength and does not necessarily represent the
number of cord plies in the tire.
6. Beads
All plies are tied into bundles of steel wire. The beads are the parts which
fit the tire perfectly on the rim, preventing the tire from slipping out of the
rim contour while the vehicle is in motion.

1 2 3

1 Steel breaker tire

2 Steel radial tire
3 Steel radial tire, belt on carcass

Tubes and Flaps

The function of the tube is to retain air under pressure within the pneumatic
tire. The flap protects the tube from damage by the rim or tire beads.
O-Ring (rim packing)
This rubber ring prevents air from leaking through gaps in the rim when the
tubeless tire is inflated.
Steel breaker tire
Steel breaker Off-the-Road tires feature breaker material of the several
patterns which has been changed from nylon to steel in order to resist
cutting and cut bursting.
Side Steel Breaker tire
In this tire the steel-breaker extends to the sidewall of the tire to protect it
against damage. The construction is similar to that described above.
Steel Radial tire

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This tire consists of two parts; steel cord plies arranged parallel to the cross
section, and a steel belt section encompassing the tread cross section. The
bead sections, which are bundles of bead wire, are covered with especially
strong rubber chafers. The strong steel cords of the carcass sustain the
outer forces of the load and inflation pressure, while the tightened steel
belts sustain the circumferential forces. The overall performance of the Off-
the-Road steel radial tires can be summed up as follows.
• Less generation of heat ensures durability at high speeds
• Greater traction, floatation and stability
• Greater resistance to cuts
• Higher ton-mile-per-hour rating
The advantages mentioned above result from less distortion of the tread,
even contact with the ground end lower heat built-up.
9.8.6 Tire mounting and dismounting on rim
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.

Crushing hazard. Can cause severe injury or death. Tire may

overturn during handling.

General mounting procedures: The following procedures are required for all
Tubeless Type tyres over 16” size, but are also applicable to smaller sizes.

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Tire dismounting from rim

This can be done vertically or horizontally. Be sure to remove the valve core
and deflate completely before dismounting.
1. Ensure the tire is fully deflated.

2. Use the proper tool and method to drop the beads on the gutter side of
the rim. Be careful not to damage the beads.
Slant the bead breaker about 10 degrees, so that it holds firmly. As it can
fly with lethal force, should it slip off, be sure to stand to one side when
applying hydraulic pressure. Watch your fingers, as bead braker and
rams apply pressure to bead flanges.
3. Remove the lock ring with the proper tool.

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4. Remove the O-ring and discard it.

5. Remove the bead seat band with the proper tool.

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6. Remove the rim flange from the rim base. Loosen the bead on the back
side and take the tire off of the rim.

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Rim Inspection
Note! Do not try to repair wheel parts by brazing, welding or reworking.
Replace damaged parts with new or corresponding parts of the same
size, type and make.

• Check for rim damage, distortion and corrosion.

• Clean rim, especially where the bead sits against the flange, where the
flange contacts lock ring sections, and gasket seat sections of the O-ring.
• A new O-ring should be used at each mounting. Never remount an old
one.
• Consult the tire manufacturer for necessary tools. Off-the-Road tires
require tire irons and a bead remover.
• Be sure to use rim parts of the same brand. Do not mix brands, or use a
rim flange of inappropriate size. Parts which have been damaged, that is,
broken, bent or clipped, can cause serious damage.
• The following points distinguish tubeless tire mounting from tube type
tires used on construction vehicles.
1. The presence of a rubber O-ring inserted between the bead seat and rim
base for sealing.

2. The lack of a rim base valve slot.

3. The tapered one-piece bead seats band cannot be divided.
4. No rim pockets for bead dropping.

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Tire vertical mounting on rim

1. Clean the rear flange first and insert it into the rim base until it reaches
the back flange. Make sure the rear flange boss (drive lug) fits into the
rim base groove. Fix the rim with a regular valve.

2. Mount the tire onto the rim base, by pushing as close as possible to the
back flange. Check that the rear flange drive lug fits snugly into the rim
base back flange groove. Then fix the front flange to the rim base so that
the drive lug on the flange is about 5 inches in a clockwise position from
the drive lug slot on the rim base and put it in between the flange and the
rim base. Line up the drive lug in the flange, the drive lug slot in the
tapered bead seat band and push the outside tire beads so that the O-
ring grooves and lock ring appear.

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3. Set the flange and tapered bead seat band in position and insert the lock
ring. Tap with a hammer to check that the lock ring drive lug fits into the
rim base groove. Line up all slots and drive lugs. Use a lead or brass
hammer to shift any parts when necessary.

4. Install a new O-ring (never use an old one as it becomes seriously

distorted in making a seal). Lubricate it with soap (or other solution
recommended by the manufacturer) and slip the ring into the O-ring
groove first; hold it tightly with both hands during this operation. Do not
turn or twist it when inserting into the groove.
5. Draw the tapered bead seat band and front flange together until they
touch the lock ring. Check that rims are correctly assembled before
inflating the tire. To fix the beads securely to the rim, inflate the tire to the
operational pressure and then reduce to recommended storage pressure.
6. Be sure to stand to one side when tapping lock rings with a hammer
during the first stage of inflation. Should a lock ring fly off, it as well as
other parts flying off, could cause very serious injury.

Do not inflate tires either multi-piece rim unless the wheel is behind a
suitable restraining device or placed in a tire in a tire inflation safety
cage. During tire inflation tire may burst. Do not stand in front of the
wheel assembly. Use an extension hose so that you can stand on
one side.

Never remove, move or store a tire that is inflated to full

pressurization. They should have only just enough air pressure
(70kPa) to hold the rim parts firmly in place. During handling the tire
may burst and cause serious injury or material damage. A broken rim
part can fly apart and cause serious injury.

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Tire horizontal mounting on rim

This method is similar to vertical mounting except for the following points:
1. The rim base should be placed on a wood or metal block with the lock
ring groove facing upward. Allow enough space so that the tire will be on
the floor after it is mounted on the rim. The block must not get in the way
of the rear flange; in other words, the blocks should not extend more than
1/2 inch beyond the rim base.

2. On some tires hoisting is necessary to bring the bead seat band into
contact with the tire. Inflate the tire in the hoisted position.

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10 General Hydraulics

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10.1 Hydraulic oil

Hydraulic temperatures during normal operation:
Hydraulic oils meeting DIN 51524-3 (HVLP) or ISO 6743-4 HV can be used

40 - 50 °C ISO VG 32
50 - 60 °C ISO VG 46
60 - 80 °C ISO VG 68
70 - 90 °C ISO VG 100

Viscosity (cold start):

above - 15 °C ISO VG 32
above + 0 °C ISO VG 46
above + 5 °C ISO VG 68
above + 15 °C ISO VG 100

Filling capacity:
• appr. 215 L

Factory filling oil:

• Shell Tellus S2 V 68 (former product name Shell Tellus T68)
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.

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10.2 Hydraulic diagram

Hydraulic diagram.

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Hydraulic diagram transmission.

10.3 General hydraulic maintenance

Heat, dirt and cavitation are the three main causes of hydraulic system
failure. Probably dirt is the worst of the three. Dirt in a hydraulic system has
exactly the same effect as it does in a fuel system. Most dirt is abrasive,
and when it works its way into the hydraulic system it results rapid wear of
the components. It stands to reason that if dirt is kept out of the hydraulic oil
the various components of the hydraulic system will remain clean. Thus,
the problem is to keep the oil clean. This can be done following four basic
precautions :
1. Keep all hydraulic oil containers covered.

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2. Use only equipment known to be clean when transfering oil from storage
tanks to hydraulic system reservoirs.
3. Set up and follow a definite maintenance program for filters and strainers.
4. Adjust or replace packing and seals when necessary.
Always remember that in addition to make the parts of heavy equipment to
move, hydraulic oil also provides lubrication and cooling for the hydraulic
system components. When dirt or water gets into the hydraulic oil, all three
of these functions are affected.
Usually oil can become exposed to two types of contaminants:
1. Dirt which attacks the hydraulic oil from the outside. This includes dust,
lint, rust, and scale.
2. Soluble and insoluble products which form through oil additive
deterioration.
The first group of contaminants can be controlled by taking the precautions
outlined above. Contamination resulting from the deterioration of hydraulic
oil additives cannot be completely controlled through preventive
maintenance. We know, that the formation of such contaminants is
accelerated when the hydraulic system overheats. Therefore, when
overheating is prevented, the formation of soluble and insoluble products is
reduced. However, even under the most careful maintenance,
contamination due to oxidation, condensation, and the formation of acids
causes the oil to become harmful to hydraulic system components.
Therefore, most authorities agree that all of the hydraulic oil should be
drained from the system on a regular maintenance schedule. This is the
only way to eliminate the accumulation of deterioration products from the
system. Therefore, it is always recommended to followmanufacturers’
recommendations and suggestions offered by oil company representatives.

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10.3.1 General troubleshooting

Start inspection of the hydraulic system at the beginning of the system and
check the operation of each part until the trouble is found. Once you have
found the section in which the trouble lies, it is merely necessary to locate
the exact component in that section which is not operating properly.
Keep in mind when servicing hydraulic system:
1. Hydraulic systems operate with a high line pressure. Sometimes it is
necessary to work on a line that is under pressure. If so, be careful. Shut
down the machine if possible.
2. Always use the correct tools. Some parts of the hydraulic system are
easily damaged, particularly if some makeshift tool is used when a
precision tool is required.
3. Use recommended service procedures. Don’t experiment until you are
absolutely sure you know what you are doing.
Function disturb- Cause of the function Way of repairing
ance disturbance
Air in system Check complete system for air leaks and repair.
Cavitation (vacuum on Check for restrictions on the intake side of intake
the intake due of the line, clogged pump, plugged air vent in reservoir,
Noisy pump
pump due to not enough and oil of too high viscosity. Make necessary re-
oil) pairs.
Worn pump Repair or replace pump.
Check system from reservoir to pump. Be sure fil-
Intake clogged
ters and strainers are not clogged.
Low oil level Check oil level
Check intake side of system for leaks and correct
No pressure in Air leak in intake
condition.
system
If oil viscosity is too high, some types of pumps
Oil viscosity too high cannot pick up prime. Drain system and refill with
oil of proper viscosity.
Faulty pump Repair or replace pump.

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10.3.2 Basic causes of hydraulic system failures

Three of the most common causes of hydraulic system failures are dirt,
heat and cavitation.
Dirt can do more damage than either heat or cavitation. However, heat and
cavitation are also deadly to any hydraulic system.
Excessive heat can also affect packing and seals and O-rings. If oil and air
leaks form then the effectiveness of the hydraulic system is quickly
reduced. Dirt is able to get into the system around damaged packing and
seals, which further shortens the life of the system. Normally, overheating
can be prevented by following few simple rules:
1. Always use a hydraulic oil of proper viscosity. The use of an oil of greater
viscosity than that recommended, particularly in areas of low ambient
temperatures, will cause increased fluid friction and overheating.
2. Always connect hoses and clip them into position according to
manufacturers’ recommendations. Rerouting a hose too close to the
unit’s transmission or engine can cause the hose to overheat. This
results in overheating of the hydraulic oil passing through it. Also, avoid
using undersized hoses and be sure to install the hoses so that there are
no sharp bends. These can increase friction and, as a result, raise the oil
temperature.
3. When pumps, cylinders, and other hydraulic system components become
worn, replace them. Worn parts allow excessive oil leakage which in turn
requires the pumps to operate at full output over long periods. This
longer cycle increases the length of time during which fluid friction is
generated within system, increasing the oil temperature.
4. Always keep the outside and inside of the hydraulic system clean. Dirt on
the outside of the system acts as an insulation and prevents normal
cooling. Dirt on the inside of the system causes wear which results in oil
leakage. Either way, dirt causes heat.
Excessive air in a system can usually be recognized by erratic and uneven
operation of the hydraulic system. Oil cavitation is also caused by
excessive air in the system. It’s simply a condition where air is mixing with
the oil. When oil cavitates, it overheats.
To eliminate air:
1. Adjust and replace packings and seals when necessary. When replacing
seals and packings, use only those products recommended by the
manufacturer.
2. When installing hoses, make sure they are properly supported. Vibrating
hoses can loosen connections and allow air to enter the system.
Periodically check all hose fittings and connections to make sure they are
properly tightened.

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If one or more of the components of a hydraulic system becomes faulty,

hydraulic system will slow down and become sluggish, or it will lose
pressure. To locate a faulty component, check the time it takes a hydraulic
system to complete a cycle and the check to see if the pressure output is
normal.
10.3.3 Checking hydraulic system for leaks
Leaks are a common symptom of more extensive troubles in a hydraulic
system, the subject is being emphasized here once again. Hydraulic
system leaks can be classified into two major types: external leaks and
internal leaks.

External leaks
External leaks on the pressure side of a hydraulic system are easy to locate
because of the presence of hydraulic fluid. Watch over the various
components of the hydraulic system in order to identify and correct
pressure leaks as soon as they start. External leaks which occur on the
intake side of the pump are much more difficult to detect.
To find out leaks, check all intake fittings and connections for leaks.
Remember that overtightening can be even more troublesome than
undertightening. Manufacturers’ recommendations should be used as a
guide. The number of Nm (or kpm) recommended for tightening, will ensure
a tight seal and yet not be so tight as to result in distortion of one or both
members.
Leaks on the intake side of the system can usually be detected by adding
oil to the area of the connection. If the pump noise caused by aeration
discontinues either completely or partially, you then know that you have
found the connection where air is being taken into the system.

Internal leaks
As the various components of a hydraulic system wear, internal leakage
within the components becomes more and more evident. As leakage
increases, overheating will become a problem. When this happens, other
components of the system will begin to fail. Therefore it is important that the
hydraulic system be kept in good working order. Internal leakage can
usually be checked by either by-pass or draw tests.
10.3.4 Low temperature starting
Relatively hot oil should never be introduced into a cold pump since pump
seizure may occur from unequal expansion rates. Fluid temperatures
should not exceed 22°C over the surface temperature of the pump upon
introduction of the fluid. It is also quite important on cold starting that load is
removed from the pump until the fluid has achieved the minimum viscosity
requirements to prevent damage from internal cavitation. When the
recommended operation viscosity and temperature has been achieved,
load may be increased.

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10.3.5 Prevent of cavitation formation

Cavitation is phenomenon which occurs in the low pressure side of the
hydraulic system, in other words in suction lines. Usually this means pump
suction lines, but also when cylinders are working as pumps, cavitation
could occur. When cavitating, oil pressure is clearly below atmospheric air
pressure. Because oil always contains air, it gathers together to form air
bubbles. When this oil with air bubbles finds its way to the higher pressure
side (for example in pump), air bubbles collapses rapidly producing shock
waves. These shock waves inflict wearing in hydraulic component
structures.
Cavitation could occur if:
• Oil level in tank is too low
• There is a leak in the pump suction line joints
• There is a improper type of hydraulic fluid in system
• Deterioration of the hydraulic fluid or the presence of harmful
contamination
• Water in the hydraulic circuit
• Oil temperature is very low
10.3.6 Oil filters
Despite utmost care in the handling and dispensing of the hydraulic fluid it
is probable that some foreign particles will find their way into the hydraulic
fluid. Because such particles are apt to be abrasive in nature and as such
will detract from both the operation and life of the hydraulic pumps, motors
and valves, it is recommended that a filter designed to remove such
contaminants be incorporated in all hydraulic systems.
Periodic replacement of fully contaminated filter media must be made to
maintain overall efficiency.
10.3.7 Servicing filters and strainers
When a filter becomes clogged, it can no longer do its job. Most hydraulic
filter assemblies are equipped with a by-pass valve which allows the oil to
by-pass a clogged filter element. Because of the by-pass valve, more and
more hydraulic oil will by-pass around the filter element as it fills up with
dirt.
Filter elements should be replaced as per recommend intervals in
maintenance manual. Elements should be changed more often than
recommended if alarm appears on the display. Use only genuine parts.

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10.3.8 Level of oil in tank

Maintaining sufficient oil in the hydraulic tank at all times is a significant
factor in successful operation.
Regular frequent inspections of the level should be made to guard against
leakage and to make prompt correction if it should occur.
If the oil level is neglected and allowed to fall too low. Two negative
developments may occur.
1. If oil level falls too low, air may be drawn into the pump suction and
contribute to cavitation. It may also cause noisy and irregular operation of
the system even though frothing does not develop.
2. Low oil level is likely to produce some increase in oil temperature due to
the fact that the system has lost heat dissipating capacity. It will also
increase the rate of oil oxidation and loss of initial properties.

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10.3.9 Oil storage and handling

WARNING
EXPLOSION AND FIRE HAZARD!
Flammable vapors with the fire source could cause an explosion or a
fire which could cause death or severe injury.
Ventilation is vital to the prevention of flammable liquid fires and
explosions. It is important to make sure that air flow through the
storage is constant and prevents the accumulation of any flammable
vapors.
Do not smoking or use open flame when handling hydraulic fluids or
in place where stored fluids.

To prevent the introduction of such impurities as dirt, water, lint into the fluid
medium, the following rules should be carefully observed:
1. Store drums on their sides and under protective cover. Water collecting
on the top of a drum, even though it is sealed, will gradually work its way
through the bung seals into the fluid.
2. Before opening a drum, clean the top carefully so that dirt will not fall into
the fluid.
3. Inspect and keep clean all containers and equipment used for storage or
dispensing of hydraulic fluids.
4. Before adding oil to a hydraulic system, wipe off the fill plug with a clean,
lint-free cloth.
5. Make certain that the fluid tank is protected against the admission of
contaminants. Possible openings which may provide entrance and which
should be checked include fill plugs, inspection plates, vents, missing
tank cover bolts and seals around pipes which extend through the cover
of the tank.
6. Use electric oil fill pumps, if fitted to machine. The use of the fill pump
ensures the oil is filtered as it enters the machine’s oil tanks.
Selecting the right hydraulic fluid is an important step in securing the
maximum performance and service life from hydraulic equipment. See
section “Hydraulic oil”. For normal conditions of operation only oils of
mineral base should be used for this purpose.
The hydraulic fluid must serve both as a lubricant to protect the rubbing
surfaces of pumps and fluid motors and as a medium for the efficient
transmission of hydraulic pressure. Other desirable characteristics are good
rust prevention qualities, resistance to cavitation.

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Proper body or viscosity of the hydraulic fluid is an important physical

property which must be suitable for the requirements of hydraulic units to
assure efficient operation. The correct viscosity will also be influenced by
the temperature and pressure at which the system operates.

10.4 Hydraulic pressure test points

1 2 6 5

11 14

12
9
10 7 8 3 4

Boom and bucket tilt pressure points

1 2

1 MP207 Bucket tilt cylinder rod side

2 MP206 Bucket tilt cylinder piston side

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Lift cylinder pressure points

3 4

3 MP204 Boom lift cylinder rode side

4 MP203 Boom lift cylinder piston side

Steering cylinder pressure points

6
5

5 MP103 Steering cylinder piston side

6 MP104 Steering cylinder rod side

Speed pedal pressure point

8 MP702 Speed pedal pressure

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Centralized pressure measuring points

11 13

12 14

10 7

7 MP701 Boost pump

10.5 Hydraulic oil tank

The machine is equipped with a 145 l hydraulic system tank. The hydraulic
system tank is equipped with a filter breather and the tank is vented to
operate at atmospheric pressure.
Suction pipe(s) and replaceable return filters for hydraulics are inside the
tank. If filter restriction reaches a critical level, the warning is shown on the
VCM-display.
Two sight glasses in the hydraulic tank make the checking of oil level easy.
With cold oil, the oil level must be between the sight glasses when box is
lowered. At operating temperatures the oil level must be seen in upper sight
glass.
To clean the oil tanks, the top cover (12) and inspection hole cover (11)
must be removed.

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4 3 2 1 6 12

10 8 9 7

1 Hydraulic oil return filter Z3421

2 Return filter pressure sensor S3076
3 Hydraulic oil return filter Z3521
4 Return filter pressure sensor S3077
5 Hydraulic oil tank sight glasses
6 Hydraulic oil tank breather Z2441
7 Hydraulic oil level (warning) limit switch S3012
8 Hydraulic oil temperature sensor B2001
9 Hydraulic oil level (alarm) limit switch S3056
10 Hydraulic tank draining valve
11 Main hydraulic inspection cover
12 Tank cover with gasket

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10.5.1 Hydraulic oil level monitoring

The hydraulics oil tank has two level sensors. When the oil level decreases
below the upper sensor, the system gives a warning. When the oil level
decreased below the lower sensor, the system gives an alarm. All alarms
and warning are recorded in the alarm log.
Alarms and warnings have a parameter set filtering time, which prevents
unnecessary alarms.

Forced functions (requires service password)

Forced functions windows are used to control the machine’s different

functions by using the display module’s buttons instead of the machine’s
control buttons. A forced functions window can replace a broken control
actuator; for example, if the steering joystick is broken, the machine can be
driven for service using a forced functions window.
Test functions may cause unexpected movements of the machine. Always
be sure when test functions are done that there is no-one beside the
machine and the machine has enough free space around it.

Forcing digital outputs of the module

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This window is used for forcing the digital outputs of each connector of a
module on or off:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

The digital output of the operating voltage of the oil level sensors:
Function Module Connector pin
Level sensors user voltage Middle XM 2.1

Measurement data of the modules (requires service password)

The measurement data windows shows the values and status of the
connector pins. The windows are used for help in troubleshooting. From the
module measurement window, select the Middle module connector pins
XM1, XM2 and XM3, then press theOK button. The measurement windows
corresponding to the connector pins will open.
The connector pins for hydraulic oil level monitoring are listed in
the ”Inputs” and ”Outputs” tables in the section, ”System
notifications and troubleshooting (Hydraulic oil level monitoring)”.

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System notifications and troubleshooting (Hydraulic oil level monitoring)

Inputs
Connector
Actuator Description Signal level Module
pin
Hydraulic oil
Level sensor level warning Float / 24 V Middle XM1.19
(S312)
Hydraulic oil
Level sensor level alarm Float / 24 V Middle XM3.22
(S356)

Outputs
Connector
Actuator Description Signal level Module
pin
Level sensors
Sensor 24 V / 0 V Middle XM2.1
supply voltage
Level sensors,
Sensor GND Middle XM2.13
ground

Module No Alarm text Alarm log

Middle 106 Hydraulic oil level warning X
Middle 107 Hydraulic oil level alarm X

Description: Hydraulic oil level warning (or) Hydrauliic oil level alarm
Action 1: Hydraulic oil tank
• Add more oil into the tank or check the oil level.
Action 2: Wiring
• If the warning is activated, detach connector pin XM1.19 and measure
the voltage.
• If the alarm is activated, detach the connector pin XM3.22 and measure
the voltage.
• If the voltage is the same as the machine’s operating voltage, replace the
Middle module.
Action 3: Sensor current supply
• If the warning is activated, measure voltage.
• If the alarm is activated, measure the voltage.
• If there is no voltage, repair the cabling of the current supply.
Action 4: Sensor output
• If the warning is activated, measure voltage.
• If the alarm is activated, measure voltage.

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• If there is no voltage, replace the level sensor.

Action 5: Wiring
• If the warning is activated, measure the resistance to connector XM1.19.

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10.5.2 Changing the hydraulic oil

The preferred time for draining the tank and changing the oil is after the
system has been operating for a period or at the end of a day’s run when
the hydraulic fluid is thoroughly warmed up. By draining when the oil is
warm and immediately after the system is stopped, the used oil will usually
carry off the greatest quantity of impurities. It is also good practice to flush
the tank and system for further removal of impurities before the fresh
change of hydraulic fluid is introduced. It is recommended to use regular
hydraulic oil for flushing and the oil to be circulated for 30 minutes or more
by running the pumps. When system is noticeable dirty, a small quantity (5
to 10%) of petroleum solvent (such as Mobisol A) may be added to the
flushing charge to help loosen up impurities in the system. Pumps may then
need to run a longer period to ensure the desired cleaning action.
1. Make sure the hydraulic system is warm.
• Oil flows more easily when warm and carries away more dirt and
foreign material with it.
2. Remove the filter assembly cover (2).

7 2

4 5 3

3. Remove the bottom plate (1) and open the draining valve (3) to allow the
oil to drain completely to a large enough container.
4. Remove the filter assemblies (6) from the tank as well .
5. Open the mounting screws (6 pcs) from the tank inspection cover (4) and
remove cover.
6. Remove the O-Ring (5).

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7. Clean the inside of the tank.

• If it is difficult to clean the tank, use a mixture of five parts of fuel oil
to one part of clean lubricating oil.
• Be sure to flush the bottom of the tank.
• Ensure all of the flushing solution is removed from the tank.
8. Thoroughly wash the tank exterior with cleaning solvent.
9. Replace the oil filter element (6) and breather element (7) with new ones.
10. Install all of the components removed from the tank.
11. Reconnect all disconnected hoses and connections.
12. Close the draining valve (3) and make sure that all plates and
components have been installed and properly tightened.
13. Refill the oil tank to recommended level.
• Oil level should be between the sight glasses (8).
• When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer’s requirements.
• Filling must be done through the filter (6).
14. Prime all variable displacement type pumps and bleed air from suction
lines.
• See section Bleeding the suction lines.
15. Make sure that all of the hydraulic system control joysticks are in the
neutral position.
16. Start the engine and allow it to run at idle for 5 minutes.
17. Operate the transmission, bucket and steering through their complete
cycles a few times.
• Repeat this step until the machine movements are functioning
smoothly. This will indicate that all air has escaped from the system.
18. Add enough hydraulic oil to the tank to bring the oil to the recommended
level.
• Oil level should be between the sight glasses when bucket is at
down position.
19. Carefully check all connections in the hydraulic system for leaks.
20. Dispose all of the used oil and material according to local environmental
regulations.

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10.5.3 Reasealing the hydraulic oil tank

1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Make sure that the boom is lowered and resting on it's stops.
3. Install the frame articulation locking device.
4. Before performing any maintenance work on hydraulic system, the
emergency steering and suspension circuits must be depressurized.
5. Drain the oil from the hydraulic tank.

C B

A
D

• Open the lower cover plate and remove the cover cap of draining
valve.
• Open the drain valve (A) to allow to the oil to drain completely to a
large enough container.
6. Open the hydraulic line connections from the return filter assembly.
7. Remove the mounting bolts from filter housing cover (B).
• Remove the return filter.
8. Open the cover mounting bolts (C)
9. Attach a hoist to the cover and remove the cover from the tank.
10. Clean the tank cover and the tank.

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11. Fit a new gasket to the cover and refit the cover onto the tank.
• Use some gasket lubricant on the gasket.
• Make sure that when the cover is remounted, it does not fold on the
tank openings.
12. Install the mounting bolts and tension them.
13. Install all removed components in reverse order.
• Replace all o-rings, gaskets and filters during assembly of the
components to the tank.
14. Reseal the tank inspection covers (D).
15. Fill the hydraulic tank with oil and prime the suction lines to pumps.
• Oil level should be between the sight glasses.
• See section Bleeding the suction lines.
16. Start the engine and check the hydraulic oil tank for any leaks.
• Check for correct oil levels.
17. Remove the frame articulation locking device.

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10.5.4 Repairing the tank

Hits from i.e rocks can damage the hydraulic oil tank and cause cracks. A
crack may form also in one of the tubes or baffles in the tank. When this
happens, the tank must be repaired. If the crack can be welded, there are
certain safety precautions that you should take. Although hydraulic oil is not
an explosive, it is combustible. Therefore, before welding a crack in the
tank, proceed as follows:
If you must weld the machine, remove the alternator wires and open
the main switch before welding.

Take into consideration the fire and explosion hazard created by

welding. Make sure that the machine and its surroundings are clean
and fireproof. Remove flammable materials from welding area or
shield from sparks, heat. Keep a fire extinguisher in the welding area.
Keep a fire watch in area during and after welding.

1. Thoroughly drain all hydraulic oil from the tank and system.
2. Remove all of the strainers and other removable parts from the inside of
the tank. Then, clean the tank thoroughly. This can be done adequately
with steam. If chemicals of any type are used, be sure to clean the tank
in well ventilated area and wear protective clothing and goggles.
Never use oxygen, for it supports combustion even better than air
does.

3. Before welding, fill the tank with a non combustible material such as
carbon dioxide gas or nitrogen to prevent the possibility of explosion. If
neither of these gases are available, use clean water.
4. After completing the welding operation, remove all traces of the
noncombustible material which was put in the tank to prevent an
explosion.
5. Connect and install all the equipment which were removed or
disconnected.

10.6 Oil temperature monitoring

The hydraulic and transmission oil temperature is measured with an analog
sensor that is connected to the Middle module.
The system gives an alarm if the sensor signals differ from the calibrated
values. Sensor calibration, as well as alarm and warning limits are set
according to section ”Sensor calibration”.
A filtering time should be set by parameters for the alarm (how long the
error is active before an alarm is given).

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Oil temperature monitoring window

The sensor data for brake temperatures are shown in Gauge window 1:
• Hydraulic oil temperature
• Transmission oil temperature
Active alarms and warnings are shown with the symbols in the gauge
window. They appear on the left side of the sensor symbol for the alarm or
warning it applies to.
The alarm and warning limits are shown in the info window.
The gauge window also shows the box counter, machine speed (or other
selected measurement option), and the time.

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Measurement data of modules (requires service password)

The measurement data windows show the values and status of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want in the measurements menu window
and press theOk button. The measurement data window of the connector
opens.
The connector pins for oil temperature monitoring are listed in
the ”Inputs” and ”Outputs” tables in the section ” System
notifications and troubleshooting (Oil temperature monitoring”.

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10.6.1 System notifications and troubleshooting (Oil temperature monitoring)

Inputs
Signal level Connector
Actuator Description Module
pin
Hydraulic oil
Temperature
temperature PT 1000 Middle XM3.13
sensor
(B301)
Transmission
Temperature
oil temperature PT 1000 Middle XM3.14
sensor
(B302)

Outputs
Connector
Actuator Description Signal level Module
pin
Transmission
Sensor oil temp sensor Ref +12 V Middle XM3.1
supply (B302)

Module No Alarm text Alarm log

Middle 24 Hydraulic oil temp high alarm X
Middle 25 Hydraulic oil temp high warning X
Middle 132 Hydraulic oil temp low warning X
Middle 133 Hydraulic oil temp low alarm X

Description: Hydraulic oil temp out of limits

Action: Check the hydraulic oil temperature

Module No Alarm text Alarm log

Hydraulic oil temp sensor (B301)
Middle 26 X
high error
Hydraulic oil temp sensor (B301)
Middle 27 X
low error

Description 1:
Action 1: Sensor
• Measure and check the current value of the sensor from “The
measurement data windows” (refer chapter “Oil temperature monitoring”,
section “Measurement data of the modules”)..
• Change the sensor if it is broken.
Action 2: Cabling
• Measure the resistance from sensor pole 1 against the ground.
Resistance should be 0 ohm.

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• Fault is in the cabling.

Action 3: Cabling
• Remove the Middle module connector pin XM3.13 cable and measure it
to sensor pole 2. Resistance should be approx. 0 ohm.
• Fix the cabling if it is broken.
Description 2: Module
Action 1: Module
• If the malfunction was not repaired by the actions of Description 1, the
Middle module is broken. Replace the module.

Module No Alarm text Alarm log

Module ref 12V out of limits (pins
Middle 90 X
XM3/1 or XM3/9)

Description: Module ref 12V out of limits (pins XM3/1 or XM3/9)

Action 1: Wire harness
• Detach the connector pin that caused the alarm from the module.
• Check if the alarm is still active.
• If the alarm is not active anymore, check the wiring. Power consumption
may be too heavy.
Action 2: Module
• If action 1 does not correct the malfunction, the module may be broken.
Change module if needed.

Module No Alarm text Alarm log

Middle 142 Transmission oil temp. high alarm X
Middle 143 Transmission oil temp. high warning X
Middle 161 Transmission oil temp. Low warning X
Middle 162 Transmission oil temp. Low alarm X

Description:
Action: Check the transmission hydraulic oil temperature.

Module No Alarm text Alarm log

Transmission oil temperature sensor
Middle 144 X
(B302) high error
Transmission oil temperature sensor
Middle 145 X
(B302) low error

Description 1: Transmission oil temperature sensor (B302) high or low

error

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Action 1: Sensor
• Measure and check the current value of the sensor from “The
measurement data windows” (refer chapter “Oil temperature monitoring”,
section “Measurement data of the modules”)..
• Change the sensor if it is broken.
Action 2: Cabling
• Measure the voltage of sensor pole 1, which should be 12 V.
• Fault is in the Middle module or connector pin XM3.1 (this is given by a
separate alarm).
Action 3: Cabling
• Remove the Middle module connector pin XM3.14 cable and measure it
to sensor pole 2. Resistance should be approx 0 ohm.
• Repair the cabling if it is broken.

Description 2: Module
Action: Module
• If the malfunction was not repaired by the actions of description 1, the
Middle module is broken. Replace the module.

10.7 Filter monitoring

In the critical filters of the machine are sensors, which give an alarm if a
filter is clogged. These filters are: hydraulic return filter, brake return filter,
engine air filter, drive pump filter and pilot oil pressure filter.
Filter alarms are marked in the alarm log. The alarms have a filter time, set
by parameters, which prevent irrelevant alarms.
Transmission, hydraulic, and brake oil filters have their own parameters for
low temperature. Alarms are not sent if the oil temperature is colder then
the set parameter value of the oil.
There is a separate input for each filter sensor of the Middle module. When
the input is activated, a warning appears on the display.

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Forced functions (requires service password)

Forced functions windows are used to control the machine’s different

functions by using the display module’s buttons instead of the machine’s
control buttons. A forced functions window can replace a broken control
actuator; for example, if the steering joystick is broken, the machine can be
driven for service using a forced functions window.
NOTE! Test functions may cause unexpected movements of the machine.
Always be sure when test functions are done that there is no one beside
the machine and the machine has enough free space around it.

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Forcing the digital outputs of modules

This window is used for forcing the digital outputs of each connector of a
module on or off:
1. In the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens. The connector pin values are shown according to their status
when the window was opened.
3. Switch the output (or outputs) to be forced on or off. ”1” forces the output
on ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button. The forcing
stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

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Measurement data of the modules (requires service password)

The measurement data windows show the values and status of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want on the measurements menu window
and press theOK button. The measurement data window of the connector
opens.
The connector pins for filter monitoring are found in the ”Inputs”
and ”Outputs” tables in the section, ”System notifications and
troubleshooting (Filter monitoring)”.

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10.7.1 System notifications and troubleshooting (Filter monitoring)

Inputs
Signal level Connector
Actuator Description Module
pin
Brake oil return
Sensor Float / 24 V Middle XM1.18
filter
Pilot pressure
Sensor 24 V / Float Middle XM2.18
filter
Sensor Engine air filter 24 V / Float Middle XM2.21
Hydraulic oil re-
Sensor 24 V / Float Middle XM3.18
turn filter
Drive pump -/
Sensor Transmission 24 V / Float Middle XM3.19
oil filter

Outputs
Signal level Connector
Actuator Description Module
pin
Filter sensor
Sensor 24 V / Float Middle XM2.1
supply voltage

Module No Alarm text Alarm log

Middle 50 Pilot oil filter blocked X
Middle 51 Hydraulic return filter blocked X
Middle 73 Brake oil return filter blocked X
Middle 74 Air intake filter blocked X
Middle 178 Transmission oil filter blocked X

Description 1: Pilot oil filter blocked

Action: Filter
• Check the pilot oil filter.
Description 2: Transmission oil filter blocked
Action: Filter
• Check the drive pump transmission filter.
Description 3: Hydraulic return filter blocked
Action: Filter
• Check the hydraulic return filter.
Description 4: Air intake filter blocked

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Action: Filter
• Check the air intake filter.
Description 5: Brake oil return filter blocked
Action: Filter
• Check the brake oil return filter.

10.8 Suction lines

Suction lines consist of main suction pipe, pump and hoses. The main
suction pipe leads the oil from bottom of the tank to the pump and forward
through the hoses. Brake release pump unit, emergency steering pump unit
(option) and hydraulic transmission unit has a separate suction pipes,
which are separately connected to the tank.

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1 Main suction pipe

2 Pump
3 Hose

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10.8.1 Bleeding the suction lines

Always bleed the air from the suction lines have been opened, hydraulic oil
is changed or the pump has been replaced. Bleed the air from the suction
lines by opening the bleed plug at the suction connection. Also bleed air
through the suction side bleed plug of the pump.

3 2 3 2
3 9
3
4
4

7
16
1 8 15
10 11 12 13 14

1 Tank return line 2 Air bleed plug

3 Control pressure (upstream 4 Stroking pressure chamber
of orifice)
5 Bypass valve 6 Pilot pressure inlet
7 Pilot pressure outlet 8 Boost pressure
9 Measuring high pressure 10 Suction line & bleed plug
11 Service line fixing threads 12 Boost pressure outlet
13 Boost pressure inlet 14 Measuring pressure A
15 Tank return line 16 Measuring pressure B

1. Disconnect the case drain line from the variable displacement type pump.
2. Prime the variable displacement type pump case with hydraulic oil.
3. When the pump drive is primed connect the case drain valve to the pump
4. Bleed the air from the suction side of the pump by opening bleed plug
(2).
5. Bleed air from the suction lines by opening bleed plug (10).
6. Close the bleed plug after you have bled the lines.
• If necessary, use compressed air to pressurize the hydraulic tank.
• Pressure: max. 0.4 bar.
7. Run the engine on idle with no load for at least 5 minutes.
8. Shut down the engine and check the system for any leaks.

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10.9 Pilot pressure control unit

1 Pilot pressure generation block (first section)

2 Pilot pressure generation block (second section)
3 Pressure accumulator

Pilot control pressure unit contains valve block, pressure accumulator and
follow-up valve.

Pilot pressure generation block (1)

Pilot pressure valve block includes the following components:

Shuttle valve
The shuttle valve directs the hydraulic pressure from the inlet connections
P1 and P2 to the pressure reducing valve.

Pressure reducing valve

The pressure reducing valve reduces pilot control pressure unit outlet
pressure to 35 bars.

Non-return valve
The non-return valve prevents hydraulic oil flow from the pilot control
pressure line to pressure reducing valve

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Relief valve
Relief valve protects the pilot control circuit from too high pressure if the
pressure-reducing valve is damaged. Relief valve limits the pressure to 45
bar if malfunction occurs.

Pilot pressure generation block (2)

Pilot pressure valve block includes the following components:

Pressure filter
The pressure filter cleans the hydraulic oil from contaminants. The pressure
filter is equipped with 6 bar by-pass valve and electric dirt indicator
(S3080). The electric dirt indicator gives an alarm to the VCM if the
pressure is 5 bar greater and the by-pass valve allows the hydraulic oil to
flow past the filter, when pressure is more than 6 bar greater.

Solenoid valve (Y3067)

Solenoid valve drains the pressure accumulator and pilot pressure line
through 8 mm orifice to tank, when ignition power is off.

Solenoid valve (Y3113)

Solenoid valve prevents pilot pressure entering to steering and boom /
bucket control valves when the door is open.

Pressure accumulator Z3131 (3)

Pressure accumulator volume is 0,75 liter and the pre-charge pressure is
15 bars. When the external pressure in the line is more than 15 bars,
accumulator charges, in other words stores hydraulic energy. If the external
pressure falls in the line, the accumulator discharges and releases the
hydraulic oil it has stored.

10.10 Hoses and tubing

In order to prevent leakage, vibration, and abrasion of lines and hoses, and
also to provide a neat, orderly hydraulic system, certain rules should be
followed when replacing hoses and lines:
1. Replace lines and hoses in the same positions they were before removal.
Equipment manufacturers put a lot of effort and planning into routing all
lines so that they will not be exposed to excessive vibration and abrasion.
2. Avoid sharp bends in hoses and tubing. Sharp bends in hydraulic lines of
any type act as restrictions and cause overheating. When you are
installing a hose line where it must be bent, always check the minimum
bend radius with the manufacturer’s catalog. The figure listed will be for
nonflexing applications. If the manufacturer’s specification is not
available, a rule of thumb is to avoid bending the hose to a radius smaller
than ten times the outside diameter of the hose. In areas where hose
flexing will occur during operation of the equipment, a larger minimum
bend radius is necessary. When installing tubing or piping, the ideal bend
radius is 2 to 3 times the inside diameter.

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3. Never overtorque swivel nuts. They need only to be tightened firmly.

Giving a swivel nut that extra turn beyond this point can cause damage to
the swivel nut and to the sealing surfaces.
4. Keep lines as short as possible. The longer the line, the more there is
internal resistance. Therefore, avoid replacing lines with new ones that
are longer than the originals. On the other hand, do not try to shorten
lines to the extent that you must use bends which have a radius that is
smaller than the recommended minimum in order to make them reach
the point of connection. Measure the original line carefully, taking into
account all bends. Then replace it with a line of the same length. One
thing that should be kept in mind when installing hoses is that they have
a tendency to decrease in length somewhat when pressurized.
Therefore, it is important never to cut a hose so short that when it is
installed between two points it has no bend whatsoever. In other words,
allow a slight bend so that the hose can shorten somewhat in length
when it is pressurized.
5. Use proper clamps, adapters, and fittings. This is important for several
reasons. If brackets are not used to support hoses as recommended by
the manufacturer, abrasion will result from hoses rubbing against each
other and against various parts of the equipment. This shortens the life of
the hoses, resulting in premature replacement. Be sure that hose clamps
are the correct size. Be sure to use only recommended fittings. If the
fittings do not match the hoses exactly, restriction or leakage will be the
result.
6. Use the proper tools. Never use such tools as a pipe wrench on hose or
tubing fittings. Instead, use flare nut wrenches when possible, and when
they are not available, use open end wrenches of correct size. Never
attempt to keep them from leaking by using sealing compounds.
7. When you disconnect a line or hose froma hydraulic system, be sure to
cap or plug the line and also the fitting from which it was removed. Never
use rags or waste material for plugging lines or components of the
system.

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Hose standard and temperature resistance

Maximum op-
Type Standard erating tem- Size Color
perature
R1T
SAE: R1AT
1-reinforced +100°C from -04 to -20 Black
EN: 1SN
hose
R2T
SAE: R2T
2-reinforced +135°C from -04 to -32 Blue
EN: 2SN
hose
4SH SAE: R9 / R12
+100°C from -08 to -24 Black
4-spiral hose EN: 4SP / 4SH
R4
SAE: R4 +135°C from -16 to -40 Blue
Suction hose
R1TR
SAE: R1AT(-R)
Fire suppression +100°C from -04 to -12 Red
EN: 1SN
hose
FH
+150°C from -04 to -08 Black
Fuel hose

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Hose pressure resistance and bending radius

Max operating Burst pres-
Type Size Size Bending radius
pressure sure
R1T 04 1/4" 225 bar 95 mm
R1T 06 3/8" 180 bar 130 mm
R1T 08 1/2" 160 bar 180 mm
R1T 20 1 1/4" 60 bar 420 mm
Max operating
Type Size Size Burst pressure Bending radius
pressure
R2T 04 1/4" 400 bar 1585 bar 100 mm
R2T 06 3/8" 330 bar 1320 bar 125 mm
R2T 08 1/2" 275 bar 1100 bar 180 mm
R2T 10 5/8" 225 bar 900 bar 200 mm
R2T 12 3/4" 210 bar 830 bar 240 mm
R2T 16 1" 165 bar 650 bar 300 mm
R2T 20 1 1/4" 125 bar 500 bar 420 mm
R2T 24 1 1/2" 90 bar 360 bar 500 mm
R2T 32 2" 75 bar 310 bar 630 mm
Max operating
Type Size Size Burst pressure Bending radius
pressure
4SH 08 1/2" 425 bar 1800 bar 120 mm
4SH 10 5/8" 400 bar 1700 bar 140 mm
4SH 12 3/4" 420 bar 1680 bar 280 mm
4SH 16 1" 380 bar 1520 bar 340 mm
4SH 20 1 1/4" 325 bar 1400 bar 460 mm
4SH 24 1 1/2" 290 bar 1160 bar 560 mm
Max operating
Type Size Size Burst pressure Bending radius
pressure
R4 16 1" 17 bar 68 bar 152 mm
R4 20 1 1/4" 14 bar 56 bar 203 mm
R4 24 1 1/2" 10 bar 40 bar 254 mm
R4 32 2" 7 bar 28 bar 305 mm
R4 40 2 1/2" 4 bar 16 bar 356 mm

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Max operating pres- Burst pres-

Type Size Size Bending radius
sure sure
R1TR 04 1/4" 225 bar 95 mm
R1TR 08 1/2" 160 bar 160 mm
R1TR 12 3/4" 105 bar 220 mm
Max operating
Type Size Size Burst pressure Bending radius
pressure
FH 04 1/4" 150 bar 600 bar 50 mm
FH 06 3/8" 100 bar 400 bar 64 mm
FH 08 1/2" 82 bar 320 bar 89 mm

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10.10.1 Marking of hydraulic hoses

1 2 3 4 5 6 4 5 6 7 8

1 2 3
Code Hose type Hose size Code Length [mm]
R1T 1-reinforced hose 04 # # # # Hose length [mm]
R2T 2-reinforced hose 06 6
4SH 4-spiral hose 08 Code Joint type
R4 Suction hose 10 A Straight (female)
R1TR Fire suppression hose 12 B 90° (female)
FH Fuel hose 16 C 90° long (female)
CH Coolant hose 20 D 45° (female)
ACH Air Conditioner hose 24 I Straight joint
XX Other - Drawing 28 H 45° pipe joint
4 32 L 90° pipe joint
Code Thread 40 T Straight (male)
M Metric XX X Other - Drawing
R R (BSPP) 60 5 0 No joint
J JIC 37° (UNF) Joint size 7
S SAE 45° (UNF) 00 Code Fitting angle
3F Flange SAE 3000 psi 04 0 Straight
6F Flange SAE 6000 psi 06 ### Fitting angle (degrees)
N Banjo 08 8
V ORFS 10 Code Option
U O-ring Freon-hoses 12 0 Standard hose
X Other - Drawing 16 PH Protective sleeve
0 No thread 20 SM Protective spiral - steel
24 SS Protective spiral - plastic
28 FS Fire retardent hose
32 XX Special - Drawing
40
XX

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Size R-Thread ORFS (UNF-thread) J- & S-system (UNF)

04 1/4" 7/16" -20
05 1/2" -20
06 3/8" 11/16" 9/16" -18
08 1/2" 13/16" 3/4" -16
10 5/8" 7/8" -14
12 3/4" 1 13/16" 1 1/16" -12
16 1" 1 7/16" 1 3/16" -12
20 1 1/4" 1 5/16" -12
24 1 1/2" 1 5/8" -12
28 1 3/4" 1 7/8" -12
32 2"

Distance between the sealing surfaces (L) [mm]

L<300 mm, tolerance +4.5 mm
L>300 mm, tolerance +1.5%
Fitting angle for joints tolerance ±3°

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10.11 Hydraulic component symbols

2
18

3
19

5 21

6 22

8
25

9 26

10 27

11 28

29
13

14 31

16 32

17 33

1 Working line (pressure, suction, return and 2 Pilot Flexible line.control line.
feed line).
3 Drain or bleed line. 4 Flexible line.

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5 Electric line. 6 Dotted line surrounds the components

which are assembled in one unit.
7 Shaft, lever, rod, piston rod. 8 Pipeline junction.
9 Crossed pipelines. 10 Direction of flow in hydraulics (e.g. oil flow
in pumps and motors).
11 Direction of flow in pneumatics (e.g. air flow 12 Direction.
in compressors and air motors).
13 Direction of rotation. 14 Path and direction of flow through valves.
Small perpendicular line shows the move-
ment of the arrow.
15 Indication of the possibility of regulation. 16 Spring.
17 Adjustable spring. 18 Fixed capacity hydraulic pump with one
flow direction.
19 Fixed capacity hydraulic pump with one two 20 Compressor.
directions.
21 Variable displacement type hydraulic pump. 22 Electric motor (Sandvik Mining and Con-
struction uses the same mark for heat en-
gines).
23 Fixed capacity hydraulic motor with one flow 24 Fixed capacity hydraulic motor with two
direction. flow directions.
25 Single-acting cylinder. 26 Single-acting cylinder returned by spring.
27 Double-acting cylinder. 28 Cylinder with plunger.
29 Muscular control - general symbol (without 30 Muscular control - by lever.
indication of control type).
31 Muscular control - by pedal. 32 Mechanical control - by spring (e.g. return
movements).
33 Mechanical control - Detent (e.g. for keeping
control valve spool in given position).

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45
35

36
47

48
38

39 50

34 Electrical control - by solenoid (one wind- 35 Electrical control - by solenoid (two windings
ing). operating in opposite directions).
36 Control by pressure - indirect control. 37 Control by pressure - direct control (internal
path).

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38 Valve is a square or a row of squares in 39 Directional control valves which open or close
which every square shows one operating one or more blow paths (e.g. boom controls).
position of the valve. Directional control valve is a row of squares
in which the lines are connected to the
square representing the basic position. Port
markings on the directional control valves: P
= pressure from pump T = tank A,B,C...=
work lines X,Y,Z...= pilot pressure lines
a,b,c...= pilot pressure lines.
40 One flow path. 41 Two flow paths.
42 One flow path (two ports closed). 43 Two flow paths (one port closed).
In the following examples the first number shows the quantity of connection (ports) and the sec-
ond number the quantity of operating positions. Control pressure connections are not indicated.
44 3/2 control valve, pilot control in both di- 45 4/3 control valve, controlled by lever, spring-
rections. centered.
46 3/3 control valve (mobile control valve). 47 Shut-off valve (e.g. ball cock).
48 Pressure relief valve (safety valve). Inlet 49 Without a relief port.
pressure is controlled by opening the ex-
haust port to the tank or to the atmos-
phere against the opposing force. (Hy-
draulic valve on the left and pneumatic
on the right).
Pressure reducing valve (pressure regu-
lator). The unit which with a variable inlet
pressure gives a substantially constant
output pressure, if the inlet pressure re-
mains higher than the required outlet
pressure.
50 With a relief port. 51 Over center valve. The valve allows free flow
in one direction. Flow is possible in the oppo-
site direction if the external pilot pressure
opens the valve or the force caused by inlet
pressure exceeds the spring force.
52 Non-return valve. Opens by small pres- 53 Non-return valve. Opens by significant pres-
sure difference between inlet and outlet. sure difference against the spring (e.g. oil fil-
ters).

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54 63

55
65

56
68

58 70

59
71

73
61

62 74

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54 Pilot-controlled non-return valve. Pilot pres- 55 One-way restrictor. Unit allows free flow
sure opens the valve. to one direction but restricts the flow to
the other. Restricted flow is adjustable.
(e.g. for controlling the speed of cylinder
movement.)
56 Shuttle valve. The inlet port connected to the 57 Throttle valve.
higher pressure is automatically connected to
the outlet port while the other inlet port is
closed.
58 Flow control valve. Flow control valve. Varia- 59 Simplified symbol for the previous one.
ble output.
60 Variable output with a relief port. 61 Simplified symbol for the previous one.
62 Flow dividing valve. The valve divides the 63 Power take-off. Plugged (for connecting a
flow into two flows in a fixed ratio substantial- pressure gauge or power take-off).
ly independent of pressure variations.
64 Power take-off. Connected. Fitted with me- 65 Tank, a general symbol.
chanically opened non-return valves.
66 Tank with the inlet pipe above fluid level. 67 Tank with the inlet pipe below fluid level.
68 Pressure accumulator. 69 Filter or strainer.
70 Water tap. Manual draining. 71 Lubricator. The unit adds small quantities
of oil to the air passing through the unit.
72 Air cooler. 73 Water cooler.
74 Pressure electric switch. 75 Pressure sensor.

76 Cartridge valve (for example in boom suspen-

sion in loaders). 76

77 Measurement point
78 Cartridge valve (for example in boom suspen-
sion in loaders). 77

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11 Steering

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11.1 Steering hydraulic diagram

Steering Hydraulic Diagram

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11.2 Steering system description

3
1

Steering system main components

1. Pilot pressure control unit 2. Steering Cylinder A3121

V3401
3. Steering main valve V3102 4. Steering pump P3111
The machine has center-articulated power steering with one steering
cylinder(2.). The steering-pump P3111 (4.) is mounted to the pump drive
unit. The pump delivers oil to a hydraulically controlled steering main valve
V3102 (3).
The steering pilot pressure is controlled with hydraulic pilot control joystick
(V3111). The Pilot pressure is regulated to 35 bar in the pilot pressure
generation block V3401 (1.). Moving the steering joystick causes the pilot
control valve spool to open and let the pilot pressure to enter the spoold
end of the steering main valve.The steering main valve spool position
corresponds proportionally to the pilot pressure controlled by the steering
joystick movement.
When the steering joystick is released there is no oil flow from the pilot
control valve and springs force the steering main valve spool to return to its
center position and cylinder ports will be closed. This causes the machine
to remain in the turning angle determined earlier with the steering joystcik.
If the steering joystick is in neutral position and the ejector function
(optional) is not in use, the steering circuit oil flows through the steering
main valve (V3102) to the bucket main valve (V3201).

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11.3 Steering main valve

Main components

1 Main pressure-relief valve

2 Pilot controlled and spring-centered proportional valve spool
3 Safety relief-valves with combined port-relief and an anti-cavitation
function
4 Non-return valve

Description of function
The main pressure relief valve limits the maximum valve inlet pressure to
220 bar. The proportional valve spool adjusts the steering angle of the
machine by adjusting the hydraulic flow going to the steering cylinder.A
safety relief valves limits the pressure at the steering cylinder to 125 bar
prevents cavitation.
The non-return valve stops the pressure of the steering cylinder escaping to
the pressure side of the pump P3111. If the machine is equipped with an
optional ejector bucket, the steering main valve is equipped with an
additional valve section V3105 which includes one spring centered
hydraulically pilot controlled proportional valve spool and two safety relief
valves and one non-return valve.

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11.3.1 Checking and adjusting the steering main relief valve

1. Ensure that the machine is on a level surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Install the frame articulation locking device.
3. Before adjusting the steering main relief valve, the bucket main relief
valve opening pressure must be adjusted.
• Adjust the opening pressure by turning the adjustment screw (A)
approx. one turn to closed position.

4. Check that the steering main relief valve is not in fully closed position.
5. Connect a 400 bar pressure gauge to the quick disconnect fitting at
MP101 (B) on the steering valve.

6. Start the engine and run it at idle.

7. Move the bucket control lever to “bucket haul” position against the
stoppers and keep it there.
8. Record the gauge reading
• The pressure should be 220 bar (±5 bar).
9. If the reading does not match the specification
• The main relief valve needs to be adjusted by turning adjusting screw
(C).
• The main relief valve is malfunctioning and it must be overhauled.

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10. When adjusting is done, adjust the bucket main relief valve (A) back to
its original position.
• For adjusting the bucket main relief valve see Chapter Boom /
bucket hydraulics, section Checking and adjusting the bucket main
relief valve.

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11.3.2 Removing the steering main valve

Only perform maintenance work when the machine is parked on a

DANGER
SKIN INJECTION HAZARD!
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

WARNING
FIRE HAZARD!
Leaks can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

1. Ensure that the machine is on an even surface, the parking brake is

applied and movement in the driving is prevented by, for example, wheel
chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Install the frame articulation locking device.
4. Before servicing the hydraulic system, make sure that the hydraulic
system is depressurized.

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5. Release hydraulic pressure from steering hydraulic circuit.

• This can be done safely by the steering test points.
• Release the pressure gradually.
• Use an oil drain contain to collect any oil.

6. Remove the hoses and piping from the main valve.

• Place oil drain container under the valve.
• Plug the open ends of the hoses, pipes and steering main valve.

7. Remove the mounting bolts (4pcs) from the main valve.

8. Remove the main valve from the machine for repair or replacement.

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

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11.3.3 Installing the steering main valve

Only perform maintenance work when the machine is parked on a

When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer’s requirements.

DANGER
SKIN INJECTION HAZARD!
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

WARNING
FIRE HAZARD!
Leaks can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

1. Be sure that the frame articulation locking device is installed.

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2. Check and replace all o-rings and damaged pipes or hosing that fit to the
main valve.

3. Re-fit the main valve to the machine and tension the mounting bolts
(4pcs. M12x35 8.8).
4. Refit all pipes, hosing and attachments to the main valve.
5. Check hydraulic oil level..
• Fill if necessary.
6. Remove the frame articulation locking device.
7. Operate the steering hydraulics at 1200rpm to bleed air from the circuit
until hydraulic action is smooth.
8. Install the frame articulation locking device.
9. Check the main valve and hoses for leaks.
10. Check steering valve pressures.
• See section: Checking and adjusting the steering main relief valve.
11. Stop the engine.
• Complete any adjustments and checks to the main valve if required.
12. Remove the frame articulation locking device.

11.4 Emergency steering (option)

When the emergency steering is turned on, the pump unit A3141 provides
oil flow to generate hydraulic pressure required to steer the machine. The
pump is powered by the electric motor M3020. Spring-loaded non-return
valve V3167 keeps 15 bar backpressure on the circuit that is allowed
through shuttle valve V3164 for pilot pressure generation unit. Pressure
relief valve V3181 limits the pressure to 100 bar on the pressure side of the
pump unit. Non-return valve V3161 does not allow the oil flow of the pump
P3111 to enter the emergency steering system in a normal operating
situation.

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11.4.1 Emergency steering control

The emergency steering activates automatically when the motor stops or
stalls in an abnormal way. This function allows the operator to safely steer
the unit out of the way of danger. When the engine stops suddenly, the
system activates and an electric pump generates oil pressure to allow the
steering to function for a few additional seconds. The amount of time that
pump functions is defined with a parameter (default 10 seconds).
With the emergency steering test button it is possible to control the
emergency steering pump on and allow steering. Maximum testing time is
limited with parameter. Emergency steering test is not possible if the
emergency stop is activated or the engine is running. If testing is prevented
based on the above, an alert will appear on the display giving the reason
for this. These will not be left in the log. Pushing the button will, however,
cause a log entry about having tested the emergency steering, like when
testing the brakes.
The emergency steering pump is always operated for a certain time period
defined by a parameter, after starting the machine. When using emergency
steering pump after starting, emergency steering valve remains energized.
The symbol to the right on the main window shows the status of the
emergency steering. The symbol is grey when emergency steering is not
activated, and becomes red when emergency steering is activated.

Forced functions (requires service password)

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Forcing the digital outputs of modules

This window is used for forcing the digital outputs of each connector of a
module on or off:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE!SEND

Digital outputs of automatic central lubrication control:

Function Module Connector pin

Emergency steering pump Middle XM1.17

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Testing the emergency steering button

This window is used for testing the emergency steering with a testing
button. In the test, control the emergency steering pump on and allow
emergency steering. When pressing the emergency steering button, the
picture of a button on the right-hand side of the symbol becomes black.
Emergency steering will be on for a time period defined by a parameter
(default 10 s).
Emergency steering cannot be tested if the emergency stop is activated or
the motor is running (an alert appears on the display in these situations).
The information window tells which button can be used for testing the
emergency steering.

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Measurement data of the modules (requires service password)

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System notifications and troubleshooting (Emergency steering control)

System Interlocks
The system prevents emergency steering in the following situations:
• Emergency stop is activated
• The door is open

Inputs
Signal level Connector
Actuator Description Module
pin
Emergency
Switch 24 V / Float Chair XC3.22
steering test

Outputs
Signal level Connector
Actuator Description Module
pin
Emergency
Pump 24 V / 0 V Middle XM1.17
steering pump

Module No Alarm text Alarm log

Emerg. steering pump relay
Middle 61 X
signal short to ext. voltage
Emerg. steering pump relay
Middle 62 X
signal short to ground

Description 1: Voltage in the uncontrolled output.

Action 1: Voltage feed connection
• Remove the connector pin XM1.17 of the Middle module.
• If the alarm stopped, the fault is in wire harness, short circuit to operating
voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the Middle module may be
broken. Change the module if needed.
Description 2 : Short circuit to ground
Action 1: Voltage feed connection
• Remove the connector pin XM1.17 of the Middle module.
• Try using the Emergency Steering Pump again. If the alarm does not go
on again, the fault is in wire harness, short circuit to ground.
• Repair the wire harness.
Action 2: Module

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• If action 1 does not correct the malfunction, the Middle module may be
broken.
• Change the module if needed.

Module No Alarm text Alarm log

Middle 66 Emergency steering activated

Description: Emergency steering has been switched on because the

engine has been stopped unexpectedly.
Action: Engine
• Start the engine.

Module No Alarm text Alarm log

Emergency steering test error.
Middle 120
Door open!
Emergency steering test error.
Middle 121
E-stop activated!
Emergency steering test error.
Middle 124
Engine running!

Description 1: Emergency steering test error. Door open! (alarm no 120)

Action: Door open
• See chapter “Door switch diagnostic”.
Description 2: Error in testing the Emergency steering button, emergency
stop active (alarm no 121)
Action: Emergency stop
• Testing is prevented because emergency stop is active. Deactivate the
emergency stop and restart testing.
Description 3: Error in testing the Emergency steering button, the motor is
running (alarm no 124)
Action: Engine
• Testing is prevented because the engine is running. Stop the engine and
restart testing.

Module No Alarm text Alarm log

Middle 152 Emergency steering test X

Description: Testing of Emergency steering button has been started

Action: Emergency steering button
• No action needed, the test button for Emergency steering has been
pressed.

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11.5 Steering cylinder

13 12
11
9
8
7
6

3
2
18
1

18
5
2

16
13
14 1
13

15
14

When the wheels face straight ahead, cylinder extension is 50%. If the
machine is turned to the left, the cylinder retracts. When the machine is
turned to the right, the cylinder extends.
All cylinders are similar design. They are single stage, double acting
hydraulic cylinders. The steering cylinder is mounted between the front and
rear frames on left side of the machine. In the cylinder end there is ball joint
bearing (2) fastened with circlips (1). In steering cylinder the front end ball
joint bearing is mounted to the front frame instead of piston rod.
The piston (15) is secured to the rod (17) by two hexagon socket set
screws (14). On the outer diameter of the piston two slip rings (13) and a
piston seal (14) are located in their own respective grooves. Between the
piston and rod there is a o-ring (16) to make the fastening tight.
The gland assembly (13) is held in place at the end of the cylinder tube (3)
by hexagon socket set screw (5). O-ring (9) and seal ring (8) are fitted into
a groove on the outside diameter of the gland assembly. Located in the
internal bore of the gland assembly is a piston rod dirt ring (6) and a rod
guide rings (7) and a rod seal (11) and a wiper (12) . The seals prevents

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leakage past the rod. The wiper cleans dirt from the rod as it retracts. For
the lubrication of the ball joint bearings there are two grease nipples (18) in
the cylinder ends.
Cylinder rod movement within the housing is accomplished by applying
pressurized oil flow on either side of the piston and allowing the oil on the
opposite side of the piston to return back to hydraulic oil tank.

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11.5.1 Removing the steering cylinder hoses

Only perform maintenance work when the machine is parked on a

DANGER
SKIN INJECTION HAZARD!
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

WARNING
FIRE HAZARD!
Leaks can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

1. Ensure the machine is on a level surface and positioned straight, the

parking brake is applied and movement is prevented with wheel chocks.
2. Ensure the box is empty and resting on stops.
3. Install the frame articulation locking device.
4. Before performing any maintenance work on hydraulic system, make
sure that the hydraulic system is depressurized.

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5. Release hydraulic pressure from steering hydraulic circuit.

• This can be done safely by the steering test points.
• Release the pressure gradually.
• Use an oil drain contain to collect any oil.

6. Loosen the clamps of the hoses at the cylinder, making sure there is no
pressure and then remove them completely.
• Plug the open ends of the hoses and cylinders.
7. Open the clamps from the frame side.
• Plug the open ends.
8. Remove the hoses.

Ensure safe and environmentally protective disposal of process

materials and exchange parts.

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11.5.2 Removing the steering cylinder

Only perform maintenance work when the machine is parked on a

Ensure that lifting equipment is in good condition and correctly

rated.

DANGER
SKIN INJECTION HAZARD!
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

WARNING
FIRE HAZARD!
Leaks can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

1. Ensure that the machine is on an even surface, the parking brake is

applied and movement is prevented by, for example, wheel chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Position the loader so that the cylinder being removed is fully extended.
4. Install the frame articulation locking device.

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5. Remove the front pin and the caps from the cylinder by opening the
screws (4 pcs).
• Use extraction screws if required.

6. Retract the cylinder rod, use machine hydraulics if required.

• Note! Frame articulation locking device must be installed if machine
hydraulic is used to retract the cylinder rod.
7. Before servicing the hydraulic system, make sure that the hydraulic
system is depressurized.
8. Release hydraulic pressure from steering hydraulic circuit.
• This can be done safely by the steering test points.
• Release the pressure gradually.
• Use an oil drain contain to collect any oil.

9. Remove hydraulic hoses and lubrication lines.

• Cap and plug open ends from the cylinder and hoses so no foreign
particles can enter.
• Note! Check that there are no leaks. Leaks can cause fires.

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10. Attach a hoist to the cylinder to support its weight.

11. Remove the rear end of the cylinder by opening the screws (8 pcs).
• Use extraction screws if required.

12. Remove cylinder from machine using a hoist.

• Note! The weight of the steering cylinder is aprox. 100 kg.

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11.5.3 Steering cylinder disassembly

15 16
13
12
9

2 18

2
1
17
14
11
10
7 8
6
5
4
3
2
1

1. Remove hex socket set screw (4) 1 pcs.

2. Unscrew the cylinder gland with an appropriate gland wrench (14).
3. Fully extend the cylinder and pull out piston rod (17) with piston (6) and
gland assembly.
4. Remove wear rings (7) and seal (8) from the piston.
5. Remove piston locking hex socket set screws (4) 2 pcs. and unscrew
piston (6).
6. Remove the seal (9) inside the piston.
7. Pull away the gland assembly and removing seal (10), o-ring (11), slip
ring (12), rod seals (13), seal (15) and wiper (16).
8. Remove the circlips (2) 4 pcs.
9. Remove the transverse bearing (1) 2pcs.
10. Remove the grease nipples (18) 3 pcs.

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11.5.4 Steering cylinder reassembly and installation

Assemble the component parts in the reverse order they were
disassembled.
Note! Piston lock screws must be re-drilled to 120° from each other (see
drawing).

The lock screws must be secured by punching two holes near the screws
with an arbor.
M10 thread, 2 pcs, 13 mm deep holes.
Tightening torques:
• Piston: 50,0 kpm (500 Nm)
• Gland: 50,0 kpm (500 Nm)
11.5.5 Inspection and repair
1. Clean all parts thoroughly.
2. Replace all o-rings, backup rings, seals, wear rings and wiper.
3. Inspect the cylinder bore, piston rod and piston for signs of scratches,
burrs or other damage which could cause a failure.
4. Use a fine stone to remove burrs or small scratches.
5. Replace any part showing damage or excessive wear.

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11.5.6 Installing the steering cylinder hoses

Only perform maintenance work when the machine is parked on a

DANGER
SKIN INJECTION HAZARD!
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

WARNING
FIRE HAZARD!
Leaks in fuel or hydraulic systems can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

1. Check hoses, connectors and other components for any damage.

• Replace any damaged parts.
2. Install the hoses back to the cylinder and to the other ends.

3. Check hydraulic oil level.

• Fill if necessary.
4. Remove the frame articulation locking device.

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5. Start the engine.

6. Operate the steering trough its full cycle a few times to bleed air from the
hydraulic circuit.
• Continue until steering is functioning smoothly.
7. Shut down the engine and check the steering cylinders for any leaks.
8. Check hydraulic oil level. Fill if necessary.

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materials and exchange parts.

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11.5.7 Installing the steering cylinder

When changing or adding fluids and oils, only use new fluids and
oils meeting manufacturer’s requirements.

DANGER
SKIN INJECTION HAZARD!
The high-pressure oil spray can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.

WARNING
FIRE HAZARD!
Leaks can cause fires.
Tighten any loose connections and replace damaged fuel and
hydraulic oil lines, tubes and hoses.

1. Refit the cylinder to the machine using hoist.

• Fit all new grease seals to the cylinder using tape to hold seals in
place.

2. Check all pins and bushes and replace them if required.

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3. Install rear pin to the cylinder by fastening the screws (8 pcs).

• Make sure that all parts are lubricated before installation.

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4. Connect all hoses and lubrication lines to the cylinder.

• Make sure that all connections are tight.

5. Check hydraulic oil level.

• Fill if necessary.

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6. Use machine hydraulics if necessary to extend the cylinder rod and align
the front pin.
• Install front pin to the cylinder by fastening the screws (4 pcs).
• Make sure that all parts are lubricated before installation.
• Note! Frame locking pin must be installed if machine hydraulic is
used to retract the cylinder rod.

7. Remove the frame articulation locking device.

8. Start the engine.
• Operate the steering hydraulics at 1000 rpm to bleed air from the
circuit until hydraulic action is smooth.
9. Check the cylinder for leaks.
11.5.8 Steering cylinder bypass test
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.

Only perform maintenance work when the machine is parked on a

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Rod side leakage test

High-pressure oil spray hazard. The high-pressure oil spray can
cause serious injury. Allow the pressure to be released from the
hydraulic circuit before opening the plugs or connectors.

1. Ensure that the machine is on an even surface, the parking brake is

applied and movement in the driving is prevented by, for example, wheel
wedges.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Install the frame articulation locking device.
4. Open the cover plates from the side where the steering cylinder is being
tested.

5. Release hydraulic pressure from steering hydraulic circuit.

• This can be done safely by using a capillary test hose into the steer
test points.
• Gradually screw the quick connects on to release the pressure in a
control manner.
• Use an oil drain contain to collect any oil.

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6. Disconnect the rod side hydraulic line from the steering valve of the
cylinder to be tested.
• Cap the steering valve to eliminate any high-pressure oil injection
hazard during the test.

7. Allow the cylinder rod side oil to drain into an oil drain container via the
disconnected hose, until completely drain and all oil flow has stopped.
• Secure the hose to the oil drain container.
8. With the second person observing the container and rod side hose end
from a safe position, start the engine and move the steering lever to
pressurize the piston side hydraulic circuit of the cylinder being tested.
• If oil is observed coming from the cylinder, the piston seals are
bypassing in this direction (piston to rod side).
• In this case the cylinder needs to be replaced or overhauled.
9. Shut down the engine.
10. Release hydraulic pressure from steering hydraulic circuit.
11. Remove the cap from the steering valve and reconnect the rod side
cylinder hose to the valve.
• Use new O-rings.

12. Check hydraulic oil level. Refill if necessary.

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13. Remove the frame articulation locking device

14. Start machine and operate steering through it full cycle few times to
ensure smooth function.
• Check steering system for oil leaks.
15. Shut down the machine.

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Piston side leakage test

High-pressure oil spray hazard. The high-pressure oil spray can
cause serious injury. Allow the pressure to be released from the
hydraulic circuit before opening the plugs or connectors.

1. Ensure the machine is on an even surface, the parking brake is applied

and movement in the driving is prevented with wheel chocks.
2. Ensure the bucket is lowered and the boom is resting on stops.
3. Install the frame articulation locking device.
4. Open the cover plates from the side where the steering cylinder is being
tested.

5. Release hydraulic pressure from steering circuit.

• This can be done safely by using a capillary test hose into the
steering test points.
• Gradually screw the quick connects on to release the pressure in a
control manner.
• Use an oil drain container to collect any oil.

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6. Disconnect the piston side hydraulic hose from the steering hydraulic
valve of the cylinder to be tested.
• Cap the steering valve connector to eliminate any high-pressure oil
injection hazard during the test.

7. Allow the cylinder piston side oil to drain into an oil drain container via the
disconnected hose, until completely drain and all oil flow has stopped.
• Secure the hose to the oil drain container.
8. With the second person observing the container and piston side hose
end from a safe position, start the machine and move the steering
joystick to pressurize the rod side hydraulic circuit of the cylinder being
tested.
• If oil is observed coming from the hose, the piston seals are
bypassing in this direction (rod side to piston side). in this case the
cylinder needs to be replaced or overhauled.
9. Shut down the machine.
10. Release hydraulic pressure from steering circuit.

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11. Remove the cap from the steering hydraulic valve and reconnect the
piston side cylinder hose to the valve.
• Replace o-ring seals.

12. Check hydraulic oil level. Refill if necessary.

13. Remove the frame articulation locking device.
14. Start machine and operate steering through it full cycle few times to
ensure smooth function.
• Check steering components for oil leaks and repair as needed.
15. Shut down the machine.

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12 Boom / Bucket Hydraulics

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12.1 Boom and bucket hydraulic diagram

Boom Lift Bucket Tilt

A2221 A2221 A2222

MP203 MP204 MP206 MP207

V3201

a1 A1 B1 a2 A2 B2

V3261 V3263
P1 T1

4.5 bar

280 bar

280 bar
P2
MP201

230 bar
T2
b1 b2

Ejector (option)

V3223 V3223
Y3031 Y3032

V3266 V3266
MP101
V3266 V3266

V3211
4 2 1 3
Lift Up Lift Down Tilt Up Tilt Down

V3162

P3124

P3111 P3211 T P

V3401

Steering Boom and Bucket

Displacement 31.09 cm3/rev Displacement 25.04 cm3/rev
Flow rate 70 l/min @ 2400 rpm Flow rate 56 l/min @ 2400 rpm

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12.2 Boom and bucket system description

2 4
1

3
5

1. Bucket pump pressure 2. Boom and bucket pump

measuring point (P3211)
3. Suction line 4. Boom main valve (V3201)
5. Bucket main valve (V3201) 6. Tilt cylinder (A2222)
7. Lift cylinders (A2221) 8. Junction block
The boom and bucket pump (P3211)is mounted to the pump drive unit. It
delivers oil to the hydraulically-controlled bucket main-valve (V3201).The
bucket pilot pressure is controlled with a hydraulic pilot control joystick
(V1111).
The pilot pressure is regulated to 35 bar in the pilot pressure generation
block (V3401). The pilot pressure moves the valve spools causing
corresponding cylinder to move by oil flow from bucket pump (P3211)
through bucket main valve to lift (A2221)) and tilt (A2222) cylinders.
The bucket main valve spool position corresponds proportionally to the pilot
pressure. The pilot pressure is controlled by the bucket joystick. When the
bucket joystick is released there is no oil flow from the pilot control valve
and springs force the bucket main valve spool return to its center position
and cylinder ports close. When the steering is not used the output of
steering pump (P3111) can be used for the bucket hydraulics.

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12.2.1 Ejector bucket (option) control

The bucket ejector plate (option) is operated with

the boom/bucket joystick. To drive the plate out,
press the ejector plate button on the joystick (2).
and push the joystick forward. Make sure that
you remember to pull back the ejector plate by
pulling back on the joystick while pressing the
ejector button.

1,2,3...
4 3

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12.2.2 Boom floating (option)

System components

1 2

1 Solenoid valve Y3065

2 Solenoid valve Y3066
3 Tank drain line
4 Boom limit switch S2034

System control
Function is enabled when boom limit switch S2034 (4) is closed, ie boom
lifting angle is less than 10 degrees.
Pushing the right hand joystick button (5) activates the relay K0137 which
activates the solenoid valves Y3065 (1) and Y3066 (2). Solenoid valves
allows oil drainage from lift cylinders via drain line (3) to the tank and boom
is floating. Indicator light H0039 (7) in the instrument panel is illuminating
when the function is active.

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5
7
6

5 RHS Joystick button (S1003), Boom float ON

6 RHS Joystick button (S1004), Boom float OFF
7 Indicator light (H0039)

Pushing the right hand joystick button (6) deactivates the relay K0137
which deactivates the solenoid valves Y3065 and Y3066. Solenoid valves
block oil drainage line (3) and boom is not floating. Indicator light H0039 in
the instrument panel turns off.
Incase the boom rises over 10 degrees the proximity switch S2034 opens
and floating function is disabled.

12.3 Bucket main valve

Main components

4 2 4 2

1 3 3 3 3

1 Main pressure relief valve 2 Pilot controlled proportional

valve spools
3 Safety relief valves 4 Non-return valves

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Description of function
The boom and bucket main valve contains one main pressure relief valve
(1), two spring centered hydraulically pilot controlled proportional valve
spools (2), four safety relief valves (3) with combined port-relief and anti-
cavitation function and two non-return valves (4). The main pressure relief
valve limits the maximum valve inlet pressure to 230 bars. The main valve's
first section proportional valve spool (2) adjusts the position of the boom by
adjusting the hydraulic flow going to the lift cylinders. Safety relief valves
limit the pressure at lift cylinders to 280 bar and prevents cavitation. The
second proportional valve spool (2) moves the bucket by adjusting the
hydraulic flow going to the breakout cylinder. Safety relief valves limit the
pressure at breakout cylinder to 280 bar and prevents cavitation. Non-
return valves prevent the pressure of cylinders escaping to the pressure
side of the pump.

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12.3.1 Removing the bucket main valve

1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Make sure that the bucket is lowered and resting on it's stops.
3. Install the frame articulation locking device.
• Installing the frame articulation device is presented in chapter Safety
and Environmental instructions
4. Make sure that there is no hydraulic pressure in the boom and bucket
hydraulic system.
• Install a capillary test hose to pressure measuring point MP201.
5. Open the engine cover to gain access to the bucket main valve.

6. Remove the hydraulic lines from the valve.

• Clearly mark and plug the ends of all hoses.

7. Open the 4 screws holding the valve assembly and remove the valve.

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12.3.2 Installing the bucket main valve

1. Make sure that the frame articulation locking device is installed.
2. Check and replace all O-rings and damaged pipes or hosing that fit into
the bucket valve.
3. Install the valve to the machine frame and tension the mounting bolts.

4. Install all pipes and hosing to the bucket main valve.

5. Check the hydraulic oil level.

Fill if necessary.
6. Remove the frame articulation locking device.
7. Start the engine and operate the bucket to bleed air from the circuit until
hydraulic action is smooth
8. Install the frame articulation locking device.
9. Check the bucket main valve and hoses for leaks.
10. Check the bucket pump pressure.
• See section default pressure settings for correct pressure.
11. Stop the engine
12. Remove the frame articulation locking device.

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12.3.3 Checking and adjusting the bucket main relief valve

1. Ensure that the machine is on an even surface, the parking brake is
applied and movement is prevented by wheel chocks.
2. Install the frame articulation locking device.
3. Connect a 400 bar pressure gauge to the quick disconnect fitting MP201
(A) on the main valve junction block .

4. Start the engine.

5. Start the engine and run it at idle.
6. Move the bucket control joystick to the ”bucket up” position and keep it
there.
7. Check the pressure from the gauge.
• The correct pressure is 230 bar (± 8 bar)
8. If the readings do not match the specification.
• Adjusted the main relief valve to 230 bar by turning the adjustment
screw (B).
• The main relief valve is malfunctioning and should be overhauled or
changed.

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12.4 Tilt cylinder

9
7 6
8
1

16
7 17
4
3

14
13 18
12 15
9

5 2

6 11
10

Tilt Cylinder A2222

All cylinders have a similar design. they are single-stage, double acting
hydraulic cylinders. The bucket (tilt) cylinder is mounted to the front frame.
in the cylinder ends there are ball joint bearings (9.) fastened with C-clips
(6.).
The piston (17.) is secured to the rod (2.) with two lock screws (16.). The
piston has 2 wear rings (18.). There is an O-ring(15.) between the piston
and rod to ensure a tight fit.
The gland assembly (3.) is held in place at the end of the cylinder tube (1.)
with allen head bolts (5.).
The cylinder rod movement within the housing is accomplished by applying
pressurized oil flow on either side of the piston and allowing oil on the
opposite side of the piston to return back to the hydraulic tank.

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12.4.1 Tilt cylinder leakage test

Only perform maintenance work when the machine is parked on a

Double check that you are not disconnecting the piston side
hydraulic line. If disconnected, bucket will move to dump position
and high pressure fluid will flow out possibly causing accident.

1. Make sure that the machine is on an level surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Make sure that the bucket is lowered and the boom is resting on stops.
3. Install the frame articulation locking device.
• Installation is presented in chapter Safety and Environmental
instructions.
4. Remove dump cylinder hydraulic test point cover.

High-pressure oil spray hazard. The high-pressure oil spray can

cause serious injury. Allow the pressure to be released from the
hydraulic circuit before opening the plugs or connectors.

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5. Release hydraulic pressure from tilt cylinder.

• This can be done safely by using a capillary test hose into the test
points (A).
• Gradually screw the quick connects on to release the pressure in a
control manner.
• Use an oil drain contain to collect any oil.

A
A

6. Disconnect the rod side hydraulic line (B) at the cylinder end and plug the
port of block.

7. Allow the cylinder rod side oil to drain into an oil drain container via the
disconnected hose, until completely drain and all oil flow has stopped.
• Secure the hose to the oil drain container.
High pressure fluid. Be sure to place the control lever in the proper
position. If pushed to the ”dump” position, high pressure fluid will be
directed out of the plugged port and eject the plug.

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8. With the second person observing the container, rod side hose end and
junction block from a safe position, start the engine and pull bucket
control joystick to ”HAUL” position to pressurize the piston side hydraulic
circuit of the cylinder being tested.
9. If oil flows from the disconnected hose, the cylinder piston seal is leaking.
10. Shut off the engine.
11. Remove the plug and reconnect the cylinder hose.
12. Raise and dump the bucket at working rpm until function operates
smoothly.
12.4.2 Removing the tilt cylinder hoses
1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented with wheel chocks.
• Shut down the engine.
2. Bleed hydraulic pressure from tilt cylinder by connecting a capillary test
hose into the test point(1) on the junction block.
3. Place an oil drain container under the machine where the hoses are to be
removed.
4. Remove the cylinder guards.

5. Loosen the clamps(2) on the hoses at the cylinder end, making sure
there is no pressure and then remove them completely.

2 1 3

6. Loosen the clamps from the junction block(3).

7. Remove the hose(s) from the machine
• You will need to twist the hoses slightly to remove them from their
location.
8. Plug open ends and connectionsíL

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12.4.3 Removing the tilt cylinder

1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Install the frame articulation locking device.
• Installing the frame articulation locking device is presented in chapter
Safety and Environmental Instructions.
3. Remove the bucket.
• Removing the bucket is presented in chapter Frame Structures
4. Remove the tilt cylinder hoses
• Removing the tilt cylinder hoses is presented in chapter Boom/
Bucket Hydraulics
5. Attach a suitable hoist to the cylinder to support its weight.
• Note! The cylinder weighs approx. 270kg.
6. Remove the right-side flange from the upper cylinder pin.

7. Remove the left-side pin flange.

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8. Remove the upper cylinder pin.

9. Remove the bucket tilt cylinder.

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12.4.4 Tilt cylinder disassembly

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

20 21 22

22 23

1. Remove allen head bolts (16).

2. Fully extend the cylinder and pull out piston rod (15) with piston (7) and
gland assembly.
3. Remove wear rings (2 and 6), seal (4) and piston rings (3 and 5) from the
piston.
4. Remove piston locking screws (1) 2 pcs. and unscrew piston (3).
5. Remove the seal (20) inside the piston.

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6. Pull away the gland assembly and disassemble it by unscrewing allen

head bolts (19) and removing wiper housing (18), wiper (17), o-ring (13),
support ring (14), slip rings (8, 9 and 11) and rod seals (10 and 12).
7. Remove the circlips (22).
8. Remove the transverse bearing (23).
9. Remove the grease nipples (21).
12.4.5 Inspection and repair
1. Clean all parts thoroughly.
2. Replace all o-rings, backup rings, seals, wear rings and wiper.
3. Inspect the cylinder bore, piston rod and piston for signs of scratches,
burrs or other damage which could cause a failure.
4. Use a fine stone to remove burrs or small scratches.
5. Replace any part showing damage or excessive wear.

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12.4.6 Reassembly and installation

Assemble the component parts in the reverse order they were

disassembled.
Note! Piston lock screws must be re-drilled to 120° from each other (see
drawing).

The lock screws must be secured by punching two holes near the screws
with an arbor.

Tightening torques:

• Piston 100.0 kpm (1000 Nm)

• Gland assembly: (tilt cylinder) 18.0 kpm (180 Nm)
• Gland assembly: (lift cylinder) 8.0 kpm (80 Nm)
• Wiper housing bolts 1.6 kpm (16 Nm)

Installation
1. Install the cylinder in the loader.
2. Spacers are used at each end of the cylinder mountings between the
cylinder and the frame.
3. Install flanges or cotter pins to cylinder fastening pins.
4. Connect the lines.
5. Start the engine and operate the control levers in both directions
repeatedly to remove the air from the system.
6. Check oil level in the hydraulic reservoir.
• Adjust the oil level if necessary.

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12.4.7 Installing the tilt cylinder hoses

1. Slide the new hoses into position, fitting new o-rings to them.
• Twist the hose slightly to get it through the piping block and into
position.
• Fit wear protective hose wrap to new hose/s to prolong service life.
2. Remove the caps from the ends of the hose and fit the hose end into the
clamps on the cylinder, leaving it loose.

2 1 3

3. Install the other end of the hose to the junction block(3.) fitting the clamps
and tightening them.
4. Install the other end to the cylinder(2) end and tighten the clamps.
5. Install the cylinder guard.

6. Once the hoses have been replaced, check the hydraulic oil level and fill
if required.
7. Start the machine
Check the replaced components for leaks and rectify and fault as
required.
8. Raise the boom and tilt the bucket back and fourth until the function
operates smoothly.
9. Check the hydraulic oil level and fill if necessary.

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12.4.8 Installing the tilt cylinder

1. Fit all new grease seals to cylinder using tape to hold the seals in place.
2. Refit the tilt cylinder to the machine

3. Install the pin to the cylinder. Make sure that all parts are lubricated
before installation.

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4. Make sure that the holes pin flanges line up with the bolt holes in the
frame.

5. Connect all hoses and lubrication lines to cylinder pins and associated
parts.
• Installing the cylinder hoses is presented in chapter Boom/Bucket
Hydraulics.
6. Refit the bucket.
• Installing the bucket is presented in chapter Frame Structures.
7. Remove the frame locking device

12.5 Lift cylinders

All hydraulic cylinders have a similar design. They are single-stage, double-
acting hydraulic cylinders. The lift cylinders are mounted to the front frame
and the boom. The cylinder heads have ball joint bearings (1) fastened with
circlips (6). The piston (3) is secured to the rod (5) by two lock screws (7).
On the outer diameter of the piston the wear rings (14) and a piston seal
(19). Between the piston and rod there is an O-ring (13) to make the
fastening tight. The gland assembly (9) is held in place at the end of the
cylinder tube (8) by allen head bolts (11). There is an O-ring (20) and a seal
(16) is fitted into a groove on the outside diameter of the gland assembly.
Located in the internal bore of the gland assembly are seals (17 and 18),
slip-rings ( 10) and a wiper (4). The seals prevents leakage past the rod.
The wiper cleans dirt from the rod as it retracts. For the lubrication of the
ball joint bearings there are grease nipples (2) in the cylinder ends. Cylinder
rod movement within the housing is accomplished by applying pressurized
oil flow on either side of the piston and allowing the oil on the opposite side
of the piston to return back to hydraulic oil receiver.

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2
12
15
12
9
16
1

19
7

8 6
18 10
20 4

13
1 17 5 3
14

Lift Cylinder A2221

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12.5.1 Lift cylinder leakage test

WARNING
HIGH PRESSURE FLUID HAZARD
High pressure fluid could cause death or severe injury.
Depressurize the hydraulic system before servicing.

Only perform maintenance work when the machine is parked on a

1. Ensure that the machine is on an level surface, the parking brake is

applied and movement is prevented with wheel chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Install frame articulation locking device.
4. Bleed hydraulic pressure from both lift cylinders by connecting a test
hose into the test point on the junction block.

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5. Disconnect the piston side hydraulic line of the distributor block.

6. Cap the open cylinder line from hydraulic valve.

High pressure fluid. Be sure to place the lever in the down position. If
placed in the boom up position, high pressure fluid will be directed
out of the plugged hydraulic line and eject the plug.
9. If oil flows from the disconnected line, the left side cylinder piston seal is
leaking.
10. If oil flows from the junction block, the right side cylinder piston seal is
leaking.
11. Shut off the engine.
12. Remove cap from hydraulic line and reconnect the hydraulic hose.
13. Raise and lower the bucket at 1000 rpm until function operates
smoothly.

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12.5.2 Removing the lift cylinder hoses

1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented by wheel chocks.
2. Make sure that the bucket is lowered and the boom is resting on stops.
3. Install frame articulation locking device.
• Installation is presented in chapter Safety and environmental
insructions.
4. Bleed hydraulic pressure from the lift cylinder by connecting a test hose
into the test points (1 and 2)
5. Place an oil drain container under the machine where the hoses are to be
removed.
6. Loosen the clamps on the hose at the cylinder.

7. Remove the clamps (3,4,5 and 6) from the piping block.

4 5
3 6

1 2

8. Remove the hoses from the machine.

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12.5.3 Removing the lift cylinders

1. Make sure that the machine is on an even surface, the parking brake is
applied and movement is prevented by wheel chocks.
2. Install the frame articulation locking device.
3. Start the machine.
4. Raise the boom and install the boom support pins. Roll the bucket to full-
tilt position.
5. Shut down the machine
6. Bleed hydraulic pressure from lift cylinder by connecting a capillary test
hose into the test points (1. and 2.) on the junction block.

4 5
3 6

1 2

7. Remove the greasing lines from upper end of the cylinder you are
removing. Plug the open ends.
8. Remove the hydraulic lines(3 and 4 or 5 and 6) of the cylinder you are
not removing.
• Plug the open ends.
• If you are removing both cylinders do not remove the lines.
9. Remove the retaining plate fastening screws from the upper cylinder-pin
of the cylinder.
10. Attach a suitable hoist to cylinder to support its weight.
• Make sure that the lifting equipment is in good condition and
correctly rated.
11. Remove the upper pin and v-seals from between the cylinder and
frame/lift arm.
12. Start the machine.
13. Carefully retract the cylinder rod or rods using machine hydraulic.
14. Shut down the machine
15. Bleed hydraulic pressure from lift cylinder by connecting a capillary test
hose into the test point on the junction block (1 and 2).

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16. Remove hydraulic hoses from the side of the cylinder to be removed.
Plug the open ends.

17. Remove the greasing lines from lower end of the cylinder. Plug open
ends.
18. Remove retaining plate fastening screws from lower end of the cylinder.
19. Remove the pin and v-seals from between the lower cylinder and frame/
lift arm.

20. Remove the cylinder from the machine using the hoist. The lift cylinder
weighs approx. 85 kg.

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12.5.4 Lift cylinder disassembly

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18
19

19 20

1. Remove the allen head bolts (14).

2. Fully extend the cylinder and pull out piston rod (6) with piston (5) and
gland assembly.
3. Remove wear rings (2 and 4) and seal (3) from the piston.
4. Remove piston locking screws (1) 2 pcs. and unscrew piston (5).
5. Remove the seal (17) inside the piston.
6. Pull away the gland assembly and disassemble it by unscrewing allen
head bolts (16) and remove the wiper housing (15), wiper (13), slip rings
(7 and 9), rod seals (8 and 10), O-ring (11) and support ring (12).
7. Remove the circlips (19).
8. Remove the transverse bearing (20).
9. Remove the grease nipples (18).

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12.5.5 Inspection and repair

1. Clean all parts thoroughly.
2. Replace all o-rings, backup rings, seals, wear rings and wiper.
3. Inspect the cylinder bore, piston rod and piston for signs of scratches,
burrs or other damage which could cause a failure.
4. Use a fine stone to remove burrs or small scratches.
5. Replace any part showing damage or excessive wear.

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12.5.6 Reassembly and installation

Assemble the component parts in the reverse order they were

disassembled.
Note! Piston lock screws must be re-drilled to 120° from each other (see
drawing).

The lock screws must be secured by punching two holes near the screws
with an arbor.

Tightening torques:

• Piston 100.0 kpm (1000 Nm)

• Gland assembly: (tilt cylinder) 18.0 kpm (180 Nm)
• Gland assembly: (lift cylinder) 8.0 kpm (80 Nm)
• Wiper housing bolts 1.6 kpm (16 Nm)

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12.5.7 Installing the lift cylinder hoses

1. Install the new hoses into position with new O-rings.
2. Install the hose end into the clamps on the cylinder leaving it loose.

3. Install the other end of the hose to the piping block (3-6).

4 5
3 6

1 2

• Install the clamps and tighten them.

4. Fit the other end of the hose to the cylinder and tighten the cylinder end
clamps.
5. After you have changed the hoses, do a check of the hydraulic oil level.
• Fill if necessary.
6. Start the machine.
• Check the components for leaks and rectify any fault as required.
• Stop the engine.

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12.5.8 Installing the lift cylinders

1. Install all new V-seals to the cylinder using tape to hold the seals in place
during installation.
2. Install the lift cylinder into the machine using a hoist.

• The cylinder weighs approx. 85kg

• Make sure that the lifting equipment has sufficient lifting capacity.
3. Install the lower cylinder pin.

• Lubricate all parts.

• Make sure that the pin retaining plates line up with the bolt holes in
the frame.
4. Connect all hoses to the cylinders and junction block.
• Make sure that all hose connections are tight.
• For more information see section Installing the lift cylinder hoses.
5. Check the hydraulic oil level.
• Fill if necessary.
6. Start the engine.
7. Extract the cylinder rod using the machine hydraulic and use a hoist
when positioning the upper end of the lift cylinder.
8. Shut down the engine.
9. Install the upper cylinder pin.
• Lubriacte all parts

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10. Connect lubrication lines to cylinder pins

11. Start the engine.
• Lift the boom slightly
• Shut down the engine
12. Remove the boom locking devices.
13. Start the engine and check functions.
• Slowly raise and lower the boom until function operates smoothly.
• Check the replaced componentes for leaks and rectify any fault as
required.
• Check the hydraulic oil level and fill if required.
14. Shut down the engine.

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13 Brake System

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13.1 Brake system hydraulic diagram

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13.2 Brake system description

Main components

2 5
6

3
1

1 Brake pedal valve V1501 2 Pressure accumulators

Z3531 and Z3532
3 Brake pump P3521 4 Suction line
5 Brake release pump unit 6 Park brake block V3515

System description
Oil flow from the brake charging pump P3513 enters to park brake block
V3515. The pressure in accumulators Z3531 and Z3532 is maintained by a
hydraulically controlled pump. The pump's constant pressure regulator is
limited to 190 bar.
The two accumulators supply oil to the brake releasing circuit through brake
pedal which reduces the maximum axle release pressure to 138 bar. Brake
activation can be done proportionally by pressing the brake pedal valve
which allows the axle springs to activate the brakes due to lower pressure.

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13.2.1 Park brake block

The solenoid valve Y3052 controls the brake accumulators pressure
discharging. The brake accumulators are discharged by cutting off the
control current from the solenoid, i.e. when the ignition key is turned to the
“0” position, the solenoid valve deactivates and pressure accumulator oil
drains to the hydraulic oil tank through the solenoid valve. The solenoid
valves Y3001 and Y3048 are for activating park and emergency brakes by
opening pathways to the tank through from both axles. When the brakes
are released, the solenoid valves plug connections to the tank and opening
pathway from the brake pedal valve (Pedal OUT) to axles.
The pressure transducer B3034 monitors the accumulators charging
pressure. Pressure transducer B3056 monitors the front axle pressure and
B3057 the rear axle pressure. Pressure switch S3048 indicates the brake
accumulator pressure and gives a starting signal for the brake release
pump.
13.2.2 Brake pedal valve

V1501

138 bar

P A
T

The pedal is a pressure reducing valve. When you press the brake pedal, it
proportionally connects the hydraulic control line of the brakes to the tank
line.
When the machine operates and the brake pedal is in the rest position, the
pressure in the hydraulic control line from the pedal is 115...138 bar.
You can see the release pressure from the VCM system gauge window.
13.2.3 Pressure accumulators
The capacity of brake system pressure accumulators is 5,6L (2 x 2,8L) .
The pre-charging pressure is 90 bar. When the system pressure in the
hydraulic line is over 90 bar, the accumulators charge, or in other words
stores hydraulic pressure. If the external pressure in the line falls, for
example when the brake pedal is pressed, the accumulator discharges, and
release the hydraulic pressure they have stored.

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Testing the brake accumulator

After new installation of, or repair to accumulators, check pre-charge
pressure p 0 at least once during the first month.
If no gas losses are detected during the first check, the second check is to
be carried out after approx. 6 months. If the results of the second check are
satisfactory, testing every 6:th month (1000h) will suffice thereafter.

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Measuring the brake accumulators pre-charge pressure Po

Only perform maintenance work when the machine is parked on a

Measure the gas pre-charge pressure p0with a pressure gauge.

1. Ensure that the machine is on a level surface, the parking brake is
applied and movement is prevented with wheel chocks.
2. Start the engine to fill the accumulators with fluid.
3. Stop the engine.
• Wait a while so the pressure accumulators discharges to the tank.
4. Install the frame articulation locking device.
5. Release the residual pressure from the accumulators by connecting a
capillary test hose to the measuring junction MP501 (A) at the brake
charging valve.
NOTE!Be careful connecting the hose, because the accumulators may
be pressurized.

A B

6. Detach the cover caps from the pressure accumulators and connect a
400 bar (40 MPa) pressure gauge to the gas charging valves (B) of both
accumulators alternately.
7. The accumulator pre-charge p0 should be 90 bar (9,0 MPa).
• If necessary, increase or decrease the pre-charge pressure.
8. Disconnect the pressure gauge and attach the cover caps.
9. Disconnect a capillary test hose from the charging valve measuring point
MP501 (A) and attach the cover cap.

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If accumulator must recharge, see separate piston accumulator

operation and service-manual for instructions to recharge the piston
accumulator.

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13.2.4 Brakes control

Parking brake
Control the parking brake with the mushroom shaped button in the cabin,
which is connected to the Chair module. The button has three positions:
brake engaged, brake released, and reset (returns automatically with a
spring to the released position). The parking brake is controlled by and
on/off hydraulic valve.
When the parking brake is engaged, it can be released after the button has
been pulled out into the reset position and the gear is in neutral. The brakes
are released only when both inputs of the button are active. The brakes are
released when the button is held in the reset position until feedback
information comes from the pressure sensors in the brake circuits, i.e.
brakes have adequate release pressure.
If the emergency brake is engaged because of a malfunction (e.g. ABA),
the button might already be in the released position. In this case it is
necessary to reset the parking brake button
The parking brake will engage when the button is pressed in, when the
engine stops, and when the emergency stop is activated.
The status of the parking brake is indicated by a symbol in the lower right
corner of the main window. The symbol is grey when the parking brake is
released, and becomes red when the parking brake is engaged

Parking brake test

See chapter: Testing the brakes

Automatic Brake Activation (ABA)

The control system activates brakes automatically during malfunction,
which is refered to by ABA.
ABA engages the parking brake with a parameter defined ramp (enables
slow braking) in the following situations:
• The brake accumulator pressure falls under the allowed limit (chapter
“Brake pressure monitoring”)
• Transmission charging pressure falls under low alarm limit (chapter
“Transmission oil pressure monitoring”).
• Engine is not running.
• Door is open.
If driving direction selector is not in neutral, when trying to release parking
brake, releasing is denied.
After these situations occur, the operator must release the parking brake by
pressing the release button.

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ABA Brake tests

ABA functions can be tested by performing two separate tests. The first test
is to test the pressure sensor operation. The second test is to check that
the control system engages the parking brake according to the pressure
sensor signal.

Transmission pressure sensor test

Open the transmission pressure sensor test window from the functions test
window by pressing Brake. Then select Low transmission oil pressure
engages brakes.

• To check that the transmission oil pressure sensor is working properly,

first ensure that the machine is on level ground, then shut down the
motor.
- The transmission oil pressure should decrease to 0 bar.

• Then start the motor and ensure that the transmission oil pressure
increases to the normal level.
- This must be checked from the gauge in the window.
• Next, press OK to continue the test.

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• The Brake engage test window appears.

- The parking brake should be released.

• Wait for the brakeline pressure to increase to the normal level.

• Press the TEST ON button, and the brake engage limit value will
increase over the actual transmission oil pressure.
- This can be seen from the Brake activation limit field.
- Normally, this limit value is 8 bar, and at any time, if the pressure
drops under this limit, brakes are engaged automatically after 3
seconds.
• The brakes are engaged if the front and rear brake circuit measurement
values are under 10 bar.
• The transmission oil pressure test is complete.
- As soon as the test window is closed, the brake engage limit will
return back to normal value.

Low brake charging pressure engages the parking brake test

From the brake engagement test window, select Low brake charging
pressure engages brake.

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• To check that the brake charging oil pressure sensor is working properly,
first ensure that the machine is on level ground, then shut down the
motor.
- The charging pressure should decrease to 0 bar.

• Then start the motor and ensure that the pressure increases to normal
level (152 – 190 bar).
- This must be checked from the gauge in the window.
• Next, press OK to continue the test.
• The brake engage test window appears.

• The motor should be shut down and immediately after, the ignition key
should be turned back to the I-position
• Press the TEST ON button and release the parking brake.
- Check that the front and rear brake circuits pressure increase to the
normal level.

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• Lower the brake charging pressure using the brake pedal.

- When the pressure decreases below the brake engage limit (value in
the charging pressure brake engage limit field), brakes are
automatically engaged.
- This can be seen from the front and rear brake circuit measurements
in the same window; pressures drop to under 10 bar.
• The test function is turned off automatically when you exit this window
and the ABA test functions are complete.

Neutral Brake
The neutral brake is taken into use with an option parameter
The neutral brake prevents driving the machine downhill in neutral gear.
The neutral brake only functions in manual mode.
A window appears on the display that informs that the neutral brake is
activated.
The neutral brake engages the parking brake, when the gear has been on
neutral (Clutch pressure switch) for a time period defined with a parameter
(the default value is 3 seconds). When the operator releases the parking
brake, a gear must be selected within the time period.

Brake release in case of machine break down (option)

If the machine breaks down, it is possible to produce the pressure needed
for releasing the brakes with a special brake release pump. The pump can
be started with the on/off button in the cabin. When controlling the pump
also enable the brake releasing, contrary to the normal conditions The
pump stays on for as long as the button is pressed down. The engine
should not be running when using the brake release pump.
The brake release pump is always operated for a certain time period
defined by a parameter after starting the machine engine.

Forced functions (requires service password)

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Forcing brakes
The window is used for forcing the following functions: inching, gearing,
starting/stopping the engine, and braking.

The functions to be forced are chosen on the right-hand side column (Off =
function not forced, On = function forced). On the left-hand side column, the
value can be set according to which function is to be forced.
Forcing the brakes
1. Select Brake as the function to be forced.
2. Set the forcing values for the control. Set the status of motor starting in
the left-hand side field (0 = motor not started, 1 = motor started).
3. Set the status of the motor running in the middle field. (0 = motor not
running, 1 = motor running).
4. Start the forcing by pressing and holding the SEND button. The forcing
stays active until you release the button. All forcing is deactivated also
when you leave the window.
5. Stop the motor by setting the value 0 in the middle field and pressing the
SEND button.

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Forcing the digital outputs of modules

Digital outputs of brakes control:

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Connector
Function Module
pin
Brake circuit 1 control Middle XM1.7
Brake circuit 2 control Middle XM1.8
Brake release pump Middle XM2.22

Diagnostics of sensors and brake pressure

When rear- and front brake pressure difference is more, than defined by
parameter, an error message is generated. Pressure alarm reset can’t be
performed before pressure difference is lower, than defined with alarm limit
and hysteresis parameter.
If brake circuit charging pressure is lower than defined by alarm limit,
brakes are engaged, as described in chapter ABA.
See chapter ”Brake pressure monitoring”.

Diagnostics window for releasing the parking brake

The top of the window shows the status of the safety interlocks that affect
functions. If the symbol is black, the safety interlock is activated. If all
symbols are grey, the function is allowed. Safety interlocks shown from the
left to the right in the window:

• Door switch, door open

• Emergency stop must be active
• Transmission oil pressure must not be too low (adjust by parameters)
• The charging pressure for brake pressure accumulator must not be too
low (adjust by parameters)
• The engine is not running
Diagnostics data of the window:
• The control status of the module is shown below the module symbol: 0 =
the program does not control the parking brake on, 1 = the program
controls the parking brake on
• The charging pressure of the brakes is shown next to the brake symbol
at the top of the window (charg)

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• The pressure of the front brake circuit is shown next to the brake symbol
in the middle (actual 1)
• The pressure of the rear brake circuit is shown next to the lowest brake
symbol (actual 2)
The information window shows the lower limit for charging pressure of
brake releasing. The lower limit is set by parameters and requires a factory
password.

Testing the buttons

These windows are used for testing the functioning of the brake buttons.
When pressing the button that activates the function, the picture of a button
on the right-hand side of the symbol becomes black.
Test the functioning of the parking brake test button in Button Test 1 window
(the symbol of the test is shown in the information window)

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• Test the functioning of the parking brake in Button Test 3 window (P-
brake).

- When the parking brake button is pressed down, the Engage button
becomes black.
- When the parking brake button is in the resetting position, the
Release button becomes black.
- When the parking brake button is released, both buttons are grey.

Measurement data of the modules (requires service password)

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Testing the brakes

1. Use the brake test button to test the condition of the parking and service
brake system.

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Parking brake test

1. Move on to the test by pressing the Yes button.
• By pressing the No button, the test is not performed, a message
Brake test cancelled appears and the program returns to the main
window.

2. Check that brake pedal is not pressed and select driving direction.

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3. Raise the engine RPM to a constant level and press the speed pedal
down.
• When brakes are engaged, machine movement during the test is not
allowed.
• If machine moves, test result is not acceptable and you must fail the
test.

4. Release the speed pedal and set driving direction to neutral.

• When the required conditions are met, the test proceeds
automatically from the parking brake test to the service brake pedal
test.

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Service brake pedal test

Parking brake test must be successfully completed before performing the
service brake pedal test.
1. Release parking brake carefully.
• NOTE! Machine may begin to move!

2. Wait that the brake pressure measurement is performed.

3. Press brake pedal fully down.

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4. Keep engine running, release the service brake and ensure that parking
brake is not engaged.
• This message is showed at least 3 seconds on the display.

If brake pressures drop under the defined limits If brake pressures do not drop under the de-
after engine shutdown, a pop up appears. fined limits after engine shutdown, a pop up ap-
pears.

Repair the brakes before using the machine.

The parking brake and service brake pedal test is

now done.

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Accepting the brake test results

1. The brake test results are presented in two windows. To accept the brake
test results, press the Accept button.
The brake test is complete and the window disappears automatically
after 3 seconds.
Please note! See correct values (requirements and test results) from the
VCM display. Values shown in the adjacent brake test results chart are
only indicative, not necessarily from your machine.

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2. If you discarded the brake test and pushed the Fail button, the display
will show the text Brake tests failed. Repair brakes before using the
machine. The driver has to set off the window by pushing the display
button 1.

Brake test log entries

Accepted or discarded brake tests are shown by four lines in the events
log.
The information shown includes max rpm / machine movement, brake
pressure front, brake pressure rear and information if operator accepted or
did not accept the brake test results.

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Aborted brake test

After choosing the driving direction, you have 30 seconds to raise the
engine rpm to the required level (to press the accelerator pedal down) and
hold them there for 3 seconds. If this does not happen, the following
window appear.

In case the engine is turned off, the parking brake test is interrupted and a
window informing of this appears on the display. Leaving this window opens
the main window.

In case the cabin door is open and the parking brake test is started, the test
will not start and a window informing of this appears on the display. This
window also appears when the parking brake test is interrupted by opening
the cabin door. In this case, the parking brake test is aborted and the
parking brake will be engaged if it has been released during the test.
Leaving this window opens the main window.

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Checking the neutral brake function

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

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System notifications and troubleshooting (Brakes control)

Inputs
Signal level Connector
Actuator Description Module
pin
Parking brake
Switch 24 V / Float Chair XC1.16
release (reset)
Parking brake
Switch 24 V / Float Chair XC1.17
engage
Parking brake
Switch 24 V / Float Chair XC3.23
test
Clutch pressure
Pressure
switch (Neutral 24 V / Float Middle XM2.20
switch
brake)
Brake release
Switch 24 V / Float Chair XC2.19
pump

Outputs
Signal level Connector
Actuator Description Module
pin
Brake circuit 1
Sensor 24 V / Float Middle XM1.7
control
Brake circuit
Sensor 24 V / Float Middle XM1.8
2control
Brake release
Switch 24/0 V Middle XM2.22
pump

Module No Alarm text Alarm log

Chair 68 Parking Brake button error X

Description: Park Brake button error (malfunction of the parking brake

button)
Action 1: Wire harness
• Set the parking brake into the middle position.
• Check the status of the inputs for the parking brake button in the
measurements window (see chapter ”Diagnostics”). Only Engage should
be active.
• If Release is active, check the wiring of the Chair module connector pin
XC1.16.
Action 2: Wire harness
• Press the parking brake button down.

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• Check the status of the inputs for the parking brake button in the
measurements window (see chapter Brakes control, section "Diagnostics
window for releasing the parking brake”). None of the parking brake
button inputs should be active
• If Engage is active, check the wiring of the Chair module connector pin
XC1.17.

Module No Alarm text Alarm log

Brake release pump relay signal
Middle 36 X
short to ext. voltage
Brake release pump relay signal
Middle 37 X
short to ground
Brake circuit 1 signal short to
Middle 54 X
ground
Brake circuit 1 signal short to ext.
Middle 55 X
voltage
Brake circuit 2 signal short to
Middle 59 X
ground
Brake circuit 2 signal short to ext.
Middle 60 X
voltage

Description 1: A short circuit to ground

Action 1: Wire harness
• Detach the connector pin that caused the alarm from the module:

Connector
Alarm no Function
pin
54 XM1.7 Brake circuit 1
59 XM1.8 Brake circuit 2
37 XM2.22 Brake release pump
• Check whether the alarm stops when you force the output in question in
the Forcing window (see chapter “Brakes control”, Section ”Forced
functions”).
• If the alarm stops, the fault is in the wire harness, short circuit to ground.
• Repair the wiring.
Action 2: Module
• If action 1 does not correct the malfunction, the module may be broken.
Change the module if needed.
Description 2: Voltage in an uncontrolled output of the brakes connected
to the module.
Action 1: Wire harness

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• Detach the connector pin that caused the alarm from the module:
Connector
Alarm no Function
pin
55 XM1.7 Brake circuit 1
60 XM1.8 Brake circuit 2
36 XM2.22 Brake release pump
• Check whether the alarm stops when you force the output in question in
the Forcing window (see chapter “Brakes control”, Section ”Forced
functions”).
• If the alarm stops, the fault is in the wire harness, short circuit to
operating voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 does not correct the malfunction, the module may be broken.
Change the module if needed.

Module No Alarm text Alarm log

Safety features activated. Unable to
Middle 63 X
release parking brake
Safety feature ABA activated. Park-
Middle 64
ing brake engaged.
Middle 71 Parking brake engage, motor cut out
Parking brake engaged. E-stop acti-
Middle 72
vated.
Middle 84 Parking brake engaged, door open!

Description: Reason for the parking brake to engage

Action 1: An action caused the alarm
• Check the reason for the activation of the safety interlock that caused the
alarm.

Module No Alarm text Alarm log

Unable to release parking brake. E-
Middle 83
stop activated.
Unable to release parking brake.
Middle 93
Door open!
Unable to release parking brake.
Middle 94
Motor not running!

Description: A condition that prevents the parking brake to be released

Action: Remove the condition that prevents the parking brake from being
released

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• Release the emergency stop (alarm 83).

• Close the door (alarm 93).
• Start the motor (alarm 94).

Module No Alarm text Alarm log

Middle 102 ABA Control on

Description: Parking brake engaged

Action: Check the reasoning for the function activated
• Check the alarm log for other alarms from the brakes.
• Proceed according to other alarms that have occurred.

Module No Alarm text Alarm log

Brake test not allowed, engine not
Middle 117
running

Description: Parking brake test notifications

Action: Parking brake test (alarm 117).
• Parking brake test on.
• No actions necessary.

Module No Alarm text Alarm log

Middle 157 Brake release pump activated X

Description: Brake release pump activated

Action: Brake release pump
• No actions are necessary. The alarm informs that the brake release
pump is in use.

Module No Alarm text Alarm log

Middle 160 Neutral brake function engaged X

Description: Neutral brake function engaged

Action: Neutral brake
• Neutral brake engaged.
• Switch into a gear.

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13.2.5 Brake pressure monitoring

The brake circuit has 3 analog sensors. The system gives an alarm if the
sensor signals are not within the calibrated values.
The charging pressure of the brakes is measured with an analog sensor
that is connected to the Middle module. The system gives an alarm if the
signal differs from the calibrated value.
Sensor calibration, as well as alarm limits and warning limits, are set
according to section ”Sensor Calibration” (requires factory password). A
filtering time must be set for alarms (how long can the error be active,
before an alarm is given).
When the brake pedal is pressed, the brake circuit pressure decreases
under the limit set by parameters, causing the brake lights to illuminate.(For
more information, refer to chapter "Lights control”, section “Brake lights and
blinkers”).

Brake pressure monitoring window

The following data from the brake pressure sensors are shown in gauge
window 3:
• Brake circuit charging pressure

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• Brake circuit front pressure

• Brake circuit rear pressure
Active alarms and warning are shown with the following symbols in the
gauge window. The symbol appears on the left side of the symbol for the
sensor.
The alarm and warning limits for the sensors are shown in the information
window.

Diagnostics window for releasing the parking brake

See chapter ”Brake control”, section ”Diagnostics”.

Measurement data of the modules (requires service password)

The measurement data windows show the values and status of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want on the measurements menu window
and press theOK button. The measurement data window of the connector
opens.
The connector pins for brake pressure monitoring are listed in
the ”Inputs” and ”Outputs” tables in the section ”System notifications
and troubleshooting (Brake pressure monitoring”.

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Forced functions (requires service password)

Forced functions windows are used to control the machine’s different

Forcing digital outputs of modules

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3. Switch the output (or outputs) to be forced on or off.

• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

The digital outputs of pressure sensor operating voltages:

Function Module Connector pin
Brake circuit pressure sensor (B358, B357 and
Middle XM2.1
B334) supply voltage

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System notifications and troubleshooting (Brake pressure monitoringl)

Inputs
Signal level Connector
Actuator Description Module
pin
Brake circuit actual pres-
Sensor 4…20 mA Middle XM3.5
sure, Front (B356)
Brake circuit actual pres-
Sensor 4…20 mA Middle XM3.6
sure, Rear (B357)
Brake circuit charging
Sensor 4…20 mA Middle XM2.12
pressure (B334)

Outputs
Connector
Actuator Description Signal level Module
pin
Brake circuit pressure sen-
Sensor sor (B356, B357 and 24 V / 0 V Middle XM2.1
B334) supply voltage

Sysrtem interlocks
• No alarms are given if the motor is not running.

Module No Alarm text Alarm log

Front brake actual pressure high
Middle 28 X
alarm
Front brake actual press. High warn-
Middle 29 X
ing
Front brake circuit pressure low
Middle 154 X
warn.
Front brake circuit pressure low
Middle 155 X
alarm

Description: Front brake actual pressure out of limits.

Action: Check the circuit pressures and function of brake hydraulics.

Module No Alarm text Alarm log

Front brake circuit actual pressure
Middle 30 X
sensor (B356) high
Front brake circuit actual pressure
Middle 31 X
sensor (B356) low

Description 1: Front brake circuit actual pressure sensor (B356) high or

low

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Action1: Sensor
• Measure and check the sensor voltage value from “The measurement
data windows” (refer chapter “Brake pressure monitoring”, section
“Measurement data of the modules”).
• Replace the sensor if it is broken.
Action 2: Cabling
• Measure the voltage from pole A, which should be the same as the
machine operating voltage.
• Fault in the cabling or Middle module connector pin XM2.1 (this is given
by a separate alarm).
Action 3: Cabling
• Measure the connection from pole B to the ground.
Action 4: Cabling
• Detach the Middle module connector pin XM3.5 cable and measure the
voltage to the ground. 0 bar should be approx. 4 mA.
Description 2: Fault in the module
Action: Module
• If the malfunction is not repaired by the actions of description 1, the
Middle module is broken. Replace the module.

Module No Alarm text Alarm log

Rear brake actual pressure high
Middle 32 X
alarm
Rear brake actual press. High warn-
Middle 33 X
ing
Rear brake circuit pressure low
Middle 122 X
warning.
Rear brake circuit pressure low
Middle 123 X
alarm

Description: Rear brake actual pressure out of limits.

Action: Check the circuit pressures and function of brake hydraulics.

Module No Alarm text Alarm log

Rear brake circuit actual pressure
Middle 34 X
sensor (B357) high
Rear brake circuit actual pressure
Middle 35 X
sensor (B357) low

Description 1: Rear brake circuit actual pressure sensor (B357) high or

low
Action 1: Sensor

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• Measure and check the sensor voltage value from “The measurement
data windows” (refer chapter “Brake pressure monitoring”, section
“Measurement data of the modules”).
• Replace the sensor if it is broken.
Action 2: Cabling
• Measure the voltage from pole A, which should be the same as the
machine operating voltage.
• Fault in the cabling or Middle module connector pin XM2.1 (this is given
by a separate alarm).
Action 3: Cabling
• Measure the connection from pole B to the ground.
Action 4: Cabling
• Detach the Middle module connector pin XM3.6 cable and measure the
voltage to the ground. 0 bar should be approx. 4 mA.
Description 2: Fault in the module
Action: Module
• If the malfunction is not repaired by the actions of description 1, the
Middle module is broken. Replace the module.

Module No Alarm text Alarm log

Pressure differ in pedal and rear
Middle 97 X
brake circuit (brakes may drag)
Pressure differ in pedal and front
Middle 98 X
brake circuit (brakes may drag)
Pressure differ in front and rear
Middle 99 X
brake circuit (brakes may drag)

Description: Pressure differ in front and rear brake circuit (brakes may
drag)
Action: Module
• Check “Brake circuit 1 actual pressure” and “Brake circuit 2 actual
pressure”.
• Note! Brakes may drag.

Module No Alarm text Alarm log

Brake circuit charging pressure high
Middle 146 X
alarm
Brake circuit charging pressure high
Middle 147 X
warning

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Module No Alarm text Alarm log

Brake circuit charging pressure low
Middle 148 X
warning
Brake circuit charging pressure low
Middle 149 X
alarm

Description: Error in the measured pressure

Action: Check the brake circuit charging pressure

Module No Alarm text Alarm log

Brake circuit charging pressure sen-
Middle 150 X
sor (B334) high error
Brake circuit charging pressure sen-
Middle 151 X
sor (B334) low error

Description 1: Brake circuit charging pressure sensor (B334) high or low

error
Action 1: Sensor
• Measure and check the voltage value of the sensor from “The
measurement data windows” (refer chapter “Brake pressure monitoring”,
section “Measurement data of the modules”).
• Replace the sensor if it is broken.
Action 2: Cabling
• Measure the voltage of sensor pole A, which should be the same as the
machine’s operating voltage.
• Fault is in the cabling or the Middle module connector pin XM2.1
Action 3: Cabling
• Measure the connection between sensor pole B and GND.
Action 4: Cabling
• Detach the Middle module connector pin XM2.12 and measure the
voltage to the ground. 0 bar should be approx. 4 mA.
Description 2: Fault in the module
Action: Module
• If the malfunction is not repaired by the actions of description 1, the
Middle module is broken. Replace the module.

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14 General Electric System

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14.1 System description

Voltage feeds
The control devices (including switches and buttons) and sensors in the
machine require voltage feedin order to function. The same voltage feed
can be fed into a device sensor that belongs to several different systems

Voltage transformer 24/12V

The transformer G0003 is used to transform +24V voltage to +12V which is
used as the voltage source for the 12V output.
14.1.1 Voltage monitoring

Voltage monitoring handling

All modules must monitor their operating voltage. The display gauge
windows show the voltage measured by the Chair module. The under and
over voltages defined in this calibration window of this measuring apply to
other modules as well.
To avoid too many alarms, this alarm must have a hysteresis parameter,
which limits the amount of alarms.
Engine starting disables low voltage alarms. Alarms are filtered also after
engine starting for parameter defined time.
If the voltage of a module exceeds the high limit, the alarm is set on. Alarm
reset can be performed only when supply voltage has dropped below alarm
limit – hysteresis.
If the voltage of a module drops below low limit, the alarm is set on. Alarm
reset can be performed only when supply voltage has dropped below alarm
limit + hysteresis.
Parameters are defined in chair module, where they are automatically
copied to all modules. So all limit and hysteresis parameters are same in all
modules. When adjusting parameters, only chair module parameter is
adjusted.

Alternator failure alarm

When engine is running and supply voltage doesn’t rise above parameter
defined value, an alarm is generated. Alarm has its own time delay
parameter. Alarm reset can’t be performed, until voltage has risen above
limit, which is defined by alarm limit added with hysteresis. Hysteresis is
given as own parameter. Alarm informs about alternator failure.

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System notifications and troubleshooting (Voltage monitoring)

Module No Alarm text Alarm log

Chair 41 Chair module supply voltage high X
Chair 42 Chair module supply voltage low X
Chair 96 Alternator failure X
Middle 52 Middle module supply voltage high X
Middle 53 Middle module supply voltage low X

Description: Electrical system failure.

Action: Check electrical system.

14.2 Circuit breakers

Location of circuit breakers boxes

The machine is equipped with two circuit breaker boxes. X3056 is located
on the left side of the rear frame, the other is located inside the operator's
compartment.

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Circuit breaker descriptions and values

F0127
F0001
F0004
F0007
F0008
F0023
F0053
F0071
F0116
F0005
F0006
F0020
F0024
F0038

Fuse ID Description Capacity

F0127 24 V power outlet 10A
F0001 Front lights 10A
F0004 Ignition switch 10A
F0007 Radio supply 10A
F0008 Rear lights 10A
Cabin corner lights, Boom float solenoid
F0023 10A
valves*
F0053 VCM system display supply 6A
F0071 VCM system chair module supply 10A
Voltage supply for emergency radio, fire sup-
F0116 6A
pression supply, brake release control pump
Emergency steering pump, brake release
F0005 pump, indicator lights supply, Ejector bucket 10A
control*
Brake release switch, brake accumulator dis-
F0006 charging valve, pilot accumulator discharge 10A
valve
F0020 Wiper motors 10A

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Fuse ID Description Capacity

F0024 Radio remote control supply 10A
F0038 Washer motors, AC unit control 10A

*) Optional

F3047 F3066 F3021 F3059

F3072 F3062

F3064

F3035

Fuse ID Description Capacity

F3072 Middle module supply 10A
F3047 Engine starter control 16A
F3066 Engine control module supply 16A
F3021 Air conditioner supply 32A
Instrument panel supply, main circuit breaker
F3059 50A
for instrument panel fuses
F3062 Break release pump supply 100A
Main circuit breaker for machine electrics,
F3064 150A
emergency steering pump*
Main circuit breaker for battery & starter mo-
F3035 400A
tor

*) Optional

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14.3 Batteries

Battery technical data

Voltage (V) 12
C20 (Ah) 71
CCA -18C 650
State WET
Grid Alloy Hybrid
Technology Vented/Flooded

Battery Dimensions
Length 278
Width 175
Height 175
Weight (Kg) 18.14

Battery storage
Hydrogen and oxygen gases are produced during normal battery operation
and escape through the battery vents. Make sure storage area is well
ventilated to avoid creating an explosive atmosphere around the battery.
It only takes a small spark, flame or burning cigarette to set off a dangerous
explosion. Therefore, ignition sources must be kept well away at all times.
Make sure that safety precautions continue to be observed after a battery
has been charged as explosive gases may still be present for several
hours.

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Battery maintenance
An exploding battery may cause serious injuries including eye injury from
flying pieces of the case or cover. Always wear safety goggles and a face
shield when working near batteries. Never lean over the battery during
charging, testing or jump-starting operations. Do not break live circuits at
the terminals of batteries because a spark invariably occurs at the point
where a ’live’ circuit is broken
Make certain the charger cable clamps or booster leads are clean and
making good connections. A poor connection can cause an electrical arc
which could ignite the gas mixture and explode the battery.
Take care to ensure tools or other metallic objects do not fall across the
terminal or any adjacent metallic part of the vehicle.
Do not smoke when working near a battery. Never strike a match or bring
any other flame near a battery.
Replace any battery that has signs of damage to the terminals, case or
cover.
When working with acid, such as filling batteries, use a face shield. If many
batteries are handled, wear protective clothing for extra safety. Extreme
care must be taken to avoid spilling or splashing electrolyte as it can burn
clothing and skin.

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14.3.1 Removing the batteries

1. Turn the main switch to "OFF"-position.
2. Open the battery box cover.

3. Disconnect the electric cable from the (-)terminal of the battery and
protect the connector.

+ -

- +

4. Disconnect the electric cable from the (+)terminal of the batter and
protect the connector.

5. Open the two fastening nuts of the battery clamping frame and remove
the frame.
6. Remove the batteries.
• Use a hoist if possible.
• Each battery weighs 18.1Kg.

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14.3.2 Installing the batteries

1. Make sure that the main switch is in the "OFF" position.
2. Place the batteries in the battery box. Attach the clamping frame of the
batteries with nuts .

3. Attach the cable connecting the batteries to the series and install the
terminal protectors.
4. Connect the wire to the (+) terminal of the battery and place the terminal
protector in place.

+ -

- +

5. Connect the wire to the (–) terminal of the battery and place the terminal
protector in place.
6. Make sure that the electric cable set properly when the battery inspection
cover is closed.

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7. Install the cover.

14.4 Emergency stop control

When the emergency stop button is pressed, an alarm appears in the main
window, and activates the emergency stop state, which causes all functions
to stop. When the functions have stopped, you must reset the emergency
stop button to start the functions again.
Emergency stop state activates in the following situations:
• A control system module is missing.
• Fire suppression is released.

Forced functions (requires service password)

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Forcing the digital outputs of modules

This window is used for forcing the digital outputs of each connector of a
module on or off:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

Digital outputs of emergency stop:

Function Module Connector pin

Emergency stop enable Chair XC2.2

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Measurement data of the modules (requires service password)

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14.4.1 System notifications and troubleshooting (Emergency stop control)

System Interlocks
• Machine is at running state
• Ignition key must be in “on” state

Inputs
Signal level Connector
Actuator Description Module
pin
Emergency
E-Stop state 24 V / Float Chair XC1.22
stop

Outputs
Signal level Connector
Actuator Description Module
pin
Emergency Emergency
24 V / 0 V Chair XC2.2
stop stop enable

Module No Alarm text Alarm log

E-stop circuit supply voltage short to
Chair 24 X
ground
E-stop circuit has short to external
Chair 25 X
voltage

Description 1: E-stop circuit supply voltage short to ground

Action 1: Wire harness
• Detach the Chair module connector pin XC2.2.
• Check whether the alarm stops when you force the output in question in
the forcing digital outputs window(see chapter ”Emergency stop control”,
section ”Forcing digital output of the modules”).
• If the alarm stopped, the fault is in the cabling, short circuit to ground.
• Repair the wire harness.
Action 2: Module
• If action 1 did not correct the malfunction, the Chair module may be
broken. Change the module if needed.
Description 2: E-stop circuit has short to external voltage
Action 1: Wire harness
• Detach the Chair module connector pin XC2.2.
• Turn off the systems operating voltage and then turn it back on again.
• If the alarm stops, the fault is in the cabling, short circuit to operating
voltage.
• Repair the wire harness.

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Action 2: Module
• If action 1 did not correct the malfunction, the Chair module may be
broken. Change the module if needed.

14.5 Remote drive control

You can choose the type of remote control with a parameter. If remote
control has been selected, the machine goes to the remote control mode
and the manual mode movements are not allowed, with the exception of
automatic central lubrication, signal for reversing and pump control. The
mode will not be changed, if the machine is moving. The machine is
considered moving if its speed exceeds 0,5 km/h.
Turning the key-switch on remote control equipment to RRC-mode affects
the engine stop output set on, for a parameter defined time. This control is
done to avoid unnecessary engine stop, when remote controller is still
‘waking’.
In RRC mode
• Request to release parking brake comes to an input in chair module,
instead of parking brake button. Conditions to release parking brake are
the same, as in manual mode.
• Engine speed is controlled to constant speed.
• Driving direction is controlled with separate inputs. Forward and reverse
are possible.

Measurement data of the modules (requires service password)

The measurement data windows show the values and status of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want on the measurements menu window
and press theOK button. The measurement data window of the connector
opens.
The connector pins for remote control are listed in the ”Inputs”
and ”Outputs” in the section ”System notifications and
troubleshooting (Remote drive control)".

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Forced functions (requires service password)

Forced functions windows are used to control the machine’s different

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Forcing digital outputs of modules

This window is used for forcing the digital outputs of each connector of a
module on or off:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

The digital outputs of the RRC:

Function Module Connector pin
RRC Parking brake release Chair XC2.6

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14.5.1 System notifications and troubleshooting (Remote drive control)

Inputs
Signal level Connector
Actuator Description Module
pin
Switch Manual / Remote mode 0/24V Chair XC1.23
RRC Parking brake re-
Switch 0/24V Chair XC1.19
lease
RRC Service brake re-
Switch 0/24V Chair XC1.20
lease
Switch RRC Gear forward 0/24V Chair XC2.8
Switch RRC Gear reverse 0/24V Chair XC2.16

Outputs
Actuator Description Signal level Module Connector pin
RRC Parking brake re-
Switch 0/24V Chair XC2.6
lease

System interlocks
• The motor will not start if the parking brake release button is not in the
correct position
• The motor will not start if the driving direction is not neutral
• The direction of the machine cannot be controlled until the parking brake
is released
• The ignition switch must be switched to the ON position for the remote
control to operate

Module No Alarm text Alarm log

Too high machine speed denies re-
Chair 29 X
mote mode

Description: Too high machine speed denies remote mode.

Action: Machine speed must be under 0,5 km/h before changing to remote
mode.

Module No Alarm text Alarm log

Chair 30 RRC mode on X

Description: RRC mode on.

Action: No action.

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14.6 Warning and alarm state

The purpose of the red and the yellow indicator lamp in the cabin is to
indicate the machine mode to the operator. The indicator lights show the
same information that the traditional gauges tell, but at one glance. The
purpose of the lights is to warn or alarm, if a measuring or signal is in
warning/alarm state and requires measures.
Alarm or warning popup and the red or yellow indicator light will become
active, if the machine or the control system does not function properly.
The red and the yellow indicator light become active regardless of the
display window the operator is at.
A popup will only appear if the user is in the windows that are allowed to
the operator. The popup will not appear in the windows that are behind the
service and factory passwords.
The popup tells the reason for the alarm/warning, the alarm limit and the
measured reading. Also the alarms with SPN / FMI numbers coming from
engine controller is showed with popup.

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WARNING active
The yellow warning lamp on the dashboard is turned on and the popup
appears to telling the reason for warning.

If the warning is continuously active, the popup disappears after the

operator resets it with the display button. Even the popup disappears the
yellow light will be on until the real reason for warning disappear. The
triangle in the main window will keep on flashing until the warning
disappear.
If the reason for warning disappears and the popup hasn’t been reset yet
by operator, also the popup disappears automatically, but not before 5
seconds minimum time has expired.
When a warning is all the time active the popup will reappear only when the
main power is switched on again, which means that the warning indication
is started from the beginning.
An active warning will always be written in the alarm log.
When moving from alarm status to warning status the popup will not be
shown and the flashing triangle in the main window will indicate the
warning.
When moving from warning status to alarm status, the yellow warning light
goes off and the procedure after this is what is said in the ALARM active
specification (see below).
Warning is always given in case of a sensor error.

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ALARM active
-The red lamp on the dashboard is turned on and the popup appears telling
the reason for the alarm.

If the alarm is continuously active, the popup disappears after the operator
resets it with the display button. After the popup disappears (reset by
operator) the red alarm light will burn until the reason for the alarm
disappear. Also the main window’s triangle will keep on flashing until the
reason for the alarm disappear.
If the reason for alarm disappear and the popup has not been reset (by
operator), also the popup disappears automatically, but not before 5
seconds minimum time has expired.
When the alarm is active, the popup will reappear only when the main
power is switched on again, which means that the warning indication starts
from the beginning.
An active alarm will always be written in the alarm log .
Testing the red and the yellow alarm light: When you turn the ignition key to
the I- position, the alarm and warning lights will turn on for 3 seconds.
In addition to the real time measurement the warning and alarm popup
windows also show those alarm and warning limit values that have been
calibrated in the calibration window.

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Measurement data of the modules (requires service password)

The measurement data windows show the values and status of the
connector pins. The windows are used as help in troubleshooting. Select
the connector of the module you want on the measurements menu window
and press theOK button. The measurement data window of the connector
opens.
The connector pins for warning and alarm lights are listed in
the ”Inputs” and ”Outputs” tables in the section ”System notifications
and troubleshooting (Warning and alarm state)”.

Forced functions (requires service password)

Forced functions windows are used to control the machine’s different

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Forcing digital outputs of modules

This window is used for forcing the digital outputs of each connector of a
module on or off:
1. On the module menu (I/O Force), select the connector of the module
whose outputs you want to force.
2. Press the OK button, the forcing window of the connector you selected
opens.
• The connector pin values are shown according to their status when
the window was opened.
3. Switch the output (or outputs) to be forced on or off.
• ”1” forces the output on,
• ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button.
• The forcing stays active until you release the button.
NOTE! The SEND button forces all the digital outputs of the connector that
has been selected to the status defined on the window.

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14.6.1 System notifications and troubleshooting (Warning and alarm state)

Inputs
No inputs.

Outputs
Signal level Connector
Actuator Description Module
pin
Indicator Alarm light yel-
24 V / Float Chair XC2.9
light low
Indicator
Alarm light red 24 V / Float Chair XC2.10
light

Module No Alarm text Alarm log

Chair 76 Yellow lamp short to ground X
Chair 77 Yellow lamp short to external voltage X
Chair 78 Red lamp short to ground X
Chair 79 Red lamp short to external voltage X

Description 1: Yellow lamp short to ground

Action 1: Wire harness
• Detach the connector pin XC2.9 from the module.
• Use forcing functions to force the output to ON state.
• If the alarm is not active anymore, the fault is in the wire harness, short
circuit to ground.
• After repairing the wiring, turn off the system main power and then turn it
back on again.
Action 2: Module
• If action 1 did not correct the malfunction, the module may be broken.
Change the module if needed.
Description 2: Yellow lamp short to external voltage.
Action 1: Wire harness
• Detach the connector pin XC2.9 from the module.
• Turn off the system main power and then turn it back on again.
• If the alarm is not active anymore, the fault is in the wire harness, short
circuit to operating voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 did not correct the malfunction, the module may be broken.
Change the module if needed.
Description 3: Red lamp short to ground

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Action 1: Wire harness

• Detach the connector pin XC2.10 from the module.
• Use forcing functions to force the output to ON state.
• If the alarm is not active anymore, the fault is in the wire harness, short
circuit to ground.
• After repairing the wiring, turn off the system main power and then turn it
back on again.
Action 2: Module
• If action 1 did not correct the malfunction, the module may be broken.
Change the module if needed.
Description 4: Red lamp short to external voltage
Action 1: Wire harness
• Detach the connector pin XC2.10 from the module.
• Turn off the system main power and then turn it back on again.
• If the alarm is not active anymore, the fault is in the wire harness, short
circuit to operating voltage.
• Repair the wire harness.
Action 2: Module
• If action 1 did not correct the malfunction, the module may be broken.
Change the module if needed.

14.7 Control system start-up diagnostics

Conditions for starting the system (the enable)
To start the system, all modules (Chair, Middle) must be fully functional and
the display must allow module control.

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Checking the backup file of the display

In connection with start-up, the system checks whether the programs and
parameters of the I/O modules correspond to the backup versions saved in
the display module.
If the program versions do not correspond to each other, the following
display window appears.

The window recommends that the program versions of the I/O modules are
updated to correspond with the backups of the display module. By pressing
theYES button, the system updates the programs and parameters
automatically. If the update is successful, a message appears in the display
window. After this, the system must be restarted.
By pressing the NO button, the system will not update, and the main
window opens. In this case, you must update the programs manually in the
module programming window. This requires a service password.For more
information, refer to chapter ”Updating Modules”.
In connection with the start-up, the system also checks whether the module
serial numbers that are saved in the display module correspond to the
serial numbers of the modules that are connected to the system. If all serial
numbers are different, the system asks the user if the display or modules
have been replaced. The system updates the parameters from the display
to the modules (or vice versa) according to this information.
If only some modules have different serial numbers, the system identifies
the modules with differing serial numbers and updates those only from the
display. (In other words, the modules that have been replaced).
In connection with the start-up, the system also checks the parameters of
the modules. If the parameters in the display’s backup file differ from the
modules’ parameters, the system asks the user if the parameters should be
updated from the display to the module, or vice versa.

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Operating voltage diagnostics of the modules

All modules monitor their operating voltage. The gauge window of the
display shows the voltage measured by the Chair module. The lower and
upper voltage limits defined in the measuring calibration window also apply
to other modules.
If the voltage of a module is above or below the limit, the following error
message appears (it is also recorded in the alarm log):
• Accumulator voltage too low, ”module name”
• Accumulator voltage too high, ”module name”

I/O module missing from the CANbus

If one or more modules stop communicating with the CANbus, the following
display window appears.

The window informs which module(s) the error applies to. In this case, the
module connectors and power supply should be checked. Replace a
broken module according to instructions in section”Changing Modules in
the system”.

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14.8 Alarm log

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• Alarm number
• Count: the number of times the alarm has occured
• Reason for the alarm

Alarm log window 1

Alarm log window 2

• The CLEAR button clears the alarms from the display (does not delete
anything).
• The History button retrieves the alarms that were cleared with the
CLEAR button back to the display.

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Alarm log window 3

• The To File button saves the alarm log as a file named
alarms.XXXXXXX.txt into the disply’s file system (”XXXXXXX” is the
serial number of the machine). If needed, the file can be sent to an
update display or with an update display application on a computer to the
computer’s hard disc. You can also send the log to a computer’s hard
disc with Etools.
• TheTo USB button saves the alarm log to a USB stick, when the USB
stick is connected.
• The Show Log button shows all the alarms that have been recorded into
the alarm log, as separate entries, without the count.

14.8.1 System notifications and troubleshooting (Alarm log)

Module No Alarm text Alarm log

Display 6 Log Cleared X

Description: Log cleared (Alarm log cleared)

Action: Alarm log
• No actions necessary, a notification that the alarm log has been cleared

Module No Alarm text Alarm log

Display 15 Alarmlog to file X

Description: Alarm log to file (alarm log saved in the display module’s file
system)
Action: Alarm log
• No actions necessary, a notification that the alarm log has been saved.

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14.9 Controling additional functions

If any options or additional functions have been installed into the machine,
the system will inform the user of these with control windows of the
additional functions.
It is possible to take into use the following additional functions in the control
system:
• Emergency Steering
• Brakes
• Neutral Brake
• Engine
• Lubrication
• RRC
• Reverse Warning
• Window washing
• Lights
• Machine
• Filtering

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Controlling additional functions in the service window (requires

service password)
The service window for controlling additional functions can be opened from
the Options button in the parameter programming menu . In this window,
it is possible to scroll through the additional functions and their parameters
that have been installed into the machine. TheOptions parameter shows if
the option has been selected in the machine. If the option is selected in the
machine, theSet field should show the value of ”1” . If the value is ”1” then
the option has not been selected and is not being used.

Taking additional functions (options) into /out of use:

1. Select the Options and press the Select button.
• A window opens, which asks the user to enter the corresponding
code (password) to the window code.
• The corresponding code is provided by Sandvik.
• The code and corresponding code are only used once, which means
that they change every time that the window is opened.
2. Enter the correct corresponding code and press the Accept button.
• This will open the setting window, in which the additional function can
be taken into use with theOption in machine parameter, by setting a
value of ”1” in the Set field.
• By setting a value of ”0” , the additional function is taken out of use.
• The machine saves the values automatically.

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3. Set other option parameters to the desired values.

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14.10 Parameter control

Restoring parameters

The parameter control window is opened by pressing the Parameters

button in the service window.
The machine’s default parameters are the parameters programmed at the
factory, which are restored by pressing the Restore default params button.
When restoring user parameters, the user is reminded of losing current
parameters.

The machine’s user parameters have been programmed into the machine
after commissioning and are restored by pressing theRestore user
params button. When restoring user parameters the user is reminded of
losing the current parameters.

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Press the OK button to move on to the parameter restoring window from

the warning window. Restore the parameters with theGO button. The
Dashboard and Rear modules are only available in systems with five
modules.
The window will show whether the restoring of parameters was successful
or not.
Default and user parameters can also be restored in the module’s
programming window. For more information, see chapter”Program
Updating of Modules”.

Saving user parameters (requires service password)

It is possible to save the adjusted parameters as user parameters with the

Make user params button. Save parameters with the SAVE button.
The window will show whether the saving of parameters was successful or
not.

14.11 Password management

Only some of the system’s windows are meant for operator use. Windows
that are meant for service personnel only, are protected with service and
factory passwords.

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Service password

Enter the service password into the password field of the service password
window. If the password is correct, the service window meant for the
service personnel opens.
Service window functions:
• Status data of the connector pins of the modules (I/O Measurement)
• Calibrating the pedal, automatic central lubrication and machine type
• Forced functions (Function Test)
• Status data of the CAN bus (CAN Bus Status)
• Time and service
• Installation package
• Programming modules (Modules and New Module)
• Parameter control (Parameters)
• Entering factory password (Factory)

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Verification of passwords during the updating of module’s programs

When a new installation package is used to update the module’s programs,
the system verifies that the passwords saved on the display are the same
as the passwords of the installation package. If the passwords differ from
each other, the system asks to verify which passwords to use.

By answeringYES, the new default passwords are taken into use. By

answering NO, the passwords remain the same as the passwords that are
saved on the display.
14.11.1 System notifications and troubleshooting (Password management)

Module No Alarm text Alarm log

Display 0 Service code entered X
Display 1 Service code wrong X

Description 1: Service code entered

Action: Service code
• No actions necessary, notification of service status activation.
Description 2: Service code wrong
Action: Service code
• No actions necessary, notification of the wrong service password
entered.

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14.12 System implementation

Installation routine
If all modules and the display are broken and new ones must be installed:
1. Using the update display, each I/O module ID must be set first.
2. Using the update display, an installation package is then sent to the
machine’s display.
• The installation package consists of display’s and I/O module’s
programs and parameters.
3. The system is restarted.
• The display module will start the installation routine of the new
system, consisting of the following display windows:

4. The following information is fed into the system during the installation
routine:
• Machine type
• Machine serial number
• Number of modules

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5. Next, the data entries are verified (Verification ).

• By answering YES , the data entries are accepted and the system
will start in the main window.
• By answering NO , the data can be re-entered.
• The data entered during the installation routine will not change even
if the display or the I/O module of the system is changed.
6. Next, the main power must be switched OFF, then ON again.
7. Next, the display will ask if it is allowed to download I/O module software
to the module.
• Press YES and wait until programs are loaded to modules.
Implementation is ready.
Software can be also loaded with CoDeSys or Etools straight to the
modules.

Possible error conditions

If, after having accepted the machine specific information, the system does
not start normally in the main window, the fault is in an error condition of the
start up routine.

14.13 Changing the control modules

Changing a single I/O module
A spare module is taken into use by turning off the system’s operating
voltage and replacing the old module with the new one.
NOTE! Connect a new module into the system only via AMP 8 connector
(CAN bus). I/O connectors (AMP23) need to be disconnected from the
module. This eliminates the possibility of a dangerous situation where the
spare module has a wrong program version that may cause unusual
functions when started.
When the system is restarted, the display module identifies the new module
automatically, and requests permission to program the new module to be
the missing module.

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Program loading
Select YES to start loading the program from the display module to the
module.
The display window shows the progress of the program loading.

When the loading has finished successfully, a separate display window

appears.

Turn off the system’s operating voltage, connect the I/O connectors
(AMP23) into the new module, and restart the module. The system starts
as usual, opening the main window.
If there is an error during program loading, a separate display window
appears.
In case of an error, turn off the system’s operating voltage and check that
the CAN connection (AMP8) of the new module is working properly. After
this, retry program loading by turning on the system’s operating voltage. If
the second program loading attempt also shows errors, program the new
module via the display module’sNew module connector. See chapter
“Program updating of modules”.

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Rejecting program loading

If you select NO when the system identifies a new module in connection
with turning on the operating voltage for a new module, a display window
appears informing that the machine cannot be used.

In this case, the new module must be programmed via the display module’s
New module connector. See chapter “Program updating of modules”.

Error condition if the system does not find a new module

If the system cannot locate the new module in connection with turning on
the operating voltage, program the new module via the display
module’sNew module connector. See chapter “Program updating of
modules”.

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Changing several I/O modules

If during system start--up more than one module is missing, a display
window appears informing that the machine cannot be used.

In this case, the new modules must be programmed via the display
module’s New module connector. See chapter “Program updating of
modules”.
The display window also shows the missing modules. You can also enter
the main window without program loading.

Changing the display module

NOTE! Never change the display module and an I/O module
simultaneously.
There is a danger that you lose the I/O module’s parameters permanently.
Load an installation package to the display with update display. After this,
connect the new display into the system and turn on the operating voltage.
The machine type data is not in the new display’s memory, so the display
searches for it in the Chair module. Also, the display’s serial number table
does not match the system’s modules. The system asks if the display or
modules has been changed. The user must answerDisplay, and the
system’s parameters will be copied from the modules to the display.

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14.14 Modules program updating

Updating manually the programs of system modules (requires service
password)

Press the Modules button in the service window to open the display
window for updating the programs of the existing I/O modules and the
display module:
1. Select the module which programs you want to update in the Module(s)
field.
• Choosing All Mods updates the programs of all modules.
2. Select the files to be updated in the File(s) field: Program, Parameters
or Both.
3. Select in the Target field, whether the updates will be loaded from the
selected I/O module —> Display module or Display module —> I/O
module.
4. Select the parameters to be updated in the Parameters field: Default or
User.
5. Start the updating by pressing the GO button.
When program updating starts, other transmission on the CAN bus is
stopped, and when you leave the window, the transmission restarts.

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Programming a new module (requires service password)

Program a new module via the ”New module” connector by connecting the
module with a proper programming cable to the display module’s CAN2
bus.
NOTE! If the RunTime version is 2.05 or older, the module must be
programmed manually according to chapter “Updating manually the
programs of system modules”. The RunTime version can be found from the
program version history (See chapter “Module program versions”)
When programming a new module, the systems operating voltage must be
turned on and the main window open. When connecting a new module to
the CAN2 connector of the display module, the system identifies the
module automatically and opens the module identifying window:
When the system has identified the module that is connected to the ”new
module” programming cable, the programming window opens.

Choose which module the new module will be programmed to be. In

addition to being able to program the new module as a system module, it
can also be programmed as a spare module.
The window also shows the statuses of all the modules that are on the CAN
bus.
Start the programming by pressing the GO button.
The display window shows the progress of the programming:

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When the programming has finished successfully, the text ”Loading

finished successfully” appears on the display window.
If there is an error during programming, the programming is interrupted with
the error message ” LOADING FAILED” .
When the programming is finished, disconnect the programmed module
from the ”new module” programming cable. After this, connect the new
module to the system and start the system.
You can open the programming window also with the New Module button
of the service window:

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Module program versions

Open the installation package version data window with the About button
from the information window of Gauge window 1:

The program version data windows show the program and RunTime
versions of the system’s I/O modules and display module, as well as the
Installation package, the date of the display’s program version and the
serial numbers of the modules:

14.15 CANbus status data

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RX= Received CAN messages, TX= Transmitted CAN messages

Open the CANbus status window with the CAN bus status button in the
service window:
• Messages that the display module has received (RX Messages )
• The time period (in milliseconds) between the starting of the display
application and the last time that the display sent or received CAN
messages. (Last Poll Time )
• The time period (in milliseconds), between the last time the display sent
or received CAN messages and the time before that. (Max Poll Interval )
• Messages that the display module has sent (TX Messages )
• The number of times that the display has sent or received CAN
messages since the application was started (Visits )
• The number of the display module’s bus off modes (Bus Offs )
• The number of received erroneous messages (RX Error counter )
• The number of sent erroneous messages (TX Error counter )
Reset the data by pressing the Reset button.

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14.16 Output preconditions

14.16.1 Introductions

Module pin types

DI (Digital input):
DI pins have 2 logical states, 0 (off) and 1 (on). Module digital inputs are for
instance used to read operator activities. When the operator presses the
horn button, module DI Horn XC3.18 changes state from 0 to 1.
AI (Analog input)
Analog inputs are used to read values from all kinds of sensors, for
instance hydraulic oil temperature sensor is connected to AI pin (XM3.13).
DO (Digital output)
DO pins have 2 logical states, 0 (off) and 1 (on). Module digital outputs are
used to control machine devices. When the operator has pressed the horn
button module DO horn XM1.15 changes state from 0 to 1. This generates
sound signal from the horn device.
PWM (Pulse width modulation)
PWM outputs are used to control proportional valves, for instance engine
cooler fan pump XM1.4.

The naming of module connectors

The following names are used throughout the whole document.
• XC1 – Chair module, connector 1
• XC2 – Chair module, connector 2
• XM1 – Middle module, connector 1
• XM2 – Middle module, connector 2

Machine function modes

Manual mode: All machine’s control devices are controlled by the driver in
the machine cabin.
RRC mode: There is no driver in the machine cabin. The machine is
controlled remotely by radio remote controller (RRC).

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14.16.2 General conditions

Enable
Enable is active when
• All modules are up and running
• After main switch is turned on it takes a few seconds before enable is
active

Emergency stop
In manual mode
Emergency stop is active when
• Enable is inactive
or
• One of the machine’s emergency buttons are pressed
14.16.3 Machine functions

Gear control
The following conditions must be fulfilled before gear control is allowed
• Enable is active
• Emergency stop is not active
• Motor is running
• Parking brake is released
• Door is closed
• Machine speed is under limit

Brake control
The following conditions must be fulfilled before the parking brake can be
released
• Enable is active
• Emergency stop is not active
• Door is closed
• Gear selector is in neutral position
• Motor is running
• Hydraulic oil level is over lower limit
• The brake accumulator pressure is in normal level
• Transmission charging pressure is in normal level

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14.16.4 Chair module outputs

Chair connector XC1 outputs

XC1.1 Sensor & Switch Supply (DO)

Output active when
• Enable is active

Chair connector XC2 outputs

XC2.1 Sensor & Switch Supply (DO)

Output active when
• Enable is active

XC2.2 Emergency stop enable (DO)

In manual mode
Output active when
• Enable is active

XC2.6 RRC parking brake released (DO)

In RRC mode (see Ch. 1.3)
Output active when
• Machine is in remote control mode
• RRC parking brake release DI XC1.19 is active

XC2.7 Beacon light (DO)

Output active when
• PAR_RotationBeacon Active is set True
• Enable is active (see Ch. 2.1)
or alternatively
• Output is on if Display force is on

XC2.9 Alarm light yellow (DO)

Output active when
• A defined warning occurs
or alternatively
• The alarm lights are on for 3 s after the ignition key is switched on.

XC2.10 Alarm light red (DO)

Output active when
• A defined alarm occurs
or alternatively
• The alarm lights are on for 3 s after the ignition key is switched on.

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XC2.22 Window Wiper (DO)

Output active when
• Enable is active
• Emergency stop is not active
• Ignition key is in “ON” state
• Window wiper DI XC1.18 is active
• Intermittent timer (is adjusted with potentiometer AI XC3.5) affects output
activation frequency
or alternatively
• Output is on if Display force is on

XC2.23 Sensor & Switch Supply (DO)

Output active when
• Enable is active

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14.16.5 Middle module outputs

Middle connector XM1 outputs

XM1.1 Sensor & Switch Supply (DO)

Output active when
• Enable is active

XM1.2 Lubrication valve (DO)

Output active when
• Option parameter “Central lubrication in use” is active
• Parking brake released
• Grease reservoir is not empty, grease end DI XM2.19 is active,
• Lubrication interval is in active state. Output state changes every time
when lubrication interval time is elapsed
or alternatively
• Enable is active
• Output is on if Display force is on

XM1.3 Engine stop (DO)

Output active when
• Enable is active
• Emergency stop is not active
• Ignition key is turned to I position
or alternatively
• Enable is active
• Emergency stop is not active
• Output is on if Display force is on

XM1.4 Engine cooler fan pump (PWM)

The setting is inverted so that the minimum current creates maximum
pressure and the maximum current creates minimum pressure
Output active when
• Enable is active
• Emergency stop is not active
• PAR_EngineCoolantControlInUse is set true
• Engine is running
or alternatively
• Output is on if Display force is on

XM1.7 Brake circuit 1 control (DO)

In manual mode

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Output active when

• Parking brake release is enabled (see Ch. 3.2)
• Parking brake engage button XC1.17 must be in disengage -position
• Parking brake release button XC1.16 must be used in release -position
• Neutral brake is inactive (if neutral brake option in use)
or alternatively
• Brake release pump is activated, XC2.19 is active
• Emergency stop is inactive
• Engine is not running
• Parking brake engage button XC1.17 must be in disengage -position
• Parking brake release button XC1.16 must be used in release -position
In RRC mode
Output active when
• Parking brake release is enabled
• RRC parking brake released DO XC2.6 is active
• RRC service brake release DI XC1.20 is active

XM1.8 Brake Circuit 2 control (DO)

In manual mode
Output active when
• Parking brake release is enabled (see Ch. 3.2)
• Parking brake engage button XC1.17 must be in disengage -position
• Parking brake release button XC1.16 must be used in release -position
• Neutral brake is inactive (if neutral brake option in use)
or alternatively
• Brake release pump is activated, XC2.19 is active
• Emergency stop is inactive
• Engine is not running
• Parking brake engage button DI XC1.17 must be in disengage -position
• Parking brake release button DI XC1.16 must be used in release -
position
In RRC mode
Output active when
• Parking brake release is enabled (see Ch. 3.2)
• RRC parking brake released DO XC2.6 is active
• RRC service brake release DI XC1.20 is active

XM1.14 Brake lights/Blinker Front left (DO)

Output active when
• Enable is active (see Ch. 2.1)

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• Blinker button is pressed, DI XC3.17 is active

or alternatively
• Enable is active (see Ch. 2.1)
• Engine running
• Brake circuit pressure below pressure limit
• Gear is in neutral position or gear is in reverse position

XM1.15 Horn (DO)

Output active when
• Enable is active
• After motor start horn is active a few seconds
or alternatively
• Enable is active
• Horn button DI XC3.18 is pressed

XM1.16 Engine start (DO)

Output active when
• Enable is active (see Ch. 2.1)
• Emergency stop is not active (see Ch. 2.2)
• Engine stop DO XM1.3 must be active
• Ignition key is turned to starting position, DI XC1.8 is active
• Engine is not running
• Gear button is in neutral position
• Brake release switch button is down position

XM1.17 Emergency steering pump (DO)

Output active when
• Option parameter “Emergency steering on” is active
• Emergency stop is not active (see Ch. 2.2)
• Emergency steering test button is pressed, DI XC3.22 is active
• Door is closed
• Engine is not running
or alternatively
• Option parameter “Emergency steering on” is active
• Motor is stopped in an unusual way

XM1.22 Brake lights/Blinker Front right (DO)

Output active when
• Enable is active
• Blinker button is pressed, DI XC3.16 is active
or alternatively
• Enable is active

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• Engine running
• Brake circuit pressure below pressure limit
• Gear is in neutral position or gear is in reverse position

XM1.23 Brake lights/Blinker Rear left (DO)

Output active when
• Enable is active (see Ch. 2.1)
• Blinker button is pressed, DI XC3.17 is active
or alternatively
• Enable is active (see Ch. 2.1)
• Engine running
• Brake circuit pressure below pressure limit
• Gear is in neutral position or gear is in reverse position

Middle connector XM2 outputs

XM2.1 Sensor & Switch Supply (DO)

Output active when
• Enable is active

XM2.2 Brake lights/Blinker Rear left (DO)

Output active when
• Enable is active
• Blinker button is pressed, DI XC3.17 is active
or alternatively
• Enable is active
• Engine running
• Brake circuit pressure below pressure limit
• Gear is in neutral position or gear is in reverse position

XM2.5 Forward valve (DO)

In manual mode
Output active when
• Gear control is allowed (see Ch. 3.1)
• Driving direction switch is pushed to forward direction, XC1.3 is active
In RRC mode
Output active when
• Gear control is allowed
• RRC switch forward direction, XC2.8 is active

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XM2.6 Reverse valve (DO)

In manual mode
Output active when
• Gear control is allowed
• Driving direction switch is pushed to reverse direction, XC1.2 is active
In RRC mode
Output active when
• Gear control is allowed
• RRC switch reverse direction, DI XC2.16 is active

XM2.16 Reverse warning horn / light (DO)

Output active when
• Emergency stop is not active (see Ch. 2.2)
• Reverse gear is on
• Intermittent timer (is adjusted with a parameter) allows to set output
active

XM2.17 Directional light front (parking light) (DO)

Output is active when
• Enable is active
• Emergency stop is not active
• Driving direction is neutral
• Parking brake is on
• Ignition key is parking position
or alternatively
• Enable is active
• Emergency stop is not active
• Backward gear is active

XM2.22 Brake release pump (DO)

Output active when
• Enable is active
• Emergency stop is not active
• Engine is not running
• Brake release pump button is pressed, XC2.19 is active
or alternatively
• Enable is active
• Emergency stop is not active
• Output is active a few seconds after motor start

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XM2.23 Directional light rear (parking light) (DO)

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15 VCM System Error Codes

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15.1 Chair module alarm index

No Alarm text Further information
1 Module booting
2 wrong NodeID
3 program cycle time too long
CANopen transmit buffer
4
full (bus overloaded
CANopen Error Frames de-
5
tected
9 Module temperature low
10 Module temperature high
14 Start message sent
E-stop circuit supply volt- System notification and trouble-
24
age short to ground shooting (Emergency stop control)
E-stop circuit has short to System notification and trouble-
25
external voltage shooting (Emergency stop control)
Control system module System notification and trouble-
26
missing. E-stop activated shooting (Emergency stop control)
System notification and trouble-
28 E-stop activated
shooting (Emergency stop control)
Too high machine speed System notification and trouble-
29
denies remote mode shooting (Remote drive control)
System notification and trouble-
30 RRC mode on
shooting (Remote drive control)
System notification and trouble-
Fire supression released.
31 shooting (Fire suppression system
E-stop activated
control)
Module supply pin XC1/1 System notifications and trouble-
33
short to ground shooting (Transmission control)
Module supply pin XC1/1 System notifications and trouble-
34
short to external voltage shooting (Transmission control)
Module supply pin XC2/1 System notifications and trouble-
35
short to ground? shooting (Transmission control)
Module supply pin XC2/1 System notifications and trouble-
36
short to external voltage? shooting (Transmission control)
Module supply pin XC2/23 System notifications and trouble-
37
short to ground shooting (Door status control)
Module supply pin XC2/23 System notifications and trouble-
38
short to external voltage shooting (Door status control)

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No Alarm text Further information

Chair module supply volt- System notifications and trouble-
41
age high shooting (Voltage monitoring)
Chair module supply volt- System notifications and trouble-
42
age low shooting (Voltage monitoring)
Module ref 5 V out of limits System notifications and trouble-
43
(pins XC3/2 or XC3/10) shooting (Window wiper control)
Module ref 12V out of limits System notifications and trouble-
44
(pins XC3/1 or XC3/9 shooting (Window wiper control)
No data received in SAE J System notifications and trouble-
64
1939 from ECM shooting (Engine control)
Cabin door switch error, System notifications and trouble-
65
both contacts open shooting (Door status control)
Cabin door switch error, System notifications and trouble-
66
both contacts close shooting (Door status control)
System notifications and trouble-
67 Engine bypass SEO used
shooting (Engine control)
System notifications and trouble-
68 Parking Brake button error
shooting (Brakes control)
Park brake released, no System notifications and trouble-
69
manual mode shooting (Brakes control)
System notifications and trouble-
76 Yellow lamp short to ground
shooting (Warning and alarm state)
Yellow lamp short to exter- System notifications and trouble-
77
nal voltage shooting (Warning and alarm state)
System notifications and trouble-
78 Red lamp short to ground
shooting (Warning and alarm state)
Red lamp short to external System notifications and trouble-
79
voltage shooting (Warning and alarm state)
Window wiper control sig- System notifications and trouble-
81
nal short to ground shooting (Window wiper control)
Window wiper control sig- System notifications and trouble-
82
nal short to external voltage shooting (Window wiper control)
Rotation beacon control System notifications and trouble-
83
signal short to ground shooting (Light control)
Rotation beacon control
System notifications and trouble-
84 signal short to external volt-
shooting (Light control)
age
System notifications and trouble-
85 Delayed engine stop popup
shooting (Engine control)

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No Alarm text Further information

Door opened during de- System notifications and trouble-
86
layed engine stop shooting (Engine control)
E-stop activated during de- System notifications and trouble-
87
layed engine stop shooting (Engine control)
Starting not allowed! Press System notifications and trouble-
88
brake button down shooting (Engine control)
System notifications and trouble-
96 Alternator failure
shooting (Voltage monitoring)
Starting not allowed! System notifications and trouble-
98
Change gear to neutral shooting (Engine control)
System notifications and trouble-
99 Engine over-rev warning
shooting (Engine control)
Both blinker switch symbols System notifications and trouble-
117
active at the same time shooting (Light control)
Cabin door switch state
118
forced from display

15.2 Display module alarm index

No Alarm text Further information
Service code en- System notifications and troubleshooting
0
tered (Password management)
System notifications and troubleshooting
1 Service code wrong
(Password management)
Factory code en- System notifications and troubleshooting
2
tered (Password management)
System notifications and troubleshooting
3 Factory code wrong
(Password management)
Master code en- System notifications and troubleshooting
4
tered (Password management)
Master code en- System notifications and troubleshooting
5
tered (Password management)
System notifications and troubleshooting
6 Log Cleared
(Password management)
System notifications and troubleshooting
15 Alarmlog to file
(Alarm log)

15.3 Middle module alarm index

No Alarm text Further information
1 Module booting
2 wrong NodeID

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No Alarm text Further information

program cycle time too
3
long
CANopen transmit buffer
4
full (bus overloaded
CANopen Error Frames
5
detected
9 Module temperature low
10 Module temperature high
14 Start message sent
Hydraulic oil temp high System notifications and troubleshoot-
24
alarm ing (Oil temperature monitoring)
Hydraulic oil tem high System notifications and troubleshoot-
25
warning ing (Oil temperature monitoring)
Hydraulic oil temp sensor System notifications and troubleshoot-
26
(B301) high error ing (Oil temperature monitoring)
Hydraulic oil temp sensor System notifications and troubleshoot-
27
(B301) low error ing (Oil temperature monitoring)
Front brake actual pres- System notifications and troubleshoot-
28
sure high alarm ing (Brake pressure monitoring)
Front brake actual press. System notifications and troubleshoot-
29
high warning ing (Brake pressure monitoring)
Front brake circuit actual
System notifications and troubleshoot-
30 pressure sensor (B356)
ing (Brake pressure monitoring)
high
Front brake circuit actual
System notifications and troubleshoot-
31 pressure sensor (B356)
ing (Brake pressure monitoring)
low
Rear brake actual pres- System notifications and troubleshoot-
32
sure high alarm ing (Brake pressure monitoring)
Rear brake actual press. System notifications and troubleshoot-
33
High warning ing (Brake pressure monitoring)
Rear brake circuit actual
System notifications and troubleshoot-
34 pressure sensor (B357)
ing (Brake pressure monitoring)
high
Rear brake circuit actual
System notifications and troubleshoot-
35 pressure sensor (B357)
ing (Brake pressure monitoring)
low
Brake release pump relay
System notifications and troubleshoot-
36 signal short to ext. volt-
ing (Brakes control)
age

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No Alarm text Further information

Brake release pump relay System notifications and troubleshoot-
37
signal short to ground ing (Brakes control)
Transmission solenoid F System notifications and troubleshoot-
40
short to ground ing (Transmission control)
Transmission solenoid F System notifications and troubleshoot-
41
short to external voltage ing (Transmission control)
Transmission solenoid R System notifications and troubleshoot-
42
short to ground ing (Transmission control)
Transmission solenoid R System notifications and troubleshoot-
43
short to external voltage ing (Transmission control)
Pilot oil pressure filter System notifications and troubleshoot-
50
blocked ing (Filter monitoring)
Hydraulic oil return filter System notifications and troubleshoot-
51
blocked ing (Filter monitoring)
Middle module supply System notifications and troubleshoot-
52
voltage high ing (Voltage monitoring
Middle module supply System notifications and troubleshoot-
53
voltage low ing (Voltage monitoring
Brake circuit 1 short to System notifications and troubleshoot-
54
ground ing (Brakes control)
Brake circuit 1 short to System notifications and troubleshoot-
55
ext. voltage ing (Brakes control)
Brake circuit 2 short to System notifications and troubleshoot-
59
ground ing (Brakes control)
Brake circuit 2 short to System notifications and troubleshoot-
60
ext. voltage ing (Brakes control)
Emerg. steering pump re-
System notifications and troubleshoot-
61 lay signal short to ext.
ing (Emergency steering control)
voltage
Emerg. steering pump re- System notifications and troubleshoot-
62
lay signal short to ground ing (Emergency steering control)
Safety features activated.
System notifications and troubleshoot-
63 Unable to release parking
ing (Brakes control)
brake
Safety feature ABA acti-
System notifications and troubleshoot-
64 vated. Parking brake en-
ing (Brakes control)
gaged
Neutral brake pressure System notifications and troubleshoot-
65
switch error ing (Brakes control)
Emergency steering acti- System notifications and troubleshoot-
66
vated ing (Emergency steering control)

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No Alarm text Further information

Engine stop signal short System notifications and troubleshoot-
67
to ground ing (Engine control)
Engine stop signal short System notifications and troubleshoot-
68
to external voltage ing (Engine control)
Cardan speed sensor A System notifications and troubleshoot-
69
failure ing (Transmission control)
Cardan speed sensor B System notifications and troubleshoot-
70
failure ing (Transmission control)
Parking brake engage, System notifications and troubleshoot-
71
engine cut out ing (Brakes control)
Parking brake engaged. System notifications and troubleshoot-
72
E-stop activated ing (Brakes control)
Brake oil return filter System notifications and troubleshoot-
73
blocked ing (Filter monitoring)
System notifications and troubleshoot-
74 Engine air filter blocked
ing (Filter monitoring)
System notifications and troubleshoot-
Transmission oil pressure
75 ing (Transmission oli pressure moni-
high alarm
toring)
System notifications and troubleshoot-
Transmission oil press.
76 ing (Transmission oli pressure moni-
high warning
toring)
System notifications and troubleshoot-
Transmission oil pressure
77 ing (Transmission oli pressure moni-
low warning
toring)
System notifications and troubleshoot-
Transmission oil pressure
79 ing (Transmission oli pressure moni-
sensor (B305) high error
toring)
System notifications and troubleshoot-
Transmission oil pressure
80 ing (Transmission oli pressure moni-
sensor (B305) low error
toring)
Unable to release parking System notifications and troubleshoot-
83
brake. E-stop activated ing (Brakes control)
Parking brake engaged, System notifications and troubleshoot-
84
door open ing (Brakes control)
System notifications and troubleshoot-
85 Fuel level low warning
ing (Fuel level monitoring)
System notifications and troubleshoot-
86 Fuel level low alarm
ing (Fuel level monitoring)
Fuel level sensor (B311) System notifications and troubleshoot-
87
high error ing (Fuel level monitoring)

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No Alarm text Further information

Fuel level sensor (B311) System notifications and troubleshoot-
88
low error ing (Fuel level monitoring)
Module ref 5V out of lim-
89
its (pins XM3/2 or XM3/10
Module ref 12V out of lim- System notifications and troubleshoot-
90
its (pins XM3/1 of XM3/9) ing (Transmission control)
Horn signal short to System notifications and troubleshoot-
91
ground ing (Sound and reversing signal)
Horn signal short to exter- System notifications and troubleshoot-
92
nal voltage ing (Sound and reversing signal)
Unable to release parking System notifications and troubleshoot-
93
brake. Door open! ing (Brakes control)
Unable to release parking System notifications and troubleshoot-
94
brake. Engine not running ing (Brakes control)
Pressure differ in pedal
System notifications and troubleshoot-
97 and rear brake circuit
ing (Brake pressure monitoring)
(brakes may drag)
Pressure differ in pedal
System notifications and troubleshoot-
98 and front brake circuit
ing (Brake pressure monitoring)
(brakes may drag)
Pressure differ in front
System notifications and troubleshoot-
99 and rear brake circuit
ing (Brake pressure monitoring)
(brakes may drag)
System notifications and troubleshoot-
102 ABA control on
ing (Brakes control)
Engine start signal short System notifications and troubleshoot-
103
to ground ing (Engine control)
Engine start signal short System notifications and troubleshoot-
105
to external voltage ing (Engine control)
Hydraulic oil level warn- System notifications and troubleshoot-
106
ing ing (Hydraulic oil level monitoring)
System notifications and troubleshoot-
107 Hydraulic oil level alarm
ing (Hydraulic oil level monitoring)
System notifications and troubleshoot-
Module supply pin XM1/1
108 ing (Transmission oli pressure moni-
short to ground
toring)
System notifications and troubleshoot-
Module supply pin XM1/1
109 ing (Transmission oli pressure moni-
short to external voltage
toring)

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No Alarm text Further information

System notifications and troubleshoot-
Module supply XM2/1
110 ing (Fuel level monitoring) (Transmis-
short to ground
sion oli pressure monitoring)
System notifications and troubleshoot-
Module supply XM2/1
111 ing (Fuel level monitoring) (Transmis-
short to external ground
sion oli pressure monitoring)
Brake test not allowed, System notifications and troubleshoot-
117
engine not running ing (Brakes control)
Emergency steering test System notifications and troubleshoot-
120
error. Door open! ing (Emergency steering control)
Emergency steering test System notifications and troubleshoot-
121
error. E-stop activated! ing (Emergency steering control)
Rear brake circuit pres- System notifications and troubleshoot-
122
sure low warning ing (Brake pressure monitoring)
Rear brake circuit pres- System notifications and troubleshoot-
123
sure low alarm ing (Brake pressure monitoring)
Emergency steering test System notifications and troubleshoot-
124
error. Engine running! ing (Emergency steering control)
Engine starting not al-
System notifications and troubleshoot-
126 lowed. E-stop state ac-
ing (Engine control)
tive!
System notifications and troubleshoot-
128 Fuel level high alarm
ing (Fuel level monitoring)
System notifications and troubleshoot-
129 Fuel level high warning
ing (Fuel level monitoring)
Close the door before System notifications and troubleshoot-
130
starting the brake test ing (Brakes control)
Hydraulic oil temp low System notifications and troubleshoot-
132
warning ing (Oil temperature monitoring)
Hydraulic oil temp low System notifications and troubleshoot-
133
alarm ing (Oil temperature monitoring)
Transmission oil temp. System notifications and troubleshoot-
142
high alarm ing (Oil temperature monitoring)
Transmission oil temp. System notifications and troubleshoot-
143
high warning ing (Oil temperature monitoring)
Transmission oil tempera-
System notifications and troubleshoot-
144 ture sensor (B302) high
ing (Oil temperature monitoring)
error
Transmission oil tempera-
System notifications and troubleshoot-
145 ture sensor (B302) low
ing (Oil temperature monitoring)
error

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No Alarm text Further information

Brake circuit charging System notifications and troubleshoot-
146
pressure high alarm ing (Brake pressure monitoring)
Brake circuit charging System notifications and troubleshoot-
147
pressure high warning ing (Brake pressure monitoring)
Brake circuit charging System notifications and troubleshoot-
148
pressure low warning ing (Brake pressure monitoring)
Brake circuit charging System notifications and troubleshoot-
149
pressure low alarm ing (Brake pressure monitoring)
Brake circuit charging
System notifications and troubleshoot-
150 pressure sensor (B334)
ing (Brake pressure monitoring)
high error
Brake circuit charging
System notifications and troubleshoot-
151 pressure sensor (B334)
ing (Brake pressure monitoring)
low error
System notifications and troubleshoot-
152 Emergency steering test
ing (Emergency steering control)
Front brake circuit pres- System notifications and troubleshoot-
154
sure low warn ing (Brake pressure monitoring)
Front brake circuit pres- System notifications and troubleshoot-
155
sure low alarm ing (Brake pressure monitoring)
Brake release pump acti- System notifications and troubleshoot-
157
vated ing (Brakes control)
Gear box control forbid- System notifications and troubleshoot-
159
den. TheEnable missing ing (Transmission control)
Neutral brake function en- System notifications and troubleshoot-
160
gaged ing (Brakes control)
Transmission oil temp. System notifications and troubleshoot-
161
low warnin ing (Oil temperature monitoring)
Transmission oil temp. System notifications and troubleshoot-
162
low alarm ing (Oil temperature monitoring)
Gear box control forbid- System notifications and troubleshoot-
163
den. E-Stop active ing (Transmission control)
Gear box control forbid- System notifications and troubleshoot-
164
den. Engine not running ing (Transmission control)
Gear box control forbid- System notifications and troubleshoot-
165
den. Door open ing (Transmission control)
Gear box control forbid-
System notifications and troubleshoot-
166 den. Parking brake not
ing (Transmission control)
released
Gear box control forbid- System notifications and troubleshoot-
167
den. FNR-Switch broken ing (Transmission control)

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No Alarm text Further information

Right rear brake and
System notifications and troubleshoot-
168 blinker light short to
ing (Lights control)
ground
Right rear brake and
System notifications and troubleshoot-
169 blinker light short to ext.
ing (Lights control)
voltage
Left rear brake and blink- System notifications and troubleshoot-
170
er light short to ground ing (Lights control)
Left rear brake and blink-
System notifications and troubleshoot-
171 er light short to external
ing (Lights control)
voltage
Driving direction reverse System notifications and troubleshoot-
172
light short to ground ing (Lights control)
Driving direction reverse
System notifications and troubleshoot-
173 light short to external volt-
ing (Lights control)
age
Reverse warning buzzer/
System notifications and troubleshoot-
176 light signal short to
ing (Sound and reversing signal)
ground
Reverse warning buzzer/
System notifications and troubleshoot-
177 light signal short to ext.
ing (Sound and reversing signal)
voltag
Transmission oil filter System notifications and troubleshoot-
178
blocked ing (Filter monitoring)
Driving direction forward System notifications and troubleshoot-
184
light short to ground ing (Lights control)
Driving direction forward
System notifications and troubleshoot-
185 light short to external volt-
ing (Lights control)
age
Front rightside light short- System notifications and troubleshoot-
193
cut ing (Lights control)
Front rightside light Volt- System notifications and troubleshoot-
194
age in pin ing (Lights control)
Left front brake and blink- System notifications and troubleshoot-
195
er light short to ground ing (Lights control)
Left front brake and blink-
System notifications and troubleshoot-
196 er light short to external
ing (Lights control)
voltage
System notifications and troubleshoot-
197 Grease end ing (Automatic central lubrication con-
trol)

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No Alarm text Further information

System notifications and troubleshoot-
Central lubrication short
198 ing (Automatic central lubrication con-
to ground
trol)
System notifications and troubleshoot-
Central lubrication short
199 ing (Automatic central lubrication con-
to external voltage
trol)
System notifications and troubleshoot-
204 Central lubrication error ing (Automatic central lubrication con-
trol)
System notifications and troubleshoot-
Central lubrication grease
205 ing (Automatic central lubrication con-
line blocked
trol)

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16 Technical Specification

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16.1 Technical data

Machine dimensions
Total length 7766 mm 306 in
Maximum width 1600 mm 63 in
Height of cabin 2127 mm 84 in
Maximum side height of bucket 3907 mm 154 in
Maximum bucket dump height 1511 mm 60 in

Measured A-weighted emission sound pressure (At high idle 2410

level rpm)
At operator’s position, LpA [dB re 20 μPa] 94 dB
Uncertainty, KpA [dB] 3 dB

Maximum gradient angle

Maximum gradient 15° bucket down
10° bucket up

Maximum gradient and tilt angles Platform angle

Boom down 20°
Bucket empty
Maximum Boom up 10°
straight gradient Boom down 20°
Bucket with full
load Boom up 5°
Boom down 15°
Bucket empty
Maximum tilt an- Boom up 7°
gle Boom down 10°
Bucket with full
load Boom up 2°

Turning radius
Inner 2886 mm 113 in
Outer 5153 mm 202 in
Turning angle ± 42°

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16.2 Machine weights

Operating weights
Total operating weight 13640 kg 30070 lb
Front axle 5220 kg 11510 lb
Rear axle 8420 kg 18560 lb

Loaded weights
Total loaded weight 18140 kg 39990 lb
Front axle 12440 kg 27430 lb
Rear axle 5700 kg 12570 lb

Capacities
Payload 4000 kg 8820 lb
Bucket volume 2.0 m3 2.6 yd3

16.3 Main components weights

Engine 420 kg 925 lb
Drive pump 262 kg 578 lb
Dropbox w/drive motor 398 kg 877 lb
Front axle 1163 kg 2564 lb
Rear axle w/cradle 1301 kg 2868 lb
Cooling radiator 120 kg 265 lb

16.4 Brake system

Brake system
Spring applied, hydraulically released,
multi-disc brakes on all four wheels,
Service brakes
two separate circuits for the front and
rear axles.
Service brakes also function as emer-
Emergency/park brake gency brakes, when the emergency
brake system is engaged.
Actuates automatically when the en-
Park brake actuation gine is shut down (i.e. hydraulic pres-
sure is off).
Brake release pressure 138 bar (2001 psi)

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16.5 Engine
Standard engine
Type Deutz BF4M2012C
Power Output 93 kW (126 hp) @ 2500 RPM
Torque 445 Nm (330 lb.-ft.) @ 1500 RPM
Number of cylinders 4 in-line
Displacement 12.13 L (740 cubic in.)
Cooling system Liquid cooled
Combustion principle Turbocharged, after cooled, direct injection
Air filtration Donaldson, Dry type (power core)
Electrical system 24 V
Starter motor 4,0 kW
Exhaust system purifier Catalytic purifier with silencer
Fuel tank capacity 150 L

16.6 Default pressure settings

Main principles for measure point numbering
Type
• MP = Measurement point
• MG = Measurement gauge
Circuit
• 1 = Steering circuit
• 2 = Box circuit
• 3 = Engine cooler circuit
• 4 = Others
• 5 = Brakes / Coolers circuit
• 7 = Transmission
Sequence number
• 0-9
Sequence number
• 0-9

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Measur-
Default
ing System Checking method
pressure
Point
Pushing the boom against
Bucket pump pres-
MP201 the stoppers, engine run- 230 ±8 bar
sure
ning at idle.
Pushing the boom against
Steering pump
MP101 the stoppers, engine run- 220 ±8 bar
pressure
ning at idle.
Drive pump pres- Driving direction forward
MP704 370 ±10 bar
sure against the wheel brakes.
Drive pump pres- Driving direction reverse
MP703 370 ±10 bar
sure against the wheel brakes.
Pilot circuit pres-
MP405 Engine running at idle. 35 ±10 bar
sure
Brake charging
MP501 Engine running at idle. 190 ±2 bar
pressure
Transmission boost
MP701 Engine running at idle. 30 +5 bar
pump pressure
Pilot pressure accu-
Machine isolated and ener-
MP125 mulator pre-charge 15 +2 bar
gy dissipated.
pressure
Brake pressure ac-
Machine isolated and ener-
MP521 cumulators pre- 90 +3 bar
gy dissipated.
charge pressure

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17 Appendices

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17.1 The tightening torques for screws and nuts

The tightening torques for screws and nuts
These values apply if the drawing shows no other specifications.
The values given in the drawings are for a lubricated screw.

When lubricating a screw, it is essential to lubricate both the thread and the screw head.
Locking with Loctite corresponds to a lubricated screw.

If screw tightening requires a torque wrench, the torque value must be mentioned in the drawing.

For Deutz, Caterpillar, Clark, and certain other components the values of the component manufacturer
apply.
The tightening torques for certain components, e.g. axles, rims and mounting screws, are given
separately.

Torque values are given in Nm units for each strength class.

8.8 10.9 12.9

thread
M4 2.9 4 5
M5 5.7 8 9.7
M6 10 14 17
M8 24 34 40
M10 48 67 80
M12 82 115 140
M14 130 180 220
M16 180 250 305
M18 275 385 465
M20 390 550 660
M22 520 740 890
M24 670 950 1150
M27 960 1350 1620
M30 1350 1900 2250

Grade 5 Grade 8 Grade 5 Grade 8

8.8 10.9 12.9 8.8 10.9 12.9
thread thread
UNC 1/4 11 15 19 UNF 1/4 12 17 21
UNC 5/16 21 31 38 UNF 5/16 23 33 41
UNC 3/8 37 54 68 UNF 3/8 43 59 73
UNC 7/16 61 87 108 UNF 7/16 69 93 115
UNC 1/2 95 130 160 UNF 1/2 100 140 175
UNC 9/16 135 185 235 UNF 9/16 150 200 250
UNC 5/8 185 260 320 UNF 5/8 210 280 345
UNC 3/4 325 455 570 UNF 3/4 365 485 600
UNC 7/8 525 730 910 UNF 7/8 580 770 960
UNC 1 770 1090 1360 UNF 1 810 1150 1430
UNC 11/8 1100 1550 1930 UNF 11/8 1170 1660 2060
UNC 11/4 1530 2160 2690 UNF 11/4 1620 2290 2850

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17.2 SGH-50 Hydraulic pumping unit

SKF SGH-50 - Hydraulic pumping

unit for dual-line SKF DuoFlex
system
(Original operating and maintenance instructions according to EU Directive 2006/42/EC)

SGH501DEN 10.12.2014 Rev. 1D

Copyright © Sandvik 641 (1146)

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TABLE OF CONTENTS

1 EU Declaration by the manufacturer ...............................................................................................................1

2 General description .........................................................................................................................................2
3 Design .............................................................................................................................................................2
4 Operation ........................................................................................................................................................3
4.1 Start-up ............................................................................................................................................................................................ 3
4.2 Filling the pumping unit ................................................................................................................................................................. 4
5 Technical specifications ...................................................................................................................................5
5.1 Technical data .................................................................................................................................................................................. 5
5.2 Connections ...................................................................................................................................................................................... 5
5.3 Symbols ............................................................................................................................................................................................ 6
6 Spare parts and maintenance..........................................................................................................................6
6.1 Spare parts....................................................................................................................................................................................... 6
6.2 Maintenance .................................................................................................................................................................................... 8

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1 EU Declaration by the manufacturer

Original Declaration by the Manufacturer on equipment to be incorporated into machinery
(Directive 2006/42/EC, Annex II, part 1, section B)

Oy SKF Ab
Teollisuustie 6 (P.O. Box 80)
FIN-40951 MUURAME
FINLAND

Herewith declares that the product

SKF-SGH-50-XX-XX

x which cannot operate independently, is intended to be incorporated into machinery or to be assembled with other
machinery to constitute machinery covered by Machinery Directive 2006/42/EC, as amended.

x conforms to the essential requirements of Machinery Directive 2006/42/EC. The following harmonized standards
have been applied:
EN ISO 12100-1/A1
EN ISO 12100-2/A1.

We furthermore declare that it is not allowed to put the machinery into service until the machinery into which it is to
be incorporated or of which it is to be a component has been found and declared to be in conformity with the provi-
sions of Machinery Directive 2006/42/EC and with national implementing legislation, i.e. as a whole, including the ma-
chinery referred to in this declaration.
The manufacturer commits to transfer the technical documentation of the certified product in electronic form on re-
quest to the competent authorities of the Member States.
All required documents for the technical documentation of the certified product, in accordance with Machinery Di-
rective 2006/42/EC Appendix VII Part B, are completely established.
Person responsible for documentation:
R&D Coordinator and Product Manager, Centralized Lubrication Systems, Muurame Unit.

Muurame 17 February 2012

Place Date

Tuomo Helminen
General Manager

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Note! See also manual "Safety and general instructions for lubrication systems".

2 General description
The pumping unit is designed for pumping lubricant into the centralized lubrication system.

3 Design
Note! The numbers in brackets are the position numbers for Figure 1.

The SKF SGH-50 pumping unit consists of a low level switch (pos. 1), a directional valve (pos. 2), a pressure relief valve
for filling the tank (pos. 3), a pump assembly (pos. 4), a filter assembly for filling (pos. 5) and a filter element (pos. 6), a
low level switch (pos. 8), a tank (pos. 9) and the tank's deaerating screw (pos. 10). The pumping unit has two (2) lubri-
cant outputs (L) and two (2) hydraulic inputs (H).

Figure 1 SKF SGH-50 (160120)

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4 Operation
When pressurization starts, hydraulic pressure is directed into one of the hydraulic inputs (H). The pump performs a
working stroke and the pressure of the lubricant increases in the lubrication line. As the pressure increases, the dosers
of the dual-line lubrication system operate and about half of the lubrication points in the system are lubricated. When
the hydraulic pressure is directed into the opposite hydraulic input, the pump performs a working stroke in the oppo-
site direction. The previously non-pressurized line is pressurized, the dosers operate and the other half of the lubrica-
tion points in the system are lubricated.
If the lubricant level drops to the alarm limit during pumping, the low level switch closes. The low level switch (pos. 1
and pos. 8) opens when the tank is filled.

4.1 Start-up

Warning Ensure that the system or component is not under pressure during maintenance. If
the system is under pressure when the components are being disconnected or opened, the compo-
nents might fling or the lubricant might burst and cause damage to people or the environment.

Note! The numbers in brackets are the position numbers for Figure 1.

1 Ensure that the surroundings of the pumping unit are clean. Impurities in the system prevent trouble-free opera-
tion and cause damage when reaching the lubrication point.
2 Connect the lubricant lines to the lubricant connections (L) in the directional valve (pos. 2).
3 Connect the hydraulic lines to the hydraulic connections (H) in the pump assembly (pos. 4).

Warning The maximum permitted pumping unit hydraulic pressure is 35 bar. If hydraulic pres-
sure exceeds the permitted limit, the pump might be damaged. If the pressure is multiple to the per-
mitted limit, there will be a risk of injury.

4 Connect the plug of the low level switch (Pos. 1).

5 Connect the hydraulic pressure on top of the tank, if desired.

Warning The maximum permitted hydraulic pressure on top of the tank is 5 bar. If hydraulic
pressure exceeds the permitted limit, the pump might be damaged. If the pressure is multiple to the
permitted limit, there will be a risk of injury.

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4.2 Filling the pumping unit

Warning Ensure that the system is not under pressure during filling. The filter element for the
grease filter (pos. 5 and 6, Figure 1) must be cleaned or replaced during filling. Remove pressure from
the grease filter before opening it with the help of a venting screw located in the filter plug. If the sys-
tem is under pressure when the components are being disconnected or opened, the components might
fling or the lubricant might burst and cause damage to people or the environment.

Note! Impurities must not be allowed to enter the pumping unit during filling. Impurities can damage the lu-
brication system or lubrication points.

Note! The numbers in brackets are the position numbers for Figure 1.

1 Ensure that the surroundings of the pumping unit are clean. Impurities in the system prevent trouble-free opera-
tion and cause damage when reaching the lubrication point.
2 Ensure that the pumping unit is not under pressure.
3 Remove pressure with the help of the venting screw located in the grease filter (5) plug.
4 Clean the grease filter and filter element and replace them when necessary.
5 Attach the filling device to the grease filter's (pos. 5) filling connection.
6 Pump until lubricant is coming out of the tank’s pressure relief valve (pos. 3).
7 If it is suspected that there is air in the tank, remove the hexagonal plug (pos. 10) located on top of the container
and open the venting screw (located under the hexagonal plug) by rotating it three round to the open direction.
When the venting screw is opened the air releases from the reservoir. After air has released close the venting
screw (torque 0,3 – 0,4 Nm) and place hexagonal plug back.
8 Make a pumping unit operation test run.

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5 Technical specifications

5.1 Technical data

Quantity Value Unit Description

t +0…+70 °C Operation temperature

pmax 35 bar Maximum hydraulic pressure
pressure 8:1 An example: 10 bar hydraulic pressure pro-
ratio duces 80 bar of grease pressure. Maximum
grease pressure is 280 bar.
~50 cm3 per Pump capacity
stroke
V 5 kg Tank size
10
m 22 kg Weight, pump with a 5 kg tank
24 Weight, pump with a 10 kg tank
Aluminium, plastic and steel Pumping unit material
470 x 350 x 180 mm Dimensions, pump with a 5 kg tank
755 x 350 x 180 Dimensions, pump with a 10 kg tank

IP67 Protection classification

5.2 Connections
Electrical connections
x DEUTZH plug DT04-4P

Hydraulic connections
x Hydraulic pressure H, 2 pcs, female thread G1/4”

Lubricant connections
x Lubricant connection L, 2 pcs, female thread G1/4”

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5.3 Symbols
Table 1 SKF SGH-50 pumping unit symbols

SKF SGH-50-A-B Abbreviation Description

SKF-SGH-50: SGH-50 SKF SGH-50 pumping unit

A: no symbol Tank size: 5 kg
10 Tank size: 10 kg
B: 8:1 Pressure ratio

Table 2 SKF SGH-50 pumping units

Type Code Description

SGH-50-8:1 11390645 Tank size: 5 kg, pressure ratio 8:1

SGH-50-10-8:1 11390652 Tank size: 10 kg, pressure ratio 8:1

6 Spare parts and maintenance

6.1 Spare parts

Figure 2 Spare parts for SKF SGH-50 pumping unit (160122)

SGH501DEN 10.12.2014 Rev. 1D

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Table 3 Spare parts for SKF SGH-50 pumping unit See Figure 2

Item Description Order code Drawing

1 SGH-50 LOW LEVEL SWITCH FCM 11390718 462540

2 DIRECTIONAL VALVE 11390720 460930
3 PRESSURE RELIEF VALVE 11402250 460929
4 SGH-50 PUMP ASSEMBLY 11601000 361641
5 GREASE FILTER GF-400 10543525
6 FILTER ELEMENT GF-400 12606550 460282
7 SEAL KIT SGH-50 11390342
8 LOW LEVEL SWITCH SGH 50 11390710 460927
9 SUCTION VALVE 11401450 460928

Table 4 11390342 Seal kit SGH-50, seal descriptions See Figure 2, Item 7

Description Order code

O-RING 6.1X1,6 NBR70 12680100

O-RING 6.3X2,4 NBR70 12680400
O-RING 14.3X2,4 NBR70 12680600
O-RING 19.2X3 NBR70 11680650
O-RING 30.3X2,4 NBR90 11680600
O-RING 42.2X3 NBR90 11680800
O-RING 59.2X5.7 NBR70 11681250
O-RING 94.5X3 NBR70 11681000
O-RING 139.2X5.7 NBR70 11681400
SHAMBAN S-55044-0320-46 11681950
SHAMBAN S-55044-1000-10 11682050
U-RING 14-24-7.3 11682300
SEAL 12.4/17.8X1.5CU 12682080
O-RING 84.5X3 NBR90 11680915
SEAL FOR HYDRAULIC PISTON 11682060

SGH501DEN 10.12.2014 Rev. 1D

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6.2 Maintenance
Warning Ensure that the system is not under pressure during maintenance procedures. Re-
move pressure from the grease filter before opening it with the help of a venting screw located in the
filter plug. If the system is under pressure when the components are being disconnected or opened, the
components might fling or the lubricant might burst and cause damage to people or the environment.

Note! Impurities must not be allowed to enter the pumping unit during filling. Impurities can damage the lu-
brication system or lubrication points.

Note! The numbers in brackets are the position numbers for Figure 2.

1 Ensure that the surroundings of the pumping unit are clean. Impurities in the system prevent trouble-free opera-
tion and cause damage when reaching the lubrication point.
2 Ensure that there is no pressure in the pumping unit or in the hydraulics on top of the tank.
3 Remove pressure with the help of the venting screw located in the grease filter (5) plug.
4 Remove the grease filter (pos. A).
5 Remove the allen screws (pos. B) located at the bottom of the tank.
6 Lift the tank and its cover off.
7 Remove suction valves and fixing screws (pos. C).
8 Replace the pump assembly (pos. 4).
9 Remove the directional valve (pos. D).
10 Make sure to replace the required seals (pos. 7).
11 Reassemble the pumping unit in reverse order.

SGH501DEN 10.12.2014 Rev. 1D

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Service
SAFEMATIC OYand Repair Manual SAFEMOBE LH204
SGH - 50

17.3 OF
FUNCTION Function
SGH - 50 of lubrication system
SYSTEM

STEERING CENTRE

ALARM-SIGNAL LAMP

PUMP UNIT
- PUMP
- LUBRICANT BARREL
- FILTER

LINE 1
LINE 2

BODY PIPES

STEERING
VALVE PRESSURE SWITCHES

CREASE DOSING
MODULE BLOCK

LUBRICATING PIPES

The operation of SGH-50 system is steered by electrically functioning steering centre. The
pump unit of the system receives its driving power from hydraulics. At the beginning of a
lubricating cycle the electrical current coming from the steering centre opens the steering
valve 1, whereat the hydraulics pump performs a working stroke and the pressure of the
lubricant in line 1 increases. When the pressure still is rising, the dosing modules work and one
half of the lubrication points of the system get lubricated. The dosing modules feed with full
pressure generated by the pump an exact, predetermined amount of lubricant to every
lubrication point, notwithstanding different counter pressures. If the pressure does not rise
higher than the adjusting value of the pressure switch in the end of the main pipe, the steering
centre switses on alarm. After a predetermined time the steering valve 1 closes and the
pressure in line 1 sinks. After a brake adjusted from the steering centre, the steering valve
2 opens, the pump performs a working stroke and pressure in line 2 rises.

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SGH - 50

ADJUSTMENT OF SGH - 50 SYSTEM

The pressurizing time of the pump shall be adjusted 1O-5O per cent longer than is required
from the start of the pump to the moment that an impuls is given. Check that even the most
extreme lubrication points of the system get lubricated. (Usually a pressurizing time of 3
minutes is adequate).

The steering centre switches on the alarm circuit, if

- the main pipe is leaking

- the lubricant is exhausted in the barrel
- there is air in the pump
- the income of pressurized air has finished or diminished to be inadequate.

The lubrication interval is so adjusted that the bearings that need most often lubrication
absolutely get their adequate lubricant amount. For those bearings which need lubrication more
seldom will analogously be chosen so small dosis range that no harmful over-dosing can take
place. (The most common lubrication intervals are from 0,5 to 3 h).
The operating pressure of a hydraulic pump can variate from 9 to 23 bar, which corresponds to
a lubricant pressure of 88-220 bar in the main lines 1 and 2.

INTRODUCTION OF SGH - 50 SYSTEM

FILLING OF THE LUBRICANT BARREL

The lubricant barrel is filled through a filling nipple at the high-pressure filter housing. The barrel
is full when extra lubricant is leaking from the safety valve of the lubricant barrel.

When the lubricant barrel is full the follower plate is in its upper position. Now the possible air in
the lubricant barrel can be removed as follows: The hexagonal plug in the cover of the lubricant
barrel will be opened. The deaerating screw in the follower plate shall be opened for about three
turns and the filling of the barrel shall be continued as long as fully airless lubricant comes out of
the hole in the deaerating screw. After that the deaerating screw shall be closed. The hexagonal
plug shall be screwed down. During the following fillings the lubricant barrel needs not to be
deaerated, if it is certain that there is no air in the barrel and it has not got in there during the
filling.

DEAERATING OF THE PUMP SGH - 50

If there is air in the pump, the pressure of the lubricant in the main piping of the system may not
increase high enough.
The pump must be deaerated as follows: The steering centre is adjusted to shorter pressurizing
time and the pump is operated with the "Extra lubrication" switch.
Deaerating screws in the housing of the non-return valve are opened for about three turns. The
pump is allowed to work as long as fully airless lubricant comes out of the holes in the
deaerating screws during the pressurizing period of both lines. After that the deaerating screws
are screwed down and the adjustments of the steering centre are returned to normal.

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SGH - 50

MAIN PIPING

When filling, or afterwards deaerating the piping, following measures must be taken into
account. All closing plugs of the dosing modules and pipe branches must be removed. The
pump is operated as long as fully airless lubricant comes out of the closing plugs nearest to the
pump and the plugs involved are fastened. Above-mentioned measures are repeated until fully
airless lubricant comes out of the openings. If the lubricant runs out of the barrel during filling,
the filling shall be performed according to paragraph 6.1.

LUBRICATING PIPES

If the lubricating pipes are long or if the length differences are great, there is reason to fill the
pipes in advance by means of a hand press.

CLEANNESS

When the system is being installed, adjusted or maintained, absolute cleanness must be
obeyed. If in doubt impurities have gone into the main or lubricating piping, lubricant has to be
pumped through the piping until the impurities come out of the main piping. During this action
the closing plugs and the couplings have to be loosened. If there are plenty of impurities in the
pipings they must be rinsed.

CONTROL AND MAINTENANCE OF SGH - 50 SYSTEM

Impurities in lubricant may cause operational disturbances in dosing modules or damage

bearings. In order to prevent impurities from coming into the system, the SGH 50 pump unit is
provided with a high-pressure filter, which has to be cleaned every six months.

If the feed pipes from the dosing modules to the lubrication points are in unsheltered places,
where they can be easily damaged, it is due to check at certain intervals that the lubricating
pipes are undamaged and that the lubricant reaches the lubrication points.

After the system has been in function for some weeks it is worth to check every lubrication
point. If necessary, the lubrication dosis can be lessened or increased by turning the hexagonal
screw.

The adjustment can be performed during some weeks or months to find the exactly right
lubricant amount for every bearing.

LUBRICANT

Safematic SGH - 50 system can be used in inside as well as in outside temperatures and all
usual lubrication oils and greases can be used in it. If thicker grease than NLGI Class 2 is
preferred, please contact oy Safematic Ltd to ensure that the lubricant is suitable for the
system.

Due to the Safematic dosing modules being fully forced operating, i.e. the dosing pistons move
to and fro with the full pressure generated by the pump, the system can be operated also in cold
weather, subject to the concerned lubricant being pump able in the concerned temperature.
Please contact Safematic Oy to ensure the suitability of the grease.

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Service and
SAFEMATIC OYRepair Manual SAFEMOBE LH204
SGH - 50

LOCATION OF FUNCTION DISTURBANCE IN SGH - 50 SYSTEM

Cause of the function

Function disturbance Way of repairing
disturbance

The alarm-signal light burning The level switch in the lubricant barrel Fill the lubricant barrel
gives alarm.

The main pipe between the pump and Locate and repair the leakege.
the dosing modules leaks.

Air in the pump. Deaerate the pump.

Air in main piping. Deaerate the main piping

Hydraulic pressure is insufficient Regulate the pressure at least at 10 -

12 bar. Notice: Sometimes occasional
changes in pressure may give cause to
the lihgting of the alarm signal lamp
even if no visible cause for the alarm
could be observed later.

One bearing gets too little lubricant or The dose is too little. Regulate the dose larger.
nothing at all.

The lubrication pipe between the Check and repair.

dosing module and the lubrication
point is damaged.

A mote in the dosing module prevents Change or clean the dosing module.
the feeding piston from moving.

The normal working pressure is Increase the working pressure

insufficient because of non-return temporarily or clean the lubrication
pressure caused by blockage in a point.
bearing.

Grease has stiffened (e.g. with cold) in Change the grease for a thinner and
the piping and the dosing module does more cold-resistant one. In grease the
not receive enough pressure. working pressure temporarily. If this
does not have any effect, warm the
piping.

A bearing gets too much lubricant The dosing module is damaged. Change the dosing module.
although the dosage adjustment is
small.

In case the location or repair of function disturbance leads to difficulties, please contact us
immediately

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SAFEGREASE 2
Service and Repair Manual DOSER GROUPS LH204

17.4 Doser groups

DOSER GROUPS

TABLE OF CONTENTS

1 GENERAL DESCRIPTION ............................................................................................................................. 1

2 DESIGN .......................................................................................................................................................... 1

3 OPERATION ................................................................................................................................................... 1

3.1Dosers with two outlets ............................................................................................................................ 1

3.2Dosers with one outlet ............................................................................................................................. 1

3.3The unfastening and fastening of the doser............................................................................................. 2

4 ADJUSTMENT................................................................................................................................................ 2

4.1General .................................................................................................................................................... 2

4.2Doser adjustments ................................................................................................................................... 2

5 TECHNICAL SPECIFICATION ....................................................................................................................... 3

5.1Technical specifications ........................................................................................................................... 3

5.2Connections ............................................................................................................................................. 4

5.3Size of lubrication dosage........................................................................................................................ 4

5.4Symbols ................................................................................................................................................... 5

6 SPARE PARTS..................................................................................................................................................7

6.1 Seal kits.....................................................................................................................................................7

6.2 Repair kits ................................................................................................................................................7

6.3 Other spare parts .....................................................................................................................................7

20 APPENDICES

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DOSER GROUPS

1 GENERAL DESCRIPTION

Note Numbers in brackets are part numbers in the drawing 461503.

A doser group consists of a base plate (pos. 1) and one or several dosers installed onto the base
plate (pos. 2). The base plate divides the lubricant to the dosers, which feed the preset amount of
lubricant to the lubrication points.

2 DESIGN

The doser includes a dosage cylinder (pos. 4) which is equipped with double sealed
piston (pos. 3) and a pilot valve for each doser (pos. 5). The movement of the piston valve is
adjusted with the adjusting screw (pos. 6). Indicator (pos. 7) shows the doser operation.

Since the lubrication outlet connections are equipped with check valves (pos. 8), the design of
the dosers makes it possible to feed small amounts of lubricant from the dosers.

3 OPERATION

3.1 Dosers with two outlets

During normal sequential operation, dosers with two outlets feed lubricant to opposite sides of
the outlet connections.

The pressure in the line increases during pressurization and the doser pilot valve moves to its
extreme position, whereupon the lubricant moves the piston. When the piston moves, it pushes
the lubricant through the base plate check valve to the lubrication pipe or lubrication hose and
further to the lubrication point.

When the pumping starts again, the directional valve directs the lubricant to another main line
whereupon the doser pilot valve directs the lubricant to the opposite side of the piston. When the
piston moves, it pushes the lubricant through the base plate check valve and further to the
lubrication point.

3.2 Dosers with one outlet

During normal sequential operation, dosers with one outlet always feed lubricant to the same
outlet connection.
The design of the doser with one outlet is different from the design of the doser with two outlets
only by the design of the pilot valve, which makes it possible to choose the outlet connection
from the base plate. The unnecessary outlet on the base plate must be plugged. The operation of
the doser with one outlet is similar to the operation of doser with two outlets.

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3.3 The unfastening and fastening of the doser

Warning When changing the dosers, make sure that there is no pressure in the system.

Caution If the doser screws are tightened too tightly, the operation of the doser
might be prevented. The maximum tightening torque is 8 Nm.

Caution When changing the doser, make sure that the type marking on the doser
and the number of outlets are identical. The last number on the doser type
shows / equals the number of outlets.

4 ADJUSTMENT

4.1 General

The lubricant dosage is adjusted by changing the movement of the piston with the adjusting
screw.

4.2 Doser adjustments

Move the adjustment screw with an allen key to perform the adjustment of the SGA-dosers.

SG-dosers are adjusted with an allen screw, which is located inside of a metal cover. The other
end of the allen screw is located in the dosage cylinder, so the adjustment affects direct to the
piston.

During both pressurizations of the lubrication cycle the doser with one outlet always feeds the
lubricant to the same lubrication point. The doser with two outlets alternately feeds the lubricant
to two different lubrication points. This has been taken into account in the adjustment graphs.

Table 1. The drawing numbers of the adjustment graphs.

Doser type (ZN, SS) Drawing number (g) Drawing number (oz.)
SGA-011, SGA-012 460120A 460221B
SGA-11, SGA-12 460122A 460146A
SGA-21, SGA-22 460123C 460142C
SG-31, SG-32 460124B 460143A
SG-41, SG-42 460126A 460145A
SG-51, SG-52 460128B 460144A

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Service and Repair Manual LH204

SGA-doser adjustment

1. Remove the plastic cover.

2. Make sure that the indicator is inside of the doser body.

Caution SGA-doser will be damaged, if the adjustment screw is adjusted against the
indicator.

3. Turn the adjustment screw to its basic position, where the adjustment screw lightly touches
the indicator.
4. Look at the adjustment graph for the number of adjustment screw turns that correspond to
the desired lubrication dosage.
5. Turn the adjustment screw outward as many turns as instructed from the doser body. The
marking slots of the indicator make the adjustment easier.
6. Replace the cover.

SG-doser adjustment

1. Remove the metal cover of the allen screw.

2. Turn the allen screw to its basic position, level with the threading on the body.
3. Look at the adjustment graph for the number of allen screw turns that correspond to the lu
brication dosage.
4. Turn the allen screw outward as many times as instructed from the doser body. If the
number of the turns is negative, turn the allen screw inside the doser. The marking slots of
the metal cover make the adjustment easier.
5. Replace the cover.

5 TECHNICAL SPECIFICATION

5.1 Technical specifications

Table 2. Technical specifications of a doser group

Value Range Unit Description
t -25…+120 °C Operation temperature range
-13…+248 °F
pmax 250 bar Max. pressure, 01-dosers
300 Max. pressure, other dosers
M 4-8 Nm Tightening torque range of the dosers

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Service and Repair Manual LH204

5.2 Connections

Input and output connections are in the base plate.

Input
• lubricant (2 pcs), main line inputs, female thread R 1/4" or NPT 1/4"

Output
• lubricant (2 pcs), main line outputs, female thread R 1/4" or NPT 1/4
• lubricant (2-12 pcs), lubrication piping outputs, female thread R 1/8" or NPT 1/8"

5.3 Size of lubrication dosage

The minimum and maximum size of the lubrication dosages during one lubrication cycle of
different type of dosers is shown in the table. The margin of error is ± 5 %.

In the test the thickness of the grease used 0.88 g/cm3.

Table 3. The minimum and maximum dosage size during one lubrication cycle.
Doser Minimum dosage Maximum dosage
SGA-011 0.30 g 1.45 g
SGA-012 0.15 g 0.70 g
SGA-11 0.50 g 2.55 g
SGA-12 0.25 g 1.25 g
SGA-21 1.50 g 8.75 g
SGA-22 0.70 g 4.35 g
SG-31 8.5 g 56.0 g
SG-32 4.3 g 28.0 g
SG-41 19.3 g 92.0 g
SG-42 9.65 g 46.0 g
SG-51 86.3 g 177.0 g
SG-52 43.1 g 88.4 g

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Service and Repair Manual LH204

5.4 Symbols

Table 4. The symbols of dosers

SGA-xxy-zz-B Abbreviation Description

SG: SG The type of lubrication system, SafeGrease
A: A Small doser (sizes 01, 1 and 2)
No symbol Big doser (sizes 3, 4 and 5)
xx: 01 Doser size 01
1 Doser size 1
2 Doser size 2
3 Doser size 3
4 Doser size 4
5 Doser size 5
y: 1 One outlet
2 Two outlets
zz: ZN Doser material,
zinc-coated and yellow-passivated steel
SS Doser material,
stainless steel AISI-316
B: No symbol Normal doser
B Special doser designed for silicone greases

Example:

SGA-012-SS

Doser material, stainless steel AISI-316

Number of outlets, 2 outlets

Doser size, size 01

Small doser

Type of lubrication system, SafeGrease

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Service and Repair Manual LH204

GROOVE 0
GROOVE 1
GROOVE 2
GROOVE 3
GROOVE 4
REQUIRED HEX KEY
4

CODE TYPE DESCRIPTION DOSAGE RANGE

12387460 SGA-011-ZN ONE LUBE POINT DOSER ZN 0.30-145 G/CYCLE 12387510
12387510 SGA-012-ZN TWO LUBE POINT DOSER ZN 0.15-0.70 G/CYCLE 12386560
12386560 SGA-011-SS ONE LUBE POINT DOSER SS 316 0.30-1.45 G/CYCLE 12386610
12386610 SGA-012-SS TWO LUBE POINT DOSER SS 316 0.15-0.70 G/CYCLE

12388800 SGA-01-KIT1 SAFE-R SEAL KIT

12388840 SGA-01-ZN-KIY2 REPAIR KIT ROR ZN DOSERS
12388850 SGA-01-SS-KIY2 REPAIR KIT ROR SS 316 DOSERS

DOSERS INCLUDE ALL NECESSARY RASTENING SCREWS AND PLUGS

ADJUSTMENT GRAPH FOR SGA-011 DOSER ADJUSTMENT GRAPH FOR SGA-011 DOSER
WITH THE ADJ. SCREW IN THE COMPLETELY IN POSITION

WITH THE ADJ. SCREW IN THE COMPLETELY IN POSITION

TURNS COUNTERCLOCKWISE

DOSAGE: G/LUBRICATION CYCLE ± 5% DOSAGE: G/LUBRICATION CYCLE ± 5%

GREASE DENSITY 0.88g/cm3

DESCRIPTION MATERIAL DIM,PATT CODE/QTY/PART

DETAIL DRAW
ITEM (WEIGHT KG) QTY
MATERIAL DESCRIPTION

SPECIFICATION OF PART

DRAWN
DESIGNED LeL SGA-011-ZN,SGA-012-ZN PREVIOUS DRG FUTURE DRG

SGA-011-SS,SGA-012-SS DATE PROJECT

DOSER 3.2.1998
SCALE DRAWING NUMBER

MUURAME - FINLAND 460120A

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Service and Repair Manual LH204
ANSUL ® INSTALLATION, A-101-10/20/30
17.5 ANSUL fire suppression
RECHARGE,system Installation, Recharge,
LT-A-101-10/20/30
Inspection and Maintenance manual (option)
INSPECTION, AND VEHICLE FIRE
MAINTENANCE SUPPRESSION
MANUAL SYSTEMS

Copyright © Sandvik 667 (1146)

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Service and Repair Manual LH204

This manual is intended for use with the Ansul A-101 Vehicle
Fire Suppression Systems.
Those who install, operate, recharge, inspect, or maintain
these fire suppression systems should read this entire
manual. Specific sections will be of par ticular interest
depending upon one's responsibilities.
As with all mechanical equipment, the A-101/LT-A-101
systems need periodic care to provide maximum assurance
that they will operate effectively and safely. Inspection
frequency should be based on 250 vehicle operating hours
or monthly, whichever comes first. Maintenance should be
conducted at 1000 vehicle operating hours or every six
months, whichever comes first. Maintenance should be
conducted in accordance with this manual and NFPA 17
(“National Fire Protection Association's Standard for Dry
Chemical Extinguisher Systems”) by a qualified, trained
service person.
Additional service and maintenance information can be
obtained in other applicable NFPA Standards.
This Ansul systems manual is limited to uses herein
described. For other applications, contact your local Ansul
distributor or Ansul Incor porated, Pre-Engineered Systems
Application Department, Marinette, Wisconsin 54143-2542.

ANSUL and CHECKFIRE are trademarks of Ansul Incorporated or its affiliates.

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REVISION RECORD
5-15-02
REV. 1

DATE PAGE REV. NO. DATE PAGE REV. NO.

10-25-00 11-3 1 5-15-02 5-3 1

5-15-02 1-1 1 5-15-02 5-4 1

5-15-02 1-2 2 5-15-02 6-1 1

5-15-02 2-1 2 5-15-02 6-2 1

5-15-02 3-2 1 5-15-02 6-3 2

5-15-02 3-3 1 5-15-02 6-4 2

5-15-02 3-4 1 5-15-02 6-5 2

5-15-02 3-5 1 5-15-02 6-6 2

5-15-02 3-6 2 5-15-02 6-7 New Page

5-15-02 4-1 1 5-15-02 6-8 New Page

5-15-02 4-2 1 5-15-02 7-1 2

5-15-02 4-3 1 5-15-02 8-1 2

5-15-02 4-4 1 5-15-02 8-2 1

5-15-02 4-5 1 5-15-02 9-1 2

5-15-02 4-6 1 5-15-02 10-1 1

5-15-02 4-7 1 5-15-02 10-2 1

5-15-02 4-8 1 5-15-02 10-3 1

5-15-02 4-9 1 5-15-02 10-4 1

5-15-02 4-10 1 5-15-02 10-5 1

5-15-02 4-11 1 5-15-02 10-6 1

5-15-02 4-12 2 5-15-02 11-1 1

5-15-02 4-13 1 5-15-02 11-2 2

5-15-02 4-14 1 5-15-02 11-4 2

5-15-02 4-15 New Page 5-15-02 11-5 1

5-15-02 4-16 New Page 5-15-02 11-6 1

5-15-02 5-1 1 5-15-02 11-7 1

5-15-02 5-2 1 5-15-02 11-8 1

Indicates revised information.

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REVISION RECORD
5-15-02

DATE PAGE REV. NO. DATE PAGE REV. NO.

5-15-02 11-9 New Page

5-15-02 11-10 New Page

Indicates revised information.

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TABLE OF CONTENTS
Service and Repair Manual LH2045-15-02
REV. 2
SECTION PAGES SECTION PAGES
I. GENERAL INFORMATION 1-1 VI. INSTALLATION INSTRUCTIONS 6-1
INTRODUCTION 1-1 MOUNTING THE BRACKETS 6-1
TWIN AGENT SYSTEM (NOT FM APPROVED) 1-1 Nozzle Bracket 6-1
FM APPROVAL 1-1 Tank Bracket 6-1
HOW THE SYSTEM OPERATES 1-2 Cartridge Bracket 6-2
IN CASE OF FIRE 1-2 Remote Actuator Bracket 6-2
MOUNTING THE DISTRIBUTION, REDUCING,
II. SYSTEM DESCRIPTION 2-1
AND TRIPLE TEES 6-2
APPLICATION METHOD 2-1
INSTALLING THE COMPONENTS 6-3
Local Application – Vehicle 2-1
Installing the Tank 6-3
Total Flooding 2-1
Installing the Nozzles 6-3
PIPING ARRANGEMENT 2-1
Installing Manual Actuators 6-3
Two Nozzle System 2-1
INSTALLING THE DISTRIBUTION NETWORK 6-5
Four Nozzle System 2-1
General Requirements 6-5
Six Nozzle System 2-1
Distribution Hose Installation 6-5
DETECTION 2-1
INSTALLING ACTUATION AND EXPELLANT
III. SYSTEM COMPONENTS 3-1 GAS LINES 6-6
TANK ASSEMBLY 3-1 General Requirements 6-6
TANK BRACKET 3-1 Installing The Actuation Gas line(s)
DRY CHEMICAL 3-2 and Pneumatic Actuator(s) 6-6
CARTRIDGE – EXPELLANT GAS 3-2 Installing Expellant Gas Line(s) 6-7
CARTRIDGE – ACTUATION GAS 3-2 INSTALLING THE DETECTION SYSTEM 6-7
CARTRIDGE BRACKET 3-2 INSTALLING ACTUATION CARTRIDGES 6-7
PNEUMATIC ACTUATOR 3-3
VII.INSPECTION 7-1
MANUAL ACTUATORS 3-3
1/4 IN. CHECK VALVE 3-3 VIII.MAINTENANCE 8-1
DISTRIBUTION TEE 3-3 SEMI-ANNUAL/1000 HOUR MAINTENANCE 8-1
REDUCING TEE 3-4 12-YEAR MAINTENANCE EXAMINATION 8-2
TRIPLE TEE 3-4
IX. RECHARGE 9-1
SAFETY RELIEF VALVE 3-4
AIR CYLINDER (OPTIONAL) 3-4 X. SYSTEM APPLICATION OPTIONS 10-1
PRESSURE SWITCH – WEATHERPROOF 3-4
PRESSURE SWITCH – XI. APPENDIX 11-1
NON-WEATHERPROOF 3-5 LARGE EXCAVATORS 11-4
NOZZLES 3-5 EXCAVATOR PROTECTION 11-9
NOZZLE BRACKETS 3-6 FUME HOOD PROTECTION
HOSE (SUPPLIED BY OTHERS) 3-6 (Not FM Approved) 11-10
SEALED BURST DISC ASSEMBLY 3-6
ENGINE SHUTDOWN DEVICE 3-6
CHECKFIRE ELECTRIC DETECTION
AND ACTUATION SYSTEM 3-6
IV. SYSTEM DESIGN – VEHICLE 4-1
HAZARD ANALYSIS 4-1
NOZZLE COVERAGE AND LOCATION 4-1
TANK QUANTITY REQUIREMENTS 4-2
System Selection Chart 4-2
DISTRIBUTION SYSTEM REQUIREMENTS 4-2
ACTUATION AND EXPELLANT GAS LINE
REQUIREMENTS 4-14
Actuation Gas Line 4-14
Expellant Gas Line 4-14
DETECTION SYSTEM REQUIREMENTS 4-14
SHUTDOWN REQUIREMENTS 4-15
ACCESSORIES 4-16
V. SYSTEM DESIGN – INDUSTRIAL 5-1
HAZARD ANALYSIS 5-1
DISTRIBUTION SYSTEM REQUIREMENTS 5-1
NOZZLE COVERAGE 5-1

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Service and Repair Manual LH204

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SECTION I – GENERAL INFORMATION
Service and Repair Manual LH204
5-15-02 Page 1-1
REV. 1

GENERAL INFORMATION TWIN AGENT SYSTEM (NOT FM APPROVED)

INTRODUCTION The system consists of both dry chemical and liquid agent.
The dry chemical portion of the system is the Ansul
The Ansul A-101/LT-A-101 fire suppression system is a pre- A-101/LT-A-101, 125, or 250 system (either standard
engineered, fixed nozzle system for protection of discharge or extended discharge) and the liquid agent
off-highway vehicles, commercial vehicles, or industrial type portion of the system consists of an agent storage tank
applications. Typical applications include surface mining containing a premixed solution of LVS wet chemical.
equipment, underground mining machines, forest
harvesting equipment, construction equipment, farming The LVS-30 (30 gallon) system is designed to discharge for
machinery, and transportation vehicles such as municipal approximately 2 minutes when two agent discharge nozzles
busses. are used.
The A-101/LT-A-101 system consists of three major The LVS Fire Suppression System is designed to operate
components: a container to store the dry chemical within a temperature range of –40 °F to +120 °F (–40 °C to
extinguisher agent; an actuation system operated manually 49 °C).
or automatically, and an agent distribution system which The dry chemical system used in conjunction with the LVS
delivers the agent from the tank through hydraulic hose and system is the Ansul A-101/LT-A-101, 125 or 250. The dry
fixed nozzles to the hazard areas. chemical system is connected to the Ansul CHECKFIRE
The fire system described is a suppression system only and Detection and Control System. the dry chemical system can
is not designed or intended to extinguish all fires, be designed as a standard discharge or as an extended
particularly when unusual amounts of combustible materials discharge system per the requirements of the A-101/LT-A-
and an ample oxygen supply are present. It is extremely 101 vehicle Fire suppression Installation, Recharge,
important that supplement fire fighting equipment be Inspection, and Maintenance Manual. Upon actuation of the
available in case the system does not totally extinguish a dry chemical system, the pneumatic time delay for the LVS
fire. system will start. During the end of the dry chemical
discharge, the time delay will allow pressure to enter the
If an automatic fire detection and actuation system has not LVS actuation line. This pressure will then actuate the
been supplied or has been disconnected, system actuation nitrogen cartridge on the LVS tank(s), causing the LVS
and discharge will not occur unless the fire suppression system to discharge the wet chemical solution.
system is manually actuated. (Use of manual system only
must be approved by authority having jurisdiction.) Reliance For detailed instructions, refer to manual Part No. 427865
on a manual release system usually results in a slower regarding the LT-A-101-125/250 system. For detailed
reaction to fire. Means to shut down the vehicle must be instructions, refer to manual Part No. 427109 regarding the
added to a manual or disconnected automatic system. LVS system.
The basic agent storage container is a tank filled with Ansul FM APPROVAL
FORAY (monoammonium phosphate base) dry chemical
which is effective on Class A, B, and C fires. A gas expellant The Ansul A-101/LT-A-101 fire suppression system has
cartridge, either carbon dioxide or nitrogen, provides been tested and is FM approved. These tests require
pressurization of the dry chemical upon actuation. extinguishment of fire initiated in open vessels and within
Automatic detection, either electric or pneumatic, and enclosures fueled with flammable liquid. In each case,
actuation, is recommended. The A-101/LT-A-101 system is these fires are allowed to progress to maximum intensity
actuated manually by a pneumatic actuator located on the before the system is actuated. The time of actuation in
dashboard or on the exterior of the vehicle. these tests is well beyond the time that a detector would
take to detect the fire and actuate the system. Other tests
The dry chemical extinguishing agent is delivered from the required by FMRC are as follows:
tank through hydraulic hose and pre-set nozzles into the fire
hazard areas or onto the fire prone surfaces. 1. Fuel in depth splash tests under a minimum hose
length, maximum temperature, and minimum clearance
Along with the fire suppression system, the total system condition to ensure that the nozzle does not cause
design must include a hand portable fire extinguisher(s) splashing of fuel.
located on board the vehicle that can be used to manually
suppress a fire that may be burning in an unprotected area. 2. Operational flow rate tests at the minimum, average, and
Refer to NFPA 10, “Standard For Portable Fire the maximum temperatures, with maximum and
Extinguisher,” for additional information. minimum hose lengths.
3. Cycle tests on all mechanical and electrical devices to
determine their structural integrity.
The A-101 systems which utilize carbon dioxide as the
expellant gas are approved for temperature ranges
of +32 °F to +120 °F (0 °C to 49 °C).
The LT-A-101 systems which utilize nitrogen as the
expellant gas are approved for temperature ranges
of –65 °F to +210 °F (–54 °C to 99 °C).

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SECTION I – GENERAL INFORMATION
Service
5-15-02 Pageand
1-2 Repair Manual LH204
REV. 2

FROM
FROMAUTOMATIC
AUTOMATIC
DETECTION
DETECTIONSYSTEM
SYSTEM

2
TOTO
OPTIONAL
1
OPTIONAL
PRESSURE
PRESSURESWITCH
SWITCH
3

7
FIGURE 1
002581
FIGURE 1
HOW THE SYSTEM OPERATES IN CASE OF FIRE
Discharge of the A-101/LT-A-101 system manually is initiated When a fire starts, the way the operator reacts is very
from a remote actuator (1). Depressing the actuator plunger important. As soon as the operator is aware of a fire, he
punctures the seal on the cartridge. The released pressure is should do the following four things:
transmitted to the pneumatic actuator/cartridge receiver (2). A 1. Turn the machine off and set the brake.
safety relief valve (3) at this point prevents too high an
actuation pressure build-up. The pressure drives a puncture 2. Quickly actuate the system by pulling the safety ring pin on
pin through the seal in the expellant gas cartridge (4). This the manual actuator and strike the red button.
releases the expellant gas which is then transmitted to the dry 3. Evacuate the vehicle.
chemical tank (5) where it fluidizes the dry chemical before 4. Stand by with a fire extinguisher.
carrying it to the fire hazard. A sealed burst disc assembly (6)
prevents the flow of dry chemical until sufficient pressure is
built up within the dry chemical tank. When the proper ! CAUTION
pressure is reached, the disc breaks allowing the gas/dry
chemical mixture to flow to the nozzle(s) (7) and discharge The fire system described in this manual is a suppression
onto the hazard. system only and is not designed or intended to extinguish
all fires, particularly when unusual amounts of combustible
Refer to appropriate CHECKFIRE design, installation and
materials and an ample oxygen supply are present. It is
maintenance manual for information on the operation of the
extremely impor tant that supplemental firefighting
automatic detection system.
equipment be available in case the system does not totally
NOTE: Mechanical or electrical means must be provided to extinguish a fire.
shut down vehicle upon system actuation.

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SECTION II – SYSTEM DESCRIPTION
Service and Repair Manual LH204
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REV. 1

SYSTEM DESCRIPTION Six Nozzle System

APPLICATION METHOD The six nozzle system can be used in vehicle or industrial
hazard protection. It can only be used in local application
The A-101/LT-A-101 system provides fire protection using systems on offroad vehicles, when minimal discharge time
total flooding and local application methods. These and agent discharge per nozzle is acceptable. The supply
methods are described below. line is divided into six branch lines by the use of a
Local Application – Vehicle distribution tee and three 1/2 in. tees. Six nozzle systems
can only be used with nominal 20, and 30 lb. tanks.
When designing a local application system for vehicle
protection, each individual hazard area must be surveyed DETECTION
and the correct type nozzle must be chosen to give the Automatic electric detection is available for the
proper coverage. It must also be determined if cer tain local A-101/LT-A-101 system.
application hazard areas require screening to adequately
protect them. Electric detection systems (CHECKFIRE MP-N*, Series I,
and SC-N) are available to provide rugged, automatic
Total Flooding detection for vehicle protection. These systems are either
Total flooding is described as “volume protection” and it is powered by the vehicle battery or by the internal module
applied only when a hazard is located in an enclosure. battery.
Openings such as doors, windows, and grating shall not be The electric detection systems can use either linear heat
more than 15% of the enclosure's total surface area (ceiling, detection or spot thermal detectors, or pneumatic linear
floors, and all walls). detectors.
Openings of 5% or less of the total surface area are * Not FM Approved
acceptable and do not require screening. Hazards with
openings greater than 5% but not over 15% can be
protected by screening.
Total flooding application is accomplished by introducing a
sufficient quantity of FORAY dry chemical through fixed
nozzles throughout the volume of the enclosure.
To enhance the effectiveness of the total flooding system in
industrial applications, all fan air movements should be shut
down and/or dampered at discharge of the dry chemical
system. Refer to NFPA 17, “Standard For Dry Chemical
Extinguishing Systems,” for additional information.

PIPING ARRANGEMENT
The A-101/LT-A-101 system utilizes three methods of
splitting the dry chemical flow from the tank to the nozzles.
Each method is approved for use on vehicle or industrial
type applications.
Two Nozzle System
The two nozzle system can be used in either vehicle or
industrial hazard protection. It can be used in total flooding,
or as a local application system on off-road vehicles. The
supply line is split into two branch lines by the use of a 3/4 x
1/2 x 1/2 in. reducing tee. Two nozzles systems can be
used with nominal 10, 20, and 30 lb. tank sizes.
Four Nozzle System
The four nozzle system can be used in either vehicle or
industrial hazard protection. It can be used in total flooding,
or as a local application system on off-road vehicles. The
supply line is divided into four branch lines by the use of a
triple tee or a split tee. Four nozzle systems can only be
used with nominal 20, and 30 lb. tanks. Four nozzle 30 lb.
systems are preferred for all systems protecting hazards in
environments which are extremely rugged, and very prone
to Class A and Class B fuel build up in hard to protect
areas, providing more agent per nozzle and longer dis
charge times.

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SECTION II – SYSTEM DESCRIPTION
Service
5-15-96 Pageand
2-2 Repair Manual LH204

NOTES:

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SECTION III – SYSTEM COMPONENTS
Service and Repair Manual LH204
5-15-02 Page 3-1
REV. 1

SYSTEM COMPONENTS TANK BRACKET

TANK ASSEMBLY The tank mounting bracket assemblies consist of heavy gauge
The tank assemblies, nominal 10, 20, and 30 lb. size, are steel back plates and clamp arms. Each style bracket is
factory filled with 8.5, 17, and 25 lb. respectively of FORAY dry constructed to properly retain the agent tank from movement or
chemical. Each tank is finished in red enamel paint. A damage in the rugged environment that these systems are
nameplate is affixed to the exterior and contains information on normal used. Each tank bracket contains rubber pads to
recharge and maintenance. Two style of tanks are available: a minimize the shock and vibration effect on the tank. The
tank containing a cartridge receiver and pneumatic actuator brackets are finished with red, air dry enamel paint. See
and a tank with 1/4 in. adapter for a pressure line from a remote Figure 2.
cartridge. See Figure 1.
A-101 MODEL 10 / LT-A-101 MODEL 10
A-101
A-101MODEL
MODEL10 10 LT-101 MODEL
LT-A-101 MODEL1010 PART NO. 24854
PART
PARTNO.
NO.24855
24855 PART
PART NO. 24966
NO. 24966 12 IN. (30.5 cm) MIN.
OPENING WIDTH

7 IN. 6 3/4 IN.

(17.8 cm) (17.1 cm)

10 1/4 IN. 10 1/4 IN.

(26 cm) (26 cm)
16 1/8 IN. 16 1/8 IN.
(41 cm) (41 cm)

000459 000459

A-101 MODEL 20 LT-A-101 MODEL 20

A-101 MODEL 20 LT-101 MODEL 20 PART NO. 24971 PART NO. 24895
A-101 MODEL 20 LT-A-101
PART MODEL 20
NO. 24894
PART NO. 24970
PART NO. 24970 PART NO. 24894 12 IN. (30.5 cm) MIN.
OPENING WIDTH

7 5/8 IN.
8 1/4 IN. (19.4 cm)
(21 cm)

8 5/8 IN.
11 IN. (21.9 cm) 19 15/16 IN.
(27.9 cm) (50.6 cm)
19 1/2 IN.
(49.5 cm)

10 1/8 IN.
000459 (25.7 cm) 003461

A-101 MODEL 30 LT-A-101 MODEL 30

A-101 MODEL 30 LT-101 MODEL 3030 PART NO. 14098 PART NO. 30494
A-101 MODEL 30 LT-A-101 MODEL
PART NO. 53000 PART NO.
NO. 29375
29375
PART NO. 53000 PART 14 IN. (35.6 cm) MIN.
OPENING WIDTH
9 IN.
9 3/4 IN. (22.9 cm)
(24.8 cm)

9 7/8 IN.
11 7/8 IN. (25 cm) 22 1/2 IN.
(30.1 cm) (57 cm)
22 1/2 IN.
(57 cm)

10 1/4 IN.
000459 003461
(26 cm)

LP-A-101 MODEL 20B / LT-LP-A-101 MODEL 20

LT-A-101 MODEL 20-B PART NO. 31171
LP-101 MODEL
LP-A-101 MODEL20-B
20-B LT-LP-A-101
PART MODEL 20-B
NO. 24425
PART
PART NO.
NO. 24427 PART NO. 24425
9 IN. 9 IN.
(22.9 cm) (22.9 cm)

9 7/8 IN. 16 IN. 9 7/8 IN. 16 IN.

(25 cm) (40.6 cm) (25 cm) (40.6 cm)

003463 10 1/4 IN.

(26 cm)
003463 FIGURE 2
FIGURE 1
FIGURE 1
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SECTION III – SYSTEM COMPONENTS
Service
5-15-02 Pageand3-2 Repair Manual LH204
REV. 1

DRY CHEMICAL CARTRIDGE – ACTUATION GAS

FORAY is a monoammonium phosphate based dry chemical The actuation gas cartridge used on the A-101/LT-A-101
which is effective on Class A, B, C related fires. FORAY agent system contains nitrogen as the actuation gas. The cartridge
is color coded yellow for easy identification. FORAY dry is a sealed pressure vessel containing gas under pressure.
chemical is shipped in 45 lb. pails, Part No. 53080. See When the cartridge seal is punctured by the pin in the remote
Figure 3. manual or pneumatic actuator, the gas flows to the actuator
on the expellant gas cartridge, causing that actuator to
puncture the seal in the expellant gas cartridge. The actuation
gas cartridges meet the requirements of DOT 3E-1800. See
Figure 5.

FIGURE33
FIGURE
000417
000417

CARTRIDGE – EXPELLANT GAS

The expellant gas cartridges used on the A-101/LT-A-101
system contain either carbon dioxide or nitrogen as their
expellant gas. The cartridge is a sealed pressure vessel RIGHT-HAND LEFT-HAND
containing gas under pressure. When the cartridge seal is A B THREAD THREAD
LT-10 2 IN. 6 13/16 IN PART NO. 13193 (DOT) PART NO. 13177 (DOT)
punctured by the pneumatic actuator pin, the gas flows into (5.1 cm) (17.3 cm) PART NO. 423423 (TC/DOT) PART NO. 423425 (TC/DOT)
the dry chemical tank, fluidizes the dry chemical, and carries
it through the distribution piping network and out the nozzles. FIGURE 5
000439

The expellant gas car tridges meet the requirements of DOT

CARTRIDGE BRACKET
3A-2100 or 3AA-1800. See Figure 4.
Several cartridge Part No.'s have been added to comply with The cartridge brackets for the expellant gas cartridges are
the requirements of Transport Canada (TC). These cartridges constructed of heavy gauge steel and formed to protect and
have been approved for both DOT and TC. secure the cartridge. The cartridge brackets are painted with
red, air dry enamel paint. See Figure 6.
CARBON DIOXIDE CARTRIDGES
LT-A-101-20 / LT-LP-A-101-20-B LT-A-101-30
PART NO. 24325 PART NO. 29193

FOR A-101-10 SYSTEM FOR A-101-20 AND

USE PART NO. 15850 (DOT) LP-A-101-20
PART NO. 423439 (TC/DOT) SYSTEMS USE PART
NO. 423441 (TC/DOT)
FOR A-101-30 SYSTEMS USE
PART NO. 423443 (TC/DOT)
NITROGEN CARTRIDGES

LT-A-101-20-B
PART NO. 31177

FOR LT-A-101-10
FIGURE 6
SYSTEMS USE PART
NO. 423429 (TC/DOT)
FOR LT-A-101-20
LT-LP-A-101-20 SYSTEMS
USE PART NO. 423429
(TC/DOT) FOR LT-A-101-30 SYSTEMS
USE PART NO. 423491 (TC/DOT)

FIGURE 4
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SECTION III – SYSTEM COMPONENTS
Service and Repair Manual LH204
5-15-02 Page 3-3
REV. 2

PNEUMATIC ACTUATOR 1/4 IN. CHECK VALVE

The pneumatic actuator, Part No. 430221, is constructed of The 1/4 in. actuation line check valve, Part No. 25627, is used
brass and mounts on top of the expellant gas cartridge(s). at the branch lines to each actuation device (whether manual
When actuated, the actuator punctures a seal in the cartridge or automatic). The check valve blocks the flow of actuation
head, allowing the expellant gas to flow into the agent tank. gas from the actuator that was actuated to the actuator(s) that
See Figure 6a. was not actuated. This prevents actuation gas from escaping
from an open actuator which may have had the cartridge
1/4 IN. ACTUATION
LINE INLET (TYP.2) removed. The check valve also keeps the gas from
pressurizing all branch actuation lines thus allowing the main
line to be of maximum length. See Figure 8.
CHECK VALVE PART NO. 25627

VENT
HOLE

1/4 IN. EXPELLANT 1/4 IN. NPT

GAS LINE OUTLET (1) Figure 6a (0.6 cm)
006433

MANUAL ACTUATORS FIGURE 8

000899
The manual actuator is available for use with either right or
left hand cartridges. Manual actuators should be mounted DISTRIBUTION TEE
near the vehicle operator and/or at a point on the vehicle that
can be reached from ground level. Two styles of manual When six nozzles are to be fed from one dry chemical tank,
actuators are available: the standard actuator with either the the distribution supply line must enter the inlet of a distribution
“S” type bracket or the “L” type bracket, and the cartridge tee, Part No. 25031, and each branch line must exit from one
guard type actuator. See Figure 7. of three outlets of the distribution tee. This is required to
CARTRIDGE GUARD ACTUATOR FOR RIGHT HAND CARTRIDGES PART NO. 19330
assure equal distribution of dry chemical to each nozzle. See
CARTRIDGE GUARD ACTUATOR FOR LEFT HAND CARTRIDGES PART NO. 16186 Figure 9.
DISTRIBUTION TEE, 1/2 IN. X 1/2 IN. X 1/2 IN. X 3/4 IN. – PART NO. 25031

“L” BRACKET PART NO. 70580

3/4 IN. NPT

INLET
1/2 IN. NPT
OUTLET –
3 PLACES

“S” BRACKET PART NO. 57661

REMOTE ACTUATOR FOR RIGHT HAND 2 1/4 IN. DIA.

(5.7 cm)
CARTRIDGES PART NO. 57452
REMOTE ACTUATOR FOR LEFT HAND FIGURE 9
CARTRIDGES PART NO. 70581 002583

FIGURE 7

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SECTION III – SYSTEM COMPONENTS
Service
5-15-02 Pageand3-4 Repair Manual LH204
REV. 1

REDUCING TEE AIR CYLINDER (OPTIONAL)

When two or four nozzles are to be fed from a single dry The air cylinder, Part No. 15733, is a system accessory
chemical tank, a 1/2 x 1/2 x 3/4 in. reducing tee, Part whose function is to shut off the fuel supply to the engine
No. 4655, is used to properly distribute the dry chemical from when the fire suppression system is actuated. It is a piston
the supply line to two branch lines. See Figure 10. operated by gas pressure from the actuation line. See
REDUCING TEE, 1/2 IN. X 1/2 IN. X 3/4 IN. – PART NO. 4655 Figure 13.
AIR CYLINDER PART NO. 15733

3/4 IN. NPT

INLET

1/8 IN. NPT

FIGURE 13
1/2 IN. NPT 003459
OUTLET
TYP.2 PLACES
FIGURE 10 PRESSURE SWITCH – WEATHERPROOF
003456
The pressure switch, Part No. 46250, is a DPST (Double-
TRIPLE TEE Pole, Single Throw) pneumatically operated, resettable switch
When four nozzles are to fed from a single dry chemical tank, used to open or close electrical circuits to either shut down
a triple tee, Part No. 16424, can be used to properly distribute equipment or turn on lights or alarms. The pressure switch is
the dry chemical from the supply line to two branch lines. See constructed of malleable iron, painted red. A 1/4 in. NPT
Figure 11. pressure inlet is used to connect the 1/4 in. hose from the
TRIPLE TEE, 1/2 IN. X 1/2 IN. X 1/2 IN. X 3/4 IN. – PART NO. 16424
actuation line. The switch rating is 2 HP-240 VAC/480 VAC,
2 HP-250 VDC, 30A-250 VAC/DC, 5A-480 VAC/DC. See
Figure 14.
PRESSURE SWITCH PART – NO. 46250
MALLEABLE
IRON FINISH –
RED PAINT BRASS RESET
TO ELECTRICAL PLUNGER
EQUIPMENT TO
MOISTURE
BE CONTROLLED
1/2 IN. NPT PROOF JOINT
OUTLET GASKET NUT
(TYP.4 “O” RING GASKET
PLACES)
NAMEPLATE
DOUBLE POLE – HEAVY
DUTY TOGGLE SWITCH
WITH FULLY ENCLOSED
BAKELITE BASE

3/4 IN. NPT

BRASS PISTON
INLET
PISTON “O”
TO RING GASKET
POWER
3/4 IN.
ELECTRICAL
FIGURE 11 CONDUIT OUTLETS
003462
1/4 IN. UNION
SAFETY RELIEF VALVE 1/4 IN. ACTUATION
HOSE
A spring-loaded pressure relief valve, Part No. 15677, is used
to prevent excessive pressure from building up in the
actuation line. The valve is set to relieve at 265 psi (18.3 bar).
After system discharge, all pressure in the actuation line can
be relieved by pulling the ring on the safety relief valve. See
Figure 12.
SAFETY RELIEF VALVE PART – NO. 15677

1/4 IN. NPT

FIGURE 14
000716
FIGURE 12
000437

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SECTION III – SYSTEM COMPONENTS
Service and Repair Manual LH204
5-15-02 Page 3-5
REV. 1

PRESSURE SWITCH – NON-WEATHERPROOF NOZZLES

The Electric Pressure Switch, Part No. 8372, is a SPDT Three types of nozzles are approved for use with the
(Single Pole-Double Throw) pneumatically operated, A-101/LT-A-101 system. One type is the F-1/2 nozzle. This
resettable switch to be used for turning off pump motors, nozzle gives a 180° fan shape pattern and can be used for
exhaust fans, conveyors and similar devices; or turning on either total flooding or local application. The second type of
alarms or electric door closures. The switch contacts are nozzle is the C-1/2. This nozzle gives a cone pattern and is
rated at 15 amp, 125, 250, or 480 VAC, 1/4 hp at 125 VAC, used for direct application to a vehicle component or burning
1/2 hp at 250 VAC or 1/2 amp at 125 VDC, 1/4 amp at surface. The third type of nozzle is the V-1/2. This nozzle
250 VDC. See Figure 15. produces a 160° fan shape pattern and is generally used for
1/2 IN. screening engine compartments, torque converters and all
COMPRESSION other hazard areas. All nozzles are constructed of brass and
FITTING
require protective blow-off caps. Exception: The F-1/2 nozzle
can utilize either a blow-off cap or the opening can be packed
with a good grade of extreme temperature silicone grease,
such as Dow Corning No. 4. See Figure 17.
F-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 16449

1 IN.
HEX
1/2 IN. NPT
PART NO. 16449

FIGURE 15 F-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 56748

000453

Explosion-Proof Pressure Switch – DPDT

The Explosion-Proof Pressure Switch, Part No. 43241, is a
DPDT (Double-Pole, Double-Throw) pneumatically operated,
resettable switch to be used for turning off pump motors,
exhaust fans, conveyors, and similar devices; or turning on
alarms or electric door closures. The switch contacts are
rated at 10 amp at 125 VAC or 5 amp at 250 VAC. The 1 IN.
HEX
pressure switch is constructed with an explosion-proof 1/2 IN. NPT
PART NO. 56748
housing suitable for hazardous environments. The switch
operates off the nitrogen pressure from the ANSUL F-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 53791

AUTOMAN release or remote pneumatic actuator.

1/4 IN. UNION 3/8 IN.

CONDUIT
OUTLET
3/8 IN. X 1/4 IN.
BUSHING

1 IN. 1/2 IN. NPT

HEX PART NO. 53791
NAMEPLATE

FIGURE 17

2 11/32 IN.
(5.9 cm)
MOUNTING
HOLES
3/4 IN. CONDUIT
OUTLET

FIGURE 16
000454

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SECTION III – SYSTEM COMPONENTS
Service
5-15-02 Pageand3-6 Repair Manual LH204

NOZZLE BRACKETS SEALED BURST DISC ASSEMBLY

Two styles of nozzle brackets are available for the The Sealed Burst Disc Assembly, Part No. 428271, is a
A-101/LT-A-101 system. Each style of bracket is constructed machined brass component containing a stainless steel burst
of unpainted 1/4 in. (6.4 mm) steel. They contain pre-punched disc inside. The disc assembly is designed to rupture when
mounting holes for the nozzle. the proper expellant gas pressure is built up within the tank.
The disc assembly is part of the agent tank shipping
An individual “L”-shaped bracket-shipping assembly, Part
assembly. After tank discharge, the complete burst disc
No. 427149, is available. This bracket is 2 in. x 3 in. (51 mm x
assembly must be removed, discarded, and replaced with a
76 mm). A second “L”-shaped bracket (in packs of 12), Part
new assembly. Replacement assemblies are available in a
No. 73871, is also available. This “L” shaped bracket is 2 in. x
15 pack, Part No. 428363.
2 in. (51 mm x 51 mm).
A straight bracket (in packs of 4), Part No. 427228, is
available. this bracket is 5 in. x 2 in. (127 mm x 51 mm). See
Figure 18.
PART NO. 427228
1 3/32 IN. 7/8 IN. (22 mm)
(28 mm) HOLE
HOLE FIGURE 20
004793

ENGINE SHUTDOWN DEVICE

The Ansul Engine Shutdown Device, Part No. 427425, can be
PART NO. 427149
used to pneumatically shut down the vehicle fuel rack by
venting the hydraulic pressure through the “safety system.”
This can be accomplished by installing the shutdown device
PART NO. 73871 in the actuation line. When the fire suppression system is
actuated, the actuation pressure opens the check valve
1 3/32 IN. located in the shutdown device,allowing the safety system
7/8 IN. DIA. (28 mm) HOLE
(2.2 cm) pressure to bleed into the holding tank.The drop in pressure
causes the valves in the fuel rack to close, thus shutting down
the engine. See Figure 21.

FIGURE 18

FIGURE 21
HOSE (SUPPLIED BY OTHERS) 004474

To assure proper performance of an A-101/LT-A-101 system,

the hose used must meet SAE 100 R5 or 100 R1 (minimum) CHECKFIRE ELECTRIC DETECTION AND ACTUATION
hose specification. For underground mining applications, the SYSTEM
hose must also be accepted by MSHA as flame resistant and Three styles of electric detection and actuation systems are
marked as follows “Flame-Resistant, USMSHA No. _____”* available: CHECKFIRE Electric Series I, CHECKFIRE
at intervals not exceeding 3 ft. (.9 m). Letters and numbers Electric SC-N, and CHECKFIRE Electric MP-N*. Each
must be at least 1/4 in. (.6 cm) high and comply all other SAE electric/pneumatic system consists of detection wiring, control
requirements including an operating temperature of –65 °F to module, actuator with nitrogen cartridge, mounting bracket,
+250 °F (–54 °C to 121 °C). (*This number is assigned to the and squib (Series I and SC-N) or gas motor (MP-N). The
manufacturer after samples have passed the required tests. CHECKFIRE Electric Series I requires power from the vehicle
The number will be different for each manufacturer.) See battery where as the CHECKFIRE SC-N and MP-N contains
Figure 19. its own internal Lithium batteries as the power source. All
styles of CHECKFIRE electric* are FM Approved when
consisting of all basic components.
* CHECKFIRE MP-N is not FM Approved
The temperature ratings of the system are as follows:
CHECKFIRE Series I: –40 °F to +140 °F
Manual Part No. 54894 (–40 °C to +60 °C)
CHECKFIRE Series SC-N: –40 °F to +140 °F
FIGURE 19 Manual Part No. 79061 (–40 °C to +60 °C)
003475
CHECKFIRE Series MP-N: +32 °F to +120 °F
Manual Part No. 427310 (0 °C to +49 °C)

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SECTION IV – SYSTEM DESIGN – VEHICLE
Service and Repair Manual LH204
5-15-02 Page 4-1
REV. 1

SYSTEM DESIGN – VEHICLE High Pressure Hoses – Hot fluid spraying from a ruptured
high pressure hose, or leaking from a loose flange or fitting
HAZARD ANALYSIS could find its way to a source of ignition.
Individuals responsible for the design of an A-101/LT-A-101 Belly Pan – The belly pan can accumulate not only leaking
system must be trained and hold a current Ansul certificate in fuel from the vehicle, but external debris, and because of its
an A-101/LT-A-101 training program. Knowledge of the fire unique location, a fire starting in the belly pan could quickly
hazards that exist in the equipment to be protected is also engulf the entire vehicle.
required. Finally, a good understanding of federal and local Hydraulic/Fuel Pumps – Because of the high pressures
fire protection codes and standards is necessary. No one involved with these pumps, fluid spraying from a leaking
should begin designing without previously becoming familiar pump could find its way to a heat source and cause ignition.
with the applicable codes. After completing the hazard analysis, determine nozzle
Having read about the A-101/LT-A-101 system and the basic coverages.
terminology and operation of the system, you should now begin
to identity the fire hazards in the equipment to be protected. NOZZLE COVERAGE AND LOCATION
Every foreseeable hazard must be identified now while you have
design flexibility; once the system is installed, adding protection The first step is to determine which nozzles are needed and
for another hazard becomes more difficult. Note that the where they should be placed to best protect the hazard.
A-101/LT-A-101 system is designed only for the protection of Nozzle selection can be made by first determining the size of
specified equipment for the foreseeable hazards that exist due the hazard and then comparing that to the nozzle's effective
to that equipment and its operation. The areas of protection are discharge pattern.
fixed at installation and are limited in number. An C-1/2 Nozzle Part No. 53791 – The cone-shape discharge
A-101/LT-A-101 system does not remove the need for a pattern of the C-1/2 nozzle will widen to a 3 ft. (.9 m) diameter
hand portable fire extinguisher on the equipment. Fuel at the maximum effective discharge range of 6 ft. (1.8 m). See
spills, welding (repair) heat or other unforeseeable causes may Figure 1.
result in fires not having A-101/LT-A-101 protection. The V-1/2 Nozzle Part No. 56748 – The V-1/2 nozzle creates a
A-101/LT-A-101 system protects the areas with high likelihood of fan- shaped discharge pattern of 160° and has a maximum
fire and potential for high damage; seldom would an effective discharge range of 4 ft. (1219 mm) in length by 15 in.
A-101/LT-A-101 system be designed to protect every square (38.1 cm) in height with a maximum width of 6 ft. (1.8 m). See
inch of the equipment to be protected. Figure 1.
An effective system design is based on a through hazard F-1/2 Nozzle Part No. 16449 – The F-1/2 nozzle also
analysis. Fire is made up of heat, fuel, and oxygen. A fire produces a fan-shaped discharge pattern, but with a 180°
hazard is any place that these three elements could be pattern at a maximum effective range of 33 in. (83.8 cm) in
brought together. Because oxygen is always present, length by 15 in. (38.1 cm) in height with a maximum width of
identifying fuel and heat sources is most critical. 5 ft. 6 in. (1.7 m) See Figure 1.
Large excavators must be considered special type hazards. C-1/2 NOZZLE
See the Appendix Section for design information or contact
Ansul Application Engineering Department.
Operator safety is also a concern when designing a fire
suppression system. The operator must have enough time to
safely exit the vehicle. In some situations, an extended
discharge dry chemical system (not FM Approved) may offer
the operator the additional time he needs to get away from
the burning vehicle. Consider egress time when designing the
final system. See Appendix Section for extended discharge
and twin agent design information.
Some common fuel sources in vehicles include flammable
liquids and greases, rubber, plastics, upholstery, and
environmental debris such as wood chips or coal dust. V-1/2 NOZZLE
Common vehicle heat sources are engine blocks, exhaust
systems, pumps, and turbochargers, as well as bearings,
gears, brakes, and electrical equipment. A potential hazard
exists when a fuel comes in contact with any heat source.
Where there is dripping or leaking fuel, the hazard can
become even more dangerous than initially considered.
Consulting with experienced operators or owners of similar
equipment can help to identify locations of previous fires and
special hazards not normally considered as common
hazards.
The following are typical vehicle fire hazards that require F-1/2 NOZZLE
consideration:
Engine Compartment – The engine compartment contains
an assortment of fluids, fuels, oils, and greases, as well as
congested wires, hoses, and accumulated debris, all very
near high heat sources.
Battery Compartments – Battery compartments are a
potential fire hazard when combustible materials build up on
the top of the battery. These materials, in the presents of
moisture, can cause a short circuit.
FIGURE 1
Transmissions, Torque Converters, and Parking Brakes –
All these components are a possible high heat source that
could cause ignition to combustible material.
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ID: BG00398452 en-US A.001.1 2015-10-19
SECTION IV – SYSTEM DESIGN – VEHICLE
Service
5-15-02 Pageand
4-2 Repair Manual LH204
REV. 2

NOZZLE COVERAGE AND LOCATION (Continued) TANK QUANTITY REQUIREMENTS

First consider the type of environment the vehicle will be
NOTICE
operating in and its temperatures. This will determine the type
When using any of the nozzle types, make of tank to choose.
certain no obstructions interfere with the
discharge pattern as it is directed to the hazard A-101/LT-A-101 systems are available in the standard model
A-101 which has a temperature range of +32 °F +120 °F
The following rules apply to selecting nozzles and nozzle (0 °C to +49 °C) and are generally used on sub-surface
locations: mining equipment.
– When choosing the proper nozzle, remember the entire Also available is the extreme temperature model LT-A-101
hazard area must be within the nozzle's pattern and which has a temperature range of –65 °F to +210 °F (–54 °C
maximum effective discharge range. to +99 °C) and is typically used on above surface vehicles.
– The narrow pattern and longer discharge range of the Knowing the number of nozzles required, next determine the
C-1/2 nozzle make it a good selection for protecting small type or size of tank(s) required. The following “System
areas or hazards that are distant from the nozzle mounting Selection Chart” will point out the various options.
location.
System Selection Chart
– Larger hazard areas may require the use of V-1/2 or F-1/2
Model Nozzle Effective Agent
nozzles.
Capacity Quantity Discharge Time per Nozzle
– Some areas may exceed the area coverage of one nozzle 10 2 8.5 sec. 4 1/4 lb. (1.9 kg)
and may require an additional nozzle(s) for protection. 20 4 8.5 sec. 4 1/4 lb. (1.9 kg)
20 6 5.7 sec. 2 7/8 lb. (1.3 kg)
– In some cases, a single nozzle can cover more than one
30 4 12.5 sec. 6 1/4 lb. (2.8 kg)
area of a common hazard such as a transmission and
30 6 8.3 sec. 4 1/8 lb. (1.9 kg)
torque converter. NOTE: Both areas must be within the
discharge pattern of the nozzle. Nozzle quantities, discharge times and amount of agent per
nozzle are all factors to consider in determining the proper
– When planning nozzle locations, make certain the effective tank size.
flow of dry chemical to all recognized hazard areas will not
be obstructed. Keep in mind, a longer discharge time and a greater amount
of agent discharge per nozzle will offer better hazard
– If obstructions cannot be avoided, an additional nozzle(s) protection.
may be needed to provide proper coverage. It is always best to choose the largest size tank available, but
– In areas where the environment may cause extreme build if space is a problem, choose a smaller tank or choose the
up of materials, such as wood debris, coal dust, garbage, low profile version.
or oil, it is always a good idea to use the largest system When the number of tanks have been determined based on
tank available and keep the nozzles per tank to a the number of nozzles for total protection, the next step in the
maximum of four. This allows the maximum amount of design process is to determine the distribution hose network
chemical per nozzle and gives the longest discharge time required.
(excluding two nozzle systems).
– Never settle for less than full coverage of each fire hazard. DISTRIBUTION SYSTEM REQUIREMENTS
After establishing nozzle locations and number required, the After the tank(s) and nozzle(s) location(s) have been
type and quantity of A-101/LT-A-101 tanks can be determined, it is necessary to sketch the hose routings to
determined. each nozzle to make certain they can be run without
interfering with vehicle components and that the length of the
supply line(s) and branch line(s) are not exceeded.

Hose Specifications
To ensure proper performance of the Ansul A-101/LT-A-101
system, the hose used must meet either SAE 100 R5 or 100 R1
hose specifications as a minimum. The hose must have an
operating temperature of –40 °F to +200 °F (–40 °C to +93 °C).
The following list of appropriate standards is for reference.
SAE Selection, Installation, and J1273 (latest revision)
Maintenance of Hose and Hose Assemblies
SAE Hydraulic Hose Fitting Standard J516 (latest revision)
SAE Hydraulic Hose Standard J517 (latest revision)
SAE Test and Procedures For J343 (latest revision)
SAE 100R Series Hydraulic Hose and
Hose Assembly Standard
For underground mining applications, hose must comply with
USBM specified flame resistance acceptance and all
applicable SAE requirements.

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Service and Repair Manual LH204
5-15-02 Page 4-3
REV. 1

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) Permanent Crimp-on Hose Couplings

Listed below is a partial list of hose manufacturers who A permanent crimp-on hose coupling is installed as a one-
manufacture hose that meets the required SAE specification piece assembly attached to the hose end and crimped on.
noted on Page 4-2: The crimp is to be made following the manufacturer's
requirements for proper hose and coupling assembly, using a
Aeroquip Parker machine that will hydraulically or electrically crimp the
Dayco Swagelok coupling permanently to the hose end.
Gates Weatherhead When using permanent crimp-on type couplings, lubricate the
Goodyear hose end, if necessary, and push the hose end all the way
Critical Specifications from SAE J517 are listed below for into the fitting in accordance with hose and hose coupling
reference: assembly instructions. Then place the hose end in the
appropriate crimping machine and cr imp the coupling. Follow
SAE 100R1 Hose all hose cr imping machine operating instructions using
Maximum Minimum Minimum equipment specified by the hose/coupling manufacturer.
Operating Burst Bend
Reusable Hose Couplings
Size Hose ID Pressure Pressure Radius
1/4 in. .250 in. +.023 2750 psi 11000 psi 4.0 in. Reusable hose couplings can be attached to new hose in the
–.008 field with no other tools than a wrench and a vise (or two
1/2 in. .500 in. +.031 2000 psi 8000 psi 7.0 in. wrenches). When reusable hose couplings are used, make
–.015 certain the corresponding couplings and the assembly
3/4 in. .750 in. +.031 1250 psi 5000 psi 9.5 in. procedures used are in accordance with the manufacturer's
–.015 specifications. Failure to follow the manufacturer's
7/8 in. .875 in. +.031 1250 psi 5000 psi 11.0 in. instructions in their entirety may result in plugged nozzle
–.015 orifices at system discharge due to chips and pieces of
SAE 100R5 Hose rubber cut from the inside of the hose during improper
1/4 in. .250 in. +.031 3000 psi 12000 psi 3.4 in. assembly.
–.000 Reusable hose couplings include a coupling shell that fits
1/2 in. .500 in. +.039 1750 psi 7000 psi 5.5 in. over the end of the hydraulic hose and a coupling insert that
–.000 installs inside the end of the hose and mates with the
3/4 in. - - - - coupling shell threads. A mandrel tool may be required when
7/8 in. .875 in. +.042 800 psi 3200 psi 7.4 in. using 1/4 in. through 1/2 in. SAE 100R5 hose to facilitate
–.000 installation of the coupling insert.
Hydraulic Hose Couplings
To attach a reusable coupling to the hose, clamp the coupling
Before connecting a hydraulic hose to the A-101/LT-A-101 fire shell in a vise and turn the end of the hydraulic hose counter-
suppression system, it must first be assembled utilizing a clockwise into the coupling shell until the end is seated
hose coupling attached to each end of the hose. Hose against the bottom of the shell. Then, back off 1/4 to 1/2 turn
couplings installed on hydraulic hose can be the permanent to allow for expansion.
crimp-on type or the reusable type. Female or male swivel
hose couplings of either the crimp-on type or the reusable NOTE: Some-rubber covered hydraulic hose ends must be
type are also acceptable. All couplings used with SAE 100R1 skived (stripped of the rubber cover) before attaching the
or SAE 100R5 hydraulic hose must be suitable for the hose coupling. Refer to the appropriate manufacturer's
chosen and must comply with Hydraulic Hose Fitting instructions.
Standard J516 as a minimum. Lubricate the hose, coupling inser t, and mandrel tool (when
When attaching a hose coupling to a hose, it is very important required) in accordance with manufacturer's instructions and
to follow all manufacturer's installation instructions. screw the inser t clockwise into the coupling shell and hose.
SAE J1273, Selection, Installation, and Maintenance of Hose Wrench tighten the insert until the hex on the insert contacts
and Hose Assemblies, paragraph 3.2, requires that the the shell. If a female swivel end is being used, use the
manufacturer's assembly instructions be followed. appropriate assembly tool and leave approximately 1/32 in. to
NOTICE 1/16 in. (.8 to 1.6 mm) clearance between the nut and the
SAE J1273, paragraph 2.10, Proper End Fitting, shell to allow the nut to swivel.
states that, “Care must be taken to insure proper NOTE: It is important to lubricate only those surfaces
compatibility exists between the hose and specified by the manufacturer of the hose and coupling used.
coupling selected based on the manufacturer's The lubricant will minimize the risk of cutting or shaving the
recommendations substantiated by testing to inside of the hose. Failure to use the proper lubricant or
industry standards such as SAE J517.” follow the appropriate lubrication instructions may result
Under no circumstances should hose and in pieces of hose plugging the gas tube in the agent
couplings from different manufacturers be storage tank or plugging a discharge nozzle orifice.
interchanged. Improper lubricant or lubrication procedures may also
Many hose manufacturers require only the couplings that they result in contamination of the hose due to the use of an
supply to be used with their hose. One manufacturer warns incompatible lubricant.
that they “will not be responsible when interchanging their
hose and/or couplings with hose and/or couplings of any After attaching hose couplings to the hose, make certain that
other manufacturer.” the hose is clean, dry and oil free. Use a solvent that is
compatible with the hose, such as Stoddard Fluid or Varsol, to
dissolve any oil remaining in the hose. Using dry air or
nitrogen, blow out each hose length until dry and clear of
metal or rubber shavings and any foreign matter before
making any connections to the A-101 system.

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ID: BG00398452 en-US A.001.1 2015-10-19
SECTION IV – SYSTEM DESIGN – VEHICLE
Service
5-15-02 Pageand
4-4 Repair Manual LH204
REV. 2

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) NOTE: When using the distribution tee, Part No. 25031, a
minimum length of 15 in. (381 mm) of 3/4 in. or 18 in.
JIC Hose Fittings and 150 lb. Fittings
(457 mm) of 7/8 in. hose, will always be required between any
JIC hose fittings meeting Hydraulic Hose Fitting Standard bend or elbow and the distribution fee.
J516 can be used in most applications. When using JIC hose
20 HOSE DIAMETERS
fittings as elbows, use only elbows that have a radiused MINIMUM LENGTH
bend. 150 lb. NPT elbows and tees can also be used to REQUIRED REDUCING
assemble hose or pipe and attach hose or pipe to the REDUCING
TEE
discharge nozzles. Make certain that all elbows used in the TEE
agent distribution line, are of the same type (i.e., either all JIC
or all 150 lb. NPT elbows). Refer to the Installation Section for
maximum and minimum elbow requirements.
NOTE: When figuring the maximum and minimum amount of
elbows in the A-101/LT-A-101 system, two (2) 45 ° fittings can TRIPLE
be counted as one 90° fitting. TEE

Heat Resistant Fire Jacket for Hydraulic Hose (Non-FM

Approved)
20 HOSE DIAMETERS
All hose assemblies, including actuation lines, expellant gas MINIMUM LENGTH
REQUIRED
lines, and agent distribution hose that will be normally exposed
to or located in areas with temperatures exceeding 200 °F
(93 °C), should be sleeved with an extreme temperature heat-
TRIPLE
resistant fire jacket. (Do not route actuation hose through fire TEE
hazard areas. If this cannot be avoided, the hose must be fire
jacketed.) Information concerning fire jacketing should be
available through your local hose supplier. If not, Bentley
Harris manufacturers a fire jacket that will withstand 20 HOSE DIAMETERS
continuous operating temperatures from –65 °F to 500 °F (– MINIMUM LENGTH
REQUIRED
54 °C to 260 °C) and short term exposures up to 2000 °F
(1093 °C). For a listing of distributors in your area, call Bentley
Harris at either 610-363-2600 or, 800-321-2295.
Dry Chemical Flow Characteristics
The assembly of piping (hose) for a dry chemical system
probably lends itself to the greatest chance for error when
installing the system. Dry chemical-gas mixtures do not flow
like liquids, and, as a result, certain basic rules must be
followed to assure correct dry chemical distribution to the SAME PLANE
nozzles.
In order to obtain equal distribution at a tee, the dry
chemicalmust enter the center opening (bull) of the tee and
LENGTH IS CRITICAL
exist the two side opening which are 180° apart. See WHEN BOTH THE
Figure 2. TEE AND THE BEND
LIE IN THE SAME
CORRECT INCORRECT PLANE

TO NOZZLE(S) TO NOZZLE(S) TO NOZZLE(S) INCOMING IF LESS THEN 20 HOSE DIAMETERS, DRY CHEMICAL WILL FLOW
TO THE OUTSIDE, EXPELLANT GAS WILL FLOW TO THE INSIDE

INCOMING TO NOZZLE(S)
FIGURE 2 CRITICAL
003477
LENGTH
DRY
When dry chemical makes a change of direction through an CHEMICAL
elbow, a tee, or a hose bend, a separation of the dry chemical FLOW

and gas mixture occurs. If a tee follows this change of

direction where separation can occur, and if this tee lies in the
same plane as the change in direction through an elbow, tee, 20 HOSE DIAMETERS
or hose bend, more dry chemical will discharge through one MINIMUM LENGTH
of the tee outlets and more gas will discharge out the other REQUIRED

tee outlet. A certain minimum length of hose must be allowed

from the bend (elbow) to the tee or from the first tee to the
second tee in order to permit the dry chemical and gas to
intermix before striking the tee. The minimum length required SAME PLANE
is equal to 20 hose diameters. 18 in.(457 mm) is required for
7/8 in. hose, 15 in. (381 mm) is required for 3/4 in. hose, and
10 in. (254 mm) is required for 1/2 in. hose. See Figure 3. FIGURE 3

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Service and Repair Manual LH204
5-15-02 Page 4-5
REV. 1

DISTRIBUTION SYSTEM REQUIREMENTS (Continued)

Dry Chemical Flow Characteristics (Continued)
If a tee follows a change in direction through an elbow,
another tee, or a hose bend and the directional change is in a
plane that is perpendicular to the plane of the tee following,
the dry chemical particles and gas will strike the rear of the
tee before branching, intermixing of the dry chemical and gas
will occur through turbu- lence and the length of hose from
the bend (elbow) or tee proceeding it is not critical. See
Figure 4.
REDUCING TEE

LENGTH NOT CRITICAL

TRIPLE TEE

LENGTH NOT
LENGTH NOT CRITICAL
CRITICAL

TRIPLE TEE

T EE
OF
NE
PLA
PLANE OF BEND

PLANES OF TEE AND BEND

ARE PERPENDICULAR

PERPENDICULAR PLANES
CHEMICAL AND GAS MIX
PROPERLY WHEN
ENTERING OTHER PLANE

LENGTH NOT
CRITICAL

TWO SEPARATE PLANES

FIGURE 4

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ID: BG00398452 en-US A.001.1 2015-10-19
SECTION IV – SYSTEM DESIGN – VEHICLE
Service
5-15-02 Pageand
4-6 Repair Manual LH204
REV. 2

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) The four nozzle split tee arrangement consists of a 3/4 in. or
7/8 in. supply line, a 1/2 in. x 1/2 in. x 3/4 in. reducing tee, two
Supply and Branch Line Requirements 1/2 in. primary branch lines, two 1/2 in. tees, and four 1/2 in.
Supply and branch lines for the A-101/LT-A-101 system are secondary branch lines each connected to one nozzle. See
defined as follows: Figure 7.
PRIMARY BRANCH LINES
TWO NOZZLE SYSTEM – Two nozzle systems consist of a EXTINGUISHER
1/2 IN. I.D. SINGLE WIRE
3/4 in. or 7/8 in. supply line, a 3/4 in. x 1/2 in. x 1/2 in. BRAID, TEXTILE OR RUBBER
COVERED HYDRAULIC HOSE
reducing tee, and 1/2 in. branch lines each connected to one
nozzle. See Figure 5. 1/2 IN. TEE

SUPPLY LINE 3/4 IN. OR

7/8 IN. I.D. SINGLE WIRE
BRAID, TEXTILE OR RUBBER
COVERED HYDRAULIC HOSE

SECONDARY BRANCH LINES

1/2 IN. I.D. SINGLE WIRE
BRAID, TEXTILE OR RUBBER
SECONDARY BRANCH LINES
COVERED HYDRAULIC HOSE
BRANCH LINES 1/2 IN. X 1/2 IN. X
1/2 IN. I.D. SINGLE 3/4 IN. REDUCINGTEE
SUPPLY LINE 3/4 IN. OR 7/8 IN. WIRE BRAID,
3/4 IN. X 1/2 IN.
I.D. SINGLE WIRE BRAID, TEXTILE OR RUBBER FIGURE 7
TEXTILE OR RUBBER COVERED X 1/2 IN. COVERED HYDRAULIC HOSE 003482
HYDRAULIC HOSE REDUCING
TEE
BRANCH LINE 1/2 IN. I.D. SINGLE
NOTE: On split tee arrangements, if the 1/2 in. secondary
WIRE BRAID, TEXTILE OR RUBBER branch line tee is not more than 20 hose diameters from the
COVERED HYDRAULIC HOSE 1/2 x 1/2 x 3/4 in. primary branch line tee, then the orientation
FIGURE 5
003480 of the tees must be perpendicular to each other as they are in
FOUR NOZZLE SYSTEM – Four nozzle systems are divided a triple tee arrangement.
into two types: Four nozzle triple tee arrangement and four SIX NOZZLE SYSTEM – Six nozzle systems consist of a
nozzle split tee arrangement. Four nozzle triple tee systems 3/4 in. or 7/8 in. supply line, a special three outlet distribution
consist of a 3/4 in. or 7/8 in. supply line into a triple tee tee, three 1/2 in. primary branch lines, three 1/2 in. tees, and
assembly consisting of a 1/2 in. x 1/2 in. x 3/4 in. reducing tee, six secondary branch lines each connected to one nozzle. See
two close nipples, and two 1/2 in. tees. The primary branch line Figure 8.
is the close nipple that connects the 1/2 in. tee to the reducing
tee. Four separate secondary branch lines are run from the
1/2 in. tee outlets each connected to one nozzle. See Figure 6.

SUPPLY LINE
BRANCH LINES

SECONDARY
BRANCH LINES

SUPPLY LINE 3/4 IN. DISTRIBUTION TEE

TRIPLE TEE PRIMARY OR 7/8 IN. I.D. SINGLE
BRANCH LINES WIRE BRAID, TEXTILE
SECONDARY OR RUBBER COVERED
BRANCH LINES HYDRAULIC HOSE

PRIMARY BRANCH LINE 1/2 IN.

I.D. SINGLE WIRE BRAID,
TEXTILE OR RUBBER COVERED
HYDRAULIC HOSE

1/2 IN. TEE

SECONDARY BRANCH LINE 1/2 IN. I.D.
SINGLE WIRE BRAID, TEXTILE OR RUBBER
PRIMARY BRANCH LINE COVERED HYDRAULIC HOSE
IS THE CLOSE NIPPLE
THAT CONNECTS THE FIGURE 8
003483
1/2 IN. TEE TO THE
SUPPLY LINE 3/4 IN. OR REDUCING TEE
7/8 IN. I.D. SINGLE WIRE
BRAID, TEXTILE OR RUBBER
COVERED HYDRAULIC HOSE
TRIPLE TEE TO REMAIN
PERPENDICULAR TO
1/2 IN. TEES AS SHIPPED

SECONDARY BRANCH LINE

1/2 IN. I.D. SINGLE WIRE BRAID,
TEXTILE OR RUBBER COVERED
HYDRAULIC HOSE FIGURE 6

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REV. 1

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) – The ten pound system must be a balanced system having
two branch lines within 10% of each other, utilizing one
Supply and Branch Line Requirements (Continued) reducing tee and a maximum of two nozzles. See
Depending upon the hazards to be protected and the Figure 9D.
placement of the system components, a selection can be
made from several balanced and unbalanced distribution
network arrangements:
3/4 IN. SUPPLY LINE
– A balanced system must be a distribution network where
the linear length of the primary branch line on one side of
the primary tee to the secondary tee must be within 10% of 1/2 IN. X 1/2 IN. X 3/4 IN.
the linear length of the other primary branch line from the REDUCING TEE

primary tee to the secondary tee. Also, the linear length of

1/2 IN. BRANCH
the secondary branch line on one side of the secondary LINE
tee must be within 10% of the linear length of the other
secondary branch line sharing the same tee. A balanced
system can be used with two, four, or six nozzle systems.
See Figure 9A.
SECONDARY
PRIMARY
BRANCH LINE
BRANCH LINE
FIGURE 9D
003487
3/4 X 1/2 X1/2 IN. 1/2 IN.
PRIMARY TEE SECONDARY
TEE – The twenty and thirty pound systems can be either
balanced or unbalanced systems, and can be arranged
utilizing three different network combinations. These
include the triple tee arrangement which utilizes the triple
tee and four nozzles (See Figure 9E), the split tee
arrangement utilizing one 3/4 in. x 1/2 in. x 1/2 in. reducing
tee, two 1/2 in. tees, and four nozzles (See Figure 9F), and
NOZZLE the distribution tee arrangement which utilizes a
distribution tee, three 1/2 in. tees, and six nozzles (See
Figure 9G)
FIGURE 9A
003484 4 NOZZLE UNBALANCED TRIPLE TEE
– In an unbalanced system, the longest branch line must be
nolonger in length than 3 times that of the shortest branch
line, with a maximum of 18 ft. total (primary plus two
secondary branches). See Figure 9B. SUPPLY LINE
6 NOZZLE UNBALANCED DISTRIBUTION TEE
SHORTEST BRANCH LINE LONGEST BRANCH LINE

1/2 IN TEE BRANCH LINES

SECONDARY
BRANCH LINES

1/2 IN TEE
PRIMARY
BRANCH

1/2 IN TEE
SECONDARY
SECONDARY TRIPLE TEE
BRANCH PRIMARY
BRANCH DISTRIBUTION
TEE BRANCH LINES

BRANCH LINES MUST BE WITHIN A 3:1 RATIO FIGURE 9B

003485
SECONDARY FIGURE 9E
– Unbalanced secondary branch line lengths must also be BRANCH LINES 003491
within a 3 to 1 ratio when they are located in the same
branch line. See Figure 9C.

SECONDARY
PRIMARY BRANCH
BRANCH

SECONDARY BRANCH LINES

(ONLY ON THE SAME BRANCH
LINE) MUST BE WITHIN A 3:1 RAT

FIGURE 9C
003486

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REV. 2

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) 2 NOZZLE BALANCED WITH REDUCING TEE – 10 LB. SYSTEM

Supply and Branch Line Requirements (Continued)

4 NOZZLE UNBALANCED SPLIT TEE

PRIMARY 1/2 IN. TEE

BRANCH LINES MAXIMUM TOTAL
LENGTH FROM
EXTINGUISHER TO
THE FARTHEST
SUPPLY LINE NOZZLE, 50 FT. 0 IN.
(15.2 m)

SECONDARY
BRANCH LINES 3/4 IN. OR 7/8 IN. I.D. SINGLE WIRE
BRAID, TEXTILE OR RUBBER
COVERED HYDRAULIC HOSE –
MAXIMUM TOTAL LENGTH FROM REDUCING
EXTINGUISHER TO REDUCING TEE
BRANCH LINES TEE, 30 FT. 0 IN. (9.1 m)
1/2 IN. X 1/2 IN. X 3/4 IN.
REDUCING TEE
SECONDARY
BRANCH LINES
FIGURE 9F 1/2 IN. I.D. SINGLE WIRE
003482
BRAID, TEXTILE OR RUBBER F-1/2, C-1/2 OR V-1/2
COVERED HYDRAULIC HOSE NOZZLE, MAXIMUM PER
EXTINGUISHER, 2

6 NOZZLE UNBALANCED DISTRIBUTION TEE

FIGURE 10
003480

SECONDARY
BRANCH LINES EXAMPLES OF TYPICAL 2 NOZZLE SYSTEMS

CLOSE
NIPPLE

PRIMARY
BRANCH LINES

SECONDARY
BRANCH LINES 1/2 IN. TEE

FIGURE 9G
003490

10 lb. 2 Nozzle Balanced System With Reducing Tee

See Figure 10 and Figure 10A.

• Maximum supply line length from extinguisher to

reducing tee is 30 ft. 0 in. (9.1 m).
• Maximum total length from extinguisher to farthest
nozzle is 50 ft. 0 in. (15.2 m).
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are
acceptable. Two (2) nozzles maximum.
• Maximum unbalanced allowed on the total system is
10% different in length from reducing tee to nozzle on
one line compared to the same distance between
reducing tee to nozzle on the other line.
NOTE: See Page 6-5 for fitting and bend limitations.
FIGURE 10A
003492

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REV. 1

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) 20, 30 lb. 4 Nozzle Balanced System With Triple Tee
See Figure 12 and Figure 12A.
Supply and Branch Line Requirements (Continued)
20, 30 lb. 2 Nozzle Balanced System With Reducing Tee • Maximum supply line length from extinguisher to triple
See Figure 11 and Figure 11A. tee is 40 ft. 0 in. (12.2 m)
• Maximum total length from extinguisher to farthest
• Maximum supply line length from extinguisher to nozzle is 50 ft. 0 in. (15.2 m).
reducing tee is 40 ft. 0 in. (12.2 m). • Any combination of F-1/2, C-1/2, or V-1/2 nozzles are
• Maximum total length from extinguisher to farthest acceptable. Four (4) nozzles maximum.
nozzle is 50 ft. 0 in. (15.2 m). • Maximum unbalanced allowed on the total system is
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are 10% different in length from 1/2 in. tee to nozzle on one
acceptable. Two (2) nozzles maximum. line compared to the same distance between the same
• Maximum unbalanced allowed on the total system is 1/2 in. tee to nozzle on the other line.
10% difference in length from reducing tee to nozzle on NOTE: See Page 6-5 for fitting and bend limitations.
one line compared to the same distance between
reducing tee to nozzle on the other line.
4 NOZZLE BALANCED WITH TRIPLE TEE – 20 LB.-30 LB. SYSTEMS
NOTE: See Page 6-5 for fitting and bend limitations.

2 NOZZLE BALANCED WITH REDUCING TEE – 20 LB.-30 LB. SYSTEMS

MAXIMUM TOTAL LENGTH

FROM EXTINGUISHER TO
MAXIMUM TOTAL THE FARTHEST NOZZLE,
LENGTH FROM 50 FT. 0 IN. (15.2 m)
EXTINGUISHER TO
THE FARTHEST
NOZZLE, 50 FT. 0 IN.
(15.2 m)
3/4 IN. OR 7/8 IN. I.D. SINGLE WIRE BRAID,
TEXTILE OR RUBBER COVERED F-1/2, C-1/2 OR V-1/2
HYDRAULIC HOSE – MAXIMUM TOTAL NOZZLE, MAXIMUM
REDUCING LENGTH FROM EXTINGUISHER TO PER EXTINGUISHER, 4
3/4 IN. OR 7/8 IN. I.D. SINGLE WIRE TEE REDUCING TEE, 40 FT. 0 IN. (12.2 m)
BRAID, TEXTILE OR RUBBER
COVERED HYDRAULIC HOSE – 3/4 IN. TRIPLE TEE TO REMAIN
MAXIMUM TOTAL LENGTH FROM PERPENDICULAR TO 1/2 IN. TEES AS SHIPPED
EXTINGUISHER TO REDUCING
TEE, 40 FT. 0 IN. (12.2 m)
1/2 IN. I.D. SINGLE WIRE BRAID,
F-1/2, C-1/2 OR V-1/2 TEXTILE OR RUBBER COVERED
1/2 IN. I.D. SINGLE WIRE NOZZLE, MAXIMUM PER HYDRAULIC HOSE
BRAID, TEXTILE OR RUBBER EXTINGUISHER, 2
COVERED HYDRAULIC HOSE EXAMPLES OF TYPICAL 4 NOZZLE SYSTEMS
FIGURE 11 CLOSE
EXAMPLES OF TYPICAL 2 NOZZLE SYSTEMS 003480
NIPPLE
FIGURE 12
003481

CLOSE
TRIPLE TEE
NIPPLE

TRIPLE
TEE

TRIPLE TEE

FIGURE 11A
003494 FIGURE 12A
003496

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REV. 2

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) EXAMPLES OF TYPICAL 4 NOZZLE SYSTEMS

Supply and Branch Line Requirements (Continued)

20, 30 lb. 4 Nozzle Unbalance System With Triple Tee TRIPLE TEE
See Figure 13 and Figure 13A.

• Maximum supply line length from extinguisher to the

triple tee is 40 ft. 0 in. (12.2 m).
• The longest branch line (including one primary and two
secondary) is 18 ft. 0 in. (5.5 m) and must not exceed a
3:1 ratio of any other branch line(s).
•The triple tee assembled using close nipples. It must TRIPLE TEE
remain in the configuration as shown in Figure 13.
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are
acceptable. Four (4) nozzles maximum.
• Secondary branch lines located on the same branch
line (sharing the same tee) must not exceed a 3:1 ratio
between each other but are not required to be within a
3:1 ratio with secondary branch line located on other
TRIPLE
branch lines. TEE
NOTE: See Page 6-5 for fitting and bend limitations.

4 NOZZLE UNBALANCED WITH TRIPLE TEE – 20 LB.-30 LB. SYSTEMS

1/2 IN. TEE TRIPLE

TEE

FIGURE 13A
003498

TRIPLE TEE

1/2 IN. TEE

1/2 IN. X 1/2 IN. X 3/4
IN.REDUCING TEE

SUPPLY LINE 40 FT.

(12.2 m) MAXIMUM
BRANCH LINES

SECONDARY
BRANCH LINES

TRIPLE TEE PRIMARY

BRANCH LINES

18 FT. (5.5 m) TOTAL

(PRIMARY PLUS
TWO SECONDARY
F-1/2, C-1/2 OR
BRANCHES)
V-1/2 NOZZLE
SECONDARY
BRANCH LINES
FIGURE 13
003497

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REV. 1

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) 4 NOZZLE BALANCED WITH REDUCING TEE – 20 LB.-30 LB. SYSTEMS
MAXIMUM TOTAL LENGTH FROM EXTINGUISHER
Supply and Branch Line Requirements (Continued) TO THE FARTHEST NOZZLE, 50 FT. 0 IN. (15.2 m)
SECONDARY
20, 30 lb. 4 Nozzle Balanced System With Reducing Tee 1/2 IN. TEE
See Figure 14 and Figure 14A.
PRIMARY
• Maximum supply line length from extinguisher to triple TEE
tee is 40 ft. 0 in. (12.2 m). PRIMARY
BRANCH LINE
• Maximum total length from extinguisher to farthest SECONDARY
BRANCH LINE
nozzle is 50 ft. 0 in. (15.2 m).
1/2 IN. I.D. SINGLE WIRE
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are 1/2 IN. X 1/2 IN. X 3/4 IN. BRAID, TEXTILE OR
REDUCING TEE RUBBER COVERED
acceptable. Four (4) nozzles maximum. HYDRAULIC HOSE
1/2 IN. TEE
• Linear length of the primary branch line on one side of
3/4 IN. OR 7/8 IN. I.D. SINGLE WIRE
the primary tee to the secondary tee must be within BRAID, TEXTILE OR RUBBER COVERED F-1/2, C-1/2 OR V-1/2 NOZZLE,
10% of the linear length of the other primary branch line HYDRAULIC HOSE – MAXIMUM TOTAL MAXIMUM PER EXTINGUISHER, 4
from the primary tee to the secondary tee. LENGTH FROM EXTINGUISHER TO
REDUCING TEE, 40 FT. 0 IN. (12.2 m)
Also, the linear length of the secondary branch line on
one side of the secondary tee must be within 10% of
the linear length of the other secondary branch line
sharing the same tee. FIGURE 14
003499
NOTE: See Page 6-5 for fitting and bend limitations.

EXAMPLES OF TYPICAL 4 NOZZLE SYSTEMS

CLOSE
NIPLE

FIGURE 14A
003500

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REV. 2

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) EXAMPLE OF TYPICAL 4 NOZZLE SYSTEMS

20, 30 lb. 4 Nozzle and 6 Nozzle Unbalanced System With

CLOSE
Reducing Tee NIPLE
See Figure 15 and Figure 15A, Figure 16 and Figure 16A.

• Maximum supply line length from extinguisher to the

reducing tee is 40 ft. 0 in. (12.2 m).
• The longest branch line (including one primary plus two
secondary) length is 18 ft. 0 in. (5.5 m) and must not
exceed a 3:1 ratio of any other branch line(s).
• Two secondary branch lines located on the same
branch line (sharing the same tee) must not exceed a
3:1 ratio between other but are not required to be within
a 3:1 ratio with secondary branch lines located on other
branch line.
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are
acceptable. Four (4) nozzles maximum.
CLOSE
NOTE: See Page 6-5 for fitting and bend limitations. NIPLE

4 NOZZLE UNBALANCED WITH TEE REDUCING

18 FT. (5.5 m) TOTAL

(PRIMARY PLUS TWO CLOSE CLOSE
SECONDARY BRANCHES) NIPLE NIPLE
PRIMARY
BRANCH LINES

SUPPLY LINE
40 FT. (12.2 m)
MAXIMUM SECONDARY
BRANCH LINES
CLOSE
1/2 IN. TEE 1/2 IN. X 1/2 IN. X 3/4 IN. NIPLE
REDUCING TEE

FIGURE 15A
F-1/2, C-1/2 OR 003502
V-1/2 NOZZLE
BRANCH LINES

SECONDARY
BRANCH LINES 18 FT. (5.5 m) TOTAL (PRIMARY
PLUS TWO SECONDARY BRANCHES)

FIGURE 15
003482

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REV. 1

DISTRIBUTION SYSTEM REQUIREMENTS (Continued) EXAMPLE OF TYPICAL 6 NOZZLE SYSTEMS

Supply and Branch Line Requirements (Continued)

20, 30 lb. 6 Nozzle Unbalanced System With Distribution Tee
See Figure 16 and Figure 16A.
6 NOZZLE UNBALANCED WITH DISTRIBUTION TEE – 20 LB.-30 LB. SYSTEMS
CLOSE
NIPLE

CLOSE
NIPLE

DISTRIBUTION TEE

3/4 IN. OR 7/8 IN. I.D.

SINGLE WIRE BRAID,
TEXTILE OR RUBBER
COVERED HYDRAULIC CLOSE
HOSE – MAXIMUM NIPLE
TOTAL LENGTH FROM
EXTINGUISHER TO
1/2 IN. SECONDARY
DISTRIBUTION
BRANCH LINE
TEE,
40 FT. 0 IN. 1/2 IN. PRIMARY
(12.2 m) BRANCH LINE

FIGURE 16A
003504
1/2 IN. TEE

F-1/2, C-1/2 OR V-1/2 NOZZLE,

MAXIMUM PER EXTINGUISHER, 6

FIGURE 16
003503

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4-14 Repair Manual LH204
REV. 2

ACTUATION AND EXPELLANT GAS LINE A-101 SYSTEM

REQUIREMENTS REMOTE MAXIMUM LENGTH 100 FT. (30.5 m) FOR LT-10 CARTRIDGE FROM
ACTUATOR ACTUATOR TO LAST TANK (SEE NOTES 1 AND 2)
SAFETY
Actuation Gas Line RELIEF VALVE

The actuation gas line is the line from the manual remote
actuators and/or the gas cartridge on the automatic detection
system to the gas cartridge actuator located on the last
A-101/LT-A-101 tank or the gas cartridge actuator for the last
LT or LP style tanks. The maximum number of actuators that
can be actuated from a single actuator cartridge is ten (10).
CHECK
The actuation line can be a maximum of 100 ft. (30.5 m) when VALVE
using an LT-10 cartridge. When more than one actuation
cartridge is in the system, a 1/4 in. check valve, Part No.
ACTUATOR
25627, must be installed to prevent the lose of actuation gas
from an actuator that may have a car tr idge removed. See NOTE: A MAXIMUM OF (10) TEN A-101/LT-A-101 SYSTEMS CAN BE ACTUATED
Figure 17. SIMULTANEOUSLY IN ANY COMBINATION (I.E., A-101, LT-A-101, LP-A-101,
OR LT-LP-A-101) (SEE NOTES 1 AND 2)
NOTE 1: If only eight (8) or less actuators are used, the
actuation line can be extended to 125 ft. (38.1 m). LT-A-101 SYSTEM
NOTE 2: The actuation line can also utilize an LT-5 cartridge. ACTUATOR SAFETY
When this is done, only eight (8) actuators or less can be RELIEF VALVE
REMOTE
used, with a maximum length of 75 ft. (22.9 m). ACTUATOR
If more than one actuator is in the system, the total length of
actuation line allowed from the actuator to the last tank must
also include any amount of hose in the other actuation lines CHECK
VALVE
up to the check valves located in those lines.
CHECK
The hose for the actuation system must meet the same VALVE
specifications as the hose used for the dry chemical
distribution network. See Pages 4-2 and 4-3 for hose and MAXIMUM
fitting specifications. EXPELLANT
GAS HOSE
Expellant Gas Line LENGTH,
20 FT. 0 IN.
The expellant gas line is the length of 1/4 in. hose located (6.1 m)
(EACH)
between the remote expellant gas cartridge (required for LT
and LP style tanks), and the expellant gas inlet on the tank. NOTE: REDUCE THE MAXIMUM ALLOWABLE NUMBER OF BASIC EXTINGUISHING
The maximum length of this line is 20 ft. (6.1 m). See UNITS BY ONE FOR EACH NON-EXTINGUISHING PNEUMATICALLY OPERATED
DEVICE EMPLOYED, I.E., BRAKE CONTROL VALVE, FUEL CONTROL AIR CYLINDER.
Figure 17.
FIGURE 17
The hose for the expellant gas line must meet the same
specifications as the hose used for the dry chemical
distribution network. See Pages 4-3 through 4-4 for hose and
fitting specifications.

DETECTION SYSTEM REQUIREMENTS

Several types of automatic detection is available for use with
the A-101 Fire Suppression System. Three types of electric
detection and one type of pneumatic.
See the following Installation Manuals for detailed information
on each type of system:
• CHECKFIRE MP-N ELECTRIC SYSTEM – Manual Part
No. 427310
• CHECKFIRE SC-N ELECTRIC SYSTEM – Manual Part
No. 423522
• CHECKFIRE ELECTRIC SERIES I SYSTEM – Manual Part
No. 54894

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SHUTDOWN REQUIREMENTS
When protecting any vehicle, especially vehicles with large coil to the relay iswired in series with N.C. pressure switch
amounts of hydraulic fluid and fuel on board, the engine must contacts. The pressure switch is connected to the pneumatic
be shut down and hydraulic pumps shut off and lines actuation line of the dry chemical system. The relay coil is
depressurized. To accomplish this, it is necessary to wire the normally energized. When the pressure switch is activated by
shutdown of these devices into the CHECKFIRE SC-N pressure in the actuation line, the switch contacts will open.
Module shutdown relay contacts. A brief description of how Loss of power or an open circuit will cause the solenoid
this is accomplished is as follows: valves to transfer, thus shutting down the air supply.
Engine Shutdown – Engine shutdown can be accomplished Another means available for fuel shutdown is to
through a normally energized fuel solenoid (supplied by pneumatically shutdown the fuel rack by venting the hydraulic
others) which is wired in series with the normally closed pressure through the “safety system.” This can be
“shutdown” relay contacts of the CHECKFIRE SC-N Control accomplished by installing the Ansul Engine Shutdown
Module or in a pressure switch. These “shutdown” relay Device, Part No. 427425, in the dry chemical system
contacts will operate (open) after the first time delay cycle is actuation line. (This is normally only an option on some
complete on the module. underground mining applications.) When the Ansul fire
Hydraulic Fluid Tank Air Shut Off and Venting – Solenoid suppression system is actuated, the actuation pressure
valves (supplied by others) can be connected to air vents of opens the check valve located in the engine shutdown
the hydraulic tank. They can be wired to N.O. contacts on a device, allowing the safety system pressure to bleed into the
relay(supplied by others). A solenoid (supplied by others), holding tank. The drop in pressure causes the valves in the
connected to the air supply line, if used, going to the hydraulic fuel rack to close, thus shutting down the engine. See
tank, can be wired to N.C. contracts of the same relay. The Figure 18.
FROM AUTOMATIC
REMOTE DETECTION SYSTEM
ACTUATOR

265 PSI
RELIEF VALVE

(2) 7/16 IN.

CLEARANCE
MOUNTING
HOLE

PORT #3 IN
(265 PSI ACTUATION PRESSURE
FROM ANSUL ACTUATION LINE)

PORT #2 OUT
(RETURN TO
HYDRAULIC
TANK)

PORT #1 IN
(VEHICLE HYDRAULIC SAFETY
SYSTEM LINE PRESSURE)
FIGURE 18
004668

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ACCESSORIES
Accessories can be added to the pneumatic actuation line to
mechanically shut off fuel, electrically shut off engines, and
electrically sound alarms.

Air Cylinder
This component is a system accessory whose function is to
shut off the fuel supply to the engine when the fire
suppression system is actuated.
The fuel shut-off is a spring-return rocker arm on the side of
the engine which has a cable link to the vehicle dashboard.
The air cylinder rod will tie into this rocker arm, in parallel to,
but not interfering with, the operator's cable control. See
Figure 19.
NOTE: WHEN USING AN LT-10 CARTRIDGE, AT 125 FT. OF HOSE, THE MAXIMUM
FORCE AT THE AIR CYLINDER IS 70 LBS.

MANUAL SHUT DOWN

ROCKET
ARM

FUEL
MANIFOLD
AIR
CYLINDER

ACTUATION HOSE LINE

FIGURE 19
003489

Pressure Switch
Two styles of pressure switches are available for various
electrical functions:
PRESSURE SWITCH PART NO. 46250 (Weatherproof) –
This pressure switch is a single pole, double throw (SPDT)
pressure switch constructed with a gasketed, water tight
housing. The switch is rated at 10A – 125V, 5A – 250 VAC.
This switch is suitable for outdoor applications.
PRESSURE SWITCH PART NO. 8372 (Non-
Weatherproof) – This pressure switch is a single pole,
double throw (SPDT) pressure switch. It is rated at 15A, 125,
250, or 480 VAC, 1/4 HP at 125 VAC, 1/2 HP at 250 VAC, or
1/2 A at 125 VDC. This switch is not weather-proof and
should not be used for outdoor applications.
PRESSURE SWITCH PART NO. 43241 – This pressure
switch is a double-pole, double-throw (DPDT) pressure
switch. The switch is constructed with an explosion-proof
housing suitable for hazardous environments. The switch
contacts are rated at 10 amp at 125 VAC or 5 amp at
250 VAC.
NOTE: When installing pressure switches in the actuation
line, the hose running to the switch must always be located
downstream of any actuation check valves.

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Service and Repair Manual LH204
5-15-02 Page 5-1
REV. 1

SYSTEM DESIGN – INDUSTRIAL 4. Ventilation Considerations

The following are typical industrial type hazards which can be The hazard ventilation system is very important when
protected by using the total flooding method: flammable liquid considering total flooding application, but should also be
storage, dip tanks, solvent cleaning tanks, transformer vaults, considered for local application overhead and tankside.
quench tanks, and furnace rooms. The ventilation system should be shut down and/or
dampered before or simultaneously with the start of the
HAZARD ANALYSIS A-101/LT-A-101 system discharge.
A thorough hazard analysis is required to determine the type 5. Electrical Considerations
and quantity of protection required.
It is recommended that all electrical power sources
Review each of the following requirements when doing a associated with the protected hazard be shut down before
hazard analysis: system discharge. This eliminates the potential of a fire
1. Hazard Type being electrically-reignited.
Record the size of the hazard, any obstructions, 6. Temperature Range
unclosable openings, size and location of external The following temperature ranges must be determined
ductwork or anything else which would concern system and noted to ensure proper placement and operation of
perfor mance. Briefly describe the type of hazard being the A-101 system:
protected. If protecting prefabricated booths, record the
manufacturer model number and anything unique about Hazard Area: Determine the minimum and maximum
the hazard. temperature of the hazard to be protected. This
temperature may be any temperature that the distribution
2. Hazard Atmosphere piping and detectors can withstand – only if the agent tank
The A-101/LT-A-101 system can be used in most and accessories are located outside of the hazard area.
industrial environments. If the hazard atmosphere is Agent Tank: The temperature range for all applications is
considered corrosive, such that the solvents, chemicals, +32 °F to +120 °F (0 °C to +48 °C) for standard type
or gases present are damaging to the A-101 system tank A-101 tanks and –65 °F to +210 °F (–54 °C to +99 °C) for
or actuators, the hardware should not be located in the LT-A-101 low temperature type tanks.
hazard. When protecting an area defined as hazardous
per NFPA 70 National Electric Code, Article 500, only DISTRIBUTION SYSTEM REQUIREMENTS
equipment that has been listed or approved for the
hazardous location, may be located in that area. The distribution system for industrial hazards must follow the
same requirements as listed for vehicle systems. See
3. Hazardous Materials Section IV, SYSTEM DESIGN – VEHICLE, for detailed hose
The A-101/LT-A-101 system uses FORAY (ABC) dry requirements for agent distribution and actuation/expellant
chemical as the extinguishing agent. The agent gas lines.
effectiveness and limitation is based on its ability to
suppress the fire with the design parameters of the Exception: For industrial hazards, only F-1/2 nozzles, Part
preengineered system. No. 16449, are approved for total flood.
a. FORAY dry chemical is effective on the following types NOZZLE COVERAGE
of fire materials: The only nozzle approved for use with A-101/LT-A-101
Class A – Surface Fires: These fires involve ordinary industrial total flooding protection is the F-1/2 nozzle.
combustible materials such as cloth, paper, rubber, and
many plastics. Single System Capabilities
Class B – Flammable Liquid and Gas Fires: These
Model 10 lb. 20-lb. 30-lb.
fires involve such materials as oils, grease, tars, oil-
based paints, lacquers, and gasoline. Total 350 cu. ft. Max 700 cu. ft. Max .1000 cu. ft.
Max.
Class C – Energized Electrical Equipment Fires: Flooding (9.9 cu. m) (19.8 cu. m) (28.3 cu. m)
Common Class C devices include control rooms, 5 ft. x 10 ft. x 10 ft. x 10 ft. x 10 ft. x 10 ft. x
transformers, oil switches, circuit breakers, rotating 7 ft. high 7 ft. high 10 ft. high
equipment, pumps, and motors. (1.5 x 3.0 x (3.0 x 3.0 x (3.0 x 3.0 x
b. FORAY dry chemical is NOT effective on the following 2.1 m) 2.1 m) 3.0 m)
types of fire materials:
Maximum No.
Deep-seated Class A Materials: Deep-seated or
of Nozzles (2) Two F-1/2 (4) Four F-1/2 (4) Four F-1/2
burrowing fires in ordinary combustibles where the
FORAY dry chemical cannot reach the point of See Figure 1 through 3 for nozzle layouts.
combustion.
Class D – Combustible Metals: Class D type
materials are reactive such as sodium, potassium,
magnesium, and titanium.
Chemicals Capable of Rapid Oxidation: Chemicals
or mixtures of chemicals such as cellulose nitrate.

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REV. 1

NOZZLE COVERAGE (Continued)

10 LB. FIRE SUPPRESSION SYSTEM – TOTAL FLOODING APPLICATION (2 NOZZLES)

5 FT. 0 IN.
(1.5 m) MAXIMUM
10 FT. 0 IN.
(3.1 m) MAXIMUM

F-1/2 NOZZLES (2) – 7 FT. 0 IN.

PART NO. 16449 3/4 X 1/2 X 1/2 (2.1 m) MAXIMUM
REDUCING TEE

3/4 IN.
HOSE

NOZZLE
DIRECTIONS

FIGURE 1
003501

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REV. 1

Nozzle Coverage (Continued)

20 LB. FIRE SUPPRESSION SYSTEM – TOTAL FLOODING APPLICATION

1/2 IN.
HOSE
10 FT. 0 IN. (3.1 m)
10 FT. 0 IN. (3.1 m)
MAXIMUM
MAXIMUM

7 FT. 0 IN. (2.1 m)

MAXIMUM
F-1/2 NOZZLES (4)
– PART NO. 16449

3/4 IN.
HOSE

5 FT. 0 IN.
(1.5 m)
MAXIMUM

NOZZLE
DIRECTIONS

FIGURE 2
003505

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REV. 1

Nozzle Coverage (Continued)

30 LB. FIRE SUPPRESSION SYSTEM – TOTAL FLOODING APPLICATION

1/2 IN.
HOSE
10 FT. 0 IN. (3.1 m) 10 FT. 0 IN. (3.1 m)
MAXIMUM MAXIMUM

10 FT. 0 IN. (3.1 m)

MAXIMUM
F-1/2 NOZZLES (4) –
PART NO. 16449

3/4 IN.
HOSE

5 FT. 0 IN.
(1.5 m)
MAXIMUM

NOZZLE
DIRECTIONS

FIGURE 3
003505

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REV. 1

INSTALLATION INSTRUCTIONS NOTE: The tank must be located in an area that will not
exceed temperature limitations or be subject to fire or
The installation of an Ansul A-101/LT-A-101 Fire Suppression damage.
system is based on the sketch developed in the System
Design Section IV.
When deciding on locations for mounting the agent tanks,
pneumatic actuators and manual actuators, locate areas
where the components will not be abused or will not interfere
with vehicle operation. Keep in mind not only the
requirements for each individual component, but how the
components are connected, and the maximum hose lengths
required between each component.
Although the sequence of installation steps may vary with
each installation, a basic A-101/LT-A-101 installation consists NOTE: TANK SHOULD BE MOUNTED IN THE UPRIGHT POSITION SHOWN (SOLID
of four general procedures: mounting the brackets, installing LINES), BUT DISCHARGE WILL NOT BE IMPAIRED IF THE CENTER LINE OF
the components, connecting the hoselines, and finally, THE MOUNTED TANK DOES NOT EXCEED 45° LEFT OR RIGHT OF TRUE
VERTICAL.
installing the gas cartridges.

MOUNTING THE BRACKETS

Nozzle Bracket
The first step is to mount the nozzle brackets. Plan to attach
nozzle brackets to secure places that will not be subjected to
abuse and make sure the locations will not interfere with FORWARD TIP,
DO NOT TIP
BACKWARD
operator or vehicle functions. 45° MAXIMUM

NOTICE
When mounting the nozzle brackets, make
certain the mounting surface is rigid and that it
is allowed by the vehicle manufacturer to weld FIGURE 2
003508
or bolt onto that surface.
1. Remove the agent tank from the bracket and weld the
1. Based on the layout sketch, locate a secure place for
bracket to the mounted surface. The bracket can be
mounting the nozzle bracket so that the nozzle will be
secured at the base, at the back, or both, depending on
properly aimed, and weld the bracket to the mounting
the mounting surface. If the bracket cannot be welded,
surface. When welding the bracket, make certain there is
bolting is acceptable. 7/16 in. mounting holes are
enough weld to keep the bracket properly in place. See
provided in the bracket to accommodate 3/8 in. fasteners.
Figure 1.
See Figure 3. Make certain when mounting the bracket
that the clamp arms can swing open wide enough for
WELD removal of the tank when required.

FIGURE 1
003507

If welding is not possible, the bracket can be drilled and

bolted to the mounting surface with the appropriate
fasteners. Make certain the bolting method does not allow
the mounting bracket to rotate out of position or interfere
with the nozzle discharge.
NOTE: A minimum of two bolts are required for proper
mounting.
BOLT OR WELD EXTINGUISHER TO VEHICLE –
Tank Bracket 3/8 IN. DIAMETER BOLT REQUIRED FIGURE 3
NOTICE 003508

The location of the tank must not cause the

hose length limitations to be exceeded.
When deciding on a mounting location for the agent tank,
locate a rigid area where the tank can be mounted in an
upright position. If necessary, the tank can be mounted up to
45° tilted to the left or right of true vertical, or tipped 45°
forward from true vertical. The agent tank cannot be tipped
backwards. See Figure 2.

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REV. 1

Cartridge Bracket MOUNTING THE DISTRIBUTION, REDUCING, AND

When installing low temperature or low profile type systems, it TRIPLE TEES
is necessary to mount the remote cartridge bracket also. The Based on the sketch done in the Design Section, locate each
location of this bracket must be such that the length of 1/4 in. tee at a point which will not cause the supply line and branch
hose between the bracket and the pneumatic inlet on the line lengths to be exceeded.
agent tank does not exceed 20 ft. (6.1 m) and the 1/4 in. hose
from each remote actuator does not exceed 100 ft. (30.5 m) 1. All distribution network fittings must be welded or clamped
with 10 actuators maximum or 125 ft. (38.1 m) with to the mounting surface. See Figure 5. All welds must be
8 actuators maximum for LT-10 cartridges. made before any hose has been installed to avoid
damage to the hose due to high welding temperatures.
1. Remove the cartridge from the bracket. Locate a rigid,
protected surface and weld or bolt the cartridge bracket 2. When locating tees, make certain the locations do not
securely. When bolting the bracket, use 5/16 in. fasteners. cause the hose to be exposed to extreme heat or physical
Make certain mounting location allows for easy removal of abuse.
the cartridge when required. 3. Make certain the end tees on the triple tee are not twisted
NOTE: The cartridge must be located in an area that will not from their original position. See Figure 5.
exceed temperature limitations or be subject to fire or damage. TRIPLE TEE
BOLT OR WELD APPROPRIATE “C” CLAMP TO
FIT AROUND 1 1/4 IN. DIAMETER TO VEHICLE
Remote Actuator Bracket
A remote manual actuator must be located in the drivers
compartment within reach of the operator, and a remote
manual actuator should be located at a point on the vehicle
accessible from ground level. When mounting any actuator,
make certain the length of hose between the actuator and the
tank or remote expellant gas cartridge does not exceed 100 ft.
(30.5 m) with 10 actuators maximum or 125 ft. (38.1 m) with 8
actuators maximum for LT-10 cartridges or 75 ft. (22.9 m) with
8 actuators maximum using an LT-5 cartridge. Also, make DISTRIBUTION TEE
certain there is enough room for cartridge removal. BOLT OR WELD APPROPRIATE “C” CLAMP TO
FIT AROUND 2 1/8 IN. DIAMETER TO VEHICLE
NOTE: The actuator must be located in an area that will not
exceed temperature limitations or be subject to fire or damage.
Try to avoid mounting actuator near engine compartment.
1. Choose a suitable mounting location and weld or bolt
each actuator bracket in place. If bolting the bracket(s),
use 3/8 in. fasteners. If welding, to avoid corrosion, paint
welded surface. See Figure 4.
2. If mounting the remote manual actuator in the dashboard
of a vehicle, the actuator can be mounted by drilling a REDUCING TEE, 1/2 IN. X 1/2 IN. X 3/4 IN.
1 5/16 in. (33.3 mm) diameter hole as shown in Figure 4.
Make certain there is enough room for the actuator body, BOLT OR WELD APPROPRIATE “C” CLAMP TO
cartridge and 1/4 in. actuation line connection under the FIT AROUND 3/4 IN. DIAMETER TO VEHICLE

dash.
“L” BRACKET “S” BRACKET

MOUNTING
BRACKET

WELD FIGURE 5
003513
IF BOLTING, USE (2)
3/8 IN. CORROSION
RESISTANT BOLTS

3/8 IN. CORROSION RESISTANT

TYPE\ (TYP. 4 PLACES)
MOUNTING HOLE FOR CARTRIDGE GUARD ACTUATOR
DASHBOARD LOCATIO

BOLT OR
WELD BACK
ENCLOSURE

1 5/16 IN.
DIAMETER
HOLE

FIGURE 4

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ID: BG00398452 en-US A.001.1 2015-10-19
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Service and Repair Manual LH204
5-15-02 Page 6-3
REV. 2

INSTALLING THE COMPONENTS Installing Manual Actuators

Installing the Tank Three types of manual actuators brackets are available for
the A-101/LT-A-101 system: “S” bracket, “L” bracket, and
1. Check each tank to make certain it is filled to its rated cartridge guard. Location of all actuators must be visible and
capacity with FORAY dry chemical. Then, re-tighten fill easily reached by operator. Location must not expose
cap. actuator to physical abuse. Actuators using the “S” bracket
2. Unscrew the bursting disc union and check that the disc is and the cartridge guard type bracket are suitable for both
free from wrinkles, dents or other deformities. internal and external mounting. The “L” type bracket is not
3. Reconnect the bursting disc union. Use a good grade of suitable for external mounting and must be installed in a way
extreme temperature silicone grease, such as Dow that will provide protection for the exposed cartridge.
Corning No. 4 or equal, on the male threads to facilitate REMOTE MANUAL ACTUATOR WITH “S” BRACKET
removal during maintenance. 1. If not already done, weld or bolt mounting bracket to the
4. Position the tank(s) in the mounting bracket(s), and secure selected surface. If welding, to avoid corrosion, paint
clamps or retaining bolts. welded surface. See Figure 4.
Installing the Nozzles
NOTICE
1. Refer to this system layout sketch from the Design Where bolting the mounting bracket is
Section IV. This sketch should give you the information performed, use 3/8 in. (corrosion-resistant)
concerning what nozzle to use where and the correct bolts of appropriate length with lockwashers
aiming point. and nuts.
2. Choose the correct nozzle(s) for each hazard area. 2. Unscrew the RED actuator button from the actuator stem,
3. Install nozzle(s) in bracket by using two lockwashers, and remove locknut, and slide actuator body through mounting
either 1/2 in. elbow(s) or coupling. See Figure 6. Aim the hole on bracket. See Figure 7.
nozzle correctly and securely tighten. 3. Rotate actuator body for desired location of actuation hose
outlet connection. Screw locknut firmly onto actuator body
and insert ring pin. Apply a non-permanent thread
adhesive, such as Locktite 242 or equal, to the RED
actuator button threads and then screw button onto the
stem. See Figure 7.

RED ACTUATOR
BUTTON

LOCK NUT

MOUNTING
BRACKET
ACTUATOR
BODY

RING PIN
FIGURE 6 AND CHAIN
003515

4. Either install nozzle blow-off cap(s) or pack nozzle

opening(s) with silicone grease to avoid build-up of foreign
materials.
NOTE: The F-1/2 nozzle is the only nozzle which silicone
grease can be used in the opening. FIGURE 7
000485

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REV. 2

INSTALLING THE COMPONENTS (Continued) 2. Unscrew RED actuator button from actuator stem, remove
locknut, and slide actuator body through mounting hole.
Installing Manual Actuators (Continued) See Figure 11.
4. Affix the appropriate operating nameplate adjacent to the 3. Rotate actuator body for desired location of actuation
manual actuator so that it is visible to attending personnel. hose outlet connection. Screw locknut firmly onto actuator
See Figure 8. body and insert ring pin. Apply a non-permanent thread
adhesive, such as Locktite 242 or equal, to the RED
actuator button threads and then screw the button onto
NAME PLATE the stem. See Figure 11.
NOTICE
The ring pin chain may not be long enough in
certain dashboard mounted locations. When
this occurs, remove the chain from the drive pin
in actuator body and attach it to an appropriate
location using either a pop rivet or a sheet
metal screw. See Figure 11.

LOCK NUT RED

FIGURE 8 ACTUATOR
000486 BUTTON
ACTUATOR
5. Make certain ring pin is inserted through the RED actuator HOSE OUTLET
button to ensure safe cartridge installation. See Figure 9. CONNECTION

6. Seal ring pin to actuator stem with visual inspection seal, ACTUATOR
BODY
Part No. 197. Make cer tain visual inspection seal is looped
through ring pin and around actuator stem. Do not wrap
seal around the boot cover. See Figure 9. DO NOT POP RIVET OR
SHEET METAL SCREW
INSTALL CARTRIDGE AT THIS TIME. RING PIN
AND CHAIN
RED ACTUATOR
BUTTON PLACE WIRE BETWEEN RED FIGURE 11
ACTUATOR BUTTON AND 003517
BOOT COVER BOOT COVER
4. Affix the appropriate operating nameplate adjacent to the
WIRE manual actuator and visible for attending operator. See
RING PIN
Figure 12.
5. Make certain ring pin is inserted through the RED actuator
button to ensure safe cartridge installation. See Figure 12.
6. Seal ring pin to actuator stem with visual inspection seal,
Part No. 197. Make cer tain visual inspection seal is looped
NOTE: DO NOT APPLY
WIRE AROUND through ring pin and around actuator stem. Do not wrap
BOOT COVER. seal around the boot cover. See Figure 12. DO NOT
FIGURE 9 INSTALL CARTRIDGE AT THIS TIME.
000487

REMOTE MANUAL ACTUATOR MOUNTED IN DASHBOARD

1. Punch or drill a 1 5/16 in. (33.3 mm) diameter hole for
mounting the actuator body. See Figure 10. Make certain
there is enough room under the dash for the actuator NAME PLATE
body, cartridge, and the 1/4 actuation hose connection.

1 5/16 IN.
(33.3 mm)
DIAMETER

FIGURE 12
000486

FIGURE 10
003511

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REV. 2

INSTALLING THE COMPONENTS (Continued) INSTALLING THE DISTRIBUTION NETWORK

Installing Manual Actuators (Continued) General Requirements
REMOTE MANUAL ACTUATOR WITH “L” BRACKET Refer to the system layout sketch completed in the Design
Section IV. Make certain all hose lengths do not exceed the
NOTICE maximum allowed.
Actuator must be installed in a way that will When installing the distribution hose, once again remember
provide protection for the exposed cartridge the following:
from physical damage. 1. Make certain the proper type and size of hose is used.
1. If not already done, weld or bolt mounting bracket to the 2. In order to obtain equal distribution at a tee, the center
selected surface. If welding, to avoid corrosion, paint opening must be used as an inlet and the opposing
welded surface. See Figure 4. openings used as outlets.
3. When any 90° bend or elbow is located in the distribution
NOTICE
hoseline preceding a tee, a minimum length of 20 hose
Where bolting the mounting bracket is diameters is required between the 90° bend and the tee.
performed, use 3/8 in. (corrosion-resistant) This length of hose is called a “critical length” and exists
bolts of appropriate length with lockwashers only when the 90° bend and the tee lie in the same plane.
and nuts.
4. The use of street elbows is not allowed.
2. Unscrew the RED actuator button from the actuator stem
5. Per SAE J1273, “Care must be taken to insure that fluid
and slide actuator body through mounting hole on bracket.
and ambient temperatures, both static and transient, do
3. Rotate actuator body for desired location of actuation hose not exceed the limitations of the hose. Special care must
outlet connection. Screw locknut firmly onto actuator body be taken when routing near hot manifolds.”
and insert ring pin. Apply a non-permanent thread 6. Use of 90° elbows is allowed if the following requirements
adhesive, such as Locktite 242 or equal, to the RED are not exceeded:
actuator button threads and then screw button onto the
– Maximum of 4 elbows from the agent tank to any nozzle
stem.
– Maximum of 2 elbows in a primary branch line
4. Affix the appropriate operating nameplate adjacent to the – Maximum of 2 elbows in a secondary branch line
manual actuator so that it is visible to attending personnel. – Minimum of 1 elbow from agent tank to a nozzle
5. Make certain ring pin is inserted through the RED actuator 7. When bends are formed in the distribution hose, the
button to ensure safe cartridge installation. following minimum bend radius must not be exceeded:
6. Seal ring pin to actuator stem with visual inspection seal, Hose Size 100RI 100R5
Part No. 197. Make cer tain visual inspection seal is looped 1/4 in. 4 in. 3 in.
through ring pin and around actuator stem. Do not wrap 1/2 in. 7 in. 5 1/2 in.
seal around the boot cover. See Figure 9. DO NOT 3/4 in. 9 1/2 in. —
INSTALL CARTRIDGE AT THIS TIME. 7/8 in. 11 in. 7 3/8 in.
NOTE: Minimum bend radius measured to inside of hose
REMOTE MANUAL ACTUATOR WITH CARTRIDGE GUARD radius.
1. Remove back box from actuator assembly. Distribution Hose Installation
2. If not already done, weld or bolt back enclosure to the
selected surface. If welding, to avoid corrosion, paint 1. Starting at the tank outlet, connect the distribution hose
welded surface. See Figure 4. from the bursting disc union to the triple, distribution, or
reducing tee. Make certain hose is routed in an ordering
NOTICE manner and avoid routing hose through fire hazard areas
if possible.
Where bolting the back enclosure is performed,
use 3/8 in. (corrosion-resistant) bolts of 2. After hose has been connected, tighten bursting disc union.
appropriate length with lockwashers and nuts. 3. Follow the sketch (completed in Hazard Analysis portion of
Design Section IV) and complete all hose branch line runs.
4. When connecting the hose to each nozzle, make certain
the aiming angle of each nozzle is not disturbed.
5. When routing hose through bulkheads, take precautions to
protect the hose from excessive wear due to constant
vehicle vibration.
6. When all distribution hose has been routed, make certain
all fittings are wrench tightened.
7. Finally, clamp the discharge hose securely at least every
five feet using industrial duty cable ties or conduit clamps.
8. When passing through bulkheads or grates, Schedule
40 nipples up to 6 in. in length may be used in the distribution
line. (Refer to NFPA17, Section 2-5 (Pipe and Fittings)).
NOTE: 3/4 in. and 1/2 in. Quik-Seal Adaptors can also be
used.

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6-6 Repair Manual LH204
REV. 2

INSTALLING ACTUATION AND EXPELLANT GAS LINES Installing The Actuation Gas line(s) and Pneumatic
Actuator(s)
General Requirements
1. Use only 1/4 in. hose for actuation and expellant gas lines NOTICE
when used on mobile or vibrating type of installations. When installing actuation gas lines, teflon tape
Hose must meet the specifications noted in Design must be utilized on all male threads. Do not
Section, Pages 4-3 through 4-4. allow tape to overlap the pipe opening, as this
2. On non-mobile or non-vibrating type installations, 1/4 in. could cause possible blockage of the gas
pipe is acceptable. Pipe must be 1/4 in. Schedule 40 black pressure. Thread sealant or compound must
iron, hot-dipped galvanized, chrome-plated, or stainless not be used.
steel pipe and fittings conforming to ASTM A120, A53, or The actuation gas line is the 1/4 in. hose installed from the
A106. Refer to Design Section for maximum allowable remote manual/automatic actuator(s) to the pneumatic
lengths. actuators(s) on the agent tank expellant gas cartridge(s). See
3. When using pipe, make certain all ends are carefully Figure 13.
reamed and blown clear of chips and scale. Inside of pipe A-101 SYSTEM
and fittings must be free of oil and dirt.
REMOTE MAXIMUM LENGTH 100 FT. (30.5 m) FOR LT-10 CARTRIDGE FROM
4. When using pipe, the pipe and fitting connections must be ACTUATOR REMOTE ACTUATOR TO LAST TANK (SEE NOTES 1 AND 2)
second male thread and wrap the tape (two turns SAFETY RELIEF
CHECK VALVE
maximum) clockwise around the threads, away from the VALVE
pipe opening.

NOTICE
Do not allow tape to overlap the pipe opening,
as this could cause possible blockage of the
gas pressure. Thread sealant or compound CHECK
VALVE
must not be used.
5. When passing through bulkheads or grates, up to 6 in. of ACTUATOR
Schedule 40 pipe may be used in the actuation and/or
expellant gas lines. (Refer to NFPA17, Section 2-5 (Pipe NOTE: A MAXIMUM OF (10) TEN A-101 SYSTEMS CAN BE ACTUATED SIMULTANEOUSLY
IN ANY COMBINATION (I.E., A-101, LT-A-101, LP-A-101, OR LT-LP-A-101) (SEE NOTES 1
and Fittings)). NOTE: 1/4 in. Quik-Seal Adaptors can also AND 2)
be used. LT-A-101 SYSTEM
6. Cast iron pipe and fittings are not allowed. ACTUATOR MAXIMUM LENGTH 100 FT. (30.5 m) FOR LT-10
REMOTE CARTRIDGE FROM REMOTE ACTUATOR TO LAST
7. Per SAE J1273, “Care must be taken to insure that fluid ACTUATOR PNEUMATIC ACTUATOR (SEE NOTES 1 AND 2)
and ambient temperatures, both static and transient, do SAFETY
not exceed the limitations of the hose. Special care must RELIEF
VALVE
be taken when routing near hot manifolds.” CHECK
VALVE

CHECK
VALVE MAXIMUM
EXPELLANT
GAS HOSE
LENGTH,
20 FT. 0 IN.
(6.1 m)
(EACH)

NOTE: REDUCE THE MAXIMUM ALLOWABLE NUMBER OF BASIC EXTINGUISHING

UNITS BY ONE FOR EACH NON-EXTINGUISHING PNEUMATICALLY OPERATED DEVICE
EMPLOYED, I.E., BRAKE CONTROL VALVE, FUEL CONTROL AIR CYLINDER.

FIGURE 13
If more than one remote actuator is in the system, the total
length of actuation line allowed from the actuator to the last
tank must also include any amount of hose in the other
actuation lines up to the check valves located in those lines.
NOTE 1: If only eight (8) or less actuators are used, the
actuation line can be extended to 125 ft. (38.1 m) when using
an LT-10 nitrogen cartridge.
NOTE 2: The actuation line can also utilize an LT-5 cartridge.
When this is done, only eight (8) actuators or less can be
used, with a maximum length of 75 ft. (22.9 m).

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INSTALLING ACTUATION AND EXPELLANT GAS LINES INSTALLING THE DETECTION SYSTEM
(Continued)
When automatic detection is part of the total system design,
Installing The Actuation Gas line(s) and Pneumatic see the appropriate Design, Installation Man ual for detailed
Actuator(s) (Continued) Information.
• CHECKFIRE ELECTRIC SERIES I SYSTEM – Manual Part
Complete the installation of all dry chemical actuation lines
No. 54894
and components by completing the following:
• CHECKFIRE SC-N ELECTRIC SYSTEM – Manual Part No.
1. Install all pneumatic actuators as follows:
423522
a. When removing actuator from the carton, check pin to
• CHECKFIRE MP-N ELECTRIC SYSTEM – Manual Part
make certain it is in the upright position. See Figure 14.
No. 427310
INSTALLING ACTUATION CARTRIDGES
1. Weigh each manual actuator cartridge to make certain it is
within the weight specifications stamped on the cartridge
body. This weight check must be performed with the
1/4 IN. (6.4 mm) shipping cap removed. Refer to appropriate manual for
MINIMUM detailed installation instructions if the system contains an
automatic CHECKFIRE Detection System.
2. Check that the puncture pin in each manual actuator is fully
FIGURE 14 retracted so that the pin will not pierce the cartridge seal
004357 during installation.
b. Securely hand tighten the pneumatic actuator cartridge 3. Install an LT-10 nitrogen cartridge into each manual
body to cartridge. actuator and hand tighten firmly.
c. Position actuator and cartridge assembly into bracket. 4. At this time, the cartridge may be installed in the
d. Using two wrenches, one on the swivel nut and one on CHECKFIRE detection system actuator.
the bottom portion, loosen the swivel nut, and rotate 5. Finally, document the entire installation with drawing,
the top portion of the actuator to the correct position to photographs, and/or written description of the entire
align the two actuation line ports with the incoming and vehicle system and store these documents in a permanent
outgoing 1/4 in. actuation line(s). file for future reference.

! CAUTION

Each actuator contains two (2) 1/4 in. actuation ports. If

both ports are not utilized, the open port must be plugged
with a 1/4 in. pipe plug. Failure to plug the port will cause
loss of actuation gas pressure upon system actuation.
2. Install required 1/4 in. actuation lines from the remote
actuator outlet port to all actuation ports on the upper
portion of each pneumatic actuator.
3. Once all lines are securely installed, wrench tighten the
swivel nut on the upper portion of each pneumatic
actuator.
Installing Expellant Gas Line(s)
The expellant gas line is the 1/4 in. line between the remote
expellant gas cartridge and the agent tank. The gas line is
only required when the system is using either an LT or LP
type tank. See Figure 13.
The maximum length of 1/4 in. expellant gas line is 20 ft.
(6.1m).
Make certain the hose meets all the requirements as stated in
the Design section.

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SECTION VII – INSPECTION
Service and Repair Manual LH204
5-15-02 Page 7-1
REV. 2

INSPECTION
Inspection is a “quick check” that the system is operable. It is
intended to give reasonable assurance that the system is fully
charged and will operate. This is done by seeing that the
system has not been tampered with and there is no obvious
physical damage, or condition, to prevent operation. The
value of an inspection lies in the frequency, and thoroughness
with which it is conducted.
The system shall be inspected visually every 250 hours of
vehicle use or monthly (whichever comes first) by competent
personnel following an approved schedule necessitated by
conditions as determined by the operator.
To provide reasonable assurance that your Ansul
A-101/LT-A-101 system is charged and operable:
1. Note general appearance of system components for
mechanical damage or corrosion.
2. Check all hose to make certain it is securely fastened and
not cut or show signs of abrasion.
3. Make certain all hose fittings are tight.
4. Make certain the nozzles are correctly aimed, openings
are clean and not obstructed and the blow off caps are
properly installed.
5. Check nameplate(s) for readability and make certain they
are properly attached.
6. The automatic detection system should be inspected as
follows: If system is equipped with a CHECKFIRE SC-N or
MP-N electric automatic detection system, make cer tain
green “Power” LED is blinking. If system is equipped with
a CHECKFIRE Series I, push button on top of module and
note illumination of indicator light. If the system is equipped
with a CHECKFIRE Series II, push and hold the
test/control button momentarily. The internal alarm will
sound and the two outside LED's will flash. If system is
equipped with a CHECKFIRE pneumatic detection
system, make certain yellow “Low Pressure” indicator light
is not on.
7. Check to make certain hazard size or components being
protected have not changed since original installation.
8. If there are any broken or missing lead and wire seals, or
any other deficiency is noted, immediately contact the
authorized Ansul Distributor.
9. Keep a permanent record of each inspection.

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SECTION VIII – MAINTENANCE
Service and Repair Manual LH204
5-15-02 Page 8-1
REV. 2

MAINTENANCE 13. Clean actuator(s) (Part No. 430221) as follows: (See

Figure 1)
Maintenance is a “thorough check” of the system. It is
intended to give maximum assurance that the system will – Using two wrenches, one positioned on the swivel nut, and
operate effectively and safely. It includes a thorough one positioned on the bottom por tion of the actuator,
examination and any necessary repair or replacement. It will loosen the swivel nut and remove the top portion of the
normally reveal if there is a need for hydrostatic testing of the actuator.
tank. – Using a wooden dowel, push pin assembly and spring out
Maintenance shall be performed every 1000 hours or semi of the actuator body.
annually (whichever comes first). The fire suppression – Remove the gasket from inside the cartridge thread port.
system including alarms, shutdown and associated Inspect, clean, apply a good grade of low temperature
equipment shall be thoroughly examined and checked for grease, such as Dow Corning No. 4, and reinstall the
proper operation by the fire protection manufacturer, gasket. Replace if necessary.
authorized distributor or their designee in accordance with – Remove the O-Rings from the pin assembly and swivel
this manual. adaptor. Inspect, clean, apply a good grade of low
SEMI-ANNUAL/1000 HOUR MAINTENANCE temperature grease, such as Dow Corning No. 4, and
reinstall the O-Rings. Replace if necessary.
To provide maximum assurance that your Ansul
A-101/LT-A-101 system will operate effectively and safely: – Apply a small amount of grease to the puncture pin shaft.
There is a U-Cup guide inside the actuator body and when
1. Check to see that the hazard has not changed.
the pin is reinstalled into the body, the grease on the shaft
2. Remove all cartridges, install safety shipping caps, and will lubricate the U-Cup.
put in a safe place for future reinstalling.
– Clean the inner surface of the actuator body and, using a
3. Note the general appearance of the system components small diameter wire, clean the vent hole. Make certain not
checking for mechanical damage or corrosion, and check to scratch the inner surface.
that the components are securely fastened and all hose
– Reinstall spring onto puncture pin shaft and insert into
fittings are tight.
actuator body. Push pin down several times to allow
4. Check nameplates to make certain they are clean, grease to coat U-Cup. When positioned back in body,
readable, and properly attached. make certain the tip of the pin is above the gasket in the
5. Remove tank fill cap(s) and check that the agent tank is bottom of the actuator.
filled to approximately 3 in. (76 mm) from the bottom of the – Reinstall the actuator unto the cartridge. Hand tighten.
fill opening with Ansul FORAY dry chemical. Check the
– Reinstall swivel adaptor in the correct position for the
dry chemical for lumps.If lumps are present, drop one
actuation lines and wrench tighten the swivel nut. Make
from a height of 4 in. (102 mm) onto a hard surface. If the
certain all actuation and expellant lines are properly
lump does not break up completely, the dry chemical must
tightened into the actuator.
be replaced.
– Secure the assembly into the bracket.
6. Inspect threads on fill cap and on tank fill opening for SWIVEL NUT,
nicks, burrs, or cross-threading. PART NO. 430210

7. Check fill cap gasket and quad ring for elasticity, cuts, or
checking, and lightly coat them with an extreme
temperature silicone grease, such as Dow Corning No. 4
or equal.
SWIVEL ADAPTOR,
O-RING #119,
8. Disconnect bursting disc union and make certain the disc PART NO. 24899
PART NO. 430209
is free from wrinkles, dents or other deformities.
SLAVE PISTON,
9. Examine the disc to ensure that it is not wrinkled, kinked, O-RING #210,
PART NO. 56749
PART NO. 5151
dented, or deformed in any way and then apply a thin coat
of a good grade of extreme temperature silicone grease,
such as Dow Corning No. 4 or equal, to the male threads PUNCTURE PIN,
PART NO. 56104
and reconnect the bursting disc union. NOTE: Before
reconnecting, if needed, blow all lines clear with dry air or
nitrogen. SPRING,
10. Check that the nozzle openings are not obstructed and PART NO. 56105
that the nozzles are properly aimed and have not rotated
out of position.
11. Make certain each nozzle has a blow-off cap (the opening BODY,
PART NO. 430215
of an F-1/2 nozzle can be packed with an extreme
temperature silicone grease, such as Dow Corning No. 4
or equal, to avoid build-up of foreign material) and check VENT HOLE

that the caps are pliable and free of cuts and checks.
12. Unscrew the pneumatic actuator(s) from the cartridge
receiver(s) and inspect all threaded areas for nicks, burrs,
and cross threads. GASKET,
PART NO. 181
FIGURE 1
006195

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REV. 1

SEMI-ANNUAL MAINTENANCE (Continued)

14. Weigh the gas cartridge which was removed earlier. It
must be +/– 1/2 oz. from the weight stamped on the
cartridge. Weight cartridge with shipping cap removed.
15. Hand tighten the cartridge into the actuator.
16. Next, remove the gaskets from the manual remote
actuators. Examine them for elasticity, cuts, and checking
and lubricate them with a light coat of extreme
temperature silicone grease, such as Dow Corning No. 4
or equal.
17. Inspect the threaded areas for nicks, burrs, or cross
threading and clean them with a stiff bristle brush.
18. Make certain cartridge is removed. Pull the ring pin and
operate the manual actuator to test the puncture lever for
free movement.
19. Next, remove the puncture pin by disassembling the
actuator and examine the pin to ensure it is sharp,
straight, free of corrosion.
20. Lubricate the puncture pin O-ring and reassemble the
actuator.
21. Insert ring pin and install visual seal, Part No. 197, to each
actuator stem.
22. Weigh each actuator cartridge. Weight must be +/- 1/4 oz.
from weight stamped on cartridge. Weight cartridge with
shipping cap removed.
23. Install cartridge into each remote actuator. Hand tighten.
24. Refer to appropriate manual for detailed maintenance
instructions if the system contains an automatic
CHECKFIRE Detection System.
25. After all actuation devices are re-armed, record date of
maintenance and inform personnel that the system is
back in operation.
12-YEAR MAINTENANCE EXAMINATION
At the 12-year maintenance examination, along with
completing the semi-annual maintenance requirements,
some A-101 components require hydrostatic testing.
The components requiring hydrostatic testing are:
– Tank – 600 psi (40.8 bar) hydro pressure.
– Actuation hose – 1000 psi (69 bar) hydro pressure
– Cartridges – After properly discharging cartridge, return to
Ansul for hydrotesting
See appropriate hydrotest requirements in NFPA 17,
“Standard For Dry Chemical Extinguishing Systems,” and
Ansul Technical Bulletin No. 50, “Hydrostatic Retest
Requirements for Ansul portables, Wheeled Units, and
Pre-Engineered Vessels,” Form No. F-81301.

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SECTION IX – RECHARGE
Service and Repair Manual LH204
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REV. 2

RECHARGE 6. Remove the tank fill cap, discard any remaining dry
chemical, and fill each tank to its rated capacity with Ansul
The first concern in Recharge is to determine the cause of the FORAY dry chemical as specified on the nameplate.
system discharge and to have the problem corrected before
rearming the fire suppression system. 7. Before securing the fill cap, brush the dry chemical from
the threads on the fill cap and tank, and clean the gasket
In the event of system discharge, the vehicle must not be seating surface on the tank opening. Coat the gasket
returned to service until the system has been recharged. lightly with a good grade of extreme temperature silicone
The system must be recharged immediately after use. A fire grease, such as Dow Corning No. 4 or equal.
condition could cause damage to the hose and nozzles and 8. Secure the fill cap, hand tighten.
possibly support members. Check all hose supports, hose,
and all fitting connections. Take the nozzles off, inspect for 9. Loosen the bolts on the expellant gas cartridge bracket or
damage, corrosion, or obstructions, clean and re-install, remove the cartridge guard on the tank.
making certain they are aimed correctly. Blow-off caps must 10. Unscrew and remove the empty expellant gas cartridge.
also be replaced.
11. Disassemble and clean the cartridge actuator by following
See Figure 1 when following the recharge steps. the instructions stated in Step No. 13, Section VIII –
Maintenance.
12. Install new cartridge per the following chart. Before
installing, weigh car tridge to determine if it is within
specifications stamped on the cartridge. Weigh cartridge
with shipping capremoved.
Type of System Cartridge Part No.
A-101-10 15850 (DOT) 423439 (TC/DOT)
LT-A-101-10 423429 (TC/DOT)
A-101-20 423441 (TC/DOT)
LT-A-101-20 423435 (TC/DOT)
LT-LP-A-101-20 423435 (TC/DOT)
A-101-30 423443 (TC/DOT)
LT-A-101-30 423491 (TC/DOT)
13. Re-install car tridge guard or retaining bolts on car tridge
bracket.
14.Return tank(s) to its bracket and tighten securely.
15. Depending on the type, either pull up the red button or pull
up the puncture lever.
16. Remove spent cartridge. Weigh fully charged one, and
install. For actuation lines up to 125 ft. (38.1 m), install
LT-10 cartridge.
NOTICE
If automatic detection system was used, refer
to appropriate Installation, Recharge Manual
for detailed recharge instructions.
17. Insert ring pin in actuator stem and seal with visual seal,
Part No. 197.
18.Reconnect actuation and, if necessary, expellant gas
hose. Wrench tighten.
Figure 1 19.Notify operating personnel that the suppression system is
003519
back in service and record date of recharge.
1. Pull ring on safety relief valve to relieve actuation
pressure.
2. Disconnect actuation system hose at cartridge receiver/
actuation assembly.
3. Open bursting disc union assembly.
4. Remove dry chemical tank from its bracket.
5. Replace ruptured sealed bursting disc assembly. Remove
used sealed disc assembly from tank outlet. Clean tank
threads. Apply a non-permanent thread sealant or Teflon
tape to male threads on new burst disc assembly. Install to
tank outlet. Wrench tighten. NOTE: Before reconnecting, if
needed, blow all lines clear with dry air or nitrogen.

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SECTION X – SYSTEM APPLICATION OPTIONS
Service and Repair Manual LH204
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REV. 1

SYSTEM APPLICATION OPTIONS

In order to help understand the design process, the following Nozzle No. 3 and 4 – Located to provide protection for the
example hazards are covered in this section. There may be sidesof the engine. Each is mounted on the side of the engine
different design approaches that can be taken for each hazard, compartment in front and aimed toward the rear and center to
but the examples are only intended to show the typical areas completely cover the engine sides.
requiring protection and the number of nozzles and tanks
Nozzle No. 5 and 6 – Located at the top of the engine
required. They will give the designer an idea of what to look for
compartment toward each side. Each is positioned to
on these types of vehicles. Also, refer to appropr iate
discharge toward the rear and center of the engine and the
CHECKFIRE Design, Installation manual for detailed
turbocharger.
information concerning detection system requirements.
Nozzle No. 7 – Located under the operator's compartment
NOTICE
toward one side and aimed to discharge across the pan area.
These are conceptual drawings. They were In addition to the pan, its discharge will protect the parking
prepared from information provided through brake disc.
vendor's sales literature to assist field
installations. The fire suppression system Nozzle No. 8 – Located under the operator's compartment but
illustrated constitutes nominal hardware is positioned to discharge dry chemical on the hydraulic lines in
requirements. The detection system has not the compartment. It is oriented so a portion of its discharge will
been shown for the purpose of clarity. The final pass through the front bulkhead to protect the hydraulic lines
system design must consider other potential leading to the front bucket.
ignition and fuel source areas not in the NOTE: Larger front end loaders will require additional
vendor's literature, meaning a pre-installation protection.
in-depth analysis of all likely areas of probable
fire incident.
FRONT END LOADER (TYPICAL 2 TANK DESIGN)
Nozzle No. 1 and 2 – Located toward the lower rear of the
engine compartment and are aimed forward and toward the
center. They are positioned to provide complete coverage of
the entire pan area.

FIGURE 1
003520

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REV. 1

DOZER (TYPICAL 3 TANK DESIGN)

Nozzle No. 1 (N1) – Locate (1) C 1/2 nozzle to discharge dry Nozzle No. 7 (N7) – Locate (1) V 1/2 nozzle to discharge dry
chemical into the engine pan from front to back. chemical across front of engine from top to bottom.
Nozzle No. 2 (N2) – Locate (1) V 1/2 nozzle to discharge dry Nozzle No. 8 (N8) – Locate (1) C 1/2 nozzle to discharge dry
chemical diagonally over the top of the engine. chemical onto the side of engine diagonally from top to bottom.
Nozzle No. 3 (N3) – Locate (1) V 1/2 nozzle to discharge dry Nozzle No. 9 and 12 (N9 and N12) – Locate (2) V 1/2 nozzles
chemical screening right side of engine under exhaust back to back to discharge dry chemical screening hydraulic
manifold. lines and top of transmission, discharging from center to right
and left sides.
Nozzle No. 4 (N4) – Locate (1) V 1/2 nozzle to discharge dry
chemical screening left side of engine under exhaust manifold. Nozzle No. 10 (N10) – Locate (1) C 1/2 nozzle to discharge
dry chemical into the belly pan and bottom of the transmission.
Nozzle No. 5 (N5) – Locate (1) C 1/2 nozzle to discharge dry
chemical onto the side of engine diagonally from top to bottom. Nozzle No. 11 (N11) – Locate (1) V 1/2 nozzle to discharge dry
chemical over the top of the transmission from back to front
Nozzle No. 6 (N6) – Locate (1) V 1/2 nozzle to discharge dry
screening opening under cab and rear end.
chemical diagonally over the top of the engine.
NOTE: Larger dozers may require additional protection.

FIGURE 2
003521

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REV. 1

TRANSIT BUS (TYPICAL 1 TANK DESIGN)

Nozzle No. 1 (N1) – Locate (1) V 1/2 nozzle at upper left rear Nozzle No. 4 (N4) – Locate (1) V 1/2 nozzle at right side of
end of engine compartment aimed to discharge diagonally engine midway from front to back aimed from rear to discharge
across engine rear from top left to bottom rear protecting front across steering pump and air compressor at engine front.
of engine and pump filters.
Nozzle No. 5 (N5) – Locate (1) V 1/2 nozzle at right side of
Nozzle No. 2 (N2) – Locate (1) V 1/2 nozzle at top rear aimed engine between engine and bus right side aimed from back to
at center to discharge horizontally across engine top and turbo front to discharge horizontally across battery connections and
charger. hydraulic reservoir.
Nozzle No. 3 (N3) – Locate (1) V 1/2 nozzle on left side of Nozzle No. 6 (N6) – Locate (1) V 1/2 nozzle midway up at right
engine midway from front to back aimed from rear at an angle side of engine rear aimed from back to front to screen right
to discharge across rear left side of engine, back of engine, side of engine and starter.
and hydraulic lines protecting the generator as well as
discharging into transmission area.

TO REMOTE
ACTUATOR

FIGURE 3
003522

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REV. 1

LANDFILL COMPACTOR (TYPICAL 3 TANK DESIGN)

Nozzle No. 1 and 12 (N1 and N12) – Locate (2) V 1/2 nozzles Nozzle No. 8 and 9 (N8 and N9) – Locate (2) V 1/2 nozzles to
to discharge dry chemical under engine in the pan area. discharge dry chemical from top of transmission area aimed to
discharge horizontally from rear of compartment to front of
Nozzle No. 2 and 3 (N2 and N3) – Locate (2) V 1/2 nozzles at
transmission top and also under cab area.
each side of engine at bottom attached to engine mount-
gusset, aimed up to screen engine sides. Nozzle No. 10 (N10) – Locate (1) V 1/2 nozzle at front under
cab aimed to discharge dry chemical horizontally from front to
Nozzle No. 4 (N4) – Locate (1) V 1/2 nozzle at top middle of
back under cab protecting valve banks.
engine compartment, in front aimed down at 45° angle,
discharging vertically onto center of engine front and top. Nozzle No. 11 (N11) – Locate (1) V 1/2 nozzle up in
articulation area aimed down with discharge pattern following
Nozzle No. 5 (N5) – Locate (1) V 1/2 nozzle to discharge dry
vehicle center line, discharging into loader tower and onto
chemical from top left rear of engine compartment onto engine
hydraulic lines in articulation area.
top and turbo.
NOTE: Larger landfill compactors may require additional
Nozzle No. 6 and 7 (N6 and N7) – Locate (2) V 1/2 nozzles to
discharge dry chemical from front of machine, 1/2 way up in protection.
transmission area aimed back at engine screening
transmission sides and discharging into bottom of pan area
with a vertical discharge pattern.

FIGURE 4
003523

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Service and Repair Manual LH204
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REV. 1

ORE HAULAGE TRUCK (TYPICAL 2 TANK DESIGN)

Nozzle No. 1 – Located at the top center of the engine Nozzle No. 5 – Located at the top left corner of the engine
compartment aimed toward the turbocharger at the rear of the compartment and aimed across the top of the engine to the
engine. It is designed to protect the top of the engine and the opposite corner. Its purpose is to protect the top of the engine
front of the turbocharger. and parts of the turbocharger and exhaust manifold.
Nozzle No. 2 – Located on the right rear corner of the engine Nozzle No. 6 – Located on the left rear corner of the engine
compartment aimed toward the front corner with the pattern compartment and aimed toward the front corner with the
oriented vertically. This is intended to screen and protect the discharge pattern oriented vertically. Its purpose is to screen
right side of the engine. and protect the left side of the engine.
Nozzle No. 3 – Located at the top right corner of the engine Nozzle No. 7 – Located at mid-engine height in the left rear
compartment and is aimed across the top of the engine to the corner of the engine compartment. The nozzle pattern is
opposite corner. Its purpose is to protect the top of the engine aimed across the rear portion of the engine at the transmission
and parts of the turbocharger and exhaust manifold. housing. This is done to protect the lower portion of the
exhaust manifold, and the left side of the transmission and
Nozzle No. 4 – Located at mid-engine height in the right rear
accessory equipment area such as the hydraulic pumps, etc.
corner of the engine compartment. The nozzle pattern is aimed
across the rear portion of the engine at the transmission Nozzle No. 8 – Located such that the dry chemical stream will
housing. This nozzle is intended to protect the lower portion of hit the parking break area.
the exhaust manifold, and the right side of the transmission
NOTE: Larger ore haulage trucks may require additional
and accessory equipment area such as hydraulic pumps, etc.
protection.

FIGURE 5
003524

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10-6 Repair Manual LH204
REV. 1

LOG SKIDDER (TYPICAL 2 TANK DESIGN)

Nozzle No. 1 and 2 – Located to discharge horizontally in the Nozzle No. 5 – Located in the compartment directly under the
front lower portion of each side of the engine compartment. operator's seat. It provides protection for the hydraulic lines,
This allows each nozzle to be aimed upward and toward the pump and pan area.
center of the engine's side to completely cover the side of the
Nozzle No. 6 – Located to discharge dry chemical on the
engine with dry chemical.
parking disc located on the rear portion of the skidder.
Nozzle No. 3 – Located just above the belly pan, aimed to
Nozzle No. 7 and 8 – Located to provide protection for both
completely cover the pan area.
sides of the hydraulic cable reel assembly. They are located on
Nozzle No. 4 – Located toward the rear and top of the engine the rear portion of the skidder and are aimed toward each side
compartment. It is oriented to discharge dry chemical of the reel assembly.
diagonally across the top of the engine.
NOTE: Larger log skidders may require additional protection.

FIGURE 6
003525

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SECTION XI – APPENDIX
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REV. 1

APPENDIX ACTUATION DEVICE

SYSTEM COMPONENT INDEX 70584 Remote Manual Actuator Package Includes: LT-10-L
(Left Hand) Cartridge, “S” Bracket, Elbow, Check
BASIC UNIT Valve, Seal, Operating Instruction Labels and
16559 A-101-10 Includes: Agent Tank, Tank Mounting Installation Instructions
Bracket, 101-10 Cartridge 71699 Remote Manual Actuator Package Includes: LT-10-L
16430 A-101-20 Includes: Agent Tank, Tank Mounting (Left Hand) Cartridge “L” Bracket, Elbow Check
Bracket, 101-20 Cartridge Valve, Seal, Operating Instruction Labels and
Installation Instructions
16131 A-101-30 Includes: Agent Tank, Tank Mounting
Bracket, 101-30 Cartridge 57484 Remote Manual Actuator Package Includes: LT-10-R
(Right Hand) Cartridge, “S” Bracket, Elbow, Check
31581 LT-A-101-10 Includes: Agent Tank, Tank Mounting Valve, Seal, Operating Instruction Labels and
Bracket, LT-20-R Cartridge Installation Instructions
24306 LT-A-101-20 Includes: Agent Tank, Tank Mounting 71804 Remote Manual Actuator Package Includes: LT-10-R
Bracket, LT-30-R Cartridge, Cartridge Bracket, and (Right Hand) Cartridge, “L” Bracket, Elbow, Check
Pneumatic Actuator Valve, Seal, Operating Instruction Labels and
53003 LT-A-101-30 Includes: Agent Tank, Tank Mounting Installation Instructions
Bracket, (Does Not Include Cartridge, Cartridge 70581 Remote Manual Actuator for LT-10-L (Left Hand)
Bracket or Pneumatic Actuator) Cartridge Only
24883 LT-A-101-30 Cartridge, Cartridge Bracket, and 57452 Remote Manual Actuator for LT-10-R (Right Hand)
Pneumatic Actuator for LT-A-101-30 Unit Cartridge Only
31344 LP-A-101-20-B Includes: Agent Tank, Tank Mounting 57661 “S” Type Mounting Bracket for Dashboard Actuator,
Bracket, 101-20 Cartridge, Cartridge Bracket, and Part No. 70581 and 57452
Pneumatic Actuator
70580 “L” Type Mounting Bracket for Remote Manual
24307 LT-LP-A-101-20-B Includes: Agent Tank, Tank Actuator, Part No. 70581 and 57452
Mounting Bracket, LT-30-R Cartridge, Cartridge
Bracket, and Pneumatic Actuator 32747 Remote Actuator Package, Cartridge Guard Type
(Left Hand) Includes: Actuator, LT-10-L Cartridge,
DISTRIBUTION TEES Check Valve, Operating Instruction Labels, Lead
Wire Seal
53036 Distribution Tee Package Includes: 4 Distribution 32739 Remote Actuator Package, Cartridge Guard Type
Tees (Right Hand) Includes: Actuator, LT-10-R Cartridge,
25031 Distribution Tee Check Valve, Operating Instruction Labels, Lead
53038 Triple Tee Package Includes: 2 Triple Tees Wire Seal
16424 Triple Tee 16033 Operating Instruction Labels for Manual Actuator
Includes: Nameplate “IN CASE OF FIRE 1. SHUT
53040 Reducing Tee Package Includes: 2 Reducing Tees OFF ENGINE 2. PULL RING PIN 3. PUSH LEVER”
(1/2 in. x 1/2 in. x 3/4 in.)
16459 Operating Instruction Labels for Manual Actuator
4655 Reducing Tee (1/2 in. x 1/2 in. x 3/4 in.) Includes: Nameplate “IN CASE OF FIRE 1. SHUT
419695 Y Lateral OFF POWER 2. PULL RING PIN 3. STRIKE
BUTTON”
NOZZLES
ACTUATION LINE DEVICES
57046 C-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle
Brackets, 4 Blow-Off Caps and 8 Lockwashers 15677 Safety Vent Relief Valve
57044 V-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle 53050 Safety Vent Relief Valve Package Includes: 2 Safety
Brackets, 4 Blow-Off Caps and 8 Lockwashers Vent Relief Valves
53042 F-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle 53051 1/4 in. Check Valve (Package of 2)
Brackets, 4 Blow-Off Caps and 8 Lockwashers 57488 LT and LP Model Pneumatic Actuator Assembly
53791 Nozzle C-1/2 Includes: Nozzle, Blow-Off Cap 16408 A-101 Pneumatic Actuator with Cartridge Receiver
56748 Nozzle V-1/2 Includes: Nozzle, Blow-Off Cap Assembly
16449 Nozzle F-1/2 Includes: Nozzle Only 31579 LT-A-101-10 Pneumatic Actuator Assembly
415192 Blow-Off Cap With Retaining Strap Package 8372 Pressure Switch (Shutdown)
Includes: 46250 Pressure Switch, Weather Proof, DPST (shutdown)
50 Blow-Off Caps (Part No. 415108) For V-1/2 and
C-1/2 Nozzle Only 427425 Engine Shutdown Device
73870 Blow-Off Cap Package: Includes: 50 Blow-Off Caps,
Part No. 4120, For F-1/2 Nozzle
73871 Nozzle Bracket Package: Includes: 12 Brackets,
2 in. x 2 in. Angle
427149 Nozzle Bracket, 2 in. x 3 in. Angle
427228 Nozzle Bracket, Straight 5 in. x 2 in., 4 Brackets
73872 Nozzle Lockwasher Package: Includes: 50 Lock
washers, Part No. 25581
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11-2 Repair Manual LH204
REV. 2

SYSTEM COMPONENT INDEX (Continued) SYSTEM CARTRIDGES

SYSTEM TANKS 15850 A-101-10 Cartridge (DOT)
24855 A-101-10 Includes: Charged Agent Tank with 423439 A-101-10 Cartridge (TC/DOT)
Cartridge 423441 A-101-20, LP-A-101-20-B Cartridge (TC/DOT)
24970 A-101-20 Includes: Charged Agent Tank with 423443 A-101-30 Cartridge (TC/DOT)
Cartridge 423429 LT-A-101-10 Cartridge (TC/DOT)
53000 A-101-30 Includes: Charged Agent Tank with 423435 LT-A-101-20 and LT-LP-A-101-20-B Cartridge
Cartridge (TC/DOT)
24966 LT-A-101-10 Includes: Charged Agent Tank with 423491 LT-A-101-30 Cartridge (TC/DOT)
Cartridge
13193 LT-10-R Cartridge (DOT)
24894 LT-A-101-20 Includes: Charged Agent Tank without
Cartridge 423423 LT-10-R Cartridge (TC/DOT)
29375 LT-A-101-30 Includes: Charged Agent Tank without 13177 LT-10-L Cartridge (DOT)
Cartridge 423425 LT-10-L Cartridge (TC/DOT)
24427 LP-A-101-20-B Includes: Charged Agent Tank
without Cartridge FOR SYSTEM COMPONENT INDEX FOR THE
CHECKFIRE AUTOMATIC DETECTION AND ACTUATION
24425 LT-LP-A-101-20-B Includes: Charged Agent Tank
without Cartridge SYSTEMS, SEE THE FOLLOWING INSTALLATION
MANUALS:
SYSTEM BRACKETS • CHECKFIRE MP-N ELECTRIC SYSTEM – Manual Part
24854 A-101-10, LT-A-101-10 Tank Mounting Bracket (1) No. 427310
24971 A-101-20 Tank Mounting Bracket (1) • CHECKFIRE SC-N ELECTRIC SYSTEM – Manual Part No.
423522
14098 A-101-30 Tank Mounting Bracket (1)
• CHECKFIRE ELECTRIC SERIES I SYSTEM – Manual Part
24910 A-101-30 Tank Mounting Bracket (1) (Extra Heavy) No. 54894
24895 LT-A-101-20 Tank Mounting Bracket (1)
30494 LT-A-101-30 Tank Mounting Bracket (1)
31171 LP-A-101-20-B, LT-LP-A-101-20-B Tank Mounting
Bracket (1)
31177 Cartridge Bracket Assembly for LP-A-101-20-B
24325 Cartridge Bracket Assembly for LT-A-101-20 or
LT-LP-A-101-20-B
29193 Cartridge Bracket Assembly for LT-A-101-30

RECHARGE EQUIPMENT AND MATERIAL

53080 FORAY Multi-Purpose Dry Chemical 45 lb. Pail
16511 Fill Cap Spanner Wrench (Low Profile)
428363 Bursting Disc Package (Includes: 15 Bursting Disc
Assemblies, Part No. 428271)
75382 Cartridge Scale and Hook Assembly (LT-A-101-30)
3923 Cartridge Scale and Hook Assembly
197 Lead Wire Seal
15496 Bursting Disc Union Assembly
24327 A-101 Installation, Recharge, Inspection and
Maintenance Manual
53081 Owner's Manual

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SECTION XI – APPENDIX
Service and Repair Manual LH204
10-25-00 Page 11-3
REV. 1

NOTES:

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SECTION XI – APPENDIX
Service
5-15-02 Pageand
11-4 Repair Manual LH204
REV. 2

LARGE EXCAVATORS 2. Each four nozzle agent distribution network will be

connected to two adjacent tanks using a “Y” fitting. See
Hazards and Protection Figure 1. Six nozzles systems are not allowed.
The following are generally considered to be fire hazard 3. An automatic detection and actuation system will be
areas. Hazard areas exist when an ignition source can come required, using the CHECKFIRE SC-N Detection and
in contact with a fuel source. This may be due to the close Actuation system.
proximity of the ignition source to the fuel source or due to the 4. The fire suppression system must automatically perform
configuration of the machine that may allow running or the following functions:
spraying fuel to come in contact with an ignition source. A
hazard analysis of the excavator should determine which of • Engine shutdown.
the following components will require protection. A hazard • Pressurized hydraulic tank and fuel tank venting.
analysis should also determine any other areas not listed • Fuel shutoff.
below that potentially could be considered hazard areas
requiring protection. • Electrical disconnect (Optional).
If mine personnel refuse to allow any of the above items to
1. Engine. The engine consists of various components that be performed, it should be documented and kept in the
contain or transfer fuels, components involved with job file.
lubrication, and electrical contacts and controls as well as
components that generate heat. Protection should 5. The system must also include a Remote High Level Alarm
include but not be limited to the following components: Horn, Part No. 79559 and should also include a remote
visual alarm.
• Manifolds
6. As part of the total fire suppression system package,
• Turbochargers training for mine personnel and the machine operator(s)
• Heat exchangers must be conducted and documented. Training should
• Fuel lines include but not be limited to:
• Engine block • A-101 and CHECKFIRE SC-N system description.
• Electrical equipment, such as starters, generators, • System operation.
alternators, etc. • System limitations and primary intent.
• Exhaust systems • What to do in case of fire.
• Bottom of engine, belly pan or floor area • Vehicle maintenance and fire suppression system
2. Hydraulic pump(s) and control valve banks/manifolds. maintenance.
3. Hydraulic hoses and fuel lines, including those under 7. An A-101/CHECKFIRE SC-N Maintenance Contract
operator's compartment. allowing periodic service and maintenance at scheduled
intervals should also be included.
4. Transmissions/gear reduction boxes.
NOTE: Extended discharge can also be obtained by using
5. Brakes and brake valves. NOTE: Brakes located in the
the larger LT-A-101-125/250 tanks. Refer to manual, Part
track mechanism are not required to be protected.
No. 427865, for details.
6. Drive train bearings.
7. Swing gear motors and travel clutches.
8. Ring Gear area.
9. Lubrication systems.
10. Hydraulic oil tank and fuel tank fill and outlet connections.
11. Batteries.
12. Large electrical generators and motors.
Design Parameters
1. Extended Discharge System (Not FM Approved) – Fire
suppression on large excavators may require an
extended agent discharge time to allow for operator
egress from the machine. In order to extend the time of
agent discharge from A-101 system nozzles, the number
of tanks determined by hazard analysis must be doubled.
(Refer to drawings for revised actuation and discharge
hose connection parameters and system operation.)
• 3/4 in. Extended Discharge Supply Hose Line
Connection. See Figure 1. (NOTE: Maximum of 24 in.
from each adjacent tank to the common “Y” fitting.)
• 1/4 in. Actuation Hose Detail. See Figure 2.
• CHECKFIRE SC-N Wiring Diagrams. See Figure 3 and
Figure 4.

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SECTION XI – APPENDIX
Service and Repair Manual LH204
5-15-02 Page 11-5
REV. 1

LARGE EXCAVATORS (Continued)

Design Parameters (Continued)

EACH 3/4’’ HOSE CONNECTION

FROM THE BURSTING DISK UNION TO DOUBLE A-101 EXTENDED
THE 45° ‘’Y’’ BRANCH FITTING MUST DISCHARGE TANKS
NOT EXCEED 24 INCHES (21 cm)

45° BRANCH

TO FOUR NOZZLE
DISTRIBUTION

1/4’’ DISCHARGE SUPPLY HOSE LINE CONNECTION

FOR A-101 EXTENDED DISCHARGE SYSTEM

FIGURE 1
003526

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Service
5-15-02 Pageand
11-6 Repair Manual LH204
REV. 1

LARGE EXCAVATORS (Continued)

Design Parameters (Continued)

REMOTE CHECKFIRE SC-N

MANUAL AUTOMATIC & OPTIONAL SECOND
ACTUATOR MANUAL ACTUATOR REMOTE MANUAL
ACTUATOR

THE AUTOMATIC AND REMOTE

MANUAL ACTUATOR(S) MUST
USE THE LT-10-R CARTRIDGE.
THE LT-10-R CARTRIDGE WILL
ACTUATE UP TO 20 SYSTEM
TANKS WITH UP TO 100 FT. OF
1/4 IN. ACTUATION HOSE.

1/4’’ CHECK VALVE (3)

DPDT PRESSURE
SWITCH (P/N 46250)

SAFETY VENT
RELIEF VALVE

TO LT-A-101-30 TANKS
(MAXIMUM OF 20)
WITH SAFETY VENT
RELIEF VALVE AT END
OF ACTUATION LINE
(TYP.)

LT-A-101-30 TANK
ACTUATION ASSEMBLIES

1/4’’ ACTUATION HOSE DETAIL FOR A-101

FIGURE 2
EXTENDED DISCHARGE SYSTEM 003527

(Not FMRC Approved)

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SECTION XI – APPENDIX
Service and Repair Manual LH204
5-15-02 Page 11-7
REV. 1

LARGE EXCAVATORS (Continued)

Design Parameters (Continued)

CHECKFIRE SC-N WIRING DIAGRAM

(NORMALLY ENERGIZED SHUTDOWN DEVICE)

DETECTION CIRCUIT

FUSED
POWER RELEASE CIRCUIT
SOURCE
ALARM SHUTDOWN

SC-N

FUSED (3A Min.)

12-24 POWER
SOURCE REMOTE HIGH LEVEL
ALARM HORN

VEHICLE
ALARM STROBE USED IN NORMALLY
CLOSED POSITION

DPST
PRESSURE
SWITCH

FUSED
POWER
SOURCE
ENGINE
SHUTDOWN
DEVICE

FIGURE 3
006435

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GENERAL INFORMATION
Service
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11-8 Repair Manual LH204
REV. 1

LARGE EXCAVATORS (Continued)

Design Parameters (Continued)

CHECKFIRE SC-N WIRING DIAGRAM

(NORMALLY DE-ENERGIZED SHUTDOWN DEVICE)

DETECTION CIRCUIT

FUSED
POWER RELEASE CIRCUIT
SOURCE
ALARM SHUTDOWN

SC-N

FUSED (3A Min.)

12-24 POWER
SOURCE
REMOTE HIGH LEVEL
ALARM HORN

VEHICLE
ALARM STROBE USED IN NORMALLY
CLOSED POSITION

DPST
PRESSURE
SWITCH

FUSED
POWER
SOURCE

ENGINE
SHUTDOWN
DEVICE

FIGURE 4
006436

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SECTION XI – APPENDIX
Service and Repair Manual LH204
5-15-02 Page 11-9

EXCAVATOR PROTECTION • Twin-Agent Application: Large Equipment [Operating

Weight: 1,000,000 lb. (453,600 kg) and greater]
Excavators can be classified into three categories, depending
on their hydraulic fluid capacity. Ansul has researched the Use of a twin-agent system consisting of the LVS liquid
hydraulic fluid capacities in regard to size of equipment agent system connected to an A-101-125/250 dry chemical
(operating weight). (extended discharge) system.
With the introduction of the LVS™ Liquid Agent Suppression Note 1: The liquid portion of the twin-agent scheme, at a
System (not FM Approved), we can now offer an enhanced minimum, must protect the engine(s) and hydraulic
protection scheme for large excavators, as well as other non- devices (i.e., pumps, control valves, valve banks).
road mobile equipment. The following protection schemes Additional LVS liquid agent systems may be added
are required for excavator of these specified sizes. They at the designer's discretion to cover other areas.
are as follows: Note 2: Existing systems installed in compliance with
• Standard Discharg e Application: Small Equipment Product Service Bulletin No. 77 utilizing an
(Operating Weight: 99,000 to 200,000 lb. (44,906 to extended discharge design, do not need to be
90,720 kg)) changed to twin-agent system. However, for new
system installations or major changes to an
Standard discharge application of an A-101 dry chemical existing hydraulic excavator, the design must
system can be used for this smallest class of excavators. follow the guidelines in this manual using a twin-
Design of the suppression system shall be in accordance agent system.
with the LT-A-101-30 or LT-A-101-125/250 Installation,
Recharge, Inspection, and Maintenance Manual. Excavators that fall into this class of machine include but
are not limited to:
Excavators that fall into this class of machine include but
are not limited to: • DeMag: H455S, H485S, H485SP, H655S
• Hitachi: EX5500, EX7500
• Caterpillar: 345BL-VG, 350, 350L, 375, 375L, 5080
• Komatsu: PC5500, PC8000
• Hitachi: UH261, UH30
• Liebherr: R996
• Komatsu/DeMag: H65, PC 750-6
• O&K: RH 200, RH 300, RH 400
• Liebherr: R982
General Discussion
• Link-Belt: 5800, 6000
• O&K: RH 25D, RH 30E Special design consideration must be given when protecting
• Poclain: 300, 400 large excavators to reduce the potential for reflash and
• Twin-Agent Application: Mid-Size Equipment provide additional time. Ansul requires the following as a
[Operating Weight 200,000 to 1,000,000 lb. (90,720 to minimum:
453,600 kg)] 1. Two large size agent tanks are available: a 125 lb. (56.7
Use of a twin-agent system consisting of the LVS liquid kg) tank and a 250 lb. (113.4 kg) tank. The LT-A-101-125
agent system connected to an A-101 dry chemical tank can utilize an 8-nozzle extended discharge or 12- or
(extended or standard discharge) system. The A-101 16-nozzle standard discharge distribution system. The
system can utilize 250 lb., 125 lb. or 30 lb. (nominal) agent LT-A-101-250 tank can utilize either an 8, 12, or 16 nozzle
containers. extended discharge or a 24 nozzle standard discharge
system. Both the 125 lb. and 250 lb. tanks can be used
Note 1: When utilizing a standard discharge design, all
where an extended discharge is required. See “Extended
hazard areas will require protection using both
Discharge” to determine type of system required.
agents.
Note 2: When utilizing an extended discharge design, the 2. When utilizing 30 lb. agent containers, use four nozzles
liquid portion of the twin-agent scheme need only maximum for each single or two-tank (when used as
protect the engine(s) and hydraulic devices (i.e., extended discharge) system to provide additional agent
pumps, control valves, valve banks). per nozzle and maximum system discharge time. Single
tank, two-nozzle systems may also be used for extended
Note 3: Existing systems installed in compliance with discharge.
Product Service Bulletin No. 77 utilizing an
extended discharge design, do not need to be NOTE: When protecting the engine, hydraulic devices
changed to twin-agent systems. However, for new (i.e. pumps, control valves, valve banks), hoses
system installations or major changes to an and connections on large non-road mobile
existing hydraulic excavator, the design must equipment used in surface mining, landfill
follow the guidelines in this manual using a twin- equipment, or other large specialized machines;
agent system. only 4-nozzle 30 lb. tank systems, or large
capacity (125 lb. and 250 lb.) type systems are to
Excavators that fall into this class of machine include but
be used.
are not limited to:
3. Fully automatic system, including automatic engine
• Caterpillar: 5130, 5130B, 5130ME, 5130FS, 5230,
shutdown, hydraulic oil/fuel shutoff, and agent discharge.
5230ME
• DeMag: H95, H135S, H185S, H255S, H285S 4. Remote high level alar m and flashing alar m strobe to
• Hitachi: EX1000, EX1100, EX1800, EX 2500, EX3500, enhance machine operator warning.
EX 3600, UH501, UH80, UH801 5. A safe means of egress from the operator's compartment
• Komatsu: PC1000-6, PC1100-6, PC1400, PC1500-1, without having to exit past fire hazard areas.
PC1600-1, PC1800-6, PC 3000, 3560 B, PC4000
• Liebherr: R984, R992, R991, R994, R995
• NW Engineering: 100-DH
• O&K: RH 40E, RH 75, RH 90C, RH 120C, RH 170
• Poclain: 600, 1000
• P&H: 1200
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SECTION XI – APPENDIX
Service
5-15-02 Pageand
11-10 Repair Manual LH204

EXCAVATOR PROTECTION (Continued) FUME HOOD PROTECTION (Not FM Approved)

General Discussion (Continued) Fume Hood can utilize an Ansul A-101-20 or A-101-30
system with 6 nozzles. See Figure 5.
In addition to the LT-A-101 dr y chemical system and/or
FUME HOOD
LT-A-101/LVS twin-agent system with CHECKFIRE® Electric
Detection and Control equipment, supplemental fire
protection should be included when considering protection of C-1/2 NOZZLE
(6 FT. MAXIMUM COVERAGE)
large non-road mobile equipment:
1. Cartridge operated hand portable fire extinguishers TO A-101-20 OR A-101-30
2. Secondary means of fire suppression
For any fire protection to be effective, training is critical. As a DISTRIBUTION
C-1/2 NOZZLE
TEE
minimum, comprehensive training for the machine operator (6 FT. MAXIMUM
PART
COVERAGE)
and site representatives should include: NO. 25031

1. Fire suppression system operation 48 IN.

V-1/2
2. Fire suppression system performance NOZZLES
MAXIMUM

3. Fire suppression system capabilities

V-1/2
4. Fire suppression system limitations NOZZLES

5. Response procedures
6. Safe egress procedures
It is important to make sure the site representative
understands the LT-A-101/LVS/CHECKFIRE system
capabilities as well as limitations. This information needs to
be discussed and reviewed with the appropriate end-user
personnel.
72 IN.
MAXIMUM

30 IN.
MAXIMUM
FIGURE 5
003530

The system can utilize a distribution tee and 3/4 in. supply
piping and 1/2 in. branch piping.
Standard A-101 nozzles are used for dry chemical discharge.
C-1/2 nozzles are used in the duct and V-1/2 nozzles are
used in the plenum and hood area.
The pipe length must not exceed the maximum requirement
as stated on Page 4-11 and 4-12 of this manual.
When utilizing an Ansul AUTOMAN Release, use an LT-10-R
Cartridge to supply the required actuation gas pressure to the
tank cartridge.

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Service and Repair Manual LH204
ANSUL INCORPORATED
ONE STANTON STREET
MARINETTE, WI54143-2542
715-735-7411
Litho in U.S.A.
© 2002 Ansul Incorporated
Part No.24327-06

Copyright © Sandvik 733 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204
ANSUL ® INSTALLATION, CHECKFIRE® SC-N
RECHARGE, ELECTRIC
INSPECTION, AND DETECTION AND
MAINTENANCE ACTUATION
MANUAL SYSTEM

002750

734 (1146) Copyright © Sandvik

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Service and Repair Manual LH204

This manual is intended for use with the CHECKFIRE® SC-N

Electric Detection and Actuation System.
Those who install, operate, inspect, or maintain this system
should read this entire manual. Specific sections will be of
particular interest depending upon one's responsibilities.
As with all electro-mechanical equipment, the electric detection
and actuation system needs periodic care to provide maximum
assurance that it will operate effectively and safely. Inspection
frequency should be based on the requirements of the equipment
on which the system is installed and the environment in which the
equipment will operate. On equipment working 24 hours/day,
seven days/week, maintenance should be performed on the
detection and actuation system at 250, 500, and 1000-hour
intervals. On equipment that does not work continuously,
maintenance should be performed at least every six months.
The application and use of the CHECKFIRE SC-N system is
limited to the application and uses described in this manual. For
other applications, contact your local Ansul distributor or the
Ansul technical representative in your area.

ANSUL and CHECKFIRE are trademarks.

Copyright © Sandvik 735 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
TABLE OF CONTENTS
Service and Repair Manual LH204
SECTION PAGES SECTION PAGES
SAFETY PRECAUTIONS 1 INSPECTION AND MAINTENANCE 25
TOTAL SYSTEM DESCRIPTION 2 Daily Inspections 25
Maintenance 25
SYSTEM COMPONENTS 3
Control module 3 TROUBLESHOOTING 27
Manual/automatic actuator 3 Diagnostics 27
LT-5-R Cartridge 3 History Buffer 27
Mounting Brackets 4 Troubleshooting Table 28
Splicing Device 4 PROGRAMMING 31
Linear Detection Wire 4 PC Programming 32
Thermal Spot Detector 4 Explaining the Menu 32
Pneumatic/Linear Detector 5 APPENDIX 35
Squib 5 Release Circuit Test Module Instructions 35
Squib Cable – Optional 15 ft. (4.6 m) 5 Component Index 36
Battery 5 Detection Wire Fluid Resistance Capability 38
Pressure Switch – Weatherproof 6 Warranty 39
Check Valve 6
Remote High Level Alarm 6
Release Circuit Test Module 6
USER INTERFACE 7
Field Terminations 7
Front Panel Indicators 8
Power Connections 9
Front Panel Buttons 9
Battery Replacement 9
Enclosure 9
Cover Removal 9
Strain Relief Installation 9
Mounting 9
SYSTEM PLANNING 10
Hazard Identification 10
Pre-installation Guidelines 10
INSTALLATION 12
Installation Materials 12
Mounting Bracket Installation 12
Mounting to Existing CHECKFIRE SC Bracket 13
Manual/Automatic Actuator Installation
And Connection 13
Mounting the Control Module 14
Remote High Level Alarm Installation 14
Shutdown Device Connection 15
Detection Wire Installation 15
Mounting 15
Thermal Detector Installation 16
Pneumatic/Linear Detector Installation 18
Squib Lead Connector 18
External Power Connection 19
Optional Pressure Switch/electric Pull Station 19
Function Test 19
Placing the System in Service 21
IN CASE OF FIRE 23
RECHARGE 24

736 (1146) Copyright © Sandvik

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Service and Repair Manual LH204

Copyright © Sandvik 737 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
SAFETY PRECAUTIONS
Service and Repair Manual LH204
9-1-98 Page 1

SAFETY PRECAUTIONS
For the protection of personnel and equipment being
installed, this manual contains WARNING and CAUTION ! CAUTION
statements which are listed in the steps which they apply.
These warnings and cautions are also listed here so that the Discharged lithium batteries may contain significant
manual user can become familiar with them before amounts of unused energy and should be handled with care.
performing any procedures. Do not compact for disposal. Before disposal, each battery
must be fully discharged and electrically isolated by
WARNING enclosing in a plastic bag and sealing the bag. Do not
! dispose of in fire. Check applicable solid waste disposal
regulations for proper disposal of more than one battery.
In case of fire, evacuate area to lessen the risk of injury from
flames, heat, hazardous vapors, explosions, or other
hazards that may be created.

! WARNING

The squib is an explosive device. Do not attach connector

until squib is installed in actuator body. If the squib is
actuated outside of the actuator body, possible personal
injury could result.

! CAUTION

Manual pneumatic actuation will result in immediate system

discharge which may obscure vision. Make certain vehicle is
stopped safely before manually actuating the system.
Manual actuation will bypass all auxiliary shutdown and
alarm functions.

! CAUTION

The fire suppression system could be accidentally actuated

causing the release of agent if the squib or nitrogen
cartridge is installed before the appropriate installation step
is reached.

! CAUTION

The control module could be damaged and the fire

suppression system may not operate if the squib spring
(shunt) is not removed before installing the squib connector.

! CAUTION

The fire suppression system will discharge dry chemical if

the cartridge is installed when operating the strike button.
Do not install cartridge unless puncture pin is fully retracted
with ring pin inserted and visual inspection seal installed.

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TOTAL SYSTEM DESCRIPTION
9-1-98 Service
Page 2 and Repair Manual LH204

TOTAL SYSTEM DESCRIPTION The control module may be installed where the ambient
temperature is between –40 °F to 140 °F (–40 °C to 60 °C).
The complete CHECKFIRE SC-N system is composed of
components which are combined to provide automatic fire The CHECKFIRE SC-N Detection and Actuation System is
detection and actuation for equipment hazard areas. The approved by Factory Mutual Research Corporation (FMRC).
electric detection and actuation system is designed for use Circuits
only with Ansul fire suppression systems requiring pneumatic
input as a means of actuation. In addition to the mechanical The first initiating circuit is the supervised detection circuit
pneumatic means of operating the suppression system, the designed to be connected to linear (wire) and/or spot type
CHECKFIRE SC-N also provides an automatic and manual thermal detectors that provide a contact closure input to
electric means to perform the same function. initiate a fire detected condition. The second initiating circuit is
designed to accept a contact closure type of actuating device
The CHECKFIRE SC-N system is typically used with an Ansul such as an electric manual pull station or a pressure switch.
A-101 Vehicle Fire Suppression system for 24-hour protection The initiating circuits are low impedance and designed to
of equipment. The system is particularly suited for the eliminate nuisance alarms associated with contact bounce.
protection of equipment that is subjected to extreme
environmental and physical conditions such as vehicles used Two field programmable time delays provide timing of
in forestry, mining, agriculture, construction, public shutdown and release functions associated with the operation
transportation, public utilities, land fill, and waste disposal. of the detection and electric manual pull/ pressure switch
initiation circuits.
Some of its features include linear (wire) and/or spot (thermal) 1) DETECTION INITIATING CIRCUIT
detection, supervised circuitry, internally powered, adjustable
shutdown and discharge time delays, auxiliary relays, and The detection circuit consists of two time delays:
one-button operation. The first time delay is field programmed to assign the time
between alarm (initiation of the detection circuit) and the
CHECKFIRE SC-N Electric Detection and Actuation System
operation of the shutdown relay. The first time delay is field
consists of the following components:
1. Control Module programmable for 5, 10, 20, or 30 seconds.
2. Manual/Automatic Actuator The second time delay is field programmed to assign the
3. Mounting Bracket time between the completion of the first time delay (when
4. Detection Wire the shutdown relay operates) and the operation of the
5. Thermal Detectors release circuit. The second time delay is field
6. Pneumatic/Linear Detection programmable for 0, 10, 20, or 30 seconds.
7. Squib (not shown) 2) ELECTRIC MANUAL PULL/PRESSURE SWITCH
8. LT-5-R Cartridge FEEDBACK INITIATING CIRCUIT
9. Check Valve (not shown) The second initiating circuit is field programmable to be
10. Remote High Level Alarm (not shown) used as either an electric manual pull or pressure switch
11. Squib Circuit Test Module (not shown) feedback circuit. If selected as an electric manual pull
circuit, its operation will override the first time delay function
and initiate a second time delay condition, causing the
shutdown relay to immediately operate and system release
to occur upon completion of the second time delay.
Additionally, the control module can be field programmed to
shorten the second time delay when a manual actuation
occurs. The time delay options available with the electric
manual actuation are 0, 10, 20, and 30 seconds, with the
condition that it can only be less than or equal to the
programmed time delay of the detection circuit.
Selection of the second initiating circuit as a pressure
switch feedback circuit will result in the operation of the
alarm relay and shutdown relay immediately upon
receiving the signal. The release circuit will not be initiated
from this feedback circuit because the system will already
have been pneumatically actuated from the manual
pneumatic actuator.
When this initiating circuit has operated, the Alarm and
Release LED's, along with the audio sounder, will pulse
002998
until the pressure switch is reset and then the control panel
The control module can be used as a self contained system,
is reset.
powered by its own internal lithium battery. This allows the
detection system to operate around-the-clock without use of 3) A “DELAY” button is available for the operators use.
external power. Optionally, external power can be connected Operation of the “DELAY” button will restart the first time
to the control module with the internal power also connected, delay cycle if initiated while the first time delay is active.
which results in a system with battery back-up. When Once the second time delay has started, operation of the
connected to an external 12/24 VDC supply with the internal “DELAY” button has no affect. The “DELAY” button also
battery also connected, the external power source becomes serves the dual function of silencing the auxiliary alarm
the primary supply, while the internal power source is relay. The silence function is only effective 30 seconds or
maintained in a stand-by mode of operation. more after release or pressure switch feedback operation
has occurred.
Copyright © Sandvik 739 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
SYSTEM COMPONENTS
Service and Repair Manual LH204
9-1-98 Page 3

SYSTEM COMPONENTS MANUAL/AUTOMATIC ACTUATOR

CONTROL MODULE The manual/automatic actuator, Part No. 24479, provides a
manual and automatic means of fire suppression system
The Control Module, Part No. 423504, is the basis of the actuation. By pulling the ring pin and striking the red button,
CHECKFIRE SC-N detection system. The module cover and manual system actuation can be accomplished. The system
back box is made of durable Noryl SE1 gfN3 material with a is automatically actuated by use of a squib. When the
flammabili-ty rating of UL94 V-1. The back box contains the detection circuit is activated, the control module will direct the
field interface terminal block, battery, and field wiring entrance electrical current to the squib, causing it to actuate. The
ports. The cover assembly contains the control PC board pressure generated from the squib actuation forces the
assembly, sounder, operator interface panel, and puncture pin down automatically.
environmental seal. The enclosure meets International
Standard IEC 529 requirements for dust and water spray in all A 1/4 in. NPT street elbow is supplied with the actuator for
directions. Mounting pads allow mounting to any suitable flat convenient connection of the 1/4 in. actuation line to the fire
surfaces. Steel mounting brackets are also available. suppression system. See Figure 2.
All circuitry, relays, switches, and LED's are contained on a
STRIKE
single PC board. A board mounted receptacle mates with the BUTTON
plug-in terminal block mounted in the back box. A high pitch RING
sounder is threaded into the cover and plugged into the PC PIN
board. The PC board is encapsulated to provide added
protection against moisture and dust. An RS232 interface
cable connector is provided for field programming from a PC
and for data retrieval from a trouble and alarm history buffer.
The PC board assembly contains a DIP switch for optional
SQUIB
manual programming functions without the use of a PC. See 1/4 IN. NPT TO
PORT
ACTUATION
Figure 1. LINE

FIGURE 2
000850

LT-5-R CARTRIDGE
The LT-5-R cartridge, Part No. 6979, is a pressure vessel that
is factory-filled with nitrogen to 1800 psi at 70 °F (124 bar at
21 °C). The cartridge is installed in the manual/automatic
actuator and provides the pressure required to actuate the
connected fire suppression system. Following operation, the
cartridge must be replaced. See Figure 3.

SAFETY
FIGURE 1 SHIPPING CAP
002755

CARTRIDGE

FIGURE 3
000851

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SYSTEM COMPONENTS
9-1-98 Service
Page 4 and Repair Manual LH204

MOUNTING BRACKETS LINEAR DETECTION WIRE

The CHECKFIRE SC-N Detection and Actuation System The linear detection wire consists of two spring steel
offers three types of steel mounting brackets. conductors which are separated by a heat-sensitive insulator.
At the temperature rating of the wire, 356 °F (180 °C), the
The first type, Part No. 423525, is a combined bracket for
insulator melts, allowing the two conductors to make contact.
mounting the control module and the pneumatic actuator
This contact provides electrical continuity between the two
together. See Figure 4.
conductors. The linear detection wire is supplied in lengths of
The second type, Part No. 423528, is an individual bracket for 100 ft. (30.5 m), Part No. 71230, or 500 ft. (152.4 m), Part
mounting the control module separate from the pneumatic No. 71231, and must be ordered separately. See Figure 6.
actuator. Note: When ordering this bracket, it is also
necessary to order the pneumatic actuator bracket, Part INSULATED
No. 419772. See Figure 4. SPRING STEEL
CONDUCTORS
The third type, Part No. 423531, is a retrofit bracket for
mounting a SC-N module to any existing CHECKFIRE bracket
FIGURE 6
except CT/CT+G. See Figure 4. 000855

All brackets can be fastened by either bolting or welding. Thermal Spot Detector
Brackets are painted with red enamel paint.
Thermal detectors are normally open, contact closure devices.
The fixed temperature design of these detectors will cause the
contacts to close when the temperature of the surrounding air
reaches the set point temperature of the detector. See
Figure 7.
CABLE CLAMP
WITHOUT PROTECTIVE
MOUNTING
TUBING,
BRACKET,
PART NO. 416762
PART NO.
CABLE CLAMP WITH
416221
PROTECTIVE TUBING,
PART NO. 416214

COMBINED BRACKET RETROFIT BRACKET SPOT

PART NO. 423525 PART NO. 423531 DETECTOR
002756 002757

FIGURE 7
000856

Thermal detectors are available in three preset temperatures

as shown below. Each temperature rating is stamped on the
detector.
Rated Maximum
Operating Continuous
MODULE BRACKET ACTUATOR BRACKET Temperature Use Temperature Detector
PART NO. 423528 PART NO. 419772
002758 000852 °F (°C) °F (°C) Color Part No.
FIGURE 4 270 (132) 234 (112) Blue 416218
325 (163) 280 (137) Red 416219
SPLICING DEVICE 360 (182) 312 (155) Red 416220
A remote splicing device, Part No. 71820, is required for
detection wire connection between the control module and the
linear detection wire. The splicing device is designed with
terminal screws to allow a connection interface between
standard cable and linear detection wire. When the splicing
device is used in the system, special sealing compound or
tape is required to make a proper seal. See Figure 5.

FIGURE 5
000854

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SYSTEM COMPONENTS
Service and Repair Manual LH204
9-1-98 Page 5

PNEUMATIC/LINEAR DETECTOR SQUIB CABLE – OPTIONAL 15 FT. (4.6 m)

The pneumatic/linear detector, Part No. 416113, consists of The standard cable, Part No. 79062, is 20 in. (51 cm) and is
35 ft. (10.7 m) of gas filled stainless steel tubing connected to included with the control module shipping assembly. The
a small pressure responder. When the gas in the tubing heats optional squib cable, Part No. 422747, is required to supply
up, the increase in pressure operates the responder, thus an electrical signal from a remote module to the squib located
closing the detection circuit of the control module. The in the actuator body. The squib cable is 15 ft. (4.6 m) and can
pneumatic/linear detector will operate at a temperature of be cut to whatever length is required. See Figure 10. The
900 °F (482 °C) over 12 in. (31 cm) or 300 °F (149 °C) over maximum allowable cable length from controller to actuator is
the total length. The detector assembly connects to the 15 ft. (4.6 m).
control module by means of a special wire assembly which is
supplied with the detector assembly. See Figure 8.

FIGURE 10
001058
DETECTOR
TUBE
BATTERY
The CHECKFIRE SC-N control module uses one 3.6 VDC
lithium battery, Part No. 423520. All power required to run the
detection system can be provided from this battery. Note:
External power connections are also provided to connect to
RESPONDER
vehicle power. The battery must be replaced annually or
when the YELLOW Battery LED and the Audio Alarm are
pulsing. See Figure 11.

CONNECTION TO
CONTROL MODULE
FIGURE 8
000857

SQUIB
The squib assembly, Part No. 54919, is an electrically-
actuated component containing a small charge of powder.
When the circuit is closed to the squib, a small internal wiring
bridge heats up, causing ignition of the squib. This generates
pressure, which forces the puncture pin of the actuator
through the seal in the nitrogen cartridge. See Figure 9.
FIGURE 11
002759

WARNING END-OF-LINE RESISTOR

DEVICE CONTAINS
EXPLOSIVE CHARGE. The End-Of-Line Resistor Assembly, Part No. 426461
DO NOT REMOVE SHUNT
UNTIL READY TO CONNECT (Package of 10), is required for supervision of the external
INTO ELECTRICAL SYSTEM.
input circuits. The package consists of 10 each of the
FIGURE 9 required components to assemble 10 of the resistor
000858 assemblies. See Figure 12.

LOCK
NUT

STRAIN RELIEF
CONNECTOR

TERMINAL BLOCK
WITH 4.7 K OHM
RESISTOR
CAP FIGURE 12
003050

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SYSTEM COMPONENTS
9-1-98 Service
Page 6 and Repair Manual LH204

PRESSURE SWITCH – Weatherproof CHECK VALVE

The 1/4 in. check valve, Part No. 25627, is installed in the
actuation line between the manual/automatic actuator and the
pneumatic actuator on the connected fire suppression system.
This check valve allows actuation pressure to flow to the fire
suppression system, but does not allow pressure from other
actuation devices to back up into the manual/automatic
actuator of the CHECKFIRE SC-N system. See Figure 14.
Other actuation devices in the fire suppression system also
require check valves to be installed in the same fashion. This
prevents pressure from escaping through an actuator whose
cartridge was inadvertently removed.
1/4 IN. NPT
(BOTH ENDS)

TO BE ADDED LATER
FIGURE 14
000899

REMOTE HIGH LEVEL ALARM

The remote high level alarm, Part No. 79559, is intended for
those installations where the noise level or operating
conditions may prevent the operator from recognizing the
control module alarm condition. This device is connected
through the alarm relay of the control module to a separately
fused power source. It is capable of 102 decibels at 6 to
30 volts, 0.3 amp maximum at a temperature range of –40 °F
to 170 °F (–40 °C to 76.7 °C). See Figure 15.

FIGURE 15
000861

RELEASE CIRCUIT TEST MODULE

The release circuit test module, Part No. 423541, is used in
place of the squib during test procedures to simulate squib
actuation or gas motor actuation on CHECKFIRE MP systems
(indicator lamp on). It is also used when verifying time delay
durations. See Figure 16.

FIGURE 13
000000

FIGURE 16
003015

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USER INTERFACE
Service and Repair Manual LH204
9-1-98 Page 7

USER INTERFACE Shut Down Relay Circuit (Terminals No. 14, No. 15, and
No. 16)
This section is designed to give the user overall information
on all features and components pertaining to the • Cable must be round jacketed, with an O.D. of 0.13 in. to
CHECKFIRE SC-N Control Module itself. 0.25 in., suitable for the intended usage
FIELD TERMINATIONS • 3 amp maximum load
External Power Circuit (Terminals No. 1 and No. 2) • Relay specification: 4A 250VAC, 3A 30VDC resistive
• 12 to 24VDC • Normally open, normally closed set of contacts
• Polarity must be considered – Terminal No. 1 (+), Terminal • Form “C” contact arrangement
No. 2 (–) • Contacts shown in normal condition – No. 14 (N.O.), No. 15
• 3 amp inline fuse must be used in the positive side (Common), No. 16 (N.C.)
• Cable must be round jacketed, with an O.D. of 0.13 in. to Terminal Block
0.25 in., suitable for the intended usage • Terminal connections are sized for 12 - 24 AWG
Detection Circuit (Terminal No. 3 and No. 4) • Terminal is labeled from left to right, No. 1 through No. 16
• Cable from splicing device must be round jacketed, with an • The terminals are designed as follows:
O.D. of 0.13 in. to 0.25 in., suitable for the intended usage
1. + Ext. 12/24 VDC Battery
• Polarity need not be considered
2. – Ext. 12/24 VDC Battery
Manual Pull/Pressure Switch Circuit (Terminals No. 5 and 3. + Detection Input
No. 6) 4. – Detection Input
• Can be set up for either manual pull input or pressure 5. + Manual Input
switch feedback input 6. – Manual Input
7. + Release Output
• When set up for pressure switch feedback input, operation
does not discharge system 8. – Release Output
9. Trouble Common
• Polarity need not be considered 10. Trouble N.O.
• Cable from splicing device must be round jacketed, with an 11. Alarm N.O.
O.D. of 0.13 to 0.25 in., suitable for the intended usage 12. Alarm Common
Release Circuit (Terminals No. 7 and No. 8) 13. Alarm N.C.
14. Shutdown N.O.
• Polarity must be considered – Terminal No. 7 (+), Terminal 15. Shutdown Common
No. 8 (–) 16. Shutdown N.C.
• 15 ft. maximum cable length between control module and
pneumatic actuator
• Cable from splicing device must be round jacketed, with an
O.D. of 0.13 to 0.25 in., suitable for the intended usage
Trouble Relay Circuit (Terminals No. 9 and No. 10)
• Cable must be round jacketed, with an O.D. of 0.13 in. to
0.25 in., suitable for the intended usage
• 3 amp maximum load
• Contacts are normally open in the powered, non-trouble
condition. Contacts close upon trouble
• Relay specification: 4A 250VAC, 3A 30VDC resistive
Alarm Relay Circuit (Terminals No. 11, No. 12, and No. 13)
• Cable must be round jacketed, with an O.D. of 0.13 in. to
0.25 in., suitable for the intended usage
• 3 amp maximum load
• Relay specification: 4A 250VAC, 3A 30VDC resistive
• Normally open, normally closed set of contacts
• Form “C” contact arrangement
• Contacts shown in non-alarm condition – No. 11 (N.O.),
No. 12 (Common), No. 13 (N.C.)

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ID: BG00398452 en-US A.001.1 2015-10-19
USER INTERFACE
9-1-98 Service
Page 8 and Repair Manual LH204

FRONT PANEL INDICATORS Release Trouble (Yellow)

(See Figure 17)
The Yellow Release LED and the audio will pulse at a rate of
Battery Trouble (Yellow) once every 10 seconds when a trouble condition is detected in
the release circuit. The control module will return to normal
• LED pulses once every 10 seconds when indicating battery
when the trouble condition is cleared.
trouble
The Release trouble will also pulse after the system has
• The yellow battery trouble LED will pulse when a low power
completed a discharge cycle or a pressure switch feed back
condition is detected in either of the connected supplies
signal has been received. The trouble signal in this condition
(internal or external). If only one power source is used, the
is used to indicate a recharge of the fire suppression system is
control module will automatically ignore the unconnected
necessary. A Release trouble under either of these conditions
circuit upon resetting the control module. If a power source
can only be cleared by resetting the control module.
is once connected and recognized, a subsequent loss of
that power source will be recognized as a Battery Trouble Detection Trouble (Yellow)
condition. If a power source is once connected, recognized,
and then disconnected, the disconnected supply can be The Yellow Detection Trouble LED and the audio pulse once
ignored by operating the RESET button. every 10 seconds when the control module detects a trouble
in the detection circuit. The control module will automatically
Power Normal (Green) return to normal when the trouble is cleared.
• LED pulses once every 3 seconds when indicating normal Sounder (Audio)
power
The sounder gives the audio indication for all alarm and
• The green Power Normal LED pulses “on” once every trouble outputs. The sounder will pulse at the same rate as the
3 seconds indicating power is normal from both sources of visual corresponding LED.
input power. If the power drops below an acceptable level
from either the internal or external source of input power, the The sounder gives the audio indications of the various
green Power LED will be extinguished. If only one source of outputs. The sounder is rated at 85 Db at 10 feet.
power is used, the green Power LED will extinguish when The pulse rates are as follows:
the voltage level drops below an acceptable level.
Alarm – Time Delay 1 = 2 pulses per second
Alarm (Red) Time Delay 2 = 4 pulses per second
• The alarm LED will flash if an alarm condition exists. An Trouble – 1 pulse per 10 seconds
alarm condition is caused by operation of the detection
Loss of Power – 1 pulse per 10 seconds
circuit or operation of the manual pull/pressure switch input
circuit. The alarm condition will continue until the source of Release Circuit Fired – 4 pulses per second for 30 seconds,
the alarm is removed and the control module is reset. then 1 pulse per 10 seconds
DETECTION CIRCUIT ACTIVATION MODE – Upon receipt Low Battery – 1 pulse per 10 seconds
of an input to the detection circuit, the Alarm LED and the
sounder will pulse at a rate of 2 times per second and will
continue at this rate until the first time delay period has
SOUNDER
expired.
After the first time delay, a second time delay mode is
initiated. This causes the LED and sounder to pulse at a rate GREEN

of 4 times per second. YELLOW

RED
After discharge, the LED and sounder will continue to pulse
YELLOW
at a rate of 4 times per second for 30 seconds. After that, it
will switch to the trouble mode and pulse once every
10 seconds.
ELECTRIC MANUAL RELEASE MODE – The first time
delay mode will be by-passed and the LED will pulse at a
rate of 4 pulses per second. After the time delay setting is
reached, it will pulse another 30 seconds at the same rate. FIGURE 17
After that, the control module will go into the post-discharge 002760

mode, at which time the Alarm LED and Release LED will
pulse at a rate of one pulse per 10 seconds.
PRESSURE SWITCH CIRCUIT (FEED BACK) ACTIVATED
MODE – When this mode is actuated, the Alarm LED will
pulse a minimum of 30 seconds at 4 pulses per second. The
control module will then go into the post-discharge mode
and the Alarm and Release LED will pulse at a rate of one
pulse per 10 seconds.

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USER INTERFACE
Service and Repair Manual LH204
9-1-98 Page 9

POWER CONNECTIONS
Internal
The 3.6 VDC internal lithium battery is connected to the
control module by a removable type plug. The battery must
be replaced annually or when the Yellow Battery LED and
sounder are pulsing. A label is attached near the battery
mounting location for recording the installation date.

! CAUTION

Discharged lithium batteries may contain significant RESET

DELAY
amounts of unused energy and should be handled with BUTTON BUTTON
care. Do not compact for disposal. Before disposal, each
battery must be fully discharged and electrically isolated
by enclosing in a plastic bag and sealing the bag. Do not
dispose of in fire. Check applicable solid waste disposal
regulations for proper disposal of more than one battery.
FIGURE 18
External 002760

The external power circuit can be between 12 to 24 VDC. The BATTERY REPLACEMENT
circuit must be fused at the source on the positive line. The • While in use, the battery requires replacement every year
external power source is connected to the module terminal or when the Yellow Battery LED and sounder are pulsing
block on terminals No. 1 (+) and No. 2 (–).
• The shelf life of the battery is 8 years
Both power sources, internal and external, should be utilized
whenever possible. This will always give the fire suppression • Control Module contains a label for recording battery
system a battery back-up when one of the sources are replacement date
removed for whatever reason. • Make certain used battery is disposed of properly
FRONT PANEL BUTTONS Enclosure
(See Figure 18)
• The enclosure is watertight. It meets the requirements of
Delay International Standard I EC 529, “Degrees of Protection
• Pushing the “DELAY” button during the first time delay Provided by Enclosures” for an IP 66 rating
cycle will restart the time delay cycle. If the second time Cover Removal
delay cycle has already started, the “DELAY” button will
have no effect. • The cover is attached with 4, captive, slotted screws

• The “DELAY” button can also be used to check the • When removing and installing cover, make certain seal is
diagnostics function. By depressing the delay button when always correctly in place and not twisted
the system is in the trouble condition, the LED's will flash a • Seal should always be kept clean
pattern code. Each pattern code indicates a certain type of
trouble. The code pattern is prioritized. The first trouble • A small amount of silicone lubricant will improve the seals
must be fixed before addressing the next one. Once the effectiveness.
first trouble is taken care of, depressing the “DELAY” button STRAIN RELIEF INSTALLATION
will cause the LED's to indicate the code for the next
trouble, if there is one. When the “DELAY” button is • Always use Dow Corning 737 RTV Sealant or equal on all
pressed, three short audio and visual indications will strain relief and plug male threads
acknowledge the switch has been depressed properly. MOUNTING
• In a post discharge condition, pressing the DELAY button There are four types of mounting options available for the
will silence the alarm relay if the alarm relay has been CHECKFIRE SC-N Control Module.
programmed to silence.
• Control Module can be mounted without a bracket. It has
Reset mold-ed-in mounting tabs on the back box. Note: Surface
• The “RESET” button is used to re-initialize the control must be suitable.
panel. When depressed, it provides an indication that all • Control Module can be mounted on a combined bracket
LED's and the sounder are functional. which will allow both the module and the actuator to be
mounted together.
• It is used to upload the manual programming into the
control module. • Control Module can be mounted on its own bracket and the
• If trouble(s) has not been cleared, the trouble indication will actuator can be also mounted on its own bracket, with a
maximum release cable length of 15 ft.
reappear after the RESET button is pressed.
• Control Module can be mounted to an existing
• When the “RESET” button is pressed, three short audio
CHECKFIRE SC bracket by the use of a retrofit bracket.
and visual indications will acknowledge the switch has been
depressed properly. The Control Module should never be mounted in an area
which is subject to pressure washing or steam cleaning.

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SYSTEM PLANNING
9-1-98 Service
Page 10 and Repair Manual LH204

SYSTEM PLANNING The CHECKFIRE SC-N control module contains 3 amp

30VDC shutdown relay contacts to facilitate connection of
HAZARD IDENTIFICATION shutdown devices recommended by the vehicle manufacturer.
Before the CHECKFIRE SC-N Electric Detection and Example: opening or closing of coolant over-temperature
Actuation System is installed, the hazards to be protected alarm will bring about properly sequenced engine shutdown
must be identified. These hazard locations determine where on many vehicles. Consult vehicle manufacturer for details.
the detection wire or thermal detectors and the fire Alarm Application
suppression system nozzles are required. While the agent
nozzles in existing fire suppression systems will point out the Even with an effective fire suppression/detection package, the
hazard areas, the following information should still be vehicle must be evacuated at the earliest possible moment to
reviewed to best determine detection requirements. If an assure passenger and operator safety. Most vehicles tend to
entire fire suppression/detection system is to be installed, this be very noisy, and on some, the operator cannot see the entire
information is vital in determining proper placement of vehicle and often isn't aware that a fire exists. Therefore, a
discharge nozzles and detection devices. high decibel alarm should be provided near the operator to
signal that the control module has received a detection signal.
Fire Hazard Definition
PRE-INSTALLATION GUIDELINES
A fire hazard is any area where an ignition source (high
temperature or sparks) and fuel (flammable materials) may be Before actually installing the CHECKFIRE SC-N Electric
found in close proximity. Detection and Actuation System, review all of the following
information and plan (sketch) the system layout. This will help
Examples of ignition sources are engines, exhaust piping, to avoid any unforeseen installation problems. Once an
turbochargers, battery compartments, electrical system acceptable layout has been determined, record and keep it for
equipment, torque converters, transmissions, hydraulic future reference.
pumps, parking brakes, and friction from debris packed
around parts. Control Module and Actuator Location
Occasionally other components may reach high temperatures 1. The control module and actuator must be mounted in full
due to malfunction. The potential danger from these view and accessible to the operator. They must be
components must also be examined during hazard positioned within arms reach of the operator to enable
identification. A parking brake left engaged is an example of a manual operation of the red strike button on the manual
potential high temperature source. Temperatures in excess of actuator as well as the “Delay” button (to extend time
the detection wire or thermal detector ratings will cause the delay) on the front of the control module.
detection system to activate thereby actuating the fire 2. The location must be suitable for bolting or welding if bolting
suppression system. is impractical. The mounting surface must be flat to avoid
strain on the mounting bracket.
The above mentioned heat sources can cause fire when they 3. There must be room enough to allow for proper wiring
come in contact with flammable materials such as leaking fuel: connection to the control module and to install the actuation
either broken fuel lines, slow leaks, broken hydraulic lines, or line from the fire suppression system to the
a ruptured fuel tank. Type of Class A materials are part of the manual/automatic actuator. Also, the module and actuator
vehicle itself such as electric wiring insulation, padding, plastic should be accessible for periodic inspection and
parts, the packages on the vehicle, or debris due to poor maintenance. The components should be mounted in a
maintenance. These materials can contribute to the rapid location that will not interfere with normal equipment
buildup or spreading of fire. maintenance.
Other Considerations NOTICE
The ambient temperature in the mounting
Be aware that the propagation of fire from one area to another environment must not fall below –40 °F
may cause a hazard to be larger than originally determined. (–40 °C) nor exceed 140 °F (60 °C).
Liquid fuel may spray, splash, or flow carrying the fire some
distance from the starting point. Radiation, sparks, or Linear Detection Wire Routing
conduction through metal can carry heat to an area where the The linear detection wire will begin at the detection splicing
danger of fire wouldn't normally exist. device and will be routed through the predetermined hazard
Also, consider the fire history of the equipment being areas. The detection wire need only be routed through the
protected or of similar equipment. This information may be hazard area. From the control module to the hazard area,
available through company records or vehicle operators may standard 16 AWG wiring can be used. This wiring is then
have had first hand experience enabling them to identify the connected to the detection wiring by means of a splicing
locations of previous fires as well as special hazards such as a device, Part No. 71820. At the end of the detection wire, an
hydraulic hose that frequently ruptures. end of line resistor assembly, Part No. 426461, will be
installed. The detection wire should be installed as close to the
Each hazard that is identified must have both fire suppression hazard as possible, taking into consideration the requirements
system fixed nozzles and detection wire or thermal detectors. listed in the following steps:
Equipment Shutdown 1. A splicing device, Part No. 71820, must be used for
Another factor to examine is equipment shutdown. Provisions detection wire termination. Detection circuit wiring from the
should be made to shut down any components that could controller to the splicing device should be standard 16
possibly add to the intensity of the fire (fuel pumps, hydraulic AWG twisted wire.
pumps, engine, etc.) or any components that could possibly
re-ignite the fire once it has been suppressed (battery,
electrical system). Although a properly installed fire
suppression/detection system is the primary means of
protecting equipment from fire, an effective fire protection
package also includes provisions for equipment shutdown.
Copyright © Sandvik 747 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
SYSTEM PLANNING
Service and Repair Manual LH204
9-1-98 Page 11

PRE-INSTALLATION GUIDELINES (CONTINUED) System Layout

Detection Wire Routing (Continued) Once the system components have been selected and their
locations have been determined, sketch the layout of the
2. The total length of detection wire must not exceed 750 ft.
system. This sketch should include the location of the
(229 m). If possible, it should be run continuously. Splices
components, as well as the proposed detection wire routing,
are acceptable when they are kept to a minimum and when
thermal detector locations, and pneumatic actuation hose
they are made in accordance with the splicing technique
routing. Also, indicate areas where the wire must pass
found on Page 16 of Installation Section.
through bulkheads so that there is an acceptable routing from
An end-of-line resistor assembly, Part No. 426461, is
one hazard to the next. This sketch should be as precise as
required on the end of the linear detection wire.
possible to avoid any unforeseen installation problems later.
3. Do not install the wire within 12 in. (30 cm) of a
temperature source of 356 °F (180 °C) or greater (engine
block, exhaust manifold, turbochargers, brake grids, etc.).
4. Avoid routing detection wire directly across an opening.
Where possible, install detection wire above the hazard
area or around the perimeter of a hazard compartment to
react to escaping heat. Do not allow struts, frame
members, etc. to act as heat shields between the hazard
and the detection wire.
5. Avoid areas where the detection wire may be damaged,
such as outside the vehicle, near moving parts, in areas
where debris may be thrown by wheels, or in the way of
maintenance personnel.
6. To reduce its accessibility to damage, use only as much
detection wire as is necessary to cover the hazard area.
Thermal Detector Selection and Placement
Thermal detectors are used when single point detection is
required. They are selected by temperature range relative to
the hazard temperature. The table below indicates the
thermal detector rated operating temperature required
according to the maximum hazard temperature.
Maximum
Rated Operating Continuous Use
Temperature Temperature Detector
°F (°C) °F (°C) Color Part No.
270 (132) 234 (112) Blue 416218
325 (163) 280 (137) Red 416219
360 (182) 312 (155) Red 416220

The placement of thermal detectors should be based on the

following requirements:
1. They can be wired directly to the control module using
approved cable. Cable must have a temperature rating of
392 °F (220 °C) minimum, 16-18 gauge, two conductor
with drain, with an O.D. of 0.13 in. to 0.25 in. (0.3 to
0.6 cm). Again, placement of the detectors should allow
for incoming and outgoing wire connections. At the end of
the detection circuit, an end of line resistor assembly, Part
No. 426461, must be installed.
2. Secure the detector with the provided bracket and clamps.
Pressure Switch
Mount pressure switch in a location which is not subject to
damage. Switch must be mounted in an area in which it can
be easily reset after system actuation. See Section I,
Components, for electrical rating of switch contacts. When
running the actuation hose to the switch, make certain hose
does not run through any areas which could cause damage to
the hose. Make certain hose is securely supported and not
subjected to vibration.

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INSTALLATION
Before installing the detection and actuation system, the
System Planning portion of this manual should have been
reviewed for particular application resulting in a system layout
sketch. Always read the procedure before installing each
component to become familiar with the correct installation
steps as they apply to the particular application and sketch.
NOTICE
For ease of installation, the fire
suppression system should be installed
before the detection and actuation system.
INSTALLATION MATERIALS
All hardware and tools should be on hand before beginning FIGURE 19
the installation. Check the Component Index, Pages 35-36, to 002761

make certain all necessary system components are available. Welding

Material to be supplied by the installer includes: NOTICE
– Ample cable ties or 1/4 in. (6 mm) clamps to guide and Never weld on the vehicle frame without
support the detection wire. first consulting the owner and vehicle
manufacturer.
– Non-wire braid hose (1/4 in.) to be used as a protective
covering for the detection or power wire at points of 1. Carefully mark the location of the bracket.
securement and when passing through bulkheads. 2. Clean the mounting bracket and mounting surface using a
wire brush until clean steel surfaces are available for
– Actuation line (1/4 in. hydraulic hose) and fittings to connect welding.
the electric detection and actuation system actuator to the 3. Secure the bracket to the mounting surface using 1/8 in.
fire suppression system. (See applicable Ansul Fire (3 mm) fillet welds at the top, bottom, and both sides. See
Suppression Systems installation manual for additional Figure 20.
details.) 4. Remove all weld spatter from the bracket and mounting
Tools required to perform the installation include: surface.
5. Prime and paint the exposed bare metal of the bracket and
– Drill and Drill Bit Set (or welding equipment)
mounting surface.
– 1/8 in. Blade Screwdriver
– 1/4 in. Blade Screwdriver
– Phillips Screwdriver
– Standard Sidecutters
WELD
– Small Sidecutters (1/4 in. cut) WELD
– Wire Stripper
– Low Wattage Soldering Pencil (35 watt)
– Rosin Core Solder (60/40)
– Rubberized Electrician's Tape
MOUNTING BRACKET INSTALLATION
FIGURE 20
Three mounting bracket options are available: 002761

• Mounting control module and pneumatic actuator on same

bracket
• Separate brackets for control module and pneumatic
actuator
• Control module retrofit bracket to existing CHECKFIRE SC
bracket
Bolting
1. Using the bracket as a template, carefully mark the
location of the bracket mounting holes.
2. Center punch the premarked hole locations and drill 3/8 in.
(10 mm) holes through the mounting surface.
3. Secure the bracket to the mounting surface using
appropriate length of 5/16 in. (8 mm) bolts with flat washers,
lockwashers, and nuts. See Figure 19.

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MOUNTING TO EXISTING CHECKFIRE SC BRACKET Installing The Fire Suppression System Actuation Line
In some cases, retrofitting to an existing CHECKFIRE SC Install 1/4 in. actuation hose from lower outlet on actuator to
system may be an option. To accomplish this, use retrofit pneumatic actuator on fire suppression system using a check
bracket, Part No. 423531. This bracket can be mounted valve at the intersection of each actuation device branch line.
directly to the existing SC bracket. See Figure 21. See Figure 23.
The CHECKFIRE SC-N System output (using LT-5-R
cartridge) can pressurize up to 75 lineal ft. (22.8 m) of 1/4 in.
actuation line with up to eight tanks and/or accessories.
Check valves are used to protect against pressure loss if one
or more actuator cartridges are removed or damaged; and by
isolating each branch line, they reduce the overall lineal
length of actuation line.

! CAUTION

The fire suppression system could be accidentally

actuated causing the release of agent if the squib or
LT-5-R cartridge is installed at this time. Do not install
these components until the appropriate installation step is
NUTS AND BOLTS INCLUDED
reached.
WITH RETROFIT BRACKET
FIGURE 21
002763

MANUAL/AUTOMATIC ACTUATOR INSTALLATION AND

CONNECTION DETECTION AND
ACTUATION
SYSTEM
Mounting
1. Remove jam nut from lower threads of actuator and slide
actuator through hole in mounting bracket.
ACTUATION
2. Rotate actuator so that upper squib inlet is facing control CHECK LINE
module and that actuation line outlet is accessible. VALVES

3. Reinstall jam nut and tighten firmly. (See Figure 22.) PRESSURE
RELIEF
4. Install ring pin but do not attach seal at this time. VALVE

ACTUATION
LINE

SQUIB PORT FIRE

MANUAL SUPPRESSION
ACTUATOR SYSTEM

FIGURE 23
ACTUATION LINE 002772
OUTLET

JAM NUT

FIGURE 22
002764

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MOUNTING THE CONTROL MODULE 2. Wire the alarm to the control module in accordance with the
The CHECKFIRE SC-N Control Module can be mounted to diagram in Figure 25 using 20 AWG wire. Make certain the
either a flat, rigid surface or utilizing one of the three bracket jumper is installed between the HI and LO terminals on the
options. alarm terminal block. Certain alarm models may have only
one positive terminal in which case a jumper is not used.
If mounting the control module to a flat, rigid surface, use the The ends of stranded wire must be tinned with 60/40 rosin
appropriate fasteners. core solder, using a low wattage soldering pencil, before
If mounting the control module to the SC-N bracket, complete installation. On the terminal block at the control module,
the following steps: install the wires to Terminals 11 (NO) and 12 (C).

1. With the bracket securely mounted, position the holes in NOTE: Use 0.13 to 0.25 in. diameter round jacketed
the control module mounting flanges over the threaded cable to maintain water tight integrity of control
studs on the bracket. Using the supplied mounting module strain reliefs.
hardware, securely fasten the control module to the
ALARM RELAY
bracket with four lock washers and nuts.
2. If utilizing the SC retrofit bracket, first fasten the retrofit
CHASSIS
bracket onto the existing SC bracket by using the supplied GROUND
FUSED LEAD ON NON-CHASSIS
fasteners. With the SC retrofit bracket securely fastened, SIDE (FUSE AT LOAD X 1.25, NOT
position the holes in the control module mounting flanges TO EXCEED 3 AMPS)

over the threaded studs and securely fasten.

Remove the cover from the control module. If the internal 3.6 ALARM
VDC battery is in place, disconnect the wire plug until the TERMINAL VEHICLE
BLOCK POWER
field wiring is complete. SOURCE

If the strain relief(s) and plug(s) are not in place, coat the male
threads with Dow Corning 737 RTV Sealant or equal and LEAVE JUMPER IN
PLACE (WHEN
install in holes of module back box. EQUIPPED)

At this point, the external field wiring can be installed.

FIGURE 25
REMOTE HIGH LEVEL ALARM INSTALLATION 000869

1. Using the alarm as a template, carefully mark the location

of the four mounting holes. Use either the bottom or rear
set of mounting holes depending on the mounting location.
Secure the alarm using appropriate length of 5/16 in. bolts
with lock washers and nuts. See Figure 24.

FIGURE 24
000868

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SHUTDOWN DEVICE CONNECTION DETECTION WIRE INSTALLATION

1. Install the shutdown device in accordance with MOUNTING
manufacturer's instructions. Also check with vehicle
1. Using the system layout sketch, investigate each point
manufacturer to make certain the appropriate shutdown
where the wire will be secured to the vehicle. Keep in
device is being used. The device must not exceed the
mind all the guidelines in the System Planning Section.
relay contract rating of 3 amp @ 30VDC resistive.
Do this on a vehicle that has been operated recently to
2. Terminals 14 (NO), 15 (C), and 16 (NC), are the shutdown
avoid securing the wire too close to extremely hot
relay terminals on the control module. Figure 26 illustrates
components.
a typical wiring diagram for a normally closed circuit.
Figure 27 shows a typical normally open circuit. The ends 2. After the vehicle has cooled, loosely route the wire from the
of stranded wire should be tinned with 60/40 rosin core start of the hazard throughout the proposed path through
solder, using a low wattage soldering pencil, before the hazard areas. If splicing is required, see Splicing,
connection to the control terminals. Page 16, for detailed information.
3. Secure the detection wire by completing the following
NOTE: Use 0.13 to 0.25 in. diameter round jacketed
steps: See Figure 28.
cable to maintain water tight integrity.
SHUTDOWN a. Start at the beginning of the detection wire leading into
the hazard area. Secure the detection wire every 12 to
FUSED LEAD ON NON-CHASSIS
18 in. (30 to 45 cm) using black nylon cable ties, Part
SIDE (FUSE AT LOAD X 1.25, No. 56691, and protective coverings, Part No. 56692,
NOT TO EXCEED 3 AMPS)
at points of securement. Secure more often if
necessary. Attach the wire to mounting surfaces,
decks, struts, etc., always keeping System Planning
guidelines in mind.
VEHICLE NOTICE
POWER
SOURCE Do not kink the wire by bending it in sharp
SHUTDOWN turns of 2 in. (5 cm) or less. Remove
DEVICE enough slack to avoid droops in the line,
(BY OTHERS)
but do not try to stretch the wire in any
CHASSIS
way. Do not attach detection wire to
GROUND commonly removed or replaced
equipment.
FIGURE 26
000870
! CAUTION

SHUTDOWN Detection wire must never be routed through a hole

or near sharp edges without being properly
protected. Failure to protect the wire from being cut
FUSED LEAD ON NON-CHASSIS
SIDE (FUSE AT LOAD X 1.25,
or abraded could cause it to short, causing a false
NOT TO EXCEED 3 AMPS) discharge.

b. Secure the wire at least once immediately before it

passes through a hole in a vertical or horizontal
surface. At the hole, a 1/4 in. (6 mm) rubber sleeve,
VEHICLE
POWER
Part No. 56692, or a special grommet to fit the hole
SOURCE should be used to protect the wire from wear due to
vibration. Tape the hose to the wire using electrician's
SHUTDOWN
DEVICE tape to keep it from shifting. This hose protection
(BY OTHERS) should also be used at locations where the wire would
CHASSIS
rub against other hard surfaces, rough edges, or sharp
GROUND corners.
1/4 IN.
RUBBER SLEEVE
FIGURE 27
000871 CABLE TIE

TAPE AT
BOTH ENDS
FIGURE 28
000872

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DETECTION WIRE INSTALLATION (Continued) 5. Starting at the outer jacket, wrap the entire splicing area in
rubberized electrician's tape. An acceptable brand is 3M
Splicing
Super33+. Make certain the tape is sufficiently overlapped
If possible, the detection wire should be run in a continuous so that the leads and the splicing device are completely
piece. However, if splices are required, they must be made covered.
using the following technique. See Figure 29. 6. Route the 16 gauge wire from the splicing device, through
1. Strip off about 1 1/2 in. (3.8 cm) of the detection wire outer the strain relief, to the terminal strip in the control module.
jacket to expose the internal leads. Make certain wire is not exposed to damage. See
2. Cut leads to make certain they are of equal length. Then, Figure 30.
strip off 1/2 in. (13 mm) of insulation from each of the 7. On the terminal block at the control module, install the wires
internal spring wires. to terminals No. 3 and 4. See Figure 30. Note: It is not
3. Loosen the terminal screws on the special splicing device, necessary to be concerned about polarity when installing
Part No. 71820. Insert the two incoming detection wires into these wires.
DETECTION
one end of the splicing device and the two outgoing leads CIRCUIT
into the other end so that the exposed wires overlap as
shown in Figure 29.
4. Tighten the terminal screws until the wire is secured.
5. Starting at the outer jacket, wrap the entire splicing area in
rubberized electrician's tape. An acceptable brand is 3M
Super 33+. Make certain the tape is sufficiently overlapped
so that the leads and the splicing device are completely
covered.
OUTGOING

FIGURE 30
002765

THERMAL DETECTOR INSTALLATION

SPLICING
DEVICE When installing the Ansul spot detectors, use only
components approved by Ansul. These components consist of
the following:
– Mounting Bracket Shipping Assembly, Part No. 416221 –
TAPE Consists of one mounting bracket.
OVERLAP ENTIRE
EXPOSED SPLICE – Detector Clamp Package Shipping Assembly, Part
LEADS No. 416214 (for use with protective tubing) – Consists of (2)
INCOMING
FIGURE 29 cable clamps, (2) 1/4-20 x 1/2 in. socket head screws, (4)
000873

Wiring flatwashers, (2) spacers, and (2) 1/4-20 x 5/8 in. socket
head screws.
Once the detection wire has been routed and secured in the
hazard area, complete the following steps: – Detector Clamp Package Shipping Assembly, Part
No. 416762 (for use without protective tubing) – Consists of
1. Install an end of line resistor assembly, Part No. 426461, to (2) cable clamps, (2) 1/4-20 x 1/2 in. socket head screws,
the far end of the detection wire. See instruction sheet (4) flatwashers, and (2) 1/4-20 x 5/8 in. socket head
included with end-of-line resistor shipping assembly for screws.
assembly details.
2. Near the area where the detection wire enters the hazard – Detector Connector Package Shipping Assembly, Part
area, cut the detection wire as described in Steps 1 and 2 No. 416213 – Consists of (2) connector housings, (6) pins,
in Splicing. and (2) heat shrinkable sleeves.
3. Loosen the terminal screws on the splicing device, Part – Protective Tubing Shipping Assembly, Part No. 416215 –
No. 71820. Insert the two incoming detection wires into one Consists of 100 ft. (30.5 m) of tubing.
end of the splicing device as shown in Figure 29.
– Multi-Conductor Cable, Part No. 417055 – Cable must be
4. Strip approximately 1 1/2 in. (3.8 cm) of outer jacket and
purchased by installer and must have a temperature rating
1/2 in. of internal inner insulation from the 16 gauge wire
of 392 °F (220 °C) minimum, 16-18 gauge, two conductor
which will run from the splicing device to the control
with drain, minimum O.D. of .230 in. (.58 cm).
module. Insert these leads into the outgoing side of the
splicing device so that the exposed wires overlap as shown – AMP crimping tool, Part No. 416784.
in Figure 29. There is no need to be concerned about
polarity between the mating wires. Once the wires are
inserted properly, tighten the splicing device screws until
the wire is secured.

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THERMAL DETECTOR INSTALLATION (Continued)

To properly install the thermal detector, complete the
following: CRIMP

1. Secure the mounting bracket(s) near the hazard. Make

certain the bracket does not shield the detector from the
heat or flame.
2. Attach the correct temperature range spot detector to the
bracket using (2) two flatwashers and (2) two 1/4-20 x
5/8 in. socket head screws supplied in detector clamp
package. See Figure 31.
PINS
CABLE RUBBER
CLAMP SLEEVES
PROTECTIVE
MOUNTING SHRINK SLEEVE
BRACKET RUBBER TUBING
SLEEVES 1 (GROUND)

GROUND
VIEW AA
1/4-20 x 1/2 WIRE
PINS SOCKET HEAD
SCREW

1/4-20 x 5/8
SOCKET HEAD
SCREW (2)
SPOT
DETECTOR FIGURE 31
000875

3. Starting at the Ansul CHECKFIRE Control Module,

measure and route the cable to the first detector. Note: If
protective tubing is to be used, make certain cable is run
through it between each detector. AFTER
4. The circuit cable is 3 conductor. It consists of two insulated POSITION HEAT
SHRINK TREATING
wires and one bare ground wire. Cut all wires equal in TUBING
length and strip the outer jacket and inner sheath back
1 1/4 in. (3.2 cm). Note: Make certain not to cut into the
insulation on the two insulated wires or cut into the bare FIGURE 32
000876
ground wire. See Figure 31.
5. With the outer jacket and sheath cut back, strip the 13. Complete this process on each detector in the system.
insulation on the two inner wires 1/4 in. (.6 cm). See 14. Attach the ground wire to the vehicle ground. Do this by
Figure 32. mounting a sealed junction box in a convenient, protected
6. Slide the rubber sleeves from the AMP connector over the location. The box must be mounted to a rigid support. Run
3 wires. The small end of the sleeves must be toward the the detection circuit cable to the box and attach to
striped end of the wires. See Figure 32. grounding screw. See Figure 33.
7. Slide a piece of heat shrinkable tubing onto the cable. See 15. Attach the end-of-line resistor assembly, Part No. 426461.
Figure 32. See Figure 33. See instruction sheet included with end-of-
8. Crimp the pins onto all three wires, using AMP crimping line resistor shipping assembly for detailed assembly
tool, AMP part No. 90277-1. See Figure 32. This tool is information.
required for proper crimping. It can be purchased through 16. Run cable to the terminal strip at the control module. Make
your local electronics distributor or is available through certain cable is not subject to damage. Install cable to
Ansul as Part No. 416784. terminals 3 and 4.
9. Press the pins into the connector housing. The two
insulated wires go into holes 2 and 3 and the bare ground
wire goes into hole 1. Make certain each locks into place.
The bare ground wire must go into hole 1 but it makes no
difference which of the two insulated wires goes into hole 2 E.O.L. RESISTOR
or 3. See Figure 32. ASSEMBLY, GROUND
PART NO. 426461 WIRE
10. Press the rubber sleeves into the connector holes.
11. Fit the heat shrinkable tubing over the connector so it DETECTION
CIRCUIT
covers approximately 3/8 in. to 1/2 in. (.9 cm to 1.3 cm) of
the connector. Heat the tubing with an approved heat gun,
shrinking the tubing onto the connector and cable to form GROUND SCREW
a tight, waterproof fit. See Figure 32.
12. Coat the O-ring on the detector with silicon grease, then
snap the connector onto the mounted detector and secure
cable to detector bracket using appropriate cable clamp
JUNCTION BOX
and 1/4-20 x 1/2 in. socket head screw supplied in detector
cable clamp package shipping assembly. FIGURE 33
002766

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PNEUMATIC/LINEAR DETECTOR INSTALLATION SQUIB LEAD CONNECTOR

The pneumatic/linear fire detection system, Part No. 416113, Squib connector cable assembly, Part No. 79062, is supplied
is a Systron Donner Model 808-DRV. This detection system is with the CHECKFIRE SC-N shipping assemblies (Part
completely compatible with the Ansul CHECKFIRE SC-N No. 423500 and 423538). The cable assembly is precut to
control module. 20 in. (51 cm) to reach between the actuator assembly and
Each detection system is shipped with a detailed Installation, the control module on a standard bracket. An optional
Maintenance Manual. connector assembly, Part No. 422747, is 15 ft. (4.6 m) long
and it can be cut to any length required to make the
When installation the pneumatic/linear detection system to an connection between the control module and the pneumatic
Ansul CHECKFIRE SC-N control module, use actuator.
connector/cable assembly, Part No. 416216, and install per
Figure 34. If the control module and pneumatic actuator are mounted on
the same bracket, the squib connector included with the
NOTE: Attach end-of-line resistor assembly by following the control module shipping assembly should be used and no
detailed steps listed on the instruction sheet included with the cutting to length is required.
end-of-line resistor shipping assembly.
MULTIPLE DETECTORS ! CAUTION
OUT
Do not attach squib connector to live squib at this time. If
CONTROL
MODULE
squib is connected, the squib could be actuated
TERMINAL EOL RESISTOR ASSEMBLY, accidentally during installation.
BLOCK PART NO. 426461
4.7 K, 1/8 W
1. Locate the squib connector end of the assembly at the
BLUE
GREEN
squib inlet port on the pneumatic actuator. Route the cable
GREEN RED GREEN RED from that location, through the strain relief, to the terminal
BLUE ORANGE BLUE ORANGE strip at the control module. See Figure 35.
A B C D A B C D
2. Leaving a little slack, cut off excess cable.
A B C D
3. Strip the internal wires approximately 1/4 in. (.6 cm) and
securely fasten the black/white leads to Terminal 7 and the
red/green leads to Terminal 8 on the control module. See
Figure 35.

808-DRV

RELEASE CIRCUIT
SINGLE DETECTOR
OUT

CONTROL BLACK/WHITE
MODULE RED/ WIRE
TERMINAL BLOCK GREEN
EOL RESISTOR WIRE
ASSEMBLY,
PART NO. 426461
4.7 K, 1/8 W
ORANGE
GREEN
RED BLUE

A B C D

FIGURE 35
002767

4. Attach the release circuit tester, Part No. 423541, at this

808-DRV time. This will be required when performing the functional
test, starting at Page 19.
FIGURE 34
001059

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EXTERNAL POWER CONNECTION At this point, the GREEN Power LED should be the only LED
pulsing.
In some cases, the customer may prefer external power input
from the vehicle battery. NOTICE
When performing any of the functional
This external power is wired into the control module terminal
test, make certain the release circuit
strip on Terminals No.1 (+) and 2 (–). See Figure 36. See
tester, Part No. 423541, is attached to the
Component Index in Appendix Section for list of Power Wiring
squib lead connector.
and Battery Connection Assemblies.
The following tests will verify that the system will operate
EXTERNAL 12/24 VDC CIRCUIT upon receiving an electrical signal from a detection device
TERMINALS 1 (+) AND 2 (–)
(simulated fire condition) or when actuated using an electric
pull station. The accuracy of the time delay setting(s) will also
be verified during this test. If the system is connected to a
vehicle shutdown device, the vehicle should be left running
during this test to verify that the shutdown device is
functioning. If noted results are not attained, refer to the
Troubleshooting Section of this manual for corrective action.
External Power Circuit Test
Check the external power circuit by disconnecting the fuse
and checking to see that a power trouble is present. Replace
the fuse and check to see that the control module returns to
normal.
Detection Circuit Functional Test
NOTICE
TO VEHICLE BATTERY
Before conducting the functional test,
FIGURE 36 each time delay setting must be known.
002768

OPTIONAL PRESSURE SWITCH/ELECTRIC PULL 1. Using a short length of insulated wire stripped at both
STATION ends, hold one end of the wire to Terminal 3 and hold the
other end to Terminal 4. See Figure 38.
The pressure switch circuit must be wired to Terminals 5 and DETECTION CIRCUIT
6 on the control module terminal strip. The pressure switch TERMINALS 3 AND 4
circuit must also have an end of line resistor assembly, Part JUMPER
No. 426461, installed in the circuit. See Figure 37. 3 4

NOTE: If pressure switch/electric pull station circuit is not

used, a 4.7 k ohms resistor must be connected
across terminals inside the control module. DETECTION
PRESSURE SWITCH/ELECTRIC CIRCUIT
PULL STATION CIRCUIT – WIRING
TERMINALS 5 AND 6

E.O.L. RESISTOR
ASSEMBLY,
PART NO. 426461

FIGURE 38
002770
NOTE: ALL
CONNECTIONS MUST Hold the wire on the terminals for a time which is shorter
BE WATERTIGHT. than the time programmed in for the first time delay.
PRESSURE SWITCH FIGURE 37
002769

FUNCTION TEST
Before conducting the following FUNCTION TEST, connect
the internal battery to the front cover using the battery
extender cable assembly, Part No. 426604, and connect the
Extender Test Cable Assembly, Part No. 426601, to the
terminal strip inside the back box and the mating terminal
strip inside the cover. (The Extender Test Cable Assembly
allows separation of the cover from the back box while
maintaining circuit integrity.)
Depress the “RESET” button on the control module. This will
set the module to normal. Reset will be acknowledged by the
control module with short pulses from the sounder.
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Page 20 and Repair Manual LH204

FUNCTION TEST (CONTINUED) Immediate Release Option

Detection Circuit Functional Test (Continued) 1. Using the jumper wire, hold the wire on Terminals 5 and 6.
This is the pull station circuit. If the circuit was
The following will take place while the jumper wire is being
held on the terminals: programmed for immediate release, the following will take
place:
• The RED Alarm LED and sounder will pulse at a rate of • The RED Alarm LED and the sounder will pulse at a
two times per second rate of four times per second
• The first time delay cycle will start • The alarm relay will operate (latching)
• The alarm relay will activate (non-latching) • The shutdown relay will operate (latching)
After verifying the above, remove the jumper wire. The • The release circuit (squib) will activate, causing the
control module will reset to normal (as long as the cycle for GREEN LED on the squib tester to illuminate
Time Delay No. 1 has not been exceeded). Normal is when 2. Reset squib test module by pressing the reset button on the
only the GREEN Power LED is pulsing and no other LED's tester. Do not disconnect the test module at this time.
or the Audio Alarm are operating. Also, the alarm relay will 3. Push the “RESET” button on the CHECKFIRE SC-N
return to normal. Control Module and the module will return to the normal
2. This next test will verify the settings of the time delays. condition.
Again, hold the jumper wire on Terminals 3 and 4. Continue 4. If required, make certain to reset any auxiliary shutdown
to hold the jumper wire on these terminals until the second devices.
time delay has started. Once the second time delay has
Shutdown/Time Delay/Release Option
started, the jumper wire can be removed.
The following will take place while the jumper wire is being 1. Using the jumper wire, hold the wire on Terminals 5 and 6.
held on the terminals: This is the pull station circuit. If the circuit was
• The RED Alarm LED and sounder will pulse at a rate of programmed for shutdown/time delay/release, the
two times per second following will take place:
• The first time delay cycle will start and time through its • The RED Alarm LED and sounder will pulse at a rate of
cycle four times per second
• The alarm relay will activate (non-latching) • The alarm relay will operate immediately (latching)
After the first time delay has completed its cycle, the • The shutdown relay will operate immediately (latching)
following will take place: • A single time delay cycle will start (during test, verify
• The RED Alarm LED and sounder will pulse at a rate of length of delay)
four times per second After the single time delay cycle is completed, the release
• The second time delay cycle will start and time through circuit (squib) will actuate, causing the GREEN LED on the
its cycle squib tester to illuminate.
• The alarm relay will activate (latching) 2. Reset squib test module by pressing the reset button on the
• The shut-down relay will activate (latching), causing tester. Do not disconnect the test module at this time.
3. Push the “RESET” button on the CHECKFIRE SC-N
vehicle shutdown
Control Module and the module will return to the normal
• At the end of the second time delay cycle, the release condition.
circuit (squib) will activate, causing the GREEN LED on 4. If required, make certain to reset any auxiliary shutdown
the squib tester to illuminate. devices.
3. After the jumper wire has been removed, reset squib test
Pressure Switch Option
module by pressing the reset button on the tester. Do not
disconnect the test module at this time. 1. Using the jumper wire, hold the wire on terminals 5 and 6.
4. Push the “RESET” button on the CHECKFIRE SC-N control This is the pressure switch circuit. The following will take
module and the module will return to the normal condition. place:
5. If required, make certain to reset any auxiliary shutdown
• The alarm relay will operate (latching)
devices.
• The shutdown relay will operate (latching)
Pressure Switch/Manual Pull Initiating Circuit • The RED alarm LED and the sounder will pulse at a rate
During the programming requirements of the pressure of four times per second.
switch/manual pull circuit, two options are available. The first 2. Push the “RESET” button on the CHECKFIRE SC-N
option allows the circuit to be programmed for immediate Control Module and the module will return to the normal
release and the second option allows for shutdown/time condition.
delay/release. If choosing the shutdown/time delay/release 3. If required, make certain to reset any auxiliary shutdown
option, the programming will also require a length of time devices.
delay to be chosen.
When performing this functional test, it is necessary to know
whether the first or second option was programmed into the
module.

Copyright © Sandvik 757 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
INSTALLATION
Service and Repair Manual LH204
9-1-98 Page 21

PLACING THE SYSTEM IN SERVICE c. Remove test module from squib connector and firmly
hand tighten squib connector unto squib. See
After all testing has been successfully completed, the system
Figure 41.
may be placed in service.
Make certain cartridge is not installed when completing
the following steps:
1. Install squib by completing the following steps:
HAND TIGHTEN
! CAUTION

The squib is an explosive device. Do not attach

connector onto squib until squib is installed in actuator
body. If the squib is actuated outside of the actuator
body, possible personal injury could result.

a. Screw squib into upper-right inlet hole in actuator body

and wrench tighten. See Figure 39.

SQUIB

FIGURE 41
002271

NOTICE
When the squib connector is removed
from the test module, the control module
YELLOW Release Trouble LED and
Sounder will temporarily pulse. This will
stop when squib is connected.
FIGURE 39
000882
! CAUTION
b. Unscrew protective cap from squib and remove spring
(shunt). Retain these components for possible future Make certain cartridge is not installed at this time. The
use. See Figure 40. fire suppression system will discharge dry chemical if
the cartridge is installed when operating the strike
CAUTION
button.
The control module could be damaged and the fire 2. Push “RESET” button on CHECKFIRE SC-N Control
suppression system may not operate if the squib Module to reset system. Note: Depress “RESET” button for
spring (shunt) is not removed. Always remove cap at least 3 seconds.
and spring (shunt) before installing squib 3. Pull ring pin and push strike button on manual/automatic
connector. actuator several times to ensure smooth movement.
4. Install LT-5-R cartridge, Part No. 6979, into
manual/automatic actuator by completing the following
steps. See Figure 42.
a. Make certain puncture pin is fully retracted and insert
ring pin through actuator body into puncture pin shaft.
Attach visual inspection seal, Part No. 197.
SPRING (SHUNT)
PROTECTIVE
b. Remove shipping cap and weigh cartridge before
CAP installing. Replace if weight is 1/4 ounce (7.1 g) or
more below weight stamped on LT-5-R cartridge, Part
No. 6979.
c. Screw cartridge into actuator body and hand tighten.

FIGURE 40
000883

758 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
INSTALLATION
9-1-98 Service
Page 22 and Repair Manual LH204

PLACING THE SYSTEM IN SERVICE (CONTINUED) 6. If a vehicle shutdown device is NOT installed, affix the
“WHEN FIRE ALARM SOUNDS” nameplate, Part
No. 71086, near the operator's line of vision. See
RING PINNED
AND SEALED
Figure 44.

FIGURE 44
000887

LT-5-R CARTRIDGE,
PART NO. 6979

FIGURE 42
000885

5. If a vehicle shutdown device is installed and the shutdown

time delay is being used, complete the following steps: See
Figure 43.
a. Affix the “IN CASE OF FIRE” nameplate, Part
No. 79060, near the operator's line of vision.
b. Using Label No. 79404, cut along the dotted line to
remove the required number square.
c. Peel the protective backing from the number square to
expose the adhesive.
d. Place the number square on the space provided in the
third sentence of Label No. 79060: “THIS VEHICLE
WILL AUTOMATICALLY SHUTDOWN AFTER
_____ SECONDS”

FIGURE 43
000886

Copyright © Sandvik 759 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
IN CASE OF FIRE
Service and Repair Manual LH204
9-1-98 Page 23

IN CASE OF FIRE Manual System Actuation

Read these precautions carefully until they are clearly The system can be actuated manually by pulling the ring pin
understood. All equipment operators or anyone who has any and striking the red button on the manual/automatic actuator
responsibility for the equipment should fully understand how as shown in Figure 45. Again, bring the equipment to a safe
the CHECKFIRE SC-N Detection and Actuation System stop, shut off the engine, manually actuate the system, move
operates. Every operator should be fully trained in these a safe distance from the vehicle, and stand by with a hand
procedures. portable extinguisher.
1. When the system alarm sounds, bring the equipment to a
safe controlled stop, shut off the engine, and exit. ! CAUTION
(Equipment left running may add fuel to the fire or reignite
the fire with heat or sparks.) Manual actuation will result in immediate system
Automatic Equipment Shutdown – The CHECKFIRE discharge which may obscure vision. Make certain vehicle
SC-N system is equipped with a shutdown relay and time is stopped safely before manually actuating the system.
delay. If a shutdown device is connected to the system, all Manual actuation will bypass all auxiliary shutdown and
responsible personnel should understand shutdown alarm functions.
device operation and the length of the time delay (in
seconds). If the DELAY button (on the control module
cover) is pushed and released before the end of the 2
shutdown time delay period, the time delay will STRIKE
automatically repeat itself. This delay can be repeated BUTTON
(using the DELAY button) as many times as is necessary
to stop the vehicle safely before it shuts down. (The
DELAY button can also be held in indefinitely to delay
shutdown – the shutdown delay will then restart after the
button is released.) PULL RING
PIN
2. Move away from the equipment taking a hand portable 1
extinguisher along if possible.
3.

! WARNING

In case of fire, evacuate area to lessen risk of injury FIGURE 45

from flames, heat, hazardous vapors, explosions, or 002773

other hazards that may be created.

Stand by with a hand portable extinguisher to guard
against any fire that may reignite after the fire suppression
system has been discharged. Remain alert until the
equipment cools and the possibility of reignition is no
longer a threat.

760 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
RECHARGE
Service
9-1-98 Page 24 and Repair Manual LH204

RECHARGE
For continued protection, the CHECKFIRE SC-N Detection
and Actuation System and the fire suppression system must
be recharged immediately after operation.
UPPER PORTION
Before performing the recharge steps, determine the cause of OF BODY
the system discharge.
1. Remove the 4 screws holding the cover to the back box
and remove the cover.
BASE
2. Remove the battery from the back box. Note: If system OF STEM
contains optional vehicle power, also disconnect the wire LUBRICATE O-RING
WITH SILICONE GREASE
leads at the vehicle battery.
PUNCTURE PIN
3. Remove the empty LT-5-R cartridge from the
manual/automatic actuator.
4. If the system was manually actuated – Skip steps 5, 6,
and proceed to step 7.
5. If the system was automatically actuated – Unscrew the SPRING
squib lead connector. Remove the squib from the RESET
manual/automatic actuator. POSITION
APPROXIMATELY
6. Clean and lubricate the manual/automatic actuator by 1/16 IN. (1.6 mm)
completing the following steps. See Figure 46. ± 1/16 (1.6 mm) ACTUATOR
BODY
NOTICE
If the system was actuated manually and
the squib was not actuated, cleaning is not
necessary. FIGURE 46
000888

a. Remove jam nut and slide actuator out of mounting

bracket. NOTICE
When puncture pin is fully reset, cutting
b. Unscrew upper portion of actuator body. point of pin will be located approximately
c. Using a pencil eraser, apply pressure to the bottom of 1/16 in. (1.6 mm) below threads in lower
the puncture pin. This will force the puncture pin and actuator body.
spring out of the actuator body.
7. In the case of a fire, replace all linear detection wire and
d. Thoroughly clean carbon deposits from base of stem, spot detector cable. See Section III, Installation, for
puncture pin, spring, and inside surface of actuator instructions.
body.
8. Recharge the fire suppression system in accordance with
e. After all components are clean and dry, liberally the corresponding manual.
lubricate O-rings with a good grade of extreme
9. Test the system and place into service by completing the
temperature silicone grease.
steps listed under “FUNCTIONAL TEST,” Pages 19-20.
f. Reassemble actuator, reinstall into bracket, and
10. Record date of recharge on a tag or in permanent record
securely tighten jam nut.
file. Notify operating personnel that the system is back in
g. Pull ring pin and push strike button several times to service.
spread grease and ensure free movement of puncture
pin.
h. With strike button in the up position, insert ring pin
through actuator body into puncture pin shaft. Install
visual inspection seal, Part No. 197.

Copyright © Sandvik 761 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
INSPECTION AND MAINTENANCE
Service and Repair Manual LH204
9-1-98 Page 25

INSPECTION AND MAINTENANCE NOTICE

If a vehicle shutdown device is installed,
To ensure the CHECKFIRE SC-N Electric Detection and the vehicle should be running at this time
Actuation System will operate as intended, proper inspection to verify that the device is functioning
and maintenance procedures must be performed at the properly.
specified intervals.
8. If external power is used, measure the voltage at terminals
DAILY INSPECTIONS 1 and 2 to ensure that the 12/24 VDC is present. Check
The vehicle operator must check the system daily by visually monitoring of the external power by removing the in-line
verifying that the GREEN power LED is flashing and no other fuse and checking to see that a power trouble condition is
LED is illuminated. Also, no audio alarm should be sounding. present. Replace fuse and depress the RESET button on
If any other conditions exist, contact the local authorized the control module.
Ansul distributor or whoever has been trained and authorized 9. Check first time delay – Alarm to Shutdown – Using a
by Ansul to perform inspection and maintenance checks. short length of insulated wire stripped at both ends, hold
one end of the wire to Terminal 3 and the other end to
MAINTENANCE Terminal 4 on the control module. See Figure 47.
To give maximum assurance that the system will operate as DETECTION CIRCUIT
intended, maintenance must be performed at six-month TERMINALS 3 AND 4
intervals or sooner depending on the operating environment or JUMPER
maintenance schedule. Maintenance should be performed by an 3 4
authorized Ansul distributor or someone who has been trained
and authorized by Ansul to perform maintenance checks.
1. Check all mounting bolts for tightness or corrosion. DETECTION
2. Remove the LT-5-R cartridge from the manual/automatic CIRCUIT
actuator, install shipping cap, and set aside in a safe WIRING
location.

! CAUTION

Cartridge must be removed before continuing with the

following steps or accidental system actuation will
take place when squib is actuated.
FIGURE 47
002770
! CAUTION
Using a jumper wire, temporarily short Terminals 3 and 4,
removing the jumper before the end of the first time delay
Do not actuate squib unless it is installed in actuator cycle. This will test the non-latching function of the first
body. If the squib is actuated outside of actuator body, time delay. While the wire is being held in place, the RED
it will detonate causing possible personal injury. Alarm LED will pulse and the sounder will operate.
3. Five Year Squib Replacement – The squib must be Remove the jumper wire. At this point, both the RED
replaced after being in service for five years. (The month Alarm LED and the sounder will stop pulsing and the first
and year of manufacture is stamped on the squib hex time delay will recycle back to zero. The control module
surface.) Proper disposal of the squib is accomplished by will return to normal with only the GREEN Power LED on.
actuating the squib within the actuator body. If this is 10. Check second time delay – Shutdown to Discharge –
required, skip Steps 4 and 5 which deal with installing the Once again, hold the wire on Terminals 3 and 4. The RED
test module in place of the squib. By skipping steps 4 and Alarm LED and the Audio Alarm will pulse. Hold the wire
5, the squib will be actuated during the following test on the terminals for a period longer than what the first time
procedures. delay is set up for. While holding the wire on the terminals,
time the length of the first time delay to verify that it is the
! CAUTION same as what it was set for.
At the end of the first time delay cycle, the pulse rate of
Do not actuate squib unless it is installed in actuator the Audio Alarm will change. This will start the cycle of the
body. If the squib is actuated outside of actuator body, second time delay. At this point, the timing cycle is
it will detonate causing possible personal injury. latched, and the wire jumper need not be held on the
4. Remove the squib lead connector from the squib. terminals. Also at this point, the shutdown relay will
5. Hand tighten the squib lead connector onto the test operate, causing the vehicle to shutdown.
module, Part No. 423541. Time the length of the second time delay to confirm that it
6. Inspect the detection and interconnecting wiring as is the same as what has been set.
follows: When the second time delay cycle is completed, the
a. Check for wear due to vibration at penetrations, around release circuit will activate causing the GREEN LED on
corners, etc. the test module to illuminate or in the case of the five year
b. Check for damage from direct impact or other abuse. squib replacement, the squib will fire.
c. Check for tightness at points of securement. Make
certain fasteners have not come loose which would
allow the wire to sag or shift.
7. If thermal detectors are used, check that they are securely
mounted and have not corroded or been damaged.

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ID: BG00398452 en-US A.001.1 2015-10-19
INSPECTION AND MAINTENANCE
9-1-98 Service
Page 26 and Repair Manual LH204

MAINTENANCE (Continued) 18. Reinstall LT-5-R cartridge, Part No. 6979, by completing
the following steps:
11. (If used) Reset test module by pressing the reset button on
the tester. Do not disconnect test module at this time. a. Make certain puncture pin is fully retracted and insert
ring pin through actuator body into puncture pin shaft.
12. Complete the following steps only if the squib has been Attach visual inspection seal, Part No. 197.
actuated. Otherwise, go to Step No. 13.
b. Remove shipping cap and weigh cartridge before
a. Unscrew the squib lead connector from the squib and installing. Replace if weight is 1/4 ounce (7.1 g) or more
remove the squib from the actuator body. below weight stamped on LT-5-R cartridge. (Shipping
b. Clean manual/automatic actuator by referring to Step 6 Part No. 6979).
on Page 24 in Recharge Section. c. Screw cartridge into actuator body and hand tighten.
c. Screw replacement squib into the upper-right hole in the 19. Reset any auxiliary shutdown and alarm equipment in
actuator body and wrench tighten. accordance with manufacturer's instructions.
d. 20. Record date of maintenance on an affixed tag or in a
permanent record file.
! CAUTION

The control module could be damaged and the fire

suppression system may not operate if the squib
spring (shunt) is not removed. Always remove cap
and spring (shunt) before installing squib connector.

Unscrew protective cap from replacement squib and

remove spring (shunt). Retain these components for
possible future use.
e. Line up index slot in squib lead connector with index tab
on squib. Then, hand tighten squib lead connector onto
squib.
13. Unscrew the squib lead connector from the test module.
NOTICE
When squib lead connector is removed
from test module, the YELLOW Release
LED and the audio alarm on the control
module will temporarily pulse. This will
stop when squib is connected.
14. Line up index slot in squib lead connector with index tab on
squib. Then, hand tighten squib connector onto squib.
15. Push “RESET” button on CHECKFIRE SC-N Control
Module to reset system.

! CAUTION

The fire suppression system will discharge dry

chemical if the cartridge is installed when operating the
strike button. Do not install cartridge at this time.

16. Pull ring pin and push strike button on manual/automatic

actuator several times to ensure smooth movement.
NOTICE
If lever does not operate smoothly, clean
and lubricate internal components by
completing Step No. 6 on Page 24 in
Recharge Section.
17. Yearly – Remove control module cover screws and replace
internal 3.6 VDC lithium battery, Part No. 423520. Record
date of new battery installation on label located near
battery. Reinstall control module cover and depress
“RESET” button.

! CAUTION

Contact your local waste management company for

information concerning the correct disposal of lithium
batteries.

Copyright © Sandvik 763 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
TROUBLESHOOTING
Service and Repair Manual LH204
9-1-98 Page 27

TROUBLESHOOTING Below is a listing and explanation of each type of recorded

fault:
DIAGNOSTICS
The diagnostics feature offers a means to pinpoint various Programmed – This indicates any time the unit is
trouble symptoms by displaying a flashing code on the control programmed or a programming
module status LED's. change has been made.
Switch Enabled – This indicates that the manual
If there is more than one trouble at a time, the system will
programming switch is enabled and
display them in a pre-set priority.
the program settings are being taken
In multiple trouble situations, the first trouble must be cleared from the program switch settings.
before the system will display the next one. Init Bad Log – This indicates that an error has been
The system must be in the trouble mode in order to display detected in the datalog. If this occurs,
the diagnostics codes. the datalog is automatically cleared
and reset.
With the system in the trouble mode, depress the “DELAY”
button. With the “DELAY” button depressed, the trouble Bad Checksum – Indicates that an error has been
codes will be indicated on the LED's. detected in the E-Prom. If this occurs,
the factory default program settings
LED Code Trouble are restored.
Yellow Battery LED flashing Internal battery Soft Reset – Indicates that the Reset button has
disconnected been depressed. The clock is not reset
during a soft reset.
Yellow Battery LED flashing External battery
Red Alarm LED flashing disconnected +12 (24V) Low – Indicates that the external power input
voltage has dropped below a “Normal”
Yellow Release LED flashing Release circuit is open threshold level and is in need of
Yellow Release LED flashing Release circuit has servicing.
Red Alarm LED flashing operated +12 (24V) Fault – Indicates external power input voltage
has dropped below the minimum
Yellow Detection LED flashing Detection circuit is open operating threshold or the external
Yellow Detection LED flashing Electric manual pull station power has been disconnected.
Red Alarm LED flashing circuit is open Int Batt Low – Indicates the internal battery voltage
has dropped below a “Normal”
HISTORY BUFFER threshold level and requires servicing.
The CHECKFIRE SC-N control module is programmed to Int Batt Fault – Indicates that the internal battery
record faults, alarms, and programming changes in a voltage has dropped below the
numerical sequence. The module will store approximately minimum operating threshold or the
50 recorded events. If the number of events exceeds 50, the battery has been disconnected.
earlier events will be erased to make room for the later ones. Detection TD1 – Indicates that the Time Delay 1
A sample History Buffer screen appears as follows: sequence has been initiated. This
occurs as a result of operation of the
Event detection circuit.
Number Event
Detection TD2 – Indicates the start of the Time Delay 2
0 Programmed Time (dddd:hh:mm:ss) sequence as a result of a detection
1 Detection TD1 0000:00:01:46 input.
2 Delay Engaged 0000:00:01:52 Manual TD – Indicates the start of the time delay as
3 Delay Released 0000:00:02:15 a result of the manual input circuit
being initiated.
4 Detection TD2 0000:00:02:25
Pressure Switch – Indicates activation of the pressure
5 Squib Release 0000:00:02:35 switch input circuit.
6 Soft Reset 0000:00:05:10 Delay Engaged – ndicates the delay button has been
7 All Clear 0000:00:05:13 depressed during TD1 of an alarm
8 Int Batt Low 385:12:24:32 condition.
9 Int Batt Fault 405:20:32:07 Delay Released – Indicates the time the Delay button
was released after initiating.
The recorded event indicates which circuit had a fault or an Detection Fault – Indicates an open circuit in the
alarm recorded. Along with the type of fault or alarm, the detection circuit.
history buffer also records the time, relative to the first event.
New events are recorded by days: hours: minutes: seconds Manual Fault – Indicates an open in the manual pull or
that have transpired from the last event. If power is removed pressure switch circuit.
and then restored, the counter starts over at 0000:00:00:00. Squib Fault – Indicates an open in the squib circuit
or that the squib has fired.
Squib Release – Indicates that the control module has
fired the squib.
Unknown – Indicates an unexplainable event in
the control module circuitry.

764 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
TROUBLESHOOTING
9-1-98 Service
Page 28 and Repair Manual LH204

TROUBLESHOOTING TABLE
The following table designates normal operating and trouble conditions for the CHECKFIRE SC-N Detection and Actuation System.

Green Yellow Yellow

Power Yellow Detection Release Audio Alarm Shutdown Trouble Agent
Condition Normal Power Fault Red Alarm Fault Fault Alarm Relay Relay Relay Release

battery normal pulsing off off off off off normal normal normal off
module normal once every
external power 3 seconds
not used

battery normal pulsing off off pulsing off pulsing once normal normal transferred off
detection fault once every once every every
external power 3 seconds 10 seconds 10 seconds
not used

battery normal pulsing off off off pulsing pulsing once normal normal transferred off
release fault once every every
external power 10 seconds 10 seconds
not used

battery normal pulsing off off pulsing pulsing pulsing once normal normal transferred off
detection fault once every once every every
release fault 10 seconds 10 seconds 10 seconds
external power
not used

battery fault off pulsing once off off off pulsing once normal normal transferred off
external power every every
normal 10 seconds 10 seconds
module normal

battery fault off pulsing once off pulsing once off pulsing once normal normal transferred off
external power every every every
normal 10 seconds 10 seconds 10 seconds
detection fault

battery fault off pulsing once off off pulsing once pulsing once normal normal transferred off
release fault every every every
external power 10 seconds 10 seconds 10 seconds
normal

battery fault off pulsing once off pulsing once pulsing once pulsing once normal normal transferred off
detection fault every every every every
release fault 10 seconds 10 seconds 10 seconds 10 seconds
external power
normal

alarm detected pulsing off pulsing off off pulsing twice transferred normal normal off
alarm to once every twice every every
shutdown 3 seconds second second
period – TD1

external power off pulsing once off pulsing once pulsing once pulsing once normal normal transferred off
fault every every every every
detection fault 10 seconds 10 seconds 10 seconds 10 seconds
manual pull
circuit fault
release fault
battery normal

battery fault off pulsing once off off off pulsing once normal normal transferred off
external power every every
fault 10 seconds 10 seconds

battery fault off pulsing once off pulsing once off pulsing once normal normal transferred off
external power every every every
fault 10 seconds 10 seconds 10 seconds
detection fault

battery fault
external power
fault
detection pulsing once pulsing once pulsing once
fault manual every every every
pull circuit fault off 10 seconds off 10 seconds off 10 seconds normal normal transferred off

Copyright © Sandvik 765 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
TROUBLESHOOTING
Service and Repair Manual LH204
9-1-98 Page 29

Green Yellow Yellow

Power Yellow Detection Release Audio Alarm Shutdown Trouble Agent
Condition Normal Power Fault Red Alarm Fault Fault Alarm Relay Relay Relay Release

battery fault off pulsing once off pulsing once pulsing once pulsing once normal normal transferred off
external power every every every every
fault 10 seconds 10 seconds 10 seconds 10 seconds
detection fault
manual pull
circuit fault
release fault

manual pull pulsing off pulsing off off pulsing transferred transferred normal off
circuit once every 4 times per 4 times per
activated pre 3 seconds second second
release period
(manual release
time delay)

pressure switch pulsing off pulsing off off pulsing transferred transferred normal off
activated (0 to once every 4 times per 4 times per
30 seconds 3 seconds second second
after activated)

pressure switch pulsing off pulsing off pulsing once pulsing once transferred transferred transferred off
activated once every once every every every
(post 3 seconds 10 seconds 10 seconds 10 seconds
30+ seconds
period)

shutdown to pulsing off pulsing off off pulsing transferred transferred normal off
release period once every 4 times per 4 times per
(2nd time delay) 3 seconds second second

0 - 30 seconds pulsing off pulsing off off* pulsing transferred transferred transferred fired
after release once every 4 times per 4 times per
3 seconds second second

30+ seconds pulsing off pulsing off pulsing once pulsing once transferred** transferred transferred fired
after release once every once every every every
3 seconds 10 seconds 10 seconds 10 seconds

manual pull pulsing off off pulsing once off pulsing once normal normal transferred off
circuit fault once every every every
battery normal 3 seconds 10 seconds 10 seconds
external power
normal

manual pull pulsing off off pulsing once off pulsing once normal normal transferred off
circuit fault once every every every
detection fault 3 seconds 10 seconds 10 seconds
battery normal
external power
normal

manual pull pulsing off off pulsing once pulsing once pulsing once normal normal transferred off
circuit fault once every every every every
detection fault 3 seconds 10 seconds 10 seconds 10 seconds
release fault
battery normal

external power off pulsing once off off off pulsing once normal normal transferred off
fault every every
battery normal 10 seconds 10 seconds

external power off pulsing once off pulsing once off pulsing once normal normal transferred off
fault every every every
detection fault 10 seconds 10 seconds 10 seconds
battery normal

battery fault off pulsing once off off off pulsing once normal normal transferred off
no external every every
power module 30 seconds 30 seconds
normal

battery fault off pulsing once off pulsing once off pulsing once normal normal transferred off
detection fault every every every
external power 10 seconds 10 seconds 10 seconds
not used

766 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
TROUBLESHOOTING
9-1-98 Service
Page 30 and Repair Manual LH204

Green Yellow Yellow

Power Yellow Detection Release Audio Alarm Shutdown Trouble Agent
Condition Normal Power Fault Red Alarm Fault Fault Alarm Relay Relay Relay Release

manual pull pulsing off pulsing off off* pulsing transferred transferred transferred fired
circuit activated once every 4 times per 4 times per
(0-30 seconds 30 seconds second second
after system
activation)

pressure switch pulsing off pulsing pulsing once pulsing once pulsing once transferred transferred transferred off
activated once every once every every every every
detection fault 3 seconds 10 seconds 10 seconds 10 seconds 10 seconds
(30+ seconds
after system
activation)

* Will pulse if circuit opens as a result from release

** Can be silenced at this time

Copyright © Sandvik 767 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
PROGRAMMING
Service and Repair Manual LH204
9-1-98 Page 31

PROGRAMMING Switch No. 1

The SC-N control module can be manually programmed by If this switch is ON (Enable), it disables programming
using the manual programming switch located on the control through a PC and enables the manual programming
module PC board or it can be programmed from a PC through switch. If switch No. 1 is on, the operation of the control
an RS232 interface cable. module will correspond to the settings of the other manual
programming switches
A number of settings can be programmed into the SC-N
control module: If this switch is OFF (Disable), the operation of the control
module will correspond to the settings of the PC program
• Select initiating circuit No. 2 to operate as either an electric
manual pull circuit or pressure switch feedback circuit Switch No.2
• If selected as an electric manual pull circuit, it can be This switch is used to select initiating circuit No. 2 to
programmed as either shutdown/immediate release or operate as either an electric manual pull or a pressure
shutdown/time delay/release switch feedback
• Alarm to Shutdown (Time Delay 1) can be programmed for ON = Pressure Switch Feedback
5, 10, 20, 30 seconds OFF = Electric Manual Pull
• Shutdown to Release (Time Delay 2) can be programmed
for 0, 10, 20, 30 seconds Switch No. 3
The SC-N control module is factory programmed with the This switch is used to select either the shutdown/ time
following defaults: delay/ release or the shutdown/immediate release mode
for the electric manual pull input
First time delay (Alarm to Shutdown) = 10 seconds
This switch is only active if the switch No. 2 is in the OFF
Second time delay (Shutdown to Release) = 10 seconds position
Manual Pull = Shutdown, Time Delay (10 seconds), If switch No. 3 is set to ON, then operation of the electric
Release Manual Programming Switch = Disabled manual pull station will cause the control module to go
If the factory defaults are acceptable, no additional through a shutdown/ time delay/ release sequence. The
programming is required. However, the factory program is time delay cycle will be whatever is programmed on
only active if the manual programming switch is disabled. switches No. 6 and 7
Manual Programming Switch If set to OFF, operation of the electric manual pull station
will cause the control module to activate will go to the
The manual programming switch is a PC board mounted,
shutdown and immediately operate the circuit
switch package containing 7 switches. See Figure 48. To
manually program the SC-N control module, each individual
switch must be set in the correct position. Switch No. 4 and 5
These two switches set the cycle time for time delay 1
(Alarm to Shutdown)
RS-232 SERIAL Switch No. 4 ON / Switch No. 5 ON = 5 seconds
INTERFACE CABLE
CONNECTION Switch No. 4 OFF / Switch No. 5 ON = 10 seconds
Switch No. 4 ON / Switch No. 5 OFF = 20 seconds
MANUAL INTERNAL
Switch No. 4 OFF / Switch No. 5 OFF = 30 seconds
PROGRAMMING BATTERY
SWITCHES CONNECTION
Switch No. 6 and 7
These two switches set the cycle time for time delay 2
(Shutdown to Release)
Switch No. 6 ON / Switch No. 7 ON = 0 seconds
Switch No. 6 OFF / Switch No. 7 ON = 10 seconds
INSIDE OF
COVER Switch No. 6 ON / Switch No. 7 OFF = 20 seconds
Switch No. 6 OFF / Switch No. 7 OFF = 30 seconds

After all switches have been set, the “RESET” button on the
control module must be depressed. If this is not done, the
FIGURE 48 switch settings will not be entered into the program.
002795

NOTICE
Do not remove see-through cover on
switch. Switch position(s) can be moved
by using a blunt, not sharp, object. Do not
damage switch cover.

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PROGRAMMING
9-1-98 Service
Page 32 and Repair Manual LH204

PC PROGRAMMING Inputs
PC programming is another means of setting up the SC-N The program inputs will be explained individually.
Control Module to the required options.
Detection Setup
One advantage of using the PC programming approach
versus the manual programming switch feature is, with the Time Delay 1: 10 seconds
PC, the module can be programmed to have a shorter time Time Delay 2: 10 seconds
delay period when using the manual electric pull station than
what is programmed into the second time delay cycle of the This input is to set the length of time for the time delays.
detection circuit. When using the manual programming switch Time Delay 1 (Alarm to Shutdown cycle): This time delay can
feature, the electric manual pull time delay will automatically be programmed for 5, 10, 20, or 30 seconds.
correspond to the setting of the second time delay cycle of the
detection circuit. Time Delay 2 (Shutdown to Release cycle): This time delay
can be programmed for 0, 10, 20, or 30 seconds.
The control module is field programmed through a PC
computer using an RS-232 serial interface cable. The Manual Release Setup
interface cable kit is available as Part No. 423524. Input selection: Manual pull
The internal 3.6 volt lithium battery must be installed in Time Delay before release: Shutdown, Time Delay, Release
the control module prior to programming. Time Delay: 10 seconds
EXPLAINING THE MENU This input allows for the selection of initiating circuit No. 2 to
When programming the CHECKFIRE SC-N control module, be used as either manual pull or pressure switch input.
only one menu screen will appear on the computer. All If choosing manual pull, two options are available:
programming will be done using this screen. Before starting to Shutdown/Time Delay/Release option or Shutdown/Immediate
program, the menu setups and control options will be Release. If choosing the Shutdown/Time Delay/Release
explained. option, then the program will not allow selection of a time
The following menu screen will appear when following the delay that is greater than the time delay selected for time
programming steps: Note: The underlined letter or symbol delay No. 2 in the detection set-up. If choosing the
represents the key to press to initiate the action. Shutdown/Immediate Release option, then no time delay cycle
Programmable settings are shown as bold text. is available.

Ansul CHECKFIRE SC-N Setup Program V0.43 If choosing the pressure switch input, no options are available.
Controller Model: CHECKFIRE SC-N V0.51 Manual Programming Switch: Disabled
Manual Programming Switch: Disabled
When doing manual programming, the Manual Programming
Next switch must be Enabled
Previous
When doing PC programming, the Manual Programming
Detection Setup:  Change switch must be Disabled
Time Delay 1: 10 seconds Command Keys
Time Delay 2: 10 seconds Upload Setup to Controller
Command keys are used to select the different inputs to be
Download Setup to programmed and execute various computer operations. The
Controller command keys are explained individually.
Manual Release Setup Verify Controller Setup
Next
Input Selection: Manual Pull
The down arrow command key moves the cursor down to the
Time Delay: Shutdown,
next input line. The input which the cursor is on will be
Time Delay, Release
highlighted.
Time Delay: 10 seconds
View Factory Defaults Previous
Read Datalog From The up arrow command key moves the cursor up to the input
Controller line above where it presently is. The input which the cursor is
Clear Datalog on Controller on will be highlighted.
Test Communications  Change
Security Password Change The right arrow and left arrow command keys allow for the
eXit selection of available settings on a particular input line.
Example: Changing the number of seconds of each time delay
cycle; Changing the Manual Release Input from Manual Pull to
Pressure Switch.

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PROGRAMMING
Service and Repair Manual LH204
9-1-98 Page 33

EXPLAINING THE MENU (Continued) Test Communications

Commands (Continued) The T key is used to test the communications between the
control module and the computer. When this key is
Upload setup to controller depressed, the program will indicate the status between the
The U key is used to load the inputs from the menu screen to module and the computer as either Successful
the control module. After all input selections have been made communications or No communications.
on the menu screen, depress the U key to install those inputs If the status is No communications, check the connection of
into the controller memory. Wait for verification, and then the RS-232 serial interface cable and repeat the test.
depress any key. Communications will not be established until the status line
Download setup from controller reads “Successful communications”.

The D key is used to download the inputs from the control Security password change
module to the menu screen. This is mainly used to determine The S key is used to change the user password. The program
the settings that are presently programmed in the control disc is factory programmed with a password of 111111. If a
module. This will not change what is programmed in the new password is desired, type S. The status will indicate:
controller. Enter new password:
Verify controller setup Type in the new password and press Enter. The new
The V key is used to determine the status of the control password will now be saved in the program.
module inputs. By pressing the V key, the program will verify if eXit
what is shown on the menu screen is the same as what is
programmed in the control module. The status will indicate The X key is used to exit out of the program. By pressing the
either verification pass or verification fail. If verification fail is X key, the computer will close the program.
indicated, download setup from controller to determine what Programming
is presently programmed in the control module.
Note: The internal 3.6 VDC battery must be plugged in to
View Factory default the control module before programming. Also, before PC
The F key is used to view what the default settings are from programming, make certain the DIP Switch No. 1 is set to
the factory. By depressing this key, and viewing the settings, Disable (OFF).
the module will not be changed from what is presently While programming, with the cover assembly removed from
programmed. In order to change the module back to the the back box, it is normal for the sounder and the LED's to
factory default, after viewing, depress the U key to upload the pulse once every 10 seconds. This will stop when the
settings into the module. programming is completed and the computer and internal
battery is disconnected. Note: The internal battery can be
Read datalog from controller disconnected without interfering with the program in the
The history buffer datalog is a sequential listing of events that module.
have taken place over the life of the control module. The
datalog will record events such as trouble, alarm, and Step no. 1 – Attach the RS-232 interface cable between
programming. The list of history events that have taken place the computer and the CHECKFIRE SC-N
will be displayed on the screen. The history buffer will record control module and turn on the computer.
approximately 50 events. If more than 50 events take place, Step No. 2 – Insert programming disc in “A” disc drive and
the oldest events will be erased to make room for the most bring up disc.
recent events. Step No. 3 – Double click on the “A” drive icon.
The R key is used to download the events stored in the Step No. 4 – On the next screen, double click on the
control module to a file in the computer. To view the events, “Setupsc” icon.
first, exit the menu screen by depressing X. The next screen Step No. 5 – The program screen will now ask for the
will show three files, one being the datalog file. Double click password. Type in 111111 and depress Enter.
on the datalog icon. This will open the datalog file for viewing. The password can be changed later by using
the Security password change input.
Clear datalog on controller
Step No. 6 – The program will ask for the correct
The C key is used to clear all the history events recorded in communication port to address. Not knowing
the control module history buffer. After the C key is the type of computer being used, it is
depressed, the menu screen will indicate the datalog is necessary to, by trial and error, find the
cleared. From this point on, all new events will start to be correct port. Type 1. If this is not the correct
recorded. port, the program will respond with: Failure to
connect to comm port – Press 1 to retry or
2 to Exit.

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PROGRAMMING
9-1-98 Service
Page 34 and Repair Manual LH204

EXPLAINING THE MENU (Continued) Step No. 13 – Depress the “RESET” button on the control
Programming (Continued) module.
StepNo. 14 – At this point the programming is complete.
Step No. 7 – Press 1 and then select another comport Disconnect the RS-232 serial interface cable
(2,3,4). When the correct port is chosen, the from the control module. The module will
program will respond momentarily with, continue to pulse once every 10 seconds.
“Reading Settings From Controller,” after Disconnecting the internal module battery
which the main menu will appear on the will silence the module. The internal
screen. programming will remain intact. The module
is now ready to be installed and wired.
StepNo. 15 – If all programming is complete, the program
Ansul CHECKFIRE SC-N Setup Program V0.43 can be exited and the PC can be shutdown.
Controller Model: CHECKFIRE SC-N V0.51
Manual Programming Switch: Disabled
Next
Previous
Detection Setup:  Change
Time Delay 1: 10 seconds
Time Delay 2: 10 seconds Upload Setup to Controller
Download Setup to
Controller
Manual Release Setup Verify Controller Setup
Input Selection: Manual Pull
Time Delay: Shutdown,
Time Delay, Release
Time Delay: 10 seconds
View Factory Defaults
Read Datalog From
Controller
Clear Datalog on Controller
Test Communications
Security Password Change
eXit

Step No. 8 – If the settings shown are acceptable, no

additional programming is necessary. Go to
Step No. 13.
Step No. 9 – By the use of the up arrow key ( ) or the
down arrow key ( ), move to the Setup input
requiring change.
Step No. 10 – To change an input, use the Change keys
( ). By depressing either the () key or
the ( ) key, the input which is highlighted will
change. Each time the key is depressed, a
new selected input will appear. For example,
if the Detection Setup Time Delay 1 is
highlighted, and the number of seconds
indicated is 5, by depressing the ( ) arrow
once, the time will change to 10. By
continuing to depress the ( ) arrow, the time
will change to 20, 30, and then back to 5.
When the correct time is reached, stop.
Step No. 11 – Scroll to each Setup by using the Next ( ) or
Previous ( ) keys and make what ever
changes are necessary by using the Change
( ) keys.
Step No. 12 – After all inputs are selected, depress the U
key. This will upload the inputs shown on the
menu screen to the control module. The
status will indicate: Verification pass – hit
any key. Then press any key.

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RELEASE CIRCUIT TEST MODULE INSTRUCTIONS
Service and Repair Manual LH204
9-1-98 Page 35

APPENDIX
RELEASE CIRCUIT TEST MODULE INSTRUCTIONS

GAS CARTRIDGE/
SQUIB/
OFF SWITCH

FIGURE 49
003016

Operation is as follows:
1. The receptable on the tester mates with the connector on
the gas motor actuation cable, Part No. 416129, used with
the CHECKFIRE MP. A test adapter is provided for testing
units with squib actuator cables, Part No. 79062 or Part
No. 422747.
2. A three-position slide switch is located on the side of the
enclosure to select the type of output to test (squib or gas
motor) and the third position is “OFF.”
3. Steps for operation are:
a. With slide switch, select type of output to be tested.
This will also turn the unit on.
b. Press the reset button on the tester. This will illuminate
the “READY LED” if it is not already illuminated.
c. Connect to control unit actuator cable.
d. Proceed with activating output.
e. Once the unit activates, the unit tester will indicate a
“PASS” or “FAIL” status resulting from the test.
f. The tester can then be reset by pressing the RESET
button, which will prepare it for the next test.

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APPENDIX
Service
9-1-98 Page 36 and Repair Manual LH204

COMPONENT INDEX

Part Shipping Weight

No. Assembly lb. (kg)
Main Assemblies
423500 CHECKFIRE SC-N Electric Detection and Actuation 10 (4.5)
System Includes:
423504 Control Module (module contains nuts and
washers for mounting to bracket)
24479 Manual/Automatic Actuator
423525 Combined Mounting Bracket
79062 Squib Cable with Connector
6979 Nitrogen Cartridge, LT-5-R
25627 1/4 in. Check Valve
79064 Label Package
53081 Owner's Manual
423538 (Transport Canada) CHECKFIRE SC-N Electric Detection 10 (4.5)
and Actuation System includes:
(All of the standard shipping assembly components except
Nitrogen Cartridge, Part No. 6979, is replaced with Nitrogen
Cartridge, Part No. 423836.)
423520 Battery Shipping Assembly (3.6 VDC) 1/4 (.1)
54919 Squib 1/4 (.1)
426461 End of Line Resistor Assembly (Package of 10) 1/4 (.1)
Accessory Equipment
423541 Release Circuit Test Module 1 (.5)
423525 Combined Bracket Shipping Assembly – 1 (.5)
For mounting control module and actuator together
423528 Control Module Mounting Bracket – 1 (.5)
For mounting control module separately
419772 Actuator Mounting Bracket – 1 (.5)
For mounting actuator separately
423531 Control Module Retrofit Mounting Bracket – 1 (.5)
For mounting control module to existing
CHECKFIRE SC mounting bracket
79559 Remote High Level Alarm 2 (.9)
71820 Splicing Device 1/4 (.1)
71230 356 °F (180 °C) Linear Detection Wire, 100 Ft. (30.4 m) 5 (2.3)
71231 356 °F (180 °C) Linear Detection Wire, 500 Ft. (152.4 m) 10 (4.5)
416218 270 °F (132 °C) Spot Detector 1/4 (.1)
416219 325 °F (163 °C) Spot Detector 1/4 (.1)
416220 360 °F (182 °C) Spot Detector 1/4 (.1)
416213 Spot Detector Connector Package 1/4 (.1)
416221 Spot Detector Bracket 1/4 (.1)
416762 Spot Detector Cable Clamp Package (For Use Without 1/4 (.1)
Protective Tubing)
416214 Spot Detector Cable Clamp Package (For Use With 1/4 (.1)
Protective Tubing)
416215 Flex Non-Metallic Tubing 100 Ft. (30.4 m) 4 (1.8)
(For Spot Detectors)
416784 Crimp Tool (For Spot Detector) 1 (.5)
416113 Pneumatic/Linear Detector, 35 Ft. (10.7 m) 1 (.5)
(Model 808-DRV)
416216 Cable Assembly, 15 ft. (4.6 m) (For Pneumatic/Linear 1/4 (.1)
Detector)

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APPENDIX
Service and Repair Manual LH204
9-1-98 Page 37

Component Index (Continued)

Accessory Equipment (Continued)
Part Shipping Weight
No. Assembly lb. (kg)
416378 Mounting Clips Package For Pneumatic/Linear 1/4 (.1)
Detector Sensing Element (Includes 100 Clips)
417055 Wire, 200 °C, 18 AWG-2 W/Shield and Drain Wire 500 ft. 10 (4.5)
(152 m)
56691 Nylon Cable Tie (Package of 20) 1 (.5)
56692 Rubber Sleeve (Package of 20) 2 (.9)
422747 Squib Cable with Connector – 15 ft. (4.6 m) 1 (.5)
419780 Power Wiring Assembly – 15 ft. (4.6 m) 1 (.5)
(Connector on one end)
419781 Power Wiring Assembly – 15 ft. (4.6 m) 1 (.5)
(Connector on both ends)
419782 Power Wiring Assembly – 10 ft. (3.1 m) 1 (.5)
(Connector on both ends)
419783 Battery Connection (Fused at 5 amp) 1 (.5)
423524 RS-232 PC Interface Cable Kit 1/4 (.1)
426601 Extender Cable Assembly 1/4 (.1)
426604 Battery Extender Cable Assembly 1/4 (.1)

RECHARGE EQUIPMENT
54919 Squib 1/4 (.1)
6979 LT-5-R Cartridge 2 (.9)
423520 Battery Shipping Assembly (3.6 VDC) 1/4 (.1)
423522 Installation, Maintenance, Recharge Manual 1/4 (.1)

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APPENDIX
9-1-98 Service
Page 38 and Repair Manual LH204

DETECTION WIRE FLUID RESISTANCE CAPABILITY

Resistance Rating Key:
G = GOOD
L = LIMITED
C = CONDITIONAL (Service conditions must be outlined to Ansul for
approval of wire suitability for applications.)
U = UNACCEPTABLE (Not to be used)
Agent Rating Agent Rating Agent Rating
Acetate Solvents, Crude U Creosote U Naphthalene U
Acetate Solvents, Pure U Diesel Oil, Light L Nickel Chloride G
Acetic Acid, Dilute (20%) U Ethers U Nickel Sulfate G
Acetic Acid, Glacial U Ethyl Acetate U Nitric Acid, 10% L
Acetone U Ethyl Alcohol C Nitric Acid, 70% U
Air G Ethyl Chloride U Nitrobenzene U
Alcohols C Ethylene Dichloride U Oleic Acid C
Aluminum Chloride G Ethylene Glycol L Oleum Spirits U
Aluminum Fluoride G Ferric Chloride G Perchlorethylene C
Aluminum Sulfate G Ferric Sulfate G Picric Acid, Molten U
Ammonia Liquid (Anhydrous) U Ferrous Salt Solutions G Picric Acid, Solution U
Ammonia, Chloride G Formaldehyde L Potassium Chloride G
Ammonium Hydroxide L Formic Acid L Potassium Cyanide G
Ammonium Nitrate G Fuel Oil L Potassium Hydroxide C
Ammonium Phosphate G Furfural U Potassium Sulfate G
Ammonium Sulfate G Gasoline C Soda Ash Sodium Carbonate G
Amyl Acetate U Glycerine, Glycerol L Sodium Bisulfate G
Amyl Alcohol L Grease, Petro L Sodium Chloride G
Asphalt C Heptane C Sodium Cyanide G
Barium Chloride G Hexane L Sodium Hydroxide C
Barium Hydroxide G Hydraulic Fluids & Lubricating L Sodium Hypochorite C
Barium Sulfide G Oils, Straight Petroleum Base Sodium Nitrate G
Benzene, Benzol C Water and Petroleum Oil L Sodium Peroxide C
Emulsion (FR)
Benzene (Petroleum Ether) C Sodium Phosphate G
Water and Glycol Solution L
Benzene (Petroleum Naphtha) C Sodium Silicate G
Straight Phosphate-Ester (FR) L
Borax L Sodium Sulfate G
Silicone Oils L
Boric Acid L Sodium Sulfide C
Hydrobromic Acid U
Bromine U Sodium Thiosulfate, “Hypo” G
Hydrochloric Acid, Cold C
Butyl Acetate U Soybean Oil L
Hydrochloric Acid, Hot U
Butyl Alcohol, Butanol L Stannic Chloride G
Hydrocyanic Acid C
Calcium Bisulfite L Stearic Acid L
Hydrofluoric Acid, Cold C
Calcium Chloride G Sulfur Dioxide C
Hydrofluoric Acid, Hot C
Calcium Hydroxide G Sulfur Trioxide C
Hydrogen Peroxide (Dilute) G
Calcium Hypochlorite L Sulfuric Acid, 10%, Cold L
Hydrogen Peroxide C
Carbolic Acid Phenol C (Concentrated) Sulfuric Acid, 10%, Hot L
Carbon Dioxide G Hydrogen Sulfide C Sulfuric Acid, 75%, Cold L
Carbon Disulfide U Kerosene L Sulfuric Acid, 75%, Hot L
Carbon Monoxide, Hot U Lacquer Solvents U Sulfuric Acid, 95%, Cold U
Carbon Tetrachloride L Lactic Acid C Sulfuric Acid, 95%, Hot U
Carbonic Acid G Linseed Oil L Sulfuric Acid, Fuming U
Castor Oil C Magnesium Chloride G Sulfurous Acid L
Chlorinated Solvents C Magnesium Hydroxide G Tannic Acid G
Chlorine, Dry U Magnesium Sulfate G Tartaric Acid G
Chlorine, Wet U Mercuric Chloride U Toluene U
Chloroacetic Acid U Mercury L Trichloroethylene U
Chloroform U Methyl Alcohol, Methanol L Turpentine L
Chlorosulphonic Acid U Methyl Chloride U Varnish U
Chromic Acid U Methyl Ethyl Ketone U Xylene U
Citric Acid L Methyl Isopropyl-Keytone U Zinc Chloride L
Copper Chloride G Mineral Oil L Zinc Sulfate G
Copper (II) Sulfate G Naphtha C

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APPENDIX
Service and Repair Manual LH204
9-1-98 Page 39

WARRANTY
The components of the Ansul CHECKFIRE SC-N Electric
Detection and Actuation System supplied by Ansul
Incorporated, (“ANSUL”) are warranted to you as the original
purchaser for one year from the date of delivery against
defects in workmanship and material. ANSUL will replace or
repair any Ansul-supplied component which, in its opinion, is
defective and has not been tampered with or subjected to
misuse, abuse, exposed to highly corrosive conditions or
extreme high temperatures provided that written notice of the
alleged defect shall have been given to ANSUL within
30 days after discovery thereof and prior to the expiration of
one year after delivery, and further provided that if ANSUL so
instructs, such article or part thereof is promptly returned to
ANSUL with shipping charges prepaid.
Disclaimer of Liability and Limitation of Damage
The above warranty is the only one given by ANSUL
concerning this system and only to Ansul CHECKFIRE SC-N
Electric Detection and Actuation System that has been
installed and maintained in accordance with all the directions
and requirements provided by ANSUL in the manual created
for the Electric Detection and Actuation System. THIS
WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES
WHETHER EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO FITNESS FOR PURPOSE AND
MERCHANTABILITY, AND ANSUL DOES NOT ASSUME,
OR AUTHORIZE ANY OTHER PERSON TO ASSUME FOR
IT, ANY OTHER LIABILITY IN CONNECTION WITH THE
SALE OF ITS PRODUCTS. ANSUL SHALL NOT BE LIABLE
FOR CONSEQUENTIAL OR SIMILAR DAMAGES.
For repairs, parts and service of the Ansul System, contact
your local Ansul representative, or Ansul Incorporated,
Marinette, WI 54143-2542; 800-TO-ANSUL (800-862-6785).

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Service and Repair Manual LH204
ANSUL INCORPORATED
ONE STANTON STREET
MARINETTE, WI 54143-2542
715-735-741 1
Litho in U.S.A.
© 1999 Ansul Incorporated
Part No. 423522-01

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ID: BG00398452 en-US A.001.1 2015-10-19
ANSUL
Service and Repair
® Manual DETECTION AND CHECKFIRE ® SC-N
LH204
CONTROL ELECTRIC
EQUIPMENT DATA DETECTION AND
SHEET ACTUATION
SYSTEM

FEATURES subjected to extreme environmental and actuator. The initiating circuits are low
physical conditions such as vehicles used in impedance and designed to eliminate
• FMRC Approved forestry, mining, agriculture, construction, nuisance alarms associated with contact
• Self Contained - Internal 3.6 VDC public transportation, public utilities, land fill, bounce.
Power Source and waste disposal.
First Initiating Circuit
• External 12/24 VDC Power Source The control module can be utilized as a self
Connection Available contained system, powered by its own Two field programmable time delays
internal Lithium battery. This allows the provide timing of shutdown and release
• Battery Back-up Available detection system to operate around-the- functions associated with the operation of
• Power Fault Monitoring for Both Internal clock without use of external power. the detection and electric manual
and External Power Optionally, external power can be pull/pressure switch input initiating circuits.
connected to the control module. With The first time delay is field programmed to
• Euro-Style Terminal Block for Field external power connected, the internal assign the time between the initial alarm
Connections power source provides battery back-up. condition from the detection circuit and the
• Two Part Enclosure Design Simplifies When connected to an external 12/24 VDC operation of the shutdown relay. The first
Installation and Servicing supply with the internal battery also time delay is programmable for 5, 10, 20, or
connected, the external power source 30 seconds. The second time delay is field
• Environmentally Sealed Enclosure programmed to assign the time between the
becomes the primary supply, while the
• Mounting Feet For Mounting To Any internal source is maintained in a standby completion of the first time delay (when the
Suitable Flat Surface mode of operation. shutdown relay operates) and operation of
the release circuit. The second time delay is
• Microprocessor Based Circuitry The control module may be installed where field programmable for 0, 10, 20, or
• Sealed, Membrane Push Button For the ambient temperature is between –40 °F 30 seconds.
Reset and Delay to 140°F (–40°C to 60°C).
Second Initiating Circuit
• Vibration and Shock Resistant Design
The second initiating circuit is field
• Electronic Circuitry That Meets The IEC programmable to be used as either an
Standards For Electromagnetic electric manual pull or a pressure switch
Compatibility in Heavy Industrial feedback circuit. If selected as an electric
Environments manual actuation input circuit, its operation
• Form “C” Relay Output Connection For will override the first time delay function and
Both Auxiliary Alarm and Shutdown initiate a second time delay condition,
Functions causing the shutdown relay to immediately
operate and the release to occur upon
• Normally Open Trouble Contacts expiration of the second delay. Additionally,
Available for Remote Trouble the control module can be field
Annunciation programmed, if it is so desired, to shorten
• Two Supervised Initiating Circuits - One the second time delay when a manual
For Detection and One for Either actuation occurs. The time delay options
Manual Electric Actuation or Pressure associated with the manual actuation are
Switch Feedback 0,10, 20, and 30 seconds, with the condition
• One Supervised Release Circuit that it can only be less than or equal to the
time delay associated with the detection
• Manually Field Programmable Circuits circuit.
(can optionally be PC programmed)
Selection of the second initiating circuit as a
• History File to Record The Last DESCRIPTION pressure switch feedback circuit will result
50 Alarm and Trouble Events in the operation of the alarm relay and
The complete CHECKFIRE SC-N system is shutdown relay, but will not operate the
• Built-in Diagnostic Function Identifies composed of components which are
The Source Of Trouble release circuit. Additionally, a trouble
combined to provide automatic fire condition will occur on the control module,
• Programmable Time Delays (Alarm to detection and actuation. The electric indicating the need for service.
Shutdown, Shutdown to Release) detection and actuation system is designed
for use with the Ansul fire suppression The front panel contains a “DELAY” and
APPLICATION “RESET” button. Operation of the DELAY
systems that use pneumatic actuation as a
means of system actuation. button will repeat the first time delay if
The CHECKFIRE SC-N Electric Detection initiated while time delay one is active.
and Actuation System furnishes fire The first of two initiating circuit is the Once time delay two has started, operation
detection for equipment hazard areas. Its supervised detection circuit designed to be of the DELAY switch has no affect. The
unique actuator allows actuation of a connected to linear (wire) and/or spot type DELAY button also serves the dual function
pneumatically-actuated fire suppression thermal detectors that provide a contact of silencing the auxiliary alarm relay, but is
system either manually or automatically. closure input to initiate a fire detected only effective for this function 30 seconds
The CHECKFIRE SC-N system is typically condition. The second initiating circuit is after release, or after pressure switch
used with an Ansul A-101 Vehicle Fire designed to accept a contact closure type of feedback operation has occurred.
Suppression system for 24-hour protection actuating device such as a manual electric
pull station input or a pressure switch to The RESET button is used to re-initialize
of equipment. The system is particularly the control panel when depressed, it
suited for protection of equipment that is initiate the module when the system is
actuated with the pneumatic/manual provides an indication that all LED's and the
778 (1146) Copyright © Sandvik
ID: BG00398452 en-US A.001.1 2015-10-19
sounder are functional. It is also used to OPERATIONAL ENVIRONMENTAL ORDERING INFORMATION
Service and Repair Manual
upload the manual programming into the
SPECIFICATIONS
Part No. Shipping Assembly
LH204
control module.
The front panel also contains LED's for • Operating Temperature Rating: –40 °F 423500 CHECKFIRE SC-N Electric
visual annunciation of alarm, trouble, to 140°F (–40 °C to 60 °F) (423538 Detection and Actuation System
release, and power conditions. • Humidity: 24 Hours at 85% +/– 5% at ULC) Includes: Control Module,
86 °F (30 °C) Manual/Automatic Actuator,
EMI filtering is provided on all inputs, Mounting Bracket, Squib Cable
outputs, and power circuitry. • Shock: In accordance with UL1254 Connector, LT-5-R Cartridge,
CONSTRUCTION • Vibration: In accordance with UL1254 1/4 in. Check Valve, Hardware
Kit, Label Package, and Owners
The enclosure consists of a cover assembly • Electromagnetic Compatibility: Meets Manual (Battery must be ordered
and back box which is constructed of Noryl EN 55011 and EN 50082-2 for heavy separately)
SE1GFN3 with a flammability rating of industrial environments
71230 Linear Detection Wire, 356 °F
UL94 V-1. The back box contains the field • Moisture and Dust: Meets IEC 529 for (180 °C), 100 ft. (30.5 m)
interface terminal block, battery, and field direct water spray
wiring entrance ports. The cover assembly 71231 Linear detection Wire, 356 °F
contains the control PC board assembly, SEQUENCE OF OPERATION (180 °C), 500 ft. (152.4 m)
sounder, operator interface panel, and Upon receiving an input signal from either a 416218 Spot Detector – 270 °F (132 °C)
environmental seal. The enclosure meets shorted detection wire or a closed thermal
IEC 529 requirements for dust and water 416219 Spot Detector – 325 °F (163 °C)
detector, the following functions will be
spray in all directions. Mounting feet allow performed automatically: 416220 Spot Detector – 360 °F (182 °C)
mounting to any suitable flat surface. Steel 416213 Spot Detector Package (one
mounting brackets are also available. 1. The Alarm LED will flash, the internal
sounder will pulse at a rate of two required per detector)
All circuitry, relays, switches, and LED's are times per second. The alarm relay will 416214 Spot Detector Cable Clamp
contained on a single PC board. A board transfer resulting in remote alarm Package (for use with protective
mounted receptacle mates with the plug-in operation, and the shutdown time tubing) – one required for each
terminal block mounted in the back box. A delay begins. (The operator can detector
high pitch sounder is threaded into the repeat the shutdown time delay if the
cover and plugged into the PC board. The 416762 Spot Detector Cable Clamp
DELAY button is pressed before the Package (for use without
PC board is encapsulated to provide added shutdown time delay has expired).
protection against moisture and dust. An protective tubing) – one required
2. After the shutdown time delay has for each detector
RS232 connector is provided for field expired, the Alarm LED pulse rate and
programming from a PC and for data the sounder pulse rate will change to 416215 Flex Protective Tubing – 100 ft.
retrieval from a trouble and alarm event four times per second. The shutdown (30.5 m)
history file. The PC board assembly relay will transfer resulting in 416221 Spot Detector Bracket – one
contains a DIP switch for optional manual equipment shutdown (when provided), required for each detector
programming functions without the use of a and the discharge time delay begins
PC. (when set). 416784 AMP Crimp Tool (required for
3. After the discharge time delay has spot detector assembly)
INTERNAL CONNECTIONS
expired, the control module release 416113 Pneumatic/Linear Detector, 35 ft.
The internal battery is connected to the PC circuit operates, resulting in the fire (10.7 m) (Model 808–DRV)
board via a single plug. The external power suppression system actuation. 416216 Cable Assembly, 15 ft. (4.6 m)
is connected to the field connection terminal After system discharge, the Alarm (for pneumatic/linear detector)
strip located in the back box. LED and sounder will continue to 416378 Mounting Clips Package for
The field connection terminal strip located in pulse at a rate of 4 times per second Pneumatic/Linear Detector
the back box is a 16 position terminal block for 30 seconds. After that, it will switch Sensing Element (includes
containing the following terminations: to the trouble mode and pulse once 100 clips)
every 10 seconds.
Position Circuit Description 417055 Wire, 200 °C, 18 AWG-2
1 + External 12/24 VDC Power If manual actuation is performed through w/Shield and Drain Wire 500 ft.
operation of the manual input circuit, the (152 m)
2 – External 12/24 VDC Power
first time delay will be by-passed and either
3 + Detection Input immediate release will occur or the second 56691 Nylon Cable Ties (Pkg. of 20)
4 – Detection Input time delay will begin. 56692 Rubber Sleeves (Pkg. of 20)
5 + Manual Input If manual actuation is performed by 71820 Splicing Device (for linear
6 – Manual Input operating the mechanical actuator, the fire detection wire)
7 + Release Input suppression system will immediately 419780 Power Wiring Assembly – 15 ft.
8 – Release Input discharge. The shutdown function will take (connector on one end only)
9 Trouble Common place through the pressure switch circuit (if
provided). 419781 Power Wiring Assembly – 15 ft.
10 Trouble N.O. (connector on both ends)
11 Alarm N.O. APPROVALS
419782 Power Wiring Assembly – 10 ft.
12 Alarm Common
FMRC (JI0B8A8.AF) (connector on both ends)
13 Alarm N.C.
14 Shutdown N.O. 423520 Battery Shipping Assembly
15 Shutdown Common 419783 Battery Connection
16 Shutdown N.C. 423541 Release Circuit Test Module
423522 Operation and Maintenance
Manual

ANSUL and CHECKFIRE are registered trademarks.

Copyright © Sandvik 779 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
ANSUL INCORPORATED, ONE STANTON STREET, MARINETTE, WI 54143-2542 715-735-7411 Form No. F-98131-1 © 1999 Ansul Incorporated Litho in U.S.A.
ANSUL
Service and Repair
® Manual DETECTION CHECKFIRE ® SC
LH204
AND CONTROL ELECTRIC
EQUIPMENT DETECTION AND
PARTS LIST ACTUATION
SYSTEM

FIG. PART FIG. PART

NO. DESCRIPTION NO. NO. DESCRIPTION NO.
– Actuator 24479 28 Bracket 54924
1 Knob 16470 29 Cartridge Shipping Assembly 6979
2 Boot 25883 30 Cartridge Shipping Cap 77251
3 Boot Adaptor 24418 31 Squib 24416
4 O-Ring 21964 – Hardware Package 79037
5 O-Ring 16047 32 Strain Relief (5) *
6 Stem 24417 33 Cap Screw, 1/4-20 x 1 1/2 Lg. (4) *
7 O-Ring 3469 34 Lockwasher, 1/4 in. (4) *
8 Puncture Pin 24420 35 Flatwasher, 1/4 in. (4) *
9 Spring 24421 36 Plug (2) (Not Shown) *
10 Body 24419 37 Check Valve 25627
11 Label 79548 38 Detection Wire –
12 Drive Screw 27857 – 100 Ft. (30.5 m) 71230
13 Chain 507 – 500 Ft. (152.4 m) 71231
14 Ring Pin 32342 39 Remote High Level Alarm 79559
15 Lead-Wire Seal 197 40 Squib Circuit Test Module 79200
16 Street Elbow, 1/4 in. 16635 (9 VDC Battery Not Included)
17 Gasket 181 41 Thermal Detector –
18 Hex Jam Nut 24123 – 270 °F (132 °C) 416218
– Control Module Assembly 78952 – 325 °F (163 °C) 416219
19 Enclosure Assembly 79204 – 360 °F(182 °C) 416220
20 Alarm/Shutdown Relay Module 79202 42 Label Package (Not Shown) 79064
21 Detection/Output Module 79203 – Label, Time Delay *
22 Battery Module 73140 – Sticker, Time Delay *
23 Squib Connector Assembly 79062 – Label, Fire Alarm *
24 Front Cover (MCU Module) Assembly 79201 – Label, Caution *
25 Screw (Package of 10) 417807 *Not available separately
26 Bottom Cover Assembly 78731
27 Screw (Package of 10) 417807
ANSUL and CHECKFIRE are registered trademarks.
780 (1146) Copyright © Sandvik
ID: BG00398452 en-US A.001.1 2015-10-19
ANSUL INCORPORATED, ONE STANTON STREET, MARINETTE, WI 54143-2542 715-735-7411 Form No. F-98131-1 © 1997 Ansul Incorporated Litho in U.S.A.
Service and Repair Manual LH204

Copyright © Sandvik 781 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

782 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

17.6 Donaldson air filter manual

Copyright © Sandvik 783 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

784 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

Copyright © Sandvik 785 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

786 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

Copyright © Sandvik 787 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

788 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

Cleaning Strata Precleaners on PSD Air Cleaners

Strata precleaners require little, if any, maintenance if used correctly. Assuming the
scavenge system is operating properly, the system is self-cleaning and self-maintaining.
In the event of light to moderate buildup of dust on the tubes and/or vanes, they can be
cleaned with compressed air as follows:

• Direct a compressed air jet from the backside first. When directing air from the
backside of the tubes, the engine should be off and the primary element may need
to be removed. Always keep the safety element in place during this procedure,
and clean any debris left in the housing after the procedure before reinstalling the
primary element.
• Next, direct a compressed air jet from the front of the tubes. If possible, keep the
scavenge system running during this procedure to evacuate the dislodged debris.
If this is not possible, start the system as soon as practical after the procedure to
evacuate the dislodged contaminant. Several procedures may be required if the
scavenge is not operated during cleaning.

If the buildup is heavy (for example, if the scavenge system malfunctions), the same
procedure may be used but multiple cleanings may be required. In addition, the scavenge
line should be removed and contaminant lodged in the precleaner may be evacuated
through the 76mm tube with a small brush and/or a shop-vac.

In extreme cases, the air cleaner may need to be removed from the vehicle and the
precleaner section soaked in a non-caustic cleaning solution and warm water for
approximately 30 minutes. Elements should be removed for this procedure. Rinse with
clean water and dry thoroughly at ambient temperature. Reassemble and reinstall; tighten
all connections per manufacturer’s recommendations.

Copyright © Sandvik 789 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

790 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

17.7 Pump drive unit and Drop Box Operating Instructions

Betriebsanleitung
für
Pumpenverteilergetriebe
Verteilergetriebe
Verteilerschaltgetriebe

Operating instructions Instruction de service

for de
pump drives boîtes de répartition

03
DE, GB, F

/ Edition
Auﬂage / Édition

0/1

Stiebel-Getriebebau GmbH & Co. KG - Industriestraße 12 - D-51545 Waldbröl

Telefon +49 22 91 7 91-0 - Fax +49 22 91 7 91-290
Email: info@stiebel.de - Internet: www.stiebel.de
Copyright © Sandvik 791 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

792 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

1. Technische Daten

1. Technical data

1. Caractéristiques techniques

Weitere Angaben, wie zum Beispiel Anbaumaße, Ölstand, usw. sind der Anbauzeichnung zu entnehmen, die
vom Hersteller angefordert werden kann.
Further data, such as dimensions, oil level, etc. are found in the assembly drawing which may be ordered from
the manufacturer.
Vous trouverez les autres données, comme par exemple les dimensions de montage, le niveau d’huile, etc.,
dans le dessin que vous pouvez fournir auprès du fabricant.
Copyright © Sandvik 793 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

Inhalt
1. Technische Daten
2. Vorwort 5
3. Bestimmungsgemäße Verwendung 5
4. Transport und Lagerung 5
5. Montage und Inbetriebnahme 6
6. Umbauten und Veränderungen 8
7. Wartungshinweise 8
8. Ersatzteile und Reparatur 9
9. Schmierstoffe 9
Schmierstofftabelle 22

Contents
1. Technical data

2. Foreword 10

3. Prescribed use 11

4. Transport and storage 11

5. Set-up and putting into operation 11

6. Conversions and modiﬁcations 13

7. Maintenance 14

8. Spare parts and repairs 14

9. Lubricants 15

Lubricant table 22

Sommaire
1. Caractéristiques techniques

2. Préface 16

3. Utilisation conforme à l’emploi 16

4. Transport et stockage 16

5. Montage et mise en service 17

6. Transformations et modiﬁcations 19

7. Indications de maintenance 19

8. Pièces de rechange et réparation 20

9. Lubriﬁants 21
794 (1146)Table de lubriﬁants Copyright
22 © Sandvik

Auﬂage /
Edition /
Édition 0/1
ID: BG00398452 en-US A.001.1 2015-10-19

4
Service and Repair Manual LH204

2. Vorwort
Diese Betriebsanleitung enthält wichtige Hinweise, Bei Nichtbeachtung können Personen- und Sach-
um das Getriebe und die Anlage sicher, sachge- schäden entstehen!
recht und wirtschaftlich zu betreiben.
Hinweis: Der Inhalt dieser Betriebsanleitung ist
Ihre Beachtung hilft Gefahren und Schäden zu ver- urheberrechtlich geschützt. Ohne unser Wissen
meiden. Reparaturkosten und Ausfallzeiten werden und unsere Genehmigung dürfen Abbildungen,
vermindert, die Zuverlässigkeit und Lebensdauer Zeichnungen und Daten aus dieser Betriebsanleitung
des Getriebes erhöht. weder vervielfältigt noch dritten Personen oder
Wichtig: Die mit diesem Symbol gekenn- Konkurrenzﬁrmen mitgeteilt oder zugänglich
zeichneten Informationen sind unbedingt zu lesen. gemacht werden (© 2001 und §18 UWG).
Sie warnen vor Gefahren.

3. Bestimmungsgemäße Verwendung
Das v.g. Produkt ist zum Einbau in eine Maschine Die jeweils geltenden nationalen, örtlichen und an-
bestimmt. Die Inbetriebnahme ist so lange unter- lagespezifischen Bestimmungen und Erfordernisse
sagt, bis festgestellt wurde, dass die Maschine, in zur Unfallverhütung sind zu berücksichtigen.
die o.g. Produkt eingebaut werden soll, den Bestim-
mungen der EG-Richtlinie Maschinen entspricht. Qualifiziertes Personal sind Personen, die aufgrund
ihrer Ausbildung, Erfahrung und Unterweisung so-
Das Produkt darf nur für den vereinbarten, tech- wie ihrer Kenntnisse über einschlägige Normen,
nisch ausgelegten Zweck zum Einsatz gebracht Bestimmungen, Unfallverhütungsvorschriften und
werden. Das Produkt darf nicht mit Leistungen, Betriebsverhältnisse von dem für die Sicherheit der
Drehmomenten, Drehzahlen oder äußeren Be- Anlage Verantwortlichen berechtigt worden sind, die
lastungen betrieben werden, die die konstruktive jeweils erforderlichen Tätigkeiten auszuführen, und
Auslegung (siehe technische Daten bzw. Katalog) dabei mögliche Gefahren erkennen und vermeiden
überschreiten. Einbau und Inbetriebnahme dürfen können.
nur von fachlich qualifiziertem Personal durchge-
führt werden.

4. Transport und Lagerung

Transport

Zur gefahrlosen Handhabung sind die vorhan- Nicht unter schwebenden Lasten aufhalten oder
denen Hebeösen bzw. -zapfen oder Gewinde- arbeiten!
bohrungen zu benutzen. An den Getrieben an-
gebrachte Hebeösen und ähnliche Hilfsmittel Lagerung
sind nur für das Gewicht der Getriebe ausgelegt,
Die Lagerung von der Lieferung bis zur Inbetrieb-
sie dürfen nicht dazu verwendet werden, Anbau-
nahme sollte in trockenen, staub- und erschütte-
teile wie Motoren, Hydraulikaggregate und ähn-
rungsfreien Räumen erfolgen. Bei abweichenden
liches anzuheben. Nur geeignete und technisch
Lagerbedingungen sollte beim Hersteller nachge-
einwandfreie Hebezeuge sowie Lastaufnahme-
fragt werden.
mittel (z.B. Seile, Ringschrauben etc.) mit ausrei-
chender Tragkraft verwenden. Siehe Gewichts-
angabe in den technischen Daten bzw. auf dem Korrosionsschutz
Typenschild. Die Gewichtsangaben müssen als Die standardgemäße Konservierung der Wellen,
Zirka-Angaben verstanden werden, da die Ge- Hohlwellen usw. ist unter den zuvor genannten Be-
wichte, bedingt z.B. durch unterschiedliche Öl- dingungen maximal ein Jahr wirksam. Sie ist nicht
füllungen, abweichen können. Copyright für
© Sandvik
Außenlagerung geeignet. 795 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19

5
Service and Repair Manual LH204

5. Montage und Inbetriebnahme

Montage und Inbetriebnahme dürfen nur von fach- Technische Informationen
lich qualifiziertem Personal durchgeführt werden.
Gehäuse: verwindungssteife Gehäuse aus
Aluminium oder Grauguss
Vor der Inbetriebnahme, auch dem Probelauf,
muss sichergestellt sein, dass keine Gefähr- Verzahnung: einsatzgehärtet,
dung von beweglichen und rotierenden Teilen zahnflankengeschliffen
(z.B. Wellen, Kupplungen usw.) ausgehen kann.
Schmierung: Ölbadtauchschmierung,
Das heißt, der erforderliche Berührungsschutz
muss vorhanden, oder eine gefährliche Annä- Druckumlaufschmierung
herung muss ausgeschlossen sein. Beim Probe-
lauf ohne Anbauelemente sind die Passfedern in
den Wellenenden gegen Herausschleudern zu
Montage der Getriebe
sichern.
Vor der Montage die Oberflächen, Kanten von Wel-
Bevor Arbeiten an dem Getriebe oder an an- lenstumpf, Passfeder und Zahnwellenprofilen auf
gebauten Ausrüstungen durchgeführt werden, Beschädigungen untersuchen, vorhandene Be-
muss die Stromversorgung abgeschaltet sein. schädigungen beseitigen.
Gegen unbeabsichtigtes Einschalten sind Vor-
kehrungen zu treffen. Wo notwendig, muss mit Bei Passfeder- und Zahnwellenverbindungen den
mechanischen Mitteln (spezielle Vorrichtungen, Wellenstumpf mit weißer Festschmierstoffpaste
Stützen usw.) sichergestellt werden, dass sich (z.B. Optimol White T) bestreichen. Die Paste er-
die Maschine nicht bewegen bzw. rotieren kann. leichtert die Montage der Aggregate und verhindert
Korrosion, die eine spätere Demontage deutlich er-
Vor der Inbetriebnahme muss sichergestellt schweren würde.
sein, dass Schmierstoff in der vorgeschriebenen Es ist darauf zu achten, dass die Wellendichtringe
Menge eingefüllt ist. Ölmenge und Ölqualität nicht verschmutzt, beschädigt oder mit Farbe bestri-
siehe Typenschild, technische Daten oder chen werden. Beim Lackieren der Aggregate sind
Schmierstofftabelle Seite 22. Dichtringe und Laufflächen der Wellen abzudecken
oder durch Fett zu schützen. Nur so werden Be-
Niemals ohne Entlüftungsfilter betreiben, anson-
schädigungen und somit Ölverlust vermieden.
sten verursacht der bei Erwärmung im Getriebe
entstehende Überdruck eine Ölleckage. Ölleitbleche, die ggf. an den Pumpenanbauflan-
schen angebracht sind, dürfen nicht beschädigt
Nach längerem Betrieb können Schmierstoff oder demontiert werden.
und Oberfläche des Getriebes Temperaturen er-
reichen, die zu Verbrennungen der Haut führen.

In den Getrieben entsteht Ölnebel. Daher ist Montage von Antriebs- bzw. Abtriebselementen
der Umgang mit offenem Feuer in der Nähe von
Zwischen Dieselmotor und Verteilergetriebe
Getriebeöffnungen gefährlich. Es besteht das
empfehlen wir den Einbau einer hochelastischen
Risiko eines Brandes oder einer Explosion.
Kupplung mit einer spielfreien Verbindung zwi-
schen Kupplungsnabe und Antriebswelle.
Schnelldrehende Maschinen, in die diese
Getriebe eingebaut sind, können laute
Geräusche erzeugen, die bei längerer Bei dem Anbau von Mehrfachpumpen (Tandem-
Einwirkung das Gehör schädigen. In diesem Fall pumpen) sollte eine zusätzliche Abstützung der
sollte das Bedienungspersonal mit Gehörschutz Pumpen erfolgen, um schädliche Schwingungen
ausgestattet werden. Zur Geräuschminderung der Pumpenpakete und daraus resultierende
sollten alle technischen Möglichkeiten unter Bauteilschäden zu vermeiden.
Beachtung der gesetzlichen Vorschriften
angewendet werden. Besonders wenn der Dieselmotor mit variab-
ler Drehzahl betrieben wird, sind Resonanz-
Es ist darauf zu achten, dass die Getriebe nicht schwingungen in dem gesamten Betriebs- dreh-
ständig starken Schwingungen, z.B. durch nied- zahlbereich durch geeignete Maßnahmen zu
796 (1146)
rigdrehende Dieselmotoren, ausgesetzt Copyright
sind. © Sandvik vermeiden.
ID: BG00398452 en-US A.001.1 2015-10-19

6
Service and Repair Manual LH204

Das Aufziehen von Kupplungen, Riemenscheiben Inbetriebnahme

oder ähnlichen Elementen sollte durch eine entspre-
Schmierstoff einfüllen: Ölmenge und Ölqualität
chende Vorrichtung geschehen (Gewindespindel,
siehe Typenschild, technische Daten oder Schmier-
die in die Zentrierbohrung der Welle eingeschraubt
stofftabelle Seite 22. Ölstand durch Lösen der Über-
wird). Starke Hammerschläge sind unbedingt zu
laufschraube oder mit Hilfe des Ölpeilstabes bzw.
vermeiden, da Wälzlager, Sicherungsringe und son-
des Ölstandsauges überprüfen, sofern diese Ein-
stige Innenbauteile beschädigt werden!
richtungen zur Ausstattung gehören.

Bei einigen Getriebetypen (z.B. 4387, 4508 und

Der Ölstand ist nach ca. 30, 60 und 240 Minuten
4533) wird das als Losteil mitgelieferte zentra-
Laufzeit zu überprüfen, da sich Öl in den Anbauflan-
le Stirnrad vom Kunden auf die Motorwelle mon-
schen sammelt oder zur Schmierung der Profilhohl-
tiert. Wegen der Gefahr von Zahnflankenbeschädi-
wellen dort angestaut wird. Ggf. Öl bis zum vorge-
gungen an den Stirnrädern sind Motor und Getriebe
schriebenen Ölstand auffüllen. Dies gilt auch, wenn
besonders vorsichtig zusammenzufügen. Beschä-
Ölpumpen, Ölkühler und ähnliches mit Schmierstoff
digte Zahnflanken verursachen erhöhte Laufge-
befüllt werden müssen.
räusche. Kein Gewährleistungsanspruch!

Hydraulikpumpen müssen mit den Anbauﬂan- Die Markierungen von verschraubten Peilstäben
schen öldicht verbunden werden und dürfen keinen gelten im herausgeschraubten Zustand.
axialen Druck auf die Getriebewellen ausüben! Die
Kupplungsstücke bzw. die Proﬁlverzahnungen müs-
sen vor der Montage ausreichend geschmiert wer-
den, wir empfehlen dazu Optimol White T oder Klü-
ber Staburags NBU 30 PTM.

Ausnahme: Proﬁlhohlwellen, die eine von der Ge-

triebeschmierung unabhängige Ölfüllung erhal-
ten, der zugehörige Anbauﬂansch ist dann mit Ver-
schlussstopfen für Ölstand und -ablass sowie einer
Entlüftung versehen. Diese Flansche sind nach der
Die Markierungen von eingesteckten Peilstäben
Pumpenmontage bis zur Ölstandsschraube mit Öl
(nicht geschraubte Ausführung) gelten im bis auf
aufzufüllen.
Anschlag eingesteckten Zustand.

Schmierstofffüllung
Die Getriebe werden in der Regel ohne Ölfüllung
geliefert, sie sind dann mit einem Anhänger „Ach-
tung ohne Ölfüllung“ versehen. Zum Einsatz kommt
im Normalfall Getriebeöl CLP 220 DIN 51517-3 (Mi-
neralöl) oder CLP HC 150 DIN 51517-3 (Synthe-
tiköl). Diese Qualitäten sind geeignet für normale
Betriebsbedingungen mit einer Umgebungstempe- Öl- bzw. Getriebetemperaturen bis zu 95 °C bei
ratur von -10° bis 35° C bzw. -35° bis 80° bei syn- Mineralöl bzw. bis zu 120 °C bei Synthetiköl sind
thetischer Ölfüllung. Bei besonderen Betriebs- und nicht ungewöhnlich und haben keinen negativen
Einsatzbedingungen ist Rücksprache mit dem Her- Einﬂuss auf die Funktion der Getriebe.
steller zu nehmen. Siehe Kapitel 9.

Einbaulagen
Stiebel Verteiler-, Pumpenverteiler-, Verteilerschalt-
getriebe können je nach Typ in mehreren Einbaula-
gen betrieben werden. Für von der bestellten bzw.
in der Anbauzeichnung dargestellten abweichende
Einbaulagen muss immer Rücksprache mit dem
Hersteller genommen werden.
Copyright © Sandvik 797 (1146)
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Verteilerschaltgetriebe

Die Getriebe dürfen nicht unter Last geschal- – Mechanische Schaltung: im Schaltgestänge
tet werden, die Schaltung darf nur im Still- muss ein federndes Element (Schalthilfe) ein-
stand betätigt werden. Zuwiderhandlung führt gebaut sein, damit bei ungünstiger Stellung der
zur Beschädigung der Zahnkupplung, kein Zahnkupplung im Getriebe (Zahn auf Zahn) das
Gewährleistungsanspruch. Schaltgestänge arretiert werden kann. Beim An-
lauf des Motors rastet dann die Kupplung ein.
– Pneumatische Schaltung: die Pneumatik muss Die Zug- bzw. Druckkräfte des Schaltgestänges
so beschaffen sein, dass die druckbeaufschlag- im eingeschalteten Zustand dürfen 500 N nicht
te Seite dauernd unter einem Druck von 6 bar überschreiten.
steht. In der Pneumatik muss ein Nebelöler ein-
gebaut sein, um eine einwandfreie Schmierung
des Schaltkolbens und dessen Schutz vor evtl.
Korrosion sicherzustellen.

6. Umbauten und Veränderungen

Keine Veränderungen, An- und Umbauten an dem Während der Gewährleistung dürfen die Getrie-
Getriebe oder an Komponenten, die die Sicherheit be nur mit unserer ausdrücklichen Genehmi-
beeinträchtigen können, ohne Genehmigung des gung geöffnet werden, andernfalls erlischt jegliche
Herstellers vornehmen! Gewährleistung.
Insbesondere dürfen vorhandene Schutzeinrich-
tungen (z.B. Abdeckungen, Überlastungsschutz)
nicht entfernt oder verändert werden.

7. Wartungshinweise
Regelmäßiger Ölwechsel lt. Betriebsanleitung Vorzeitiger Getriebeausfall kann auftreten durch
Siehe Kapitel 9. Schmierstoffe. Besitzen die An- Trockenlaufen, bedingt durch Ölverlust, durch
bauflansche eine eigene Ölfüllung, so ist diese als Eintreten von Wasser in das Getriebegehäuse oder
Lebensdauerschmierung ausgelegt und bedarf durch Fremdkörper in der Schmiermittelfüllung.
keines Ölwechsels. Ölmenge und Ölqualität sie-
he Typenschild oder Betriebsanleitung, wobei die
Ölmengen als Zirka-Angaben verstanden werden Bei der Durchführung von Ölwechsel, Ölauf-
müssen. Maßgebend ist immer der in der Anbau- füllen, Ölablassen oder Entnahme von Ölproben
zeichnung dargestellte Ölstand. Vor einer Ölstands- ist zu gewährleisten, dass kein Öl in den Boden,
kontrolle muss das Getriebe mindestens 30 Minu- in das Grund- und Oberflächenwasser oder in
ten in Betrieb gewesen sein, da Öl zur Schmierung die Kanalisation gelangen kann.
der Profilhohlwellen in den Pumpenanbauflanschen
angestaut wird. Ölstand durch Lösen der Überlauf- Ölpeilstäbe bzw. Überlaufschrauben dürfen nur
schraube oder mit Hilfe des Ölpeilstabes überprüfen, bei stillstehender Maschine entfernt werden.
sofern diese Einrichtungen zur Ausstattung gehö- Verletzungsgefahr!
ren. Die Markierungen von verschraubten Peilstä-
ben gelten im herausgeschraubten Zustand. Siehe Längerer Kontakt mit Schmierstoffen kann
Kapitel 9. Bei jedem Ölwechsel sind alle Dichtungen Hautschäden verursachen. Hautschutzsalbe
und Verschraubungen auf Dichtheit zu überprüfen, verwenden.
evtl. Schrauben nachziehen. Wenn möglich, sollte
täglich eine visuelle Dichtheitsprüfung durchgeführt Nach längerem Betrieb können Schmierstoff
werden. Erhöhter Ölstand im Getriebe bzw. den An- und Oberfläche des Getriebes Temperaturen er-
bauflanschen mit eigener Ölfüllung deutet auf de- reichen, die zu Verbrennungen der Haut führen.
fekte Dichtungen an den Hydraulikaggregaten hin. Bei Arbeiten an heißen Bauteilen ist Schutzklei-
798 (1146) Copyright © Sandvik dung zu tragen, z.B. Schutzhandschuhe.
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Die jeweils geltenden nationalen, örtlichen und Zur Vermeidung von Störungen, die schwere
anlagespeziﬁschen Bestimmungen und Erfor- Personen- und Sachschäden bewirken könnten,
dernisse zur Unfallverhütung und zum Umwelt- muss das zuständige Wartungspersonal dann
schutz sind zu berücksichtigen. umgehend verständigt werden. Im Zweifelsfal-
le die entsprechenden Betriebsmittel sofort ab-
Um Störungen vorzubeugen, ist es erforderlich, schalten und sichern.
die vorgeschriebenen Wartungs- und Inspekti-
onsmaßnahmen regelmäßig durchzuführen. Ver- Zur Vermeidung von Überhitzungsschäden
änderungen gegenüber dem Normalbetrieb (hö- sollten Schmutz und Staubablagerungen re-
here Leistungsaufnahme, Temperaturen oder gelmäßig von der Getriebeoberﬂäche entfernt
Schwingungen, ungewöhnliche Geräusche werden.
oder Gerüche, Ansprechen der Überwachungs-
einrichtungen usw.) lassen erkennen, dass die
Funktion beeinträchtigt ist.

8. Ersatzteile und Reparatur

Ersatzteile müssen den vom Hersteller festgelegten Die jeweils geltenden nationalen, örtlichen und an-
technischen Anforderungen entsprechen. Dies ist lagespeziﬁschen Bestimmungen und Erfordernisse
bei Originalersatzteilen immer gewährleistet. Bei Er- zur Unfallverhütung und zum Umweltschutz sind zu
satzteilbestellungen ist außer der Ersatzteilnummer berücksichtigen.
die Typ-Nummer und die Serien-Nummer (auf dem
Typenschild bzw. in den technischen Daten ersicht- Längerer Kontakt mit Schmierstoffen kann
lich) anzugeben. Ersatzteilzeichnungen und Ersatz- Hautschäden verursachen. Hautschutzsalbe
teillisten können von Stiebel angefordert werden. verwenden. Nach längerem Betrieb kann der
Schmierstoff und die Oberﬂäche des Getriebes
Reparaturen bzw. Überholungen werden von Stie-
Temperaturen erreichen, die zu Verbrennungen
bel kurzfristig ausgeführt. Für Schäden, die durch
der Haut führen. Vor Reparaturbeginn Getriebe
unsachgemäße Reparatur oder die Verwendung
abkühlen lassen.
von Nicht-Original-Ersatzteilen entstanden sind,
haftet Stiebel nicht.
Bei Eigenreparaturen für sichere und umweltscho-
nende Entsorgung von Betriebs- und Hilfsstoffen
sowie Austauschteilen sorgen.

9. Schmierstoffe
Die verwendeten Schmierstoffe müssen den Min- In der Regel können Stiebel-Verteilergetriebe mit
destanforderungen nach DIN 51517, Teil 3, bzw. mineralischem Öl betrieben werden. Dabei muss si-
ISO/DP 6743-6 für Schmieröle CLP entspre- chergestellt sein, dass die Öltemperatur 95 °C nicht
chen. Die ISO-Viskositätsklassiﬁkation entspricht übersteigt, andernfalls ist synthetisches Öl, maxi-
DIN 51519 bzw. ISO 3448. male Öltemperatur 120 °C, zu verwenden. Öltem-
peraturen über 120 °C sind unzulässig; ggf. muss
Die Schmierstoffhersteller empfehlen die in der
das Öl gekühlt werden.
Schmierstofftabelle (Seite 22) aufgeführten
Produkte. Eingesetzt werden kann auch Getriebeöl der Vis-
kositätsklasse SAE 90 EP und SAE 85W-90 EP
Der Schmierstoffhersteller ist für die Qualität
nach DIN 51512, sofern es die Klassiﬁkation API
und die technische Eignung seines Produktes
GL-4, API GL-5 oder MIL-L-2105 D erfüllt. Umge-
verantwortlich.
bungstemperatur -10 °C bis +35 °C.
Die Wahl synthetischer Schmieröle resultiert aus
den speziellen Einsatzbedingungen des Getriebes,
z.B. der Umgebungstemperatur. Maßgebend ist die
im Betrieb erreichte Öltemperatur. Copyright © Sandvik 799 (1146)
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Schmierstoffwechsel
Der erste Ölwechsel sollte nach 200 Betriebsstun- Die Markierungen von verschraubten Peilstäben
den erfolgen, danach alle 2000 Stunden, jedoch gelten im herausgeschraubten Zustand.
maximal nach 12 Monaten.
Der Schmierstoff sollte möglichst in betriebswarmem
Zustand abgelassen werden, damit ein vollstän-
diger Austausch des alten Schmierstoffes gewähr-
leistet ist. Empfehlung: bei stark verschmutztem Öl
das Getriebe mit neuem Schmierstoff spülen.
Neuen Schmierstoff einfüllen: Ölmenge und Öl-
qualität siehe Typenschild, technische Daten oder
Schmierstofftabelle Seite 22. Ölstand durch Lö-
sen der Überlaufschraube oder mit Hilfe des Ölpeil-
Die Markierungen von eingesteckten Peilstäben
stabes überprüfen, sofern diese Einrichtungen zur
(nicht geschraubte Ausführung) gelten im bis auf
Ausstattung gehören.
Anschlag eingesteckten Zustand.

Mischbarkeit von Schmierstoffen

Synthetische Schmierstoffe nicht untereinander
oder mit mineralischen Schmierstoffen mischen!
Polyalphaoleﬁne (PAO) CLP HC sind in der Regel
mit Resten von Mineralölen mischbar.
Ob Mischbarkeit möglich ist, kann verantwortlich
nur der Schmierstoffhersteller beurteilen.

Wird die Schmierstoffart gewechselt, muss das

Getriebe mit dem neuen Schmierstoff gespült
werden. Spülöl bis zum vorgeschriebenen Öl-
stand einfüllen. Getriebe ca. 15 min ohne Last
betreiben, dann Spülöl ablassen und neuen
Schmierstoff einfüllen.

2. Foreword
These operating instructions contain important ad- Advice: The content of these operating instruc-
vice on the safe, correct and economic operation of tions are protected by copyright. Illustrations, draw-
the gear and plant. ings and data from these operating instructions may
be neither reproduced nor communicated or made
Following this advice helps to prevent hazards and available to third parties or competing companies
damage, reduce repair costs and breakdown times (© 2001 and §18 UWG).
and to increase the reliability and service life of the
gear.

Important: Always read information marked with

this symbol. Such information warns of danger.

Non-observance can lead to personal injury and
800 damage
(1146) to property. Copyright © Sandvik
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3. Prescribed use
The above-mentioned product is intended for instal- Any applicable national, local and plant-specific
lation in a machine. It may not be commissioned un- conditions and requirements concerning the
til it has been ascertained that the machine in which prevention of accidents must be observed.
the above-mentioned product is to be installed com-
Qualified personnel are those persons who, on the
plies with the conditions of the EC guideline on ma-
basis of their training, experience and instruction,
chinery.
along with their knowledge of relevant standards,
The product may only be used for the technically de- conditions, regulations for the prevention of acci-
signed purpose agreed. The product may not be op- dents and operating conditions, have been author-
erated with outputs, torques or external loads which ized by the person responsible for the safety of the
exceed the structural design (see technical data and plant to carry out the necessary activities and in so
nameplate). Installation and commissioning may on- doing are able to detect and prevent possible haz-
ly be carried out by properly qualified personnel. ards.

4. Transport and storage

Transport Storage
For risk-free handling, the hoisting lugs and Storage from delivery to commissioning should be
pegs or threaded bore-holes provided must be in dry, dust-free and vibration-free areas. Enquir-
used. Hoisting lugs and similar aids attached to ies should be addressed to the manufacturer in the
the gears are designed only for the weight of the case of differing storage conditions.
gear and may not be used for raising extension
components such as motors, drum shafts or sim-
ilar. Only use suitable and technically faultless
Protection against corrosion
lifting equipment and load suspension devices
(e.g. ropes, eye bolts etc.) with sufﬁcient load- The standard preservation of the shafts, hollow
bearing capacity. See indication of weight in the shafts etc. is effective for one year maximum under
technical data or on the nameplate. The indica- the above-mentioned conditions. It is not suitable for
tions of weight must be regarded as approximate outside storage.
as weights can vary slightly, e.g. by different oil
levels! Do not remain or work under suspended
loads!

5. Set-up and putting into operation

Assembly and commissioning may only be carried Where necessary, mechanical devices (special
out by properly qualified personnel. equipment, supports etc.) must ensure that the
machine cannot move or rotate.
Before commissioning and the test run it must
be ensured that the moving and rotating com- It must be ensured before commissioning that
ponents (e.g. shafts, couplings etc.) do not rep- the specified amount of lubricant has been
resent a hazard. This means that the necessary poured into the machine. For the oil quantity and
contact protection must be provided or meas- oil grade, see nameplate, technical specifica-
ures taken to ensure a safe distance from the tions or lubricant table, page 22.
machine is maintained. During the test run with-
out attached machinery, the keys in the shaft Never operate without a vent filter otherwise the
ends are to be secured against being spun out. excess pressure resulting from the gear unit
heating up will cause an oil leak.
Before work on the gear unit or attached equip-
ment is performed, the power supply must be After prolonged operation the lubricant and gear
disconnected. Action must be taken to prevent unit surface may reach temperatures which could
Copyright © Sandvik
the power being inadvertently switched on again. cause skin burns. 801 (1146)
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Oil mist is produced in the gear units. It is there- Couplings, belt pulleys or similar elements should
fore dangerous to work with a naked flame near be mounted with the appropriate mounting device
the gear unit openings. There is a risk of fire or (threaded spindle which is screwed into the cen-
explosion. tring bore of the shaft). Severe hammering must be
avoided as anti friction bearings, retaining rings and
High-speed machines into which these gear other internals would be damaged!
units are installed may generate loud noises
which can damage your hearing if they persist. With some gearbox types (e.g. 4387, 4508 and
In this case the operating staff should be pro- 4533) the central spur wheel provided as loose piece
vided with ear protection. In order to reduce the is installed by the customer onto the motor shaft.
noise, all technical possibilities should be used Because of the danger of teeth profile damages
to observe the statutory regulations. at the spur wheels motor and gearbox are to be
joined very carefully. Damage teeth profiles cause
It must be ensured that the gear units are not increased operating noise. No warranty claim!
continuously subjected to severe vibrations, e.g.
from low-speed diesel engines. Hydraulic pumps must be connected with the mount-
ing flanges so that they are oil-tight and must not ex-
Technical information ert any axial pressure on the gear unit shafts! The
coupling elements and the splines must be ade-
housings: torsionally rigid housings made of quately lubricated before assembly; we recommend
aluminium or grey cast iron Optimol WhiteT or Klüber Staburags NBU 30 PTM.
gearing: casehardened, tooth flanks ground
Exception: Splined hollow shafts which have their
lubrication: splash lubrication, pressurised cir- own oil filling from the gear unit lubrication system;
culation lubrication the relevant mounting flange is then provided with
screw plugs for the oil level and oil drain as well as a
Assembly of the gear units breather. These flanges are to be filled with oil up to
Before assembly, check the surfaces, edges of the the oil level screw after pump assembly.
shaft end, keys and external shaft splines for dam-
age, and remedy any damage discovered. In the Lubricant filling
case of key and splined shaft connections apply lu- The gear units are as a rule supplied without oil; they
bricating paste (e.g. Optimol White T) to the shaft are then provided with a label „Caution! Not filled
end. The paste facilitates assembly of the units and with oil!“. Normally gear oil CLP220 to DIN 51517-3
prevents corrosion which would make subsequent (mineral oil) or CLP HC 150 to DIN 51517-3 (syn-
dismantling much more difficult. It must be ensured thetic oil) is used. These grades are suitable for nor-
that the shaft seals are not dirty, damaged or coated mal operating conditions at an ambient temperature
with paint. When the units are being painted, cover of -10° to +35 °C or -35° to +80 °C with synthetic oil.
the seals and running surfaces of the shafts or pro- Consult the manufacturer in the event of special op-
tect with grease. This is the only way to prevent dam- erating and application conditions. See chapter 9.
age and thus oil losses. Oil baffle plates which may
be installed on the pump mounting flanges must not
Commissioning
be damaged or dismantled.
Filling of lubricant: for oil quantity and oil quality see
Assembly of input and output elements nameplate, technical specifications or lubricant ta-
ble, page 22. Check the oil level by loosening the oil
We recommend to install a high-elastic coupling overflow screw or using the oil dipstick or the oil lev-
between the diesel engine and the gearbox with el eye if these are part of the equipment. The oil lev-
a connection without clearance between cou- el is to be checked after about 30, 60 and 240 min.
pling hub and drive shaft. running time as oil collects in the mounting flanges
or is dammed there to lubricate the splined hollow
With the mounting of multiple pumps (hydrau- shafts. If necessary, replenish oil up to the specified
lic tandem pumps) an additional support should oil level mark. This also applies if oil pumps, oil cool-
take place in order to avoid harmful oscillations ers and the like have to be filled with lubricant.
of the pump packages and from this resulting
component damages.

Particularly if the diesel engine is operated with

a variable number of revolutions, resonant vibra-
tions within the entire operating speed range are
802 (1146)
to be avoided by suitable measures. Copyright © Sandvik
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Service and Repair Manual LH204

The markings of screwed-in dipsticks apply in un- Power take-off gear units
screwed state.
The gear units must not be switched under load;
this operation may only be performed at stand-
still. Any contravention of this will result in dam-
age to the geared coupling and no claims under
the guarantee will be accepted.
– Pneumatic gear-shifting: The pneumatics must
be designed so that the side subjected to pres-
sure is continuously under a pressure of 6 bar. A
mist oiler must be installed in the pneumatic sys-
tem to ensure proper lubrication of the operating
The markings of put-in dipsticks (not screwed exe- piston and to protect it against any corrosion.
cution) apply in the status put in up to impact. – Mechanical gear-shifting: A spring element
(gear-shifting aid) must be installed in the shift
linkage so that, if the geared coupling in the
gear unit is in an unfavourable position (tooth on
tooth), the shift linkage can be locked.

When the motor starts up, the coupling then en-

gages. The tensile and compressive forces of the
shift linkage in the engaged condition must not
exceed 500 N.

Oil and gear unit temperatures up to 95 °C, or up

to 120 °C with synthetic oil, are not unusual and do
not have any negative effect on the functioning of
the gear units.

Installation positions
Stiebel power take-off, pump power take-off and
variable-speed gear units can be operated in sever-
al installation positions depending on the type. The
manufacturer must always be consulted in the event
of installation positions which deviate from the posi-
tion ordered or shown in the assembly drawing.

6. Conversions and modiﬁcations

Do not make any changes, provide attachments or During warranty the gearboxes may be opened only
perform conversion work on the gear unit or compo- with our express permission otherwise any warran-
nents which could reduce safety without the manu- ty claim expires.
facturer’s permission!
In particular any protective facilities provided (e.g.
covers, overload protection) must not be removed
or changed.

Copyright © Sandvik 803 (1146)

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7. Notes on maintenance
Change oil regularLy in accordance with the oper- Oil dipsticks and/or overflow screws may be re-
ating manual. Refer to chapter 9. lubricants. If the moved at machine in standstill only. Injury risk!
mounting flanges have their own oil filling, it is de-
signed as long-life lubrication and no oil change is Prolonged contact with lubricants can cause in-
necessary. For the oil quantity and oil grade, see jury to your skin. Use a protective skin ointment.
nameplate or operating manual; the oil quantities
are to be regarded as approximations. The oil lev- After prolonged operation the lubricant and sur-
el indicated in the assembly drawing is always de- face of the gear unit may reach temperatures
cisive. The drive must be in operation for at least 30 which can cause skin burns. When working on
minutes prior to checking the oil level, because oil is hot components, wear protective clothing, e.g.
accumulated in the pump mounting flanges for lubri- protective gloves.
cation of the profile hollow shaft. Check the oil lev-
el by undoing the overflow screw or by using the oil The applicable national, local and plant-specif-
dipstick provided these devices are part of the fit- ic regulations and requirements concerning ac-
tings. The markings of the screwed oil dipsticks ap- cident prevention and environmental protection
ply in unscrewed state. At each oil change check are to be observed.
all the seals and screw fittings for any leaks and, if
To prevent faults, it is necessary to carry out the
necessary, re tighten the screws. If possible, a vis-
regular maintenance and inspection work pre-
ual leak check should be made every day. Arise in
scribed. Any changes compared with normal op-
the oil level in the gear unit or mounting flanges with
eration (higher power input, temperatures or vi-
their own oil filling is a sign of defective seals in the
brations, unusual noises or smells, response of
hydraulic units. See chapter 9. Lubricants.
monitoring devices etc.) are an indication that
Premature gear unit failure may occur as a result of the unit is not functioning properly. To avoid faults
running dry caused by oil loss, the ingress of water which could result in injury to people or damage
into the gear unit housing or the presence of foreign to property, the maintenance staff responsible
matter in the lubricant. must be notified immediately. In case of doubt
switch off the relevant item of equipment and en-
sure it cannot be switched on again.
When changing, replenishing or draining the
oil or when taking oil samples, it must be guar- To prevent damage from overheating, dirt and
anteed that no oil can escape onto the ground, dust deposits should be regularly removed from
penetrate the ground or surface water or enter the gear unit surface.
the sewage system.

8. Spare parts and repairs

Spare parts must satisfy the technical requirements When carrying out your own repairs, make sure
speciﬁed by the manufacturer. This is always guar- that the expendables and auxiliary materials and
anteed with original spare parts. When ordering parts which have been replaced are disposed of
spare parts, the type number and serial number (to safely and without polluting the environment.
be found on the nameplate or in the technical data)
in addition to the spare part number must be indicat- The applicable national, local and plant-specif-
ed. Spare part drawings and spare parts lists can be ic regulations and requirements concerning ac-
requested from Stiebel. cident prevention and environmental protection
are to be observed.
Repairs and overhauls are carried out by Stiebel at
short notice. Stiebel does not assume any liability Prolonged contact with lubricants can cause
for damage caused by improper repair work or the skin damage. Use a protective skin ointment.
use of non-original spare parts. After prolonged operation the lubricant and the
surface of the gear unit may reach temperatures
which can cause skin burns. Before starting re-
804 (1146) Copyright © Sandvik pairs, let the gear unit cool down.
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9. Lubricants
The lubricants must comply with the minimum re- As a rule, Stiebel pump drives are operated with
quirements of DIN 51517, Part 3, and/or ISO/DP mineral oil. Here, it must be ensured that the oil tem-
6743-6 for lubricating oils CLP. The ISO viscosi- perature does not exceed 95 °C (205 °F), otherwise
ty classiﬁcation corresponds to DIN 51519 and/or synthetic oil, max. temperature 120 °C (250 °F),
ISO 3448. is to be used. Oil temperatures exceeding 120 °C
The lubricant producers recommend the products (250 °F) are inadmissible; if necessary, the oil has
listed in the lubricant table (see page 22). to be cooled.

The lubricant producer is responsible for the quality The following gear oil can also be used: viscosity
and the technical suitability of his product. class SAE 90 EP and SAE 85W-90 EP according
to DIN 51512, if it fulﬁls the classiﬁcation API GL-4,
The choice of synthetic lubricating oils results from API GL-5 or MIL-L-2105 D. Ambient temperature
the special operating conditions of the gear, i.e. the -10 °C to +35 °C.
ambient temperature. The oil temperature reached
during operation is relevant.

Lubricant change
The first oil change should be performed after 200 The markings of the oil dipstick apply in unscrewed
hours of operation. All subsequent changes should state.
be performed after 2000 hours of operation but at
the latest after 12 months.
The lubricant should be drained in as warm a state
as possible in order to ensure that the old lubricant
is completely replaced. Recommendation: if the oil
is heavily soiled, the gear should be flushed with the
new lubricant.
Filling in of new lubricant: oil quantity and oil quality
are to be found on the nameplate, technical specifi-
cations or lubricant table, page 22. Check oil levels
The markings of put-in dipsticks (not screwed exe-
by loosening the overflow screw or with the oil dip-
cution) apply in the status put in up to impact.
stick or oil level sight gauge as far as these belong
to the equipment.

Miscibility of lubricants:
Do not mix synthetic lubricants among themselves
or with mineral lubricants!
Polyalphaoleﬁne (PAO) CLP HC can normally be
mixed with residues of mineral oils.
Whether miscibility is possible only the lubricant
producer can judge responsibly.

When the type of lubricant is changed then the

gearbox must be rinsed with the new lubricant.
Fill in oil for rinsing up to the prescribed oil level.
Operate the gearbox for approx. 15 minutes with-
out load, then drain oil for rinsing and ﬁll in the
new lubricant.

Copyright © Sandvik 805 (1146)

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2. Préface
Cette instruction de service contient des indications Tout non-respect peut entraîner des dommages
importantes pour exploiter d‘une manière matériels et sur des personnes!
sûre, conforme et économique le réducteur et
l‘installation. Indication: le contenu de cette instruction de service
fait l‘objet d‘un copyright. Sans notre connaissance
En respectant, vous pourrez éviter dangers et ni notre autorisation, aucune reproduction, aucun
dommages, réduire ainsi les frais de réparation et plan ni donnée émanant de cette instruction de ser-
temps d‘immobilisation, et augmenter la ﬁabilité et vice ne peut être ni copié ni communiqué ou rendu
la longévité du réducteur. accessible à des tiers personnes ou aux sociétés
Important: Les informations caractérisées par ce concurrentes (© 2001 et §18 UWG).

symbole doivent être lues absolument. Elles

avertissent d‘un danger.

3. Utilisation conforme à l‘emploi

Le produit susmentionné est destiné au montage Les dispositions et exigences nationales, locales
dans une machine. Toute mise en service est inter- ou spécifiques à l‘installation, respectivement en vi-
dite tant qu‘il n‘a pas été constaté que la machine, gueur pour la prévention des accidents, doivent être
dans laquelle le produit susnommé doit être monté, prises en compte.
correspond aux dispositions de la directive CE sur
Le personnel qualifié sont les personnes qui, en
les machines.
raison de leur formation, expérience et instruction
Le produit ne doit être utilisé que pour l‘usage ainsi que de leurs connaissances des normes, des
convenu et techniquement conçu. Le produit ne doit dispositions, des prescriptions concernant la pré-
pas être exploité avec des performances, couples vention des accidents et de la situation de l‘entrepri-
et régimes ou autres sollicitations qui dépassent se, ont été autorisées par la personne responsable
la conception technique (voir les caractéristiques de la sécurité de l‘installation à exécuter les activi-
techniques et le catalogue). Le montage et la mise tés respectivement nécessaires, et sont en mesure,
en service ne doivent être effectués que par du per- dans ce contexte, de reconnaître et éviter tout dan-
sonnel qualifié. ger possible.

4. Transport et stockage
Transport
Pour un maniement sans danger, il faut utiliser les sur la plaque signalétique. Les indications de poids
oeillets ou tenons de levage ou les taraudages. Les doivent être comprises comme des données ap-
oeillets de levage ou autres dispositifs similaires proximatives dans la mesure où les poids peuvent
placés sur le réducteur ne sont conçus que pour le diverger en fonction, par exemple, des différents
poids du réducteur. Ils ne doivent pas être utilisés bains d‘huile!
pour soulever des autres pièces comme des mo-
teurs, arbres de tambour et autres pièces sembla-
bles. N‘utilisez que des outils de levage appropriés Ne pas séjourner ni travailler sous des charges
et techniquement parfait ainsi que des dispositifs de en suspension!
suspension de charge (par exemple, câbles, vis à
anneau de levage, etc.) disposant d‘une force por-
tante sufﬁsante! Voir les indications de poids dans
806 les
(1146)
caractéristiques techniques ou Copyright © Sandvik
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Service and Repair Manual LH204

Stockage Protection antirouille

Le stockage, de la livraison jusqu‘à la mise en servi- Le produit de conservation standard des arbres,
ce, doit avoir lieu dans des locaux secs, à l’abri delà arbres creux, etc., est efﬁcace un an dans les
poussière et non soumis à des secousses. En cas conditions susnommées. Il n‘est pas approprié pour
de dérogation à ces conditions de stockage, vous le stockage extérieur.
êtes prié de vous adresser au fabricant.

5. Montage et mise en service

Le montage et la mise en service ne doivent être ef- Les machines à rotation rapide dans les quel-
fectués que par du personnel qualifié. les ces réducteurs sont montés, peuvent produi-
re de graves pollutions sonores qui, à la longue,
Avant la mise en service et avant même la mar- endommagent l‘ouïe. Dans ce cas, le personnel
che d‘essai, il faut s‘assurer que les pièces mo- doit être équipé d‘une protection antibruit. Afin
biles et rotatives (par ex: arbres, accouplements, de réduire les émissions sonores, il faut em-
etc.) ne puissent pas constituer de danger. Cela ployer tous les moyens techniques possibles en
signifie que la protection de contact doit être en respectant les prescriptions légales.
place ou que toute approche dangereuse est ex-
Il faut veiller à ce que les réducteurs ne soient
clue. Lors de la marche d‘essai sans éléments
pas soumis continuellement à de fortes vibra-
rapportés, il faut protéger les clavettes parallèles
tions, par exemple à cause de moteurs Diesel à
dans les bouts d‘arbre contre toute éjection.
bas régime.

Avant de procéder à des travaux sur le réducteur Informations techniques

ou sur des équipements rapportés, l‘alimenta-
tion en courant doit être hors circuit. Il faut pren- boîtier: boîtier résistant àla déformation en
dre les mesures nécessaires contre toute mise aluminium ou fonte grise
en circuit involontaire. Il faut s‘assurer, partout où denture: denture oblique, cémentée et trem-
cela est nécessaire et avec des moyens mécani- pée, avec flancs de dents rectifiés
ques (dispositifs spéciaux, supports, etc.), que la
machine ne puisse pas se déplacer ou se mettre graissage: lubrification par immersion en bain
en rotation. d‘huile, lubrification par circulation
forcée
Avant la mise en service, il faut s‘assurer que le
lubrifiant a été rempli en quantité prescrite. Pour Montage des réducteurs
la quantité et la qualité de l‘huile, veuillez consul- Avant le montage, examinez si les surfaces, arêtes
ter la plaque signalétique, caractéristiques tech- du bout d‘arbre, clavette parallèle et profils à arbres
niques ou table des lubrifiants Page 22. cannelés ne sont pas endommagés et procédez, si
besoin, aux réparations nécessaires.
Ne jamais exploiter sans le filtre d‘aération, si- Pour les assemblages à clavette parallèle et à ar-
non la surpression due à l‘échauffement dans le bre à cannelure, enduire le bout d‘arbre avec de la
réducteur provoque une fuite d‘huile. pâte lubrifiante blanche (par ex. Optimol White T).
La pâte facile l’emmanche ment du réducteur et
Après une exploitation prolongée, le lubrifiant et empêche toute corrosion qui rendrait difficile un dé-
la surface du réducteur peuvent atteindre des montage ultérieur.
températures qui conduisent à une brûlure de la Lors du montage, il faut veiller en outre à ce quel es
peau. bagues à lèvres avec ressort ne soient pas encras-
sées, endommagées ou enduites de peinture. Lors
Du brouillard d‘huile naît dans les réducteurs. de la peinture de l‘agrégat, il faut couvrir les bagues
C‘est pourquoi toute manipulation avec un feu à lèvres et sur faces de roulement ou les protéger
ouvert à proximité des ouvertures de réducteur avec de la graisse. C‘est seulement ainsi que l‘on
est dangereuse. Il existe un risque d‘incendie ou peut éviter des endommagements, et ainsi une per-
d‘explosion. Copyright te
© Sandvik
d‘huile. 807 (1146)
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Les déﬂecteurs d‘huile qui, le cas échéant, sont dis- Remplissage de lubriﬁcation
posés sur les brides de montage de pompe, ne doi-
Les réducteurs sont livrés en règle générale sans
vent être ni endommagés ni démontés. bain d‘huile. Ils sont alors pourvus d‘une étiquette „At-
tention sans bain d‘huile“. On utilise normalement de
Montage des éléments d‘entraînement l‘huile d‘engrenage CLP220 DIN 51517-3 (huile mi-
et de sortie nérale) ou CLP HC 150 DIN 51517-3 (huile synthéti-
que). Ces qualités sont appropriées pour des condi-
Entre le moteur diesel et le réducteur, nous re- tions d‘exploitation normales avec une température
commandons l’installation à un embrayage très ambiante de -10° à 35 °C et de -35 à 80 °C pour le
élastique avec une relation sans jeu entre le bain d‘huile synthétique. En cas de conditions d‘ex-
moyeu d’embrayage et l’arbre primaire. ploitation et d‘utilisation particulières, veuillez-vous
adresser au fabricant. Voir chapitre 9.

Avec l’installation des pompes multiples (pom- Mise en service

pes de tandem), un soutien supplémentai-
Remplir de lubrifiant: pour quantité d’huile et pur
re devrait avoir lieu pour éviter les oscillations
qualité d’huile voir plaque signalétique, caractéristi-
nuisibles des emballages de pompe et des dom- ques techniques ou table des lubrifiants Page 22.
mages d’élément résultant.
Vérifier le niveau d’huile par résoudre de la vis de
débordement ou à l’aide de la jauge d’huile et/ou
Particulièrement si le moteur diesel est actionné des yeux de niveau d’huile, pour autant que ces
avec un nombre de tours variable, des vibrations installations fassent partie de l’équipement.
de résonance dans la gamme des vitesses de Le niveau d‘huile doit être vérifié après 30, 60 et
rotation totale par des mesures appropriées doi- 240 minutes de fonctionnement dans la mesure où
vent être évitées. l‘huile se rassemble dans les brides de montage
ou s‘amasse là pour le graissage des arbres creux
profilés. Le cas échéant, remplir l‘huile jusqu‘au
Le montage des accouplements, poulies ou niveau prescrit. Ceci est particulièrement important
éléments similaires doit avoir lieu à l‘aide d‘un si des pompes ou refroidisseurs à huile et pièces
dispositif adéquat (broche filetée qui est vissée dans similaires doivent être également remplis d‘huile.
l’alésage de centrage de l’arbre). Il faut absolument Les marquages des jaugeurs boulonnés sont en
éviter de violents coups de marteau qui pourraient vigueur dans l’état dévissé.
entraîner un endommagement des paliers à
roulement, circlips et autres éléments internes!

Avec quelques types de réducteurs (p. ex. 4387,

4508 et 4533) la roue cylindrique centrale fournie
comme pièce détachée est installée par le client sur
l’arbre du moteur. À cause du danger des détério-
rations superficielles des dents le moteur et des ré-
ducteurs doivent être joints très prudemment. Des
flancs endommagés causent des bruits de course
accrus. Pas de droit à la garantie!
Les marquages des jaugeurs encastrés (mise en
Les pompes hydrauliques doivent être reliées oeuvre non vissée) sont en vigueur dans l’état en-
aux brides de montage, d‘une manière étanche castré jusqu’à l’avis.
à l’huile, et ne doivent exercer aucune pression
axiale sur l‘arbre du réducteur! Les accouplements
et les dentures profilées doivent être suffisamment
graissés avant le montage, nous recommandons
pour cela Optimol WhiteT ou Klüber Staburags NBU
30 PTM.

Exception: arbres creux proﬁlés qui reçoivent un

remplissage d‘huile indépendant du graissage du
réducteur, la bride de montage correspondante est
alors pourvu de bouchons de fermeture ou le niveau Les températures d‘huile et de réducteur jusqu‘à
et la vidange d‘huile ainsi qu‘une purge. Ces brides 95 °C pour les huiles minérales et 120 °C pour les
doivent être remplis avec l’huile après l’assemblage huiles synthétiques ne sont pas inhabituelles et
n‘ont aucun effet négatif sur le fonctionnement des
808 de pompe jusqu’à la vis de niveau d’huile. Copyright © Sandvik
(1146)
ID: BG00398452 en-US A.001.1 réducteurs.
2015-10-19

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Positions de montage
Les réducteurs distributeurs, réducteurs distribu- positions de montage différentes, commandées ou
teurs à pompe, mécaniques mes à engrenages dis- représentées dans le plan de montage, il faut tou-
tributeurs Stiebel peuvent être exploités, selon le jours s‘adresser au fabricant.
type, dans plusieurs positions de montage. Pour les

Les mécanismesàengrenages distributeurs

Les mécaniques mes à engrenages distribu- - commutation mécanique: il faut monter un élé-
teurs ne doivent pas être commettes sous char- ment élastique (auxiliaire de commutation) dans
ge, la commutation doit avoir lieu à l‘arrêt. Toute la tringle de commutation aﬁn que celle-ci puis-
contravention conduit à un dommage de l‘accou- sent être bloquée en cas de position désavanta-
plement à dents, pas de droit à la garantie. geuse de l‘accouplement à dents dans le réduc-
teur (dent sur dent). L‘accouplement encliquette
- commutation pneumatique: le système lors du démarrage du moteur. Les forces de trac-
pneumatique doit être conçu de telle sorte que le tion et de pression de la tringle de commutation,
côté alimenté en pression soit constamment sous en état commette, ne doivent pas dépassées
une pression de 6 bars. On doit monter dans le 500 N.
système pneumatique un graisseur à brouillard
d‘huile aﬁn d‘assurer un graissage parfait du
piston de commutation et une protection de ce
dernier contre toute corrosion.

6. Transformations et modification
Ne procédez à aucune modification, transforma- Pendant la garantie, les réducteurs ne peuvent être
tion sur le réducteur ou les composants, qui pour- ouvertes qu’avec notre approbation express, sinon
rait porter atteinte à la sécurité, sans l’autorisation chaque garantie expire.
du fabricant!
En particulier, les dispositifs de protection (par ex.
couvercles, protection anti-surcharge) ne doivent
pas être enlevés ou modifiés.

7. Indications de maintenance
Changement d‘huile régulier selon l‘instruction de de la jauge dans la mesure où ces dispositifs exis-
service. Voir chapitre 9. lubrifiants. Si les brides de tent. Les repères de la jauge de niveau d‘huile s‘ap-
montage possèdent un propre bain d‘huile, ce der- pliquent à l‘état dévissé.
nier est conçu comme un graissage suffisant pour
Vérifier l‘étanchéité de tous les joints et vissages
la durée de vie et ne nécessite pas de changement
lors de chaque changement d‘huile. Le cas échéant
d‘huile. Quantité et qualité d‘huile, voir plaque signa-
resserrer les vis. Si possible, procéder tous les jours
létique ou instruction de service, les quantités d‘hui-
à un contrôle visuel de l‘étanchéité. Un niveau d‘hui-
le devant être comprises comme des indications ap-
le trop élevé dans le réducteur ou les brides de mon-
proximatives. Le niveau d‘huile indiqué dans le plan
tage avec un propre bain d‘huile est signe de joints
de montage reste déterminant. Avant de contrôler le
défectueux sur les agrégats hydrauliques.
niveau d'huile, le réducteur doit être mis en service
pendant au moins 30 minutes car l'huile de lubrifica- Une panne prématurée du réducteur peut arriver en
tion des arbres creux profilés s'accumule dans les cas de course à sec due à une perte d‘huile, la pré-
brides de montage des pompes. Vérifier le niveau sence d‘eau dans le boîtier ou par des corps étran-
d‘huile en dévissant la vis de trop-plein ou à l‘aide Copyright gers
© Sandvik
dans le bain d‘huile. 809 (1146)
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Service and Repair Manual LH204

Lors de la réalisation du changement d‘huile, Afin de prévenir les perturbations, il est nécessai-
remplissage d‘huile, vidange ou prélèvement re de réaliser régulièrement les mesures prescri-
d‘échantillons d‘huile, il faut s‘assurer que l‘huile tes de maintenance et d‘inspection. Toutes mo-
ne puisse pas parvenir dans le sol, les eaux difications par rapport à l‘exploitation normale
souterraines ou de surface ou encore dans la (puissance absorbée, températures ou vibra-
canalisation. tions plus élevées, bruits ou odeurs inhabituel-
les, déclenchement des dispositifs de surveillan-
Les jauges de niveau d‘huile et/ou les vis de ce, etc.) sont autant d‘indices d‘une perturbation
trop-plein ne doivent être enlevées qu‘à machi- du fonctionnement. Afin d‘éviter les perturbations
ne arrêtée. Danger de blessure! qui pourraient conduire aux des dommages ma-
Un contact prolongé avec des lubrifiants peut tériels ou sur des personnes, il faut informer im-
provoquer des dommages cutanés. Utiliser un médiatement le personnel de maintenance. En
savon pour protection cutanée. cas de doute, mettre les moyens d‘exploitation
correspondants immédiatement hors circuit et
Après une exploitation prolongée, le lubrifiant et les protéger.
la surface du réducteur peuvent atteindre des
températures qui conduisent à une brûlure de la Afin d‘éviter des dommages dus à la surchauf-
peau. Toujours porter des vêtements de protec- fe, il faut enlever régulièrement la saleté et les
tion, par exemple des gants, en cas de travaux dépôts de poussières sur la surface du réduc-
sur des éléments brûlants. teur et les nervures de refroidissement du mo-
teur électrique.
Les dispositions et exigences nationales, locales
ou spécifiques à l’installation, respectivement en
vigueur pour la prévention des accidents, doi-
vent être observées.

8. Pièces de rechange et réparation

Les pièces de rechange doivent correspondre aux Les dispositions et exigences nationales, locales
exigences techniques définies par le fabricant. Ceci ou spécifiques à l‘installation, respectivement en
est toujours assuré pour les pièces de rechange ori- vigueur pour la prévention des accidents, doi-
ginales. Lors des commandes de pièces de rechan- vent être observées.
ge, il faut toujours indiquer, outre le numéro de la
pièce de rechange, le numéro de type et le numé- Un contact prolongé avec des lubrifiants peut
ro de série (visibles sur la plaque signalétique ou provoquer des dommages cutanés. Utiliser un
dans les caractéristiques techniques). On peut de- savon pour protection cutanée. Après une exploi-
mander à Stiebel les plans et listes des pièces de tation prolongée, le lubrifiant et la surface du ré-
rechange. ducteur peuvent atteindre des températures qui
conduisent à une brûlure de la peau. Faire refroi-
Les réparations et remises en état sont réalisées dir le réducteur avant de commencer à réparer.
rapidement par Stiebel. Stiebel ne répond pas des
dommages dus à une réparation non conforme ou à
l‘utilisation de pièces de rechange non originales.
Si vous procédez vous-même aux réparations, as-
surez-vous d‘une élimination sûre et écologique
des matières consommables ainsi que des pièces
échangées.

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9. Lubrifiants
Les lubrifiants utilisées doivent correspondre aux Normalement, on peut utiliser une huile minérale
exigencens minimales suivant la norme DIN 51517,3 pour les boîtes de répartition Stiebel. Dans ce
e partie, ou ISO/DP 6743-6 pour les huiles lubrifian- cas, il faut qu’il soit garantie que la température
tes CLP. La classification de viscosité ISO corres- de l’huile ne dépasse pas 95 °C, autrement, il faut
pond à DIN 51519 ou ISO 3448. utiliser une huile synthétique, température maxi.
Les fabricants des huiles conseillent les produits 120 °C. Températures d’huile plus de 120 °C sont
que figurent sur la liste en page 22. inadmissible; ce cas échéant, il faut réfrigérer
l’huile.
Le producteur de lubrifiant est responsable de
la qualité et de la convenance technique de son On peut aussi utiliser une huile pour réducteurs de
produit. la classe de viscosité SAE 90 EP et SAE 85W-90
EP selon DIN 51512, pourvu que la classification
Le choix des huiles lubrifiantes synthétiques API GL-4, API GL-5 ou MIL-L-2105 D est accompli.
dépend des conditions spéciales de fonctionnement Température ambiente -10 °C à +35 °C.
des réducteurs, de la température ambiante, par
exemple. La température atteinte par l’huile pendant
le service est déterminante.

Vidange
La première vidange devrait effectuée après Les marquages des jaugeurs boulonnés sont en vi-
200 heures de fonctionnement. Toutes les geur dans l’état dévissé.
vidanges ultérieuses doivent être effectuées après
2000 heures de fonctionnement ou bien, au plus
tard, après 12 mois.
Le lubrifiant doit être si possible vidangé à chaud
afin qu’un échange complet de l’ancien lubrifiant soit
assuré. Recommendation: en cas d’huile fortement
encrassé, on doit procéderà un rincage du réducteur
avec le nouveau lubrifiant.
Remplir le nouveau lubrifiant: pour la quantité et
la qualité de l’huile, veuillez consulter la plaque
Les marquages des jaugeurs encastrés (mise en
signalétique, caractéristiques techniques ou table
oevre non vissée) sont en vigueur dans l’état en-
des lubrifiants Page 22. Vérifier le niveau d’huile
castré jusqu’à l’avis.
en desserrant la vis de trop-plein, ou à l’aide de la
jauge de niveau d’huile, purvu que ces dispositifs
font partie de l’équipement.

Miscibilité des lubriﬁants:

Ne mélangez pas les lubrifiants synthétiques parmi
lui-même ou avec les lubrifiants minéraux.
Les polyalphaolefines (PAO) CLP HC sont ha-
bituellement mixables avec les résidus d’huiles
minérales.
Si la miscibilité est possible seulement le produc-
teur du lubrifiant peut juger de facon responsable.

Si l’espèce du lubriﬁant est changée, la boîte

d’engrenages devrait être rincée avec le nouveau
lubriﬁant. Complétez l’huile pour rincer jusqu’au
niveau d’huile prescrit. Actionnez la boîte de
vitesse pour approx. 15 minutes sans charge,
alors vidangez l’huile pour rincer et remplissez
dedans nouveau lubriﬁant. Copyright © Sandvik 811 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19

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Service and Repair Manual LH204

Schmierstoffe Lubricants Lubrifiants

Mineralöl Synthetiköl
Schmierstoffart Mineral oil Synthetic oil
Lubricant type Huile minérale Huile synthétique
Type de graisse
CLP DIN 51517-3 CLP HC DIN 51517-3
Kinematische Viskosität
Kinem. viscosity
220 150
Viscositékiném.
[mm2/s] 40 °C

Umgebungstemperatur
Ambient temperature -10 -> 40 °C -35 -> 80 °C
Température ambiente

Synthogear PE 150
GEAR RSX 220
AVILUB GEAR PAO 150

Agip Blasia 220 --

Alphasyn EP 150
Alpha SP 220
Alphasyn T 150
Tribol 1100/220
Optigear Synthetic X 150

Mobilgear XMP 220 Mobilgear

SHC XMP

150

Mobilgear 600 XP 220 Mobilgear SHC 150

Renolin CLP 220

Renolin Unisyn CLP 150
Renolin CLP 220 Plus

Klüberoil Klübersynth
GEM 1-220 N GEM-4-150 N

STEELO 220 --

Omala 220 Omala HD 150

CARTER EP 220 CARTER SH 150

812 (1146) Copyright © Sandvik

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Service and Repair Manual LH204

Schmierstoffwechsel Vidange
Der erste Ölwechsel sollte nach 200 Betriebsstunden La première vidange devrait effectuée après
erfolgen, danach alle 2000 Betriebsstunden, 200 heures de fonctionnement. Toutes les
spätestens jedoch nach 12 Monaten. vidanges ultérieuses doivent être effectuées après
2000 heures de fonctionnement ou bien, au plus
tard, après 12 mois.
Lubricant change
The ﬁrst oil change should be performed after
200 hours of operation. All subsequent changes
should be performed after 2000 hours of operation
but at the latest after 12 months.

Ölwechsel durchgeführt:
Oil change performed:
Vidange effectuée:
Datum: Betriebsstunden: Unterschrift:
Date: Operating hours: Signature:
Date: Heures de fonctionnement: Signature:

Copyright © Sandvik 813 (1146)

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Service and Repair Manual LH204

814 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

17.8 Drive Pump Operating and Service Instructions

Axial Piston Variable Pump RE 92004-01-B/04.08

Replaces: 01.08
A4VG English

Series 40

Operating Instructions

Copyright © Sandvik 815 (1146)

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

The data speciﬁed above only serve to describe

the product. No statements concerning a certain
condition or suitability for a certain application can
be derived from our information. The information
given does not release the user from the obligation
of own judgment and veriﬁcation. It must be
remembered that our products are subject to a
natural process of wear and aging.

© This document, as well as the data,

speciﬁcations and other information set forth in it,
are the exclusive property of Bosch Rexroth AG.
It may not be reproduced or given to third parties
without its consent.

An example conﬁguration is shown on the title

page. The delivered product may, therefore, differ
from the product which is pictured.

The original operating instructions were created in

the German language.

816 (1146) Copyright © Sandvik

ID: BG00398452 en-US A.001.1 2015-10-19
RE 92004-01-B/04.08 | A4VG Series 40 Bosch Rexroth AG 3/56

Service and Repair Manual LH204

Contents

Contents
1 About this document .....................................................................................................................4
1.1 Related documents ...................................................................................................... 4
1.2 Abbreviations used ...................................................................................................... 5
2 General safety instructions ........................................................................................................6
2.1 Intended use .................................................................................................................. 6
2.2 Improper use.................................................................................................................. 6
2.3 Personnel qualiﬁcations .............................................................................................. 6
2.4 Safety instructions in this document ........................................................................ 7
2.5 Adhere to the following instructions ........................................................................ 7
2.6 Operator's obligations ................................................................................................. 9
3 Delivery contents ...........................................................................................................................10
4 Product description ......................................................................................................................11
4.1 Performance description........................................................................................... 11
4.2 Device description ..................................................................................................... 11
4.3 Bypass function .......................................................................................................... 18
4.4 Product identiﬁcation.................................................................................................20
5 Transport and storage .................................................................................................................21
5.1 Transporting the axial piston unit ............................................................................ 21
5.2 Storing the axial piston unit ......................................................................................22
6 Assembly ........................................................................................................................................... 24
6.1 Unpacking ....................................................................................................................24
6.2 Installation conditions ................................................................................................24
6.3 Installation position.....................................................................................................26
6.4 Assembling the axial piston unit ..............................................................................29
7 Commissioning .............................................................................................................................. 38
7.1 First commissioning ...................................................................................................39
7.2 Recommissioning after downtime .......................................................................... 41
7.3 Running-in phase ........................................................................................................42
8 Operation .......................................................................................................................................... 43
9 Maintenance and repair ............................................................................................................. 44
9.1 Cleaning and care ......................................................................................................44
9.2 Inspection .....................................................................................................................44
9.3 Maintenance ................................................................................................................45
9.4 Repair ............................................................................................................................45
9.5 Spare parts ..................................................................................................................45
10 Decommissioning ......................................................................................................................... 46
11 Disassembly and replacement .............................................................................................. 47
11.1 Required tools .............................................................................................................47
11.2 Preparing disassembly ..............................................................................................47
11.3 Disassembling the axial piston unit ........................................................................47
11.4 Preparing the components for storage or further use........................................47
12 Disposal ............................................................................................................................................. 48
12.1 Environmental protection ..........................................................................................48
13 Extension and conversion ........................................................................................................ 48
14 Troubleshooting............................................................................................................................. 49
14.1 How to proceed for troubleshooting......................................................................49
14.2 Malfunction table ........................................................................................................50
15 Technical data ................................................................................................................................. 52
16 Appendix............................................................................................................................................ 52
16.1 Address directory ......................................................................................................52
17 Index .................................................................................................................................................... 53

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About and
this document Repair Manual LH204

1 About this document

These instructions contain important information on the safe and appropriate
assembly, transport, commissioning, maintenance, disassembly and simple
troubleshooting of the A4VG series 40 axial piston variable pump.
Read these instructions completely, especially chapter
"2 General safety instructions" on page 6, before working with the A4VG axial
piston variable pump.

1.1 Related documents

The A4VG axial piston variable pump is a system component. Also observe the
instructions for the other system components.
Further information on the A4VG axial piston variable pump, its installation and
operation can be found in the Rexroth documents listed in the following table.
Table 1: Related documents
Documentation Contents
Order confirmation Contains the preset technical data of your A4VG axial piston
variable pump.
Installation drawing Contains the outer dimensions, all connections and the hydraulic
circuit diagram for your A4VG axial piston variable pump.
Data sheet RE 92004 Contains the permissible technical data for the A4VG series 40
axial piston variable pump.
Data sheet RE 90220 Describes the requirements on a mineral-oil based hydraulic fluid
for operation with Rexroth axial piston units and assists you in
selecting a hydraulic fluid for your system.
Data sheet RE 90221 Describes the requirements on an environmentally acceptable
hydraulic fluid for operation with Rexroth axial piston units and
assists you in selecting a hydraulic fluid for your system.
Data sheet RE 90223 Contains additional information on the use of Rexroth axial piston
units with HF hydraulic fluids.
Data sheet RE 90300-03-B Contains additional information on the use of Rexroth axial piston
units at low temperatures.

Also observe the generally applicable, legal or otherwise binding regulations of the
European and national legislation and the rules for the prevention of accidents and for
environmental protection applicable in your country.

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About this document

1.2 Abbreviations used

As umbrella term for "A4VG axial piston variable pump", the designation "axial piston
unit" will be used in the following.
Table 2: Abbreviations
Abbreviation Meaning
A4VG Axial piston variable pump, closed circuits
DA Automatic control, hydraulic, speed related
EP Proportional control, electric
HP Proportional control, hydraulic, pilot-pressure related
HW Proportional control, hydraulic, mechanical servo
RE Rexroth document in the English language

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General and Repair
safety instructions Manual LH204

2 General safety instructions

The axial piston unit has been manufactured according to the accepted rules of
current technology. There is, however, still a danger of personal injury or damage to
equipment if the following general safety instructions and the warnings before the
steps contained in these instructions are not complied with.
Read these instructions completely and thoroughly before working with the
axial piston unit.
Keep these instructions in a location where they are accessible to all users
at all times.
Always include the operating instructions when you pass the axial piston unit
on to third parties.

2.1 Intended use

Axial piston units are components in terms of the EU machine directive 98/37/EC
(sub units). Axial piston units are not ready-to-use machines for the purpose of the
EU machine directive. The product/component is exclusively intended for being
integrated in a machine or system or for being assembled with other components to
form a machine or system. The product may only be commissioned after it has been
installed in the machine/system for which it is intended.
The axial piston variable pump generates, controls and regulates a hydraulic-fluid flow.
It is approved for use as a hydraulic pump in hydrostatic drives in closed circuits.
Observe the technical data, operating conditions and performance limits as
specified in the data sheet and order confirmation.

The axial piston unit is not designed for private use.

Intended use includes having read and understood these instructions, especially the
chapter "2 General safety instructions".

2.2 Improper use

The axial piston unit may not be used in explosive environments.
In addition, any use of the axial piston unit other than described in chapter
“2.1 Intended use” is considered to be improper.

2.3 Personnel qualiﬁcations

Assembly, commissioning and operation, disassembly, maintenance and repair
require basic mechanical, hydraulic and electrical knowledge, as well as knowledge
of the appropriate technical terms. For transporting and handling the product,
additional knowledge is necessary with regard to working with a crane and the
corresponding attachment equipment. In order to ensure operating safety, these
activities may therefore only be carried out by qualified personnel or an instructed
person under the direction and supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute
the appropriate safety measures due to their professional training, knowledge, and
experience, as well as their understanding of the relevant conditions pertaining to
the work to be done. Qualified personnel must observe the rules relevant to the
subject area.

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General safety instructions

2.4 Safety instructions in this document

In this manual, there are safety instructions before the steps whenever there is a
danger of personal injury or damage to equipment. The measures described to avoid
these hazards must be observed.
Safety instructions are set out as follows:
SIGNAL WORD! Type of danger!
Consequences
Precautions

• Safety sign: (warning triangle): draws attention to the danger

• Signal word: identiﬁes the degree of the danger
• Type of danger: identiﬁes the type or source of the danger
• Consequences: describes what occurs if the safety instructions
are not complied with
• Precautions: states how the danger can be avoided

The signal words have the following meaning:

Signal word! Application
DANGER! Indicates an imminently hazardous situation which, if not avoided,
will certainly result in death or serious injury.

WARNING! Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION! Indicates a potentially hazardous situation which, if not avoided,

could result in minor or moderate injury or damage to equipment.

If this information is disregarded, the operating procedure

may be impaired.

2.5 Adhere to the following instructions

General instructions • Observe the regulations for accident prevention and environmental protection for
the country where the product is used and at the workplace.
• Only use Rexroth axial piston units in good technical order and condition.
– Inspect the product for obvious defects.
• Do not modify or retroﬁt the axial piston unit.
• Only use the product within the performance range provided in the technical data.
• Persons who assemble, commission, operate, disassemble or maintain Rexroth
products must not consume any alcohol, drugs or pharmaceuticals that may affect
their ability to respond.
• The warranty only applies to the delivered conﬁguration.
• The warranty is rendered void if the product is incorrectly assembled, commis-
sioned or operated, as well as if not used as intended and/or handled improperly.

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safety instructions Manual LH204

• Do not expose the product to any mechanical loads under any circumstances.
Never use the product as a handle or step. Do not place/lay any objects on it.
• The noise emission of axial piston units depends on speed, operating pressure and
installation conditions. The sound pressure level may rise above 70 dBA during
normal operating conditions. This can cause hearing damage.
– Always wear hearing protection while working in the vicinity of the operating axial
piston unit.

• The axial piston unit heats up considerably during operation. The solenoids of the
axial piston unit get so hot during operation that you may burn yourself:
– Allow the axial piston unit to cool down sufﬁciently before touching it.
– Wear heat-resistant protective clothing, e.g. gloves.

During transport • Make certain that the lifting gear has adequate lifting capacity. The weight can be
found in chapter "5 Transport and storage".

During assembly • Before assembling, make sure that all fluids have been completely removed from
the axial piston unit to prevent mixing with the hydraulic fluid used in the system.
• Make sure the relevant system component is not under pressure or voltage before
assembling the product or when connecting and disconnecting plugs. Protect the
system against being switched on.
• Lay cables and lines so that they cannot be damaged and no one can trip
over them.
• Before commissioning, make sure that all hydraulic connections are tight and that
all the connection seals and plugs are installed correctly to ensure that they are
leakproof and fluids and contaminants are prevented from penetrating the product.
• When assembling, provide for absolute cleanliness in order to prevent contami-
nants such as welding beads or metal cuttings from getting into the hydraulic lines
and causing product wear or malfunctions.

During commissioning • Ensure that all electrical and hydraulic connections and ports are occupied or
plugged. Only commission a completely installed product.

During cleaning • Plug all openings with the appropriate protective equipment in order to prevent
detergents from penetrating the system.
• Never use solvents or aggressive detergents. Use only water and, if necessary,
a mild detergent to clean the axial piston unit.
• Do not point the high-pressure cleaner at sensitive components such as, e.g. shaft
seal ring, electrical connections and electrical components.

During maintenance and repair • Perform the prescribed maintenance work at the intervals speciﬁed in the operating
instructions (see chapter "9.3 Maintenance").
• Make sure that no lines, connections or components are disconnected as long as
the system is under pressure. Protect the system against being switched on.

Disposal • Dispose of the product and the hydraulic ﬂuid in accordance with the currently
applicable national regulations in your country.

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Service and Repair Manual LH204

General safety instructions

2.6 Operator's obligations

The operator of the axial piston unit from Rexroth must provide personnel training
on a regular basis regarding the following subjects:
• Observation and use of the operating instructions and the legal regulations.
• Intended use and operation of the axial piston unit.
• Observation of the instructions from the factory security ofﬁces and of the work
instructions from the operator.

Rexroth offers training support for special ﬁelds. You can ﬁnd an overview of the
training contents in the Internet at:
http://www.boschrexroth.de/didactic.

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Delivery contentsand Repair Manual LH204

3 Delivery contents
2

1
3 2
3

Fig. 1: Axial piston unit

Included in the delivery contents are:

• 1 Axial piston unit

The following parts are also assembled on delivery:

• Transport protection for drive shaft end (1).
• Protective covers (2).
• Plastic plugs / locking screws (3).
• Flange cover and ﬁxing screws (4) (optional for versions with through drive).

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Product description

4 Product description

4.1 Performance description

The axial piston variable pump generates, controls and regulates a hydraulic-fluid
flow. It is designed for mobile applications such as construction machinery.
Refer to the data sheet and order confirmation for the technical data, operating
conditions and operating limits of the axial piston unit.

4.2 Device description

The A4VG is an axial piston variable pump with swashplate design for hydrostatic
drives in closed circuits. Flow is proportional to drive speed and displacement. The
flow can be steplessly changed by controlling the swashplate (11).
Closed circuit A hydraulic system is considered to be closed if the hydraulic fluid which flows back
from the consumer is directed directly back to the pump. Here, there is a high-pressure
side and a low-pressure side depending on the load direction (output torque on the
consumer).

Assembly of the axial piston unit

4
3
5
2

11
10 9 8 7

Fig. 2: Assembly of the A4VG series 40

1 Drive shaft 5 Control plate 10 Slipper pad

2 Retaining plate 6 Auxiliary pump 11 Swashplate
3 Stroke piston 7 Suction port
4 Control unit (using the 8 Cylinder
EP as an example here) 9 Piston

For axial piston units with swashplate design, the pistons (9) are arranged axially with
respect to the drive shaft (1). They are guided in the rotating cylinder (8) and support
themselves with the slipper pads (10) on the non-rotating swashplate (11). The drive
shaft (1) and cylinder (8) are connected to one another by means of gearing.

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Functional description
Pump Torque is applied to the drive shaft (1) by an engine. The cylinder (8) turns with the
drive shaft, turning with it the pistons (9). On each rotation, the pistons perform a
stroke movement which is defined by the pitch of the swashplate (11). The slipper
pads (10) are held on and guided along the glide surface of the swashplate by the
retaining plate (2). During a rotation, each piston moves over the bottom and top
dead centers back to its initial position. During this action, the fluid volume defined by
the piston surface and the stroke is fed in or removed through the two control slits in
the control plate (5). On the low-pressure side, fluid flows into the enlarging piston
chamber – in a closed circuit this is supported by the return and boost pressures. At
the same time, on the pressure side the fluid is pushed out of the cylinder chamber
into the hydraulic system by the pistons.
Pressure cut-off The operating pressure is limited by the pressure cut-off.
The pressure cut-off corresponds to a pressure regulator which reduces the pump
capacity once the set specified pressure value is reached so that the set pressure is
maintained but not exceeded.
High-pressure safeguarding The pressure spikes which occur during very rapid swiveling operations as well as the
maximum pressure are safeguarded by the superordinate high-pressure relief valves.
These valves open if the set value is exceeded, thereby depressurizing the low-
pressure side. The fluid quantity remains constant in the closed circuit. The leakage
at the pump and motor is replaced by the auxiliary pump (6).
Auxiliary pump The auxiliary pump continuously supplies a sufficient volume of fluid (boost volume)
from a small tank to the low-pressure side of the closed circuit via a check valve to
replenish the internal leakage of the variable pump and consumer.
Neutral valve The optional neutral valve interrupts the active control pressure and joins the two
(optional) positioning chambers for pressure equalization. The springs in the positioning
chambers move the stroke piston (3) towards the middle position (neutral position).
The reset function is influenced by the current operating pressure and the speed.
Switching off the control pressure and a bypass function for the two positioning
chambers does not ensure that the pump moves to the middle position (neutral
position).
Use an appropriate emergency-off device to ensure that the drive can be brought
to a safe position at any time. The device or system operator is responsible for the
installation of a proper emergency-off device.

The following warning notice applies to all axial piston units with the HD and EP
control units:

CAUTION! The spring return in the control unit is not a security device.
The slide valve of the control unit can be blocked in an undefined position by internal
contamination (impure hydraulic fluid, abrasion or residual contamination from system
components). As a result, the axial piston unit can no longer supply the flow specified
by the operator.
Properly install an emergency-off function to ensure that the driven consumer can
be brought to a safe position (e.g. immediate stop).
Maintain the specified cleanliness level 20/18/15 (< 90 °C) or 19/17/14 in
accordance with ISO 4406.

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Product description

Control The swivel angle of the swashplate (11) is inﬁnitely variable. By changing the swivel
angle, the piston stroke and, therefore, the displacement change. The swivel angle
is controlled hydraulically via the stroke piston (3). The swashplate is mounted for
easy motion in swivel bearings and the neutral position spring centered. Increasing
the swivel angle increases the displacement; reducing the angle results in a corres-
ponding reduction in displacement.
If the swashplate is not swiveled out, the displacement is equal to zero. Various
control units are available depending on requirements.
Additional information on the control devices, such as the circuit diagram or
characteristics, can be found in technical data sheet RE 92004.

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Control units
HW — proportional control, Depending on the swivel angle of the control lever and on the actuating direction
hydraulic, mechanical servo (a or b), the stroke cylinder of the pump is supplied with control pressure via the HW
control unit. Thus, the swashplate – and, therefore, the displacement – are inﬁnitely
adjustable. A different ﬂow direction is associated with each direction of control lever
actuation.

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Product description

HP — proportional control, Depending on the pressure difference of the pilot pressure "pst" in the two control
hydraulic, pilot-pressure related lines (port "Y1" or "Y2"), the stroke cylinder of the pump is supplied with control
pressure via the HP control unit. Thus, the swashplate – and, therefore, the
displacement – are inﬁnitely adjustable. A different ﬂow direction is associated with
each control line.

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EP — proportional control, electric Depending on the preselected current "I" at the two proportional solenoids (a or
b), the stroke cylinder of the pump is supplied with control pressure via the EP
control unit. Thus, the swashplate – and, therefore, the displacement – are inﬁnitely
adjustable. A different ﬂow direction is associated with each proportional solenoid.

Fig. 3: Cut-away view of A4VG with electric proportional control

R T1 T2 PS YST MB

X1 X2 MH G S MA

Fig. 4: Hydraulic circuit diagram of A4VG with electric proportional control

High pressure Suction pressure Control pressure

Low pressure Case drain
pressure

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Product description

DA — automatic control, Depending on the drive speed, the DA control unit generates a pilot pressure which
hydraulic, speed related charges the stroke cylinder of the pump with control pressure via a 4/3-directional
valve, allowing the swashplate – and, therefore, the displacement – to be infinitely
adjusted. Each flow direction is assigned a switching solenoid (a or b) on the 4/3-
directional valve.
You can find details on DA closed loop control in operating instructions "Hydrostatic
travel drive with DA closed loop control" – RE 90 330-01-B and in RE 90 330-03-B
(functional description and project planning notes).

Fig. 3: Cut-away view of A4VG with automatic control, hydraulic, speed related

R T1 T2 PS YST MB
B

X1 X2 MH G S MA

Fig. 4: Hydraulic circuit diagram of A4VG with automatic control, hydraulic, speed related

High pressure Suction pressure Pilot pressure

Low pressure Case drain
pressure

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4.3 Bypass function

For vehicles with hydrostatic travel drive, as long as there is no downstream
mechanical interruption of the drive train (switch to idle/free running), the flow can
be altered using a bypass function in order to tow the vehicle out of the immediate
danger zone.
Turning the corresponding screw allows the hydraulic fluid to flow freely.

2 2

Fig. 5: Activating the bypass function

Activating the To activate the bypass function:

bypass function
1. Switch off the combustion engine.
2. Use an Allen key (WAF 8) to turn the shuttle valve (1) counter-clockwise
to the stop (2).
The bypass function is now active.

Towing speed The maximum towing speed is dependent on the gear ratio in the vehicle and must be
calculated by the vehicle manufacturer. The corresponding ﬂow of Q = 30 l/min must
not be exceeded.
Towing distance The vehicle may only be towed out of the immediate danger zone.

CAUTION! Risk of damage!

Higher towing speeds and longer towing distances result in impermissible heat
generation and insufﬁcient lubrication. This damages the axial piston unit.
Only tow the vehicle out of the immediate danger zone.

CAUTION! Risk of damage!

During and after towing, the axial piston units are hot.
Wear protective clothing.

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Product description

Deactivating the bypass function To deactivate the bypass function:

1. Immediately following towing, switch off the bypass function.
2. Use an Allen key (WAF 8) to turn the shuttle valve (1) clockwise to the stop and
tighten it with a tightening torque of 50 Nm.
The bypass function is no longer active.

CAUTION! Risk of damage!

While towing with the bypass function activated, the closed hydraulic circuit empties
itself. This can result in unintended functions when restarting the travel drive.
Start the travel drive only after completely ﬁlling and air bleeding the hydraulic
circuit (see "7.1 Commissioning").

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4.4 Product identiﬁcation

The axial piston unit can be identiﬁed with the name plate. The following example
shows an A4VG name plate:
1

Rexroth 3
D-89275 Elchingen

13 TYP: A4VG110EP2D0000/40MRND6T21F0000AS00-0
4
MNR: R90XXXXXXX SC: X
12
7202
11 SN: 12345678
5
10 FD: 07W28 Rotation:
n = XXXX min-1 P = XXX kW m: XXX kg 6

Made in Germany

9 7
8
Fig. 6: Name plate A4VG

1 Manufacturer 8 Barcode
2 Internal plant designation 9 Rotational speed
3 Sample category (optional) 10 Production date
4 Direction of rotation (looking at drive 11 Serial number
shaft) — here: clockwise 12 Material number of the
5 Speciﬁed area for test stamp axial piston unit
6 Weight (optional) 13 Ordering code
7 Power

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Transport and storage

5 Transport and storage

5.1 Transporting the axial piston unit

CAUTION! Risk of damage!
Hitting or impulsive forces on the drive shaft can damage the axial piston unit.
Do not hit the coupling or drive shaft of the axial piston unit.
Do not set/place the axial piston unit on the drive shaft.
Details on the permissible axial and radial forces can be found in the data sheet.

Axial piston units can be transported with a fork lift truck or with lifting device.
Make certain that the fork lift truck or lifting device has adequate lifting capacity.

Dimensions and weights Table 3: Dimensions and weights

Size 45 65 85 110 145 175
Weight kg 57 61 80 88 107 120
Width mm The dimensions vary with the unit type. The values applicable to
your axial piston unit can be found in the installation drawing.
Height mm
Depth mm

The weight speciﬁcations may vary depending on the unit type. The exact weight can
be found on the name plate.

Transporting with lifting device

For transporting, the axial piston unit can be connected to a lifting device via a ring
screw or a lifting strap.
Transport with ring screw The drive shaft can be used to transport the axial piston unit as long as only outward
axial forces occur. Thus, you can suspend the axial piston unit from the drive shaft.
To do this, screw a ring screw completely into the thread on the drive shaft. The
size of the thread is stated in the installation drawing.
Make sure that each ring screw can bear the total weight of the axial piston unit
plus approx. 20 %.

You can hoist the axial piston unit as shown in Fig. 7 using the ring screw screwed
into the drive shaft without any risk of damage.

Fig. 7: Fixing the ring screw

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Transport with lifting strap Place the lifting strap around the axial piston unit in such a way that it passes
over neither the attachment parts (e.g. valves) nor such that the axial piston unit is
hung from attachment parts (see Fig. 8).
WARNING! Risk of injury!
During transport with lifting device, the axial piston unit can fall out of the lifting strap
and cause injuries.
Hold the axial piston unit with your hands to prevent it from falling out of the lifting
strap.
Use the widest possible lifting strap.

Fig. 8: Transport with lifting strap

5.2 Storing the axial piston unit

Requirement • The storage areas must be free from corrosive materials and gasses.
• The storage areas must be dry.
• The ideal temperature for storage lies between +5 °C and +20 °C.
• Avoid intense lights.
• Do not stack axial piston units and store them shock-proof.
• For other storage conditions, see Table 4.

Check the axial piston unit monthly to ensure proper storage.

After delivery The axial piston unit is provided ex-works with a corrosion protection packaging
(corrosion protection ﬁlm).
Listed in the following table are the maximum permissible storage times for an
originally packed axial piston unit.
Table 4: Storage time with factory corrosion protection
Standard Long-term
Storage conditions
corrosion protection corrosion protection
Closed, dry room, uniform Maximum 12 months Maximum 24 months
temperature between +5 °C
and +20 °C. Undamaged and
closed corrosion protection
ﬁlm.

The warranty is rendered void if the requirements and storage conditions are not
adhered to or after expiration of the maximum storage time (see Table 4).

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Transport and storage

Procedure after expiration of the maximum storage time:

1. Check the entire axial piston unit for damage and corrosion prior to installation.
2. Check the axial piston unit for proper function and leaks during a test run.
3. Replace the shaft seal ring if the storage time of 24 months is exceeded.

After expiration of the maximum storage time, we recommend that you have the
axial piston unit inspected by your responsible Rexroth Service partner.

In the event of questions regarding spare parts, contact your responsible Rexroth
Service partner or the service department of the manufacture's plant for the axial
piston unit, see chapter "9.5 Spare parts" for further information.

After disassembly If a dismounted axial piston unit is to be stored, it must be conserved against
corrosion for the duration of the storage.
The following instructions only refer to axial piston units which are operated with
a mineral-oil based hydraulic fluid. Other hydraulic fluids require conservation
methods that are specifically designed for them. In such a case, consult with
Rexroth Service (see chapter "9.5 Spare parts" for address).

Rexroth recommends the following procedure:

1. Clean the axial piston unit, see chapter "9.1 Cleaning and care" for further
information.
2. Completely empty the axial piston unit.
3. For storage time up to 12 months: Moisten the inside of the axial piston unit with
mineral oil and ﬁll with approx. 100 ml of mineral oil.
For storage time up to 24 months: Fill the axial piston unit with corrosion
protection VCI 329 (20 ml).
Fill via case drain port T1 or T2,
see chapter "6.4 Assembling the axial piston unit", Fig. 14.
4. Seal all ports airproof.
5. Moisten the unpainted surfaces of the axial piston unit with mineral oil.
6. Package the axial piston unit airproof together with desiccant in corrosion
protection ﬁlm.
7. Store the axial piston unit so that it is protected against jolts. See "Requirement"
in this chapter for further conditions.

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6 Assembly
Prior to assembly, the following documents must be available:
• Installation drawing for the axial piston unit (available from Rexroth),
• Hydraulic circuit diagram for the axial piston unit (in the installation drawing),
• Hydraulic circuit diagram for the system (available from the system manufacturer),
• Order conﬁrmation (contains the preset data of the axial piston unit),
• Data sheet for the axial piston unit (contains the technical data).

6.1 Unpacking
The axial piston unit is delivered in a corrosion protection ﬁlm made of polyethylene
material.
Dispose of the packaging according to the national regulations of your country.

CAUTION! Risk of parts falling out

If the packaging is not opened correctly, parts may fall out and damage the parts or
even result in injury.
Place the packaging on a ﬂat and solid surface.
Only open the packaging from the top.

6.2 Installation conditions

• The installation location and position of the axial piston unit essentially determine
the procedures during installation and commissioning (such as when ﬁlling the axial
piston unit).
• Note that you can expect certain installation positions to affect the control
device. Because of gravity, dead weight and case pressure, minor characteristic
displacements and actuating time changes may occur.

Adhere to all limits specified in the data sheet regarding temperature, viscosity,
cleanliness of the hydraulic fluid.
Make certain that the case of the axial piston unit is filled with hydraulic fluid
during commissioning and operation. This is also to be observed following
relatively long standstill periods as the axial piston unit may empty via the
hydraulic lines.

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Assembly

The case drain fluid in the case interior must be directed to the tank via the
highest case drain port. Use the line size which is appropriate for the port.
Avoid using a check valve in the case drain line (exception: see "Above-tank
installation" in chapter "6.3 Installation position").
To achieve favorable noise values, decouple all connecting lines from all vibration-
capable components (e.g. tank) using elastic elements.
Make certain that the suction line, case drain line, and return line flow into the
tank below the minimum fluid level in all operational states.
. -0,2
0,8 abs

1 2 0
-1 1
0 3 2

1 2

Fig. 9: Suction pressure

1 Absolute pressure gauge

2 Standard pressure gauge

Make certain that a minimum suction pressure of 0.8 bar absolute is present
at port "S" during operation and on cold starts in all installation positions and
installation locations for the axial piston pump, see Fig. 9. See data sheet for
additional values.
Absolute cleanliness is required. The axial piston unit must be installed in a clean
condition. Contamination of the hydraulic ﬂuid can have a considerable impact on
the service life of the axial piston unit.
Do not use any cotton waste or linty cloths for cleaning.
Use suitable liquid detergents to remove lubricants and other difﬁcult-to-remove
pollution. Detergents must not penetrate the hydraulic system.

CAUTION! Risk of damage by air inclusions!

An air pocket in the area near the bearings will damage the axial piston unit.
Make certain that the pump case is completely filled with hydraulic fluid during
commissioning and during operation with the "drive shaft upwards" installation
position.
During commissioning and during operation, the suction line must be filled with
hydraulic fluid.

CAUTION! Risk of damage by hydraulic ﬂuid loss!

With above-tank installation, the case interior may drain via the case drain line
after longer standstill periods (air enters via the shaft seal ring) or via the service
line (gap leakage). The bearings are thus insufﬁciently lubricated when the pump is
restarted.
Therefore, check the hydraulic ﬂuid level in the case interior regularly; if necessary,
recommission.

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6.3 Installation position

The following installation positions are permissible. The shown piping layout illustrates
the basic layout.

Below-tank installation (standard)

Below-tank installation is when the axial piston unit is installed outside of the tank
below the minimum hydraulic ﬂuid level.

Recommended installation positions: 1 and 2.

1 2
L1 SB SB L1
ht min ht min
hmin hmin
amin amin
R
S T2

T1
T1
T2 S

3 L1 SB 4 SB L1
ht min ht min
hmin hmin
amin amin

T2
T1
T1
T2 R

Fig. 10: Below-tank installation with installation positions 1-4

L1 Filling / air bleeding SB Bafﬂe (bafﬂe plate)

R Air bleed port ht min Min. permissible immersion depth

(200 mm)
S Suction port hmin Min. permissible spacing from suction
port to tank base (100 mm)
T1 Case drain port amin Minimum spacing from suction line to
return line (200 mm)
T2 Case drain port

Table 5: Below-tank installation

Installation position Air bleeding Filling
1 (drive shaft, horizontal) R S + T1(L1)
2 (drive shaft, horizontal) L1 S + T2 (L1)
3 (drive shaft, downward) L1 S + T2 (L1)
4 (drive shaft, upward) R + L1 S + T2 (L1)

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Assembly

Above-tank installation
Above-tank installation is when the axial piston unit is installed above the minimum
ﬂuid level of the tank.

CAUTION! Risk of damage to the product!

An air pocket in the area near the bearings will damage the axial piston unit.
Make certain that the pump case is completely filled with hydraulic fluid during
commissioning and during operation with the "drive shaft upwards" installation
position.
Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission. With above-tank installation, the case interior may drain via the
case drain line after longer standstill periods (air enters via the shaft seal ring) or
via the service line (gap leakage). The bearings are thus insufficiently lubricated
when the pump is restarted.
Make certain that the suction line is always filled with hydraulic fluid during
commissioning and operation.

Observe the maximum permissible suction height hSmax = 800 mm.

Recommendation for installation position 8 (drive shaft upwards): A check valve

in the case drain line (opening pressure 0.5 bar) can prevent draining of the case
interior.

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5 6 L1
R L2

S T2
L2
T1
T1

T2 S
hS max SB hS max
SB
ht min
ht min
hmin
hmin amin
amin

7 L2 8
S
L2
T2 T1
T1 T2 R

0,5 bar
hS max
S
SB
SB hS max
ht min
ht min
hmin
amin hmin
amin

Fig. 11: Above-tank installation with installation positions 5-8

L1/2 Filling / air bleeding SB Bafﬂe (bafﬂe plate)

R Air bleed port htmin Min. permissible immersion depth

(200 mm)
S Suction port hmin Min. permissible spacing from suction port
to tank base (100 mm)
T1 Case drain port hSmax Maximum permissible suction height
(800 mm)
T2 Case drain port amin Minimum spacing from suction line to
return line (200 mm)

Table 6: Above-tank installation

Installation position Air bleeding Filling
5 (drive shaft, horizontal) R T1 + (L1)
6 (drive shaft, horizontal) L1 S (L2) + T2 (L1)
7 (drive shaft, downward) L1 + L2 S (L2) + T2 (L1)
8 (drive shaft, upward) R + L2 S (L2) + T2

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Assembly

6.4 Assembling the axial piston unit

DANGER! Systems which are in operation pose a risk of injury!
Working on operating systems poses a danger to life and limb. The work steps
described in this chapter must only be performed on systems which are at a
standstill. Before beginning work:
Ensure that the engine cannot be switched on.
Ensure that all power-transmitting components and connections (electric,
pneumatic, hydraulic) are switched off according to the manufacturer's
instructions and are secured against being switched on again. If possible, remove
the main fuse for the system.
Ensure that the system is completely hydraulically relieved and depressurized.
Please follow the system manufacturer's instructions.
Only qualiﬁed personnel (see chapter "2.3 Personnel qualiﬁcations" on page 6)
are authorized to assemble the axial piston unit.

Preparation
1. Check the delivery contents for completeness and transport damages.
2. Compare the material number and designation (ordering code) with the details in
the order confirmation.
If the material number for the axial piston unit does not correspond to the one in
the order confirmation, contact Rexroth Service for clarification, see chapter
"9.5 Spare parts" for address.

3. Before assembling, completely empty the axial piston unit to prevent mixing with
the hydraulic ﬂuid used in the system.
4. Check the direction of rotation of the axial piston unit (on the name plate) and
make sure that this corresponds to the direction of rotation of the engine.

Fig. 12: Direction of rotation

L Counter-clockwise
R Clockwise

The direction of rotation as speciﬁed on the name plate determines the direction
of rotation of the axial piston unit as viewed on the drive shaft. For information on
the direction of rotation of the engine, please refer to the engine manufacturer's
operating instructions.

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Dimensions
The installation drawing contains the dimensions for all ports on the axial piston unit.
Also observe the instructions provided by the manufacturers of the other components
when selecting the required tools.

General instructions
During assembly (and disassembly) of the axial piston unit, observe the following
general instructions and handling instructions:
• After a short operating time, toothed belts lose a major portion of their pre-tension
and thus cause speed variations and torsional vibrations.
Torsional vibrations may cause leakages on the shaft seal ring or increased rotary
angle accelerations of the rotary group of the driven axial piston unit. Particularly at
risk are diesel drives with a small number of cylinders and low ﬂywheel mass.
• V-belt drives without automatic tensioning device are also critical with regard to
speed variations and torsional vibrations. These can also lead to leakages on the
shaft seal ring.
An automatic tensioning device can lessen the speed variations and vibrations and
thus avoid consequential damage.
• When driving an axial piston unit with the aid of a cardan shaft, vibrations may
occur which may result in leakages on the shaft seal ring of the axial piston unit
depending on the temperature and frequency.

When driving with toothed belts or v-belts, always use an automatic tensioning
device.
Fix the axial piston unit so that the expected forces and torques can be
transferred without any danger.
The permissible axial and radial loading of the drive shaft, the permissible torsional
vibrations, the optimum direction of load force, as well as the limit speeds can be
found in the data sheet.
Observe the permissible radial forces on the drive shaft when driving with radial
loading (belt drives). If necessary, the belt pulley must be separately mounted.

WARNING! Risk of damage!

Hitting or impulsive forces on the drive shaft can damage the axial piston unit.
Do not hit the coupling or drive shaft of the axial piston unit.
Do not set/place the axial piston unit on the drive shaft.
Details on the permissible axial and radial forces can be found in the data sheet.

How to assemble the axial piston unit depends on the connecting elements to the
drive side. The following descriptions explain the installation of the axial piston unit:
• with a coupling
• on a gearbox

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Assembly

Installation with coupling

How to assemble the axial piston unit with a coupling is described in detail in the
following:
1. Assemble the speciﬁed coupling half onto the drive shaft of the axial piston unit
according to the instructions of the coupling manufacturer.
The drive shaft end of the axial piston unit is provided with a threaded bore. Use
this threaded bore to pull the coupling element onto the drive shaft. Refer to the
installation drawing for the dimensions of the threaded bore.

2. Make sure that the installation location is clean and free from dirt and
contaminants.
3. Clamp the coupling hub onto the drive shaft or ensure permanent lubrication
of the drive shaft. This prevents the formation of frictional corrosion and the
associated wear.
4. Transport the axial piston unit to the installation location.
5. Assemble the coupling onto the drive according to the instructions of the
coupling manufacturer.
The axial piston unit must not be tightened down until the coupling has been
correctly assembled.

6. Fix the axial piston unit at the installation location.

7. If necessary, details on the required tools and tightening torques for the ﬁxing
screws are available from the machine or system manufacturer.
– For bell housing installation, check the coupling axial play through the bell
window according to the manufacturer's instructions.
– For ﬂange installation, align the support for the axial piston unit with the drive.

8. When using ﬂexible couplings, check that the drive is free of resonance after
completing the installation.

Installation on a gearbox
How to assemble the axial piston unit on a gearbox is described in detail in the
following:
After installing on a gearbox, the axial piston unit is covered and is difﬁcult to access:
Therefore, before installing, make sure that the centering diameter centers the
axial piston unit (observe tolerances) and that no impermissible axial or radial
forces act on the drive shaft of the axial piston unit (installation length).
Protect the spline of the drive shaft from frictional corrosion by providing
permanent lubrication.

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Completing assembly
1. Remove any mounted transport screws.
2. Remove the transport protection.
The axial piston unit was delivered with protective covers and plastic plugs or
locking screws. These must be removed before connecting. Use appropriate
tools.
3. Make certain that the sealing and functional surfaces are not damaged.

Ports which are intended for connecting lines are provided with plastic plugs or
locking screws, which serve as transport protection. If no connection is made,
these ports must be plugged with a suitable metal locking screw since the plastic
plugs are not pressure-proof.

CAUTION! Risk of damage to persons and property!

Operating the axial piston unit with plastic plugs can result in injuries or damage to
the axial piston unit.
Before commissioning, remove all plastic plugs and replace them with suitable,
pressure-proof, metal locking screws.

1
3 2
3

Fig. 13: Removing transport protection

1 Transport protection for shaft end 4 Flange cover and ﬁxing screws
2 Protective covers (optional for versions with through
drive)
3 Plastic plugs / locking screws

The adjusting screws are protected against unauthorized resetting by means of

protective caps. Removal of the protective caps will void the warranty. If you need
a modiﬁcation of the setting, please contact your responsible Rexroth Service
(address as to chapter "9.5 Spare parts").

4. For versions with through drive, assemble the auxiliary pump according to the
pump manufacturer's instructions.

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Assembly

Hydraulically connecting the axial piston unit

The machine or system manufacturer is responsible for dimensioning the lines. The
axial piston unit must be connected to the rest of the hydraulic system in accordance
with the hydraulic circuit diagram of the machine or system manufacturer.
CAUTION! Damage to the axial piston unit!
When assembling hydraulic lines and hoses under mechanical stress, they are
exposed to additional mechanical forces during operation which reduce the service
life of the axial piston unit and the entire machine or system.
Assemble hydraulic lines and hoses without mechanical stress.

CAUTION! Risk of damage!

Generally, a minimum permissible suction pressure at port "S" is specified for axial
piston pumps in all installation positions. If the pressure at port "S" drops below the
specified values, damage may occur which may lead to destruction of the axial piston
pump.
Make certain that the necessary suction pressure is achieved.
This is influenced by:
– appropriate piping of the suction cross-section
– appropriate pipe diameters
– appropriate position of the tank
– appropriate viscosity of the hydraulic fluid
– filter cartridge in the suction line (regularly check the level of soiling
of the filter cartridge)

Only connect hydraulic lines to the service and function ports.

CAUTION! Wear and malfunctions

The cleanliness of the hydraulic ﬂuid has a considerable impact on the cleanliness
and service life of the hydraulic system. Any contamination of the hydraulic ﬂuid leads
to wear and malfunctions. In particular, contaminants like e.g. welding beads or metal
cuttings in the hydraulic lines may damage the axial piston unit.
Absolute cleanliness is required.
The axial piston unit must be installed in a clean condition.
Make sure that all ports, hydraulic lines and add-on units (e.g. measuring devices)
are clean.
Make sure that no contaminants may penetrate when sealing the ports.
Take care that no detergents enter the hydraulic system.
Do not use any cotton waste or linty cloths for cleaning.
Do not use hemp as sealant under any circumstances.

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Notes on routing the lines Observe the following notes when routing the suction, pressure and case drain lines.
Make certain that the suction line (pipe or hose) is as short and straight as
possible.
The line cross section of the suction line is to be measured so that the minimum
permissible pressure at the suction port is not dropped below and the maximum
permissible pressure is not exceeded.
Observe the air tightness of the junctions and the pressure resistance of the
hose, also with respect to the external air pressure.
With the pressure lines, make certain that the pipes, hoses and connecting
elements are approved for the operating pressure range.
Always route the case drain lines so that the housing is constantly filled with
hydraulic fluid and to ensure that no air gets through the shaft seal ring even
during extended standstill periods. The case internal pressure must not exceed
the limit values listed for the axial piston unit in the data sheet under any operating
conditions. The case drain line in the tank must end up below the minimum fluid
level under all conditions (see chapter "6.3 Installation position").

The ports and fixing threads are designed for the operating pressures specified in
the data sheet. The machine or system manufacturer must ensure that the
connecting elements and lines correspond to the specified operating conditions
(pressure, flow, hydraulic fluid, temperature) with the necessary safety factors.

Procedure To connect the axial piston unit to the hydraulic system:

1. Remove the locking screws at the ports at which the connections are to be made
according to the hydraulic circuit diagram.
2. Use only clean hydraulic lines.
3. Connect the lines according to the hydraulic circuit diagram.
Either pipes or hoses must be connected to all ports according to the installation
drawing and machine or system circuit diagram or the ports plugged using
suitable locking screws.

The installation drawing contains the dimensions for all connections and ports on
the axial piston unit. Also observe the instructions provided by the manufacturers
of the other hydraulic components when selecting the required tools.

4 Make sure
– that the cap nuts are correctly tightened on the fittings and flanges (observe
tightening torques!). Mark all checked fittings using e.g. a permanent marker.
– that the pipes and hose lines and every combination of connecting piece,
coupling or connecting point with hoses or pipes have been inspected by a
technically qualified person for safe working condition.

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Assembly

Port overview
X1 X2
R R
X2 X1
X4 B X3
MH
PS

YST MB
T1 G MAT2
Fa
S A Fe

Fig. 14: Port overview of A4VG series 40

Table 7: Ports for A4VG series 40

Designation Port for Standard Peak State
pressure
(bar) 1)
A, B Service line SAE J518 2) 500 O
Fixing threads DIN 13
S Suction ISO 6149 1,2 O 3)
T1 Tank ISO 6149 10 O 4)
T2 Tank ISO 6149 10 X 4)
R Air bleed ISO 6149 10 X
X1, X2 Control pressure (upstream of oriﬁce) ISO 6149 70 X
X3, X4 5) Stroking chamber pressure ISO 6149 70 X
G Boost pressure ISO 6149 40 X
PS Pilot pressure inlet ISO 6149 40 X
YST Pilot pressure outlet ISO 6149 40 X
MA , M B Measuring pressure A, B ISO 6149 500 X
MH Measuring high pressure ISO 6149 500 X
Fa Boost pressure inlet ISO 6149 40 X 6)
Fe 5) Boost pressure outlet ISO 6149 40 X 6)
1)) Brief pressure spikes may occur depending on the application. Keep this in mind when
selecting measuring devices and armatures.
2) Only dimensions according to SAE J518
3) Plugged for external supply
4) Depending on installation position, either T1 or T2 must be connected
(see also chapter "6.3 Installation position")
5) Optional
6) Must be connected for ﬁltration in the pressure line

O = Must be connected (plugged with plastic plugs on delivery)

X = Plugged (in normal operation)

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Tightening torques The following tightening torques apply:

• Threaded hole in the axial piston unit:
The maximum permissible tightening torques MGmax are the maximum values of the
threaded holes and must not be exceeded. For values, refer to the following table.
• Armatures:
Observe the manufacturer's instruction regarding tightening torques for the used
armatures.
• Fixing screws:
For ﬁxing screws according to DIN 13/ISO 68, we recommend checking the
tightening torque in individual cases as per VDI 2230.
• Locking screws:
For the metal locking screws supplied with the axial piston unit, the required
tightening torques of locking screws MV apply. For values, refer to the following
table.
Table 8: Tightening torques of the threaded holes and locking screws
Max. permissible tightening
Required tightening torque of the
Threaded size of the ports torque of the threaded holes WAF hexagon socket
locking screws MV
MGmax
M10x1 ISO 6149 30 Nm 20 Nm 5 mm
M12x1.5 ISO 6149 50 Nm 35 Nm 6 mm
M14x1.5 ISO 6149 80 Nm 45 Nm 6 mm
M16x1.5 ISO 6149 100 Nm 55 Nm 8 mm
M18x1.5 ISO 6149 140 Nm 70 Nm 8 mm
M22x1.5 ISO 6149 210 Nm 100 Nm 10 mm
M27x2 ISO 6149 330 Nm 170 Nm 12 mm
M33x2 ISO 6149 540 Nm 310 Nm 17 mm
M42x2 ISO 6149 720 Nm 330 Nm 22 mm
M48x2 ISO 6149 900 Nm 420 Nm 22 mm
5/16-24 UNF-2B ISO 11926 10 Nm 7 Nm 1/8 in
3/8-24 UNF-2B ISO 11926 20 Nm 7 Nm 5/32 in
7/16-20 UNF-2B ISO 11926 40 Nm 15 Nm 3/16 in
9/16-18 UNF-2B ISO 11926 80 Nm 25 Nm 1/4 in
3/4-16 UNF-2B ISO 11926 160 Nm 62 Nm 5/16 in
7/8-14 UNF-2B ISO 11926 240 Nm 127 Nm 3/8 in
1 1/16-12 UN-2B ISO 11926 360 Nm 147 Nm 9/16 in
1 5/16-12 UN-2B ISO 11926 540 Nm 198 Nm 5/8 in
1 5/8-12 UN-2B ISO 11926 960 Nm 320 Nm 3/4 in
1 7/8-12 UN-2B ISO 11926 1200 Nm 390 Nm 3/4 in

Risk of mix-ups with The axial piston units are used in application areas with metric as well as with
threaded connections Imperial systems of units.
Both the system of units as well as the size of threaded hole and threaded plug
(e.g. locking screw) must match.
Due to the lack of options for visually detecting differences, there is a risk of mix-ups.

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Assembly

WARNING! Risk of damage to persons and property!

If a threaded plug which is of a different measurement system and size with respect
to the threaded hole is pressurized, the threaded plug may loosen itself or even be
ejected from the hole in a projectile-like manner.
This can result in serious injury and damage to equipment. Hydraulic fluid can be
discharged from this leakage point.
Use the drawings (installation drawing/data sheet) to determine the required
threaded plug for each fitting.
Make certain that there are no mix-ups when assembling armatures, fixing screws
and locking screws.
For all threaded holes, use a threaded plug from the same system of units and of
the correct size.

Electrical connection of axial piston unit

The machine or system manufacturer is responsible for the layout of the electric
control.
For electrically controlled axial piston units, the electric control must be connected
according to the circuit diagram of the system manufacturer.

CAUTION! Short circuit in event of penetrating hydraulic ﬂuid!

Fluid can penetrate the product and cause a short circuit.
Do not install electrically controlled axial piston units in a tank below the tank ﬂuid
level (tank installation).

1. Switch off power supply to the relevant system component.

2. Electrically connect the axial piston unit (12 or 24 V).

Changing plug position If necessary, you can change the position of the plug by turning the solenoid.
To do this, proceed as follows:

2 1. Loosen the fixing nut (1) of the solenoid. To do this, turn the fixing nut (1) one turn
counter-clockwise.
1
2. Turn the solenoid body (2) to the desired position.
3. Retighten the fixing nut. Tightening torque of the fixing nut: 5+1 Nm.

For further details and technical data, e.g. regarding the selection of a suitable mating
connector, please refer to data sheet RE 92004.

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7 Commissioning
WARNING! Danger while working in the danger zone of a machine or system!
It is not permissible to work in the danger zone of a machine or system.
The machine or system must only be operated if safe working is ensured.
Pay attention to and rectify potential danger sources before operating the
machine or system.
Nobody may stand in the danger zone of the machine or system.
The emergency stop button for the machine or system must be within the
operator's reach.
Always follow the instructions of the machine or system manufacturer during
commissioning.

CAUTION! Risk of damage to persons and property!

Commissioning of the axial piston unit requires basic mechanical and hydraulic
knowledge.
Only qualiﬁed personnel (see chapter "2.3 Personnel qualiﬁcations" on page 6)
are authorized to commission the axial piston unit.

WARNING! Risk of toxication and injury!

Contact with hydraulic fluids may damage your health (e.g. eye injuries, skin damage,
toxication upon inhalation).
Always check the lines for wear and damage before each commissioning.
While performing these checks, wear safety gloves, safety glasses and suitable
working clothes.
If hydraulic fluid should, nevertheless, come into contact with your eyes or
penetrate your skin, consult a doctor immediately.
When working with hydraulic fluids, strictly observe the safety instructions
provided by the hydraulic fluid manufacturer.

WARNING! Fire hazard!

Hydraulic fluid is easily flammable.
Keep open flames and ignition sources from the axial piston unit.

CAUTION! Missing seals and connections lead to noncompliance with the protection class!
Fluids and contaminants may penetrate and damage the product.
Prior to assembly, make sure that all seals and connectors are tight.

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Commissioning

7.1 First commissioning

CAUTION! Risk of damage to the product!
Any contamination of the hydraulic ﬂuid leads to wear and malfunctions. In particular,
contaminants like e.g. welding beads or metal cuttings in the hydraulic lines may
damage the axial piston unit.
Ensure utmost cleanliness during commissioning.
Make sure that no contaminants may penetrate when sealing the gauge ports.

CAUTION! Risk of damage to the product!

If you commission the axial piston unit without or with insufficient hydraulic fluid, the
axial piston unit is damaged immediately or even destroyed.
When commissioning or recommissioning a machine or system, make sure that
the case interior and the suction and service lines of the axial piston unit are filled
with hydraulic fluid and remain filled during operation.

When commissioning the axial piston unit, observe the basic safety instructions
and intended use provided in chapter "2 General safety instructions".

Filling the axial piston unit

You will require an approved hydraulic fluid:
The machine or system manufacturer can provide you with precise details on the
hydraulic fluid. Details on minimum requirements for mineral-oil based hydraulic fluids,
environmentally acceptable hydraulic fluids or HF hydraulic fluids for the axial piston
unit are available in the Rexroth publications RE 90220, RE 90221 and RE 90223,
respectively.
To ensure the functional reliability of the axial piston unit, cleanliness level 20/18/15
according to at least ISO 4406 is necessary for the hydraulic fluid. At very high
hydraulic fluid temperatures (+90 °C to maximum +115 °C), cleanliness level 19/17/14
according to at least ISO 4406 is necessary. For permissible temperatures, see the
data sheet.

CAUTION! Risk of damage to the product!

An air pocket in the area near the bearings will damage the axial piston unit.
Make certain that the pump case is completely filled with hydraulic fluid during
commissioning and during operation with the "drive shaft upwards" installation
position.
Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission. With above-tank installation, the case interior may drain via the
case drain line after longer standstill periods (air enters via the shaft seal ring) or
via the service line (gap leakage). The bearings are thus insufficiently lubricated
when the pump is restarted.
Make certain that the suction line is always filled with hydraulic fluid during
commissioning and operation.

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The axial piston unit should be filled with a filling unit (10 μm filter grade).
The axial piston unit must not be operated while it is being filled.

CAUTION! Danger of environmental contamination!

The discharge or spillage of hydraulic fluid while filling the axial piston unit can lead to
environmental pollution and contamination of the groundwater.
When filling and changing the hydraulic fluid, always place a catch pan under the
axial piston unit.
Observe the information in the safety data sheet for the hydraulic fluid and the
specifications provided by the system manufacturer.

1. Fill and air bleed the axial piston unit via the appropriate ports, see chapter
"6.3 Installation position". The hydraulic lines of the system must also be filled.
2. Test the direction of rotation of the engine. To do this, rotate the engine briefly at
the lowest rotational speed (inching). Make sure that direction of rotation of the
axial piston unit matches the details on the name plate, see also chapter "4.4
Product identification", Fig. 6: Name plate.
3. Operate the axial piston pump at a lower speed (starter speed for internal
combustion engines or inching operation for electric engines) until the pump
system is completely filled and bled. To inspect, drain the hydraulic fluid at the
case drain port and wait until it drains without bubbles.
4. Make certain that all ports are either connected to pipes or plugged according
to the general circuit diagram.

Testing the hydraulic ﬂuid supply

The axial piston unit must always have a sufficient supply of hydraulic fluid. For
this reason, the supply of hydraulic fluid must be ensured at the start of the
commissioning process.
When you test the hydraulic fluid supply, constantly monitor the noise development
and check the hydraulic fluid level in the tank. If the axial piston unit becomes louder
(cavitation) or the case drain fluid is discharged with bubbles, this is an indication that
the axial piston unit is not being sufficiently supplied with hydraulic fluid.
Notes on troubleshooting can be found in chapter "14 Troubleshooting".
To test the hydraulic fluid supply:
1. Allow the engine to run at the slowest speed. The axial piston unit must be
operated without load. Pay attention to leakage and noise.
2. Check the axial piston unit’s case drain line during the test. The case drain fluid
should not contain any bubbles.
3. Check the suction pressure at port "S" of the axial piston pump. Refer to data
sheet RE 92004 for the permissible value.
4. Check the case drain pressure at connected port "T1" or "T2". Refer to data sheet
RE 92004 for the permissible value.

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Commissioning

Performing functional test

WARNING! Risk of injury in case of incorrectly connected machine or system!
Any change of the connections will lead to malfunctions (e.g. lift instead of lower) and
thus represents a corresponding danger to persons and equipment.
When connecting hydraulic components, observe the speciﬁed piping according
to the hydraulic circuit diagram of the machine or system manufacturer.

Once you have tested the hydraulic ﬂuid supply, you must perform a functional test
on the machine or system. The functional test should be performed according to the
instructions of the machine or system manufacturer.
The axial piston unit is checked for functional capability before delivery according to
the technical data. During commissioning, it must be ensured that the axial piston unit
was installed in accordance with the design of the machine or system.

Performing ﬂushing cycle

In order to remove foreign bodies from the system, Rexroth recommends a flushing
cycle for the entire system.
During the flushing cycle, the axial piston unit must be operated without load. The
flushing cycle can be performed, e.g. by using an additional flushing unit. Follow
the instructions of the flushing unit's manufacturer for the exact procedure during
the flushing cycle.

7.2 Recommissioning after downtime

Depending on the installation conditions and ambient conditions, changes may occur
in the system which make recommissioning necessary.
Among others, the following criteria may make recommissioning necessary:
• Air in the hydraulic system
• Water in the hydraulic system
• Old hydraulic ﬂuid
• Other contamination

Before recommissioning, proceed as described in chapter

"7.1 First commissioning".

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7.3 Running-in phase

The bearings and sliding surfaces are subject to a running-in phase. The increased
friction at the start of the running-in phase results in increased heat development
which decreases with increasing operating hours. The volumetric and mechanical-
hydraulic efﬁciency increases as well through the conclusion of the running-in phase
of approx. 10 operating hours.

CAUTION! Risk of damage by insufﬁcient viscosity!

The increased temperature of the hydraulic ﬂuid during the running-in phase can
cause the viscosity to drop to impermissible levels.
Monitor the operating temperature during the running-in phase.
Reduce the loading (pressure, rpm) of the axial piston unit if impermissible
operating temperatures and/or viscosities occur.

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Operation

8 Operation
The product is a component which requires no settings or changes during operation.
For this reason, this chapter of the manual does not contain any information on
adjustment options. Only use the product within the performance range provided in
the technical data. The machine or system manufacturer is responsible for the proper
project planning of the hydraulic system and its control.

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9 Maintenance and repair

9.1 Cleaning and care

CAUTION! Damage to the surface caused by solvents and aggressive detergents!
Aggressive detergents may damage the seals on the axial piston unit and cause them
to age faster.
Never use solvents or aggressive detergents.

CAUTION! Damage to the hydraulic system and the seals!

A high-pressure cleaner's water pressure could damage the electronics and the seals
of the axial piston unit.
Do not point the high-pressure cleaner at sensitive components such as, e.g.
shaft seal ring, electrical connections and electrical components.

For cleaning and care of the axial piston unit, observe the following:
Plug all openings with suitable protective caps/devices.
Check whether all seals and plugs of the plug connections are securely seated to
ensure that no moisture can penetrate into the axial piston unit during cleaning.
Use only water and, if necessary, a mild detergent to clean the axial piston unit.
Remove coarse dirt from the outside of the machine and keep sensitive and
important components, such as solenoids, valves and displays, clean.

9.2 Inspection
In order to enable long and reliable operation of the axial piston unit, Rexroth
recommends testing the hydraulic system and axial piston unit on a regular basis
and to document the following operating conditions:

Table 9: Inspection schedule

Task to be carried out Interval
Hydraulic Check level of hydraulic fluid in the tank. daily
system
Check operating temperature weekly
(comparable load state).
Check quality of the hydraulic fluid. yearly or every 2000 h
(which ever occurs
first)
Axial piston unit Check axial piston unit for leakage. daily
Early detection of hydraulic fluid loss can help to
find faults on the machine or system and to rectify
them. For this reason, Rexroth recommends that
the axial piston unit and system always be kept in
a clean condition.
Check axial piston unit for noise development. daily
Check fixing elements for tight seating. monthly
All fixing elements have to be checked when the
system is switched off, depressurized and cooled
down.

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Maintenance and repair

9.3 Maintenance
The axial piston unit is low maintenance when used as intended.
The service life of the axial piston unit is heavily dependent on the quality of the
hydraulic fluid. For this reason, we recommend changing the hydraulic fluid at least
once per year or every 2000 operating hours (which ever occurs first) or having it
analyzed by the hydraulic fluid manufacturer or a laboratory to determine its suitability
for further use.
The service life of the axial piston unit is limited by the service life of the built-in
bearings. The service life can be requested from the responsible Rexroth Service
partner, see "9.5 Spare parts" for address. Based on these details, a maintenance
period is to be determined by the system manufacturer for the replacement of the
bearings and included in the maintenance schedule of the hydraulic system.

9.4 Repair
Rexroth offers a comprehensive range of services for the repair of Rexroth axial
piston units.
Repairs of the axial piston unit may only be performed by authorized, skilled and
instructed staff.
Only use genuine spare parts from Rexroth for repairing the Rexroth axial
piston units.

Tested and pre-assembled original Rexroth assembly groups allow for successful
repair requiring only little time.

9.5 Spare parts

CAUTION! Damage to persons and property due to faulty spare parts!
Spare parts that do not meet the technical requirements speciﬁed by Rexroth may
cause damage to persons or property.
Use only original spare parts from Rexroth.

The list of spare parts for axial piston units are order speciﬁc. When ordering spare
parts, please quote the material and serial number of the axial piston unit as well as
the material numbers of the spare parts.
Please address all questions regarding spare parts to your responsible Rexroth
Service partner or the service department of the manufacture's plant for the axial
piston unit.

Bosch Rexroth AG
Glockeraustraße 2
89275 Elchingen, Germany
Phone +49 (0) 73 08 82-0
Fax +49 (0) 73 08 72 74
service.elchingen@boschrexroth.de

For the addresses of foreign subsidiaries, please refer to

www.boschrexroth.com/addresses

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10 Decommissioning
The axial piston unit is a component that does not require decommissioning. For this
reason, this chapter of the manual does not contain any information
For details about how to disassemble or replace your axial piston unit, please refer to
chapter "11 Disassembly and replacement".

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Decommissioning

11 Disassembly and replacement

11.1 Required tools

Disassembly can be performed with standard tools. No special tools are necessary.

11.2 Preparing disassembly

WARNING! Risk of injuries due to disassembling under pressure and voltage!
If you do not switch off pressure and power supply before disassembling the product,
you may get injured or the device or system components may be damaged.
Make sure that the relevant system components are not under pressure or
voltage.

1. Decommission the entire system as described in the overall manual for the
machine or system.
2. Relieve the hydraulic system according to the instructions of the machine or
system manufacturer.

11.3 Disassembling the axial piston unit

Proceed as follows to disassemble the axial piston unit:
1. Make sure that the hydraulic system is depressurized.
2. Check whether the axial piston unit has cooled down far enough so that it can be
disassembled without danger.
3. Place a catch pan under the axial piston unit to collect any hydraulic ﬂuid that may
escape.

CAUTION! Danger of environmental contamination!

4. Loosen the lines and collect the escaping hydraulic ﬂuid in the collector.
5. Remove the axial piston unit. Use an appropriate lifting device.
6. Completely empty the axial piston unit.
7. Plug all openings.

11.4 Preparing the components for storage or further use

Proceed as described in section "5.2 Storing the axial piston unit".

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replacement Manual LH204

12 Disposal
Observe the following points when disposing of the axial piston unit:
1. Completely empty the axial piston unit.
2. Dispose of the hydraulic ﬂuid according to the national regulations of your
country.
3. Disassemble the axial piston unit into its individual parts and properly recycle
these parts.
4. Separate parts by:
– Cast parts
– Steel
– Nonferrous metal
– Electronic waste
– Plastic
– Seals.

12.1 Environmental protection

Careless disposal of the axial piston unit, the hydraulic fluid and the packaging
material could lead to pollution of the environment.
Therefore, dispose of the axial piston unit, the hydraulic fluid and the packaging
material in accordance with the currently applicable regulations in your country.
Dispose of hydraulic fluid residues according to the applicable safety data sheets
for these hydraulic fluids.

13 Extension and conversion

Do not convert the axial piston unit. This also includes a modiﬁcation of the adjusting
screws.
The warranty from Rexroth only applies to the delivered conﬁguration. In case of
extensions or conversions, the warranty will become void.

Adjusting screws are protected against unauthorized resetting by means of

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Disposal / Extensions and conversion

14 Troubleshooting
The following tables may assist you in troubleshooting. The tables make no claim for
completeness.
In practical use, problems which are not listed here may also occur.

14.1 How to proceed for troubleshooting

Always act systematically and targeted, even under pressure of time. Random and
imprudent disassembly and readjustment of settings might result in the inability to
ascertain the original error cause.
First obtain a general overview of how your product works in conjunction with the
entire system.
Try to ﬁnd out whether the product has worked properly in conjunction with the
entire system before the troubles occurred ﬁrst.
Try to determine any changes of the entire system in which the product is
integrated.
– Were there any changes to the product's operating conditions or operating
range?
– Were there any changes or repair works on the complete system
(machine / system, electrics, control) or on the product? If yes, which?
– Was the product or machine used as intended?
– How did the malfunction appear?

Try to get a clear idea of the error cause. Directly ask the (machine) operator.
If you cannot rectify the error, contact one of the contact addresses which can be
found under:
www.boschrexroth.com/addresses.

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14.2 Malfunction table

Table 11: Malfunction table for variable pumps
Fault Possible cause Remedy
Unusual noises Drive speed too high. Machine or system manufacturer.

Wrong direction of rotation. Ensure correct direction of rotation.

Insufficient suction conditions, e.g. air in the Machine or system manufacturer (e.g. optimize
suction line, insufficient diameter of the suction inlet conditions, use suitable hydraulic fluid).
line, viscosity of the hydraulic fluid too high,
Completely air bleed axial piston unit, fill suction
suction height too high, suction pressure too low,
line with hydraulic fluid.
contaminants in the suction line.
Remove contaminants from the suction line.

Improper fixing of the axial piston unit. Check fixing of the axial piston unit according
to the specifications of the machine or system
manufacturer. Observe tightening torques.
Improper fixing of the attachment parts, e.g. Fix attachment parts according to the
coupling and hydraulic lines. information provided by the coupling or armature
manufacturer.
Pressure-relief valve of the axial piston unit Air bleed axial piston unit
(boost pressure, high pressure, pressure cut-off). Check viscosity of the hydraulic fluid
Contact Rexroth Service.
Mechanical damage to the axial piston unit. Exchange axial piston unit, contact Rexroth
Service.
No or insufficient flow Faulty mechanical drive (e.g. defective coupling). Machine or system manufacturer.

Drive speed too low. Machine or system manufacturer.

Hydraulic fluid not in optimum viscosity range. Use suitable hydraulic fluid (machine or system
manufacturer).
External control of the control device defective. Check external control (machine or system
manufacturer).
Insufficient pilot pressure. Check pilot pressure, contact Rexroth Service.

Malfunction of the control device or controller Contact Rexroth Service.

of the axial piston unit.
Wear of axial piston unit. Exchange axial piston unit, contact Rexroth
Service.
Mechanical damage to the axial piston unit. Exchange axial piston unit, contact Rexroth
Service.

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Troubleshooting

Table 11: Malfunction table for variable pumps

Fault Possible cause Remedy
No or insufﬁcient pressure Faulty mechanical drive (e.g. defective coupling). Machine or system manufacturer.

Drive power too low. Machine or system manufacturer.

Malfunction of the control device or controller of Contact Rexroth Service.

the axial piston unit.
Wear of axial piston unit. Exchange axial piston unit, contact Rexroth
Service.
Mechanical damage to the axial piston unit. Exchange axial piston unit, contact Rexroth
Service.
Output unit defective (e.g. hydraulic motor or Machine or system manufacturer.
cylinder).
Pressure/flow fluctuations Axial piston unit not or insufficiently air bled. Completely air bleed axial piston unit.

Hydraulic fluid temperature too high Excessive inlet temperature at the axial piston unit. Machine or system manufacturer: inspect system,
e.g malfunction of the cooler, insufficient hydraulic
fluid in the tank.
Malfunction of the pressure control valves (e.g. Contact Rexroth Service.
high-pressure relief valve, pressure cut-off,
pressure control).
Malfunction of the flushing valve. Contact Rexroth Service.

Wear of axial piston unit. Exchange axial piston unit, contact Rexroth
Service.

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15 Technical data
The technical data of your axial piston unit can be found in
data sheet "RE 92004".
The data sheet can be found on the Internet under
www.boschrexroth.com/axial-piston-pumps
The preset technical data of your axial piston unit can be found in the
order conﬁrmation.

16 Appendix

16.1 Address directory

For the addresses of foreign subsidiaries, please refer to
www.boschrexroth.com/addresses

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Technical data / Appendix

17 Index
A F
Abbreviations 5 Filling 39
Above-tank installation 27 Flushing cycle 41
Address directory 52 Functional description
Assembly 24 Auxiliary pump 12
Completing 32 Closed circuit 11
General instructions 30 Control 13
On a gearbox 31 High-pressure safeguarding 12
Preparation 29 Pressure cut-off 12
With coupling 31 Pump 12
Axial piston unit Functional test 40
Assembling 29
Conversion 48 G
Dimensions 30
General instructions 30
Disassembling 47
Filling 39
Installation conditions 24 H
Installation position 26 Hydraulic ﬂuid 39
Maintaining 45
Maintenance 44 I
Repair 45 Inspection 44
Replacing 47 Installation conditions 24
Spare parts 45 Installation position 26
Storing 22 Above-tank installation 27
Unpacking 24 Below-tank installation 26
Weight 21
L
B
Lifting device 21
Below-tank installation 26
Bypass function
Activating the
M
bypass function 18 Maintenance 44, 45
Deactivating the bypass function Malfunction table 50
19
Towing distance 18 N
Towing speed 18 Name plate 20
Neutral valve 12
C
Changing solenoid position 37 O
Connecting Options
Electrical 37 Neutral valve 12
Hydraulic 33
R
D Related documents 4
Decommissioning 46, 47 Repair 45
Dimensions 30
Disassembling 47
S
Performing 47
Preparing 47 Safety instructions 7
Disposal 48 Spare parts 45

E T
Environmental protection 48 Technical data 52
Troubleshooting 49
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Service and Repair Manual LH204

Bosch Rexroth AG
Hydraulics
Axial Piston Units
Glockeraustraße 2
89275 Elchingen, Germany
Phone +49 (0) 73 08 - 82 0
Fax +49 (0) 73 08 - 72 74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm

Printed in Germany
RE 92004-01-B/04.08
Replaces: 01.08
English

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Service and Repair Manual LH204

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ID: BG00398452 en-US A.001.1 2015-10-19
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ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204
Service-Manual
Sandvik
17.10 Axle Service Manual
LH204-LH204M (72.7097.3; 72.7098.3)

Edition 10/2013
Copyright © Sandvik Original
983 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual
Service Manual LH204

Allrightsreserved

Service and Repair Manual LH204

Copyright ©
Reproduction and dissemination of this documentation in
any form (photocopying, printing or electronic
Firma Kessler & Co. GmbH &Co.KG dissemination) is prohibited without the written
permission of Kessler & Co. GmbH & Co.KG.

This documentation is not subject to revision. We
reserve the right to make modifications without prior
notice.

Table of contents axle 72.7097.3g

Chapter 1 Important remarks See the special table of contents of chapter 1

Chapter 2 Lubrication intervals and maintenance instructions See the special table of contents of chapter 2

Chapter 3 General instructions for correct assembly and disassembly See the special table of contents of chapter 3

Chapter 3 Service tools See the special table of contents of chapter 3

Chapter 4 Assembly differential and carrier assembly See below

Chapter 5 Assembly hub assembly See below

Chapter 6 Assembly planetary gear drive See below

Chapter 7 Assembly service brake See the special table of contents of chapter 7

Chapter 6
Assembly planetary gear drive
6.1 Planetary gear drive
6.1.1 Assembly of the ring gear and ring
gear carrier
Assembly of the sun gear
Chapter 7 6.1.2 Assembly of the planetary gear
Assembly of service brake 6.1.3 Adjustment of the axial clearance
Assembly of the planetary housing
See the special table of contents of chapter 7 6.1.4 Disassembly of planetary gear

Chapter 4 Chapter 5
Assembly of differential and carrier assembly Assembly of hub assembly

4.0.1 Adjustment / Checking of contact pattern of 5.1.6 Assembly of the spacer ring
bevel gear teeth 5.3 Hub assembly steer drive axle
4.0.2 Securing / Removing of the striking nut 5.3.1 Assembly of the drive axle onto
4.4 Drive assembly D108 the axle housing
4.4.1 Adjustment of the drive pinion distance 5.3.2 Assembly of hub assembly
4.4.2 Assembly of the drive pinion bearing 5.5.108 Prepare and mount wheel hub
4.4.3 Assembly of the drive pinion bearing 5.7.1 Adjusting of wheel bearings
4.1.3 Assembly of the differential Wheel safety nut
4.1.4-108 Dimension / Adjustment of backlash 5.8.1 Assembly of the face seal
4.2.3 Assembly of the ring gear support bolt 5.8.2 Assembly of the face seal
5.8.3 Assembly of the face seal
5.8.4 Assembly of the face seal

Table of contents axle 72.7098.3h

Chapter 1 Important remarks See the special table of contents of chapter 1

Chapter 2 Lubrication intervals and maintenance instructions See the special table of contents of chapter 2

Chapter 3 General instructions for correct assembly and disassembly See the special table of contents of chapter 3

Chapter 3 Service tools See the special table of contents of chapter 3

Chapter 4 Assembly differential and carrier assembly See below

Chapter 5 Assembly hub assembly See below

Chapter 6 Assembly planetary gear drive See below

Chapter 7 Assembly service brake See the special table of contents of chapter 7

Chapter 4 Chapter 5
Assembly of differential and carrier assembly Assembly of hub assembly
4.0.1 Adjustment / Checking of the contact pattern 5.1.6 Assembly of the spacer ring
of bevel gear teeth 5.3 Hub assembly steer drive axle
4.0.2 Securing / Removing of the striking nut 5.3.1 Assembly of the drive axle onto
4.1 Drive assembly A51 the axle housing
4.1.1-51 Adjustment of the drive pinion distance 5.3.2 Assembly of hub assembly
4.1.2 Assembly of the drive pinion bearing 5.5.108 Prepare and mount wheel hub
4.1.3 Assembly of the differential 5.7.1 Adjusting of wheel bearings
4.1.4-51 Dimension / Adjustment of backlash Wheel safety nut
5.8.1 Assembly of the face seal
5.8.2 Assembly of the face seal
5.8.3 Assembly of the face seal
5.8.4 Assembly of the face seal

Table of contents of important remarks

Important remarks ................................................................................................................................. 2

Checking of screw connections, safety devices and corrosion ......................................................................................................................................................... 2

Check of brakes ............................................................................................................................................................................................................................... 2

Service instructions ......................................................................................................................................................................................................................... 2

Instructions for ordering spare parts ....................................................................................................... 3

Warranty ......................................................................................................................................................................................................................................... 3

Ordering .......................................................................................................................................................................................................................................... 3

Identification plate .......................................................................................................................................................................................................................... 3

Necessary to contact Kessler & Co. GmbH & Co.KG. ....................................................................................................................................................................... 4

Important remarks
Checking of screw connections, safety devices and corrosion

For safety reasons, the vehicle operator must check and service all important screw connections and safety
devices at regular intervals.

Wheel nuts

Nuts of axle mounting bolts

Tightening screws on housing joints will break the Loctite bond, which means the
screws have to be reinstalled!
Secure screw connections and joints in accordance with specifications; in case of
doubt, contact Kessler & Co. GmbH & Co.KG.
Corrosion and cracks on support components (e.g. the axle spindle) are not
permissible for reasons of operational safety and leaks.
Supporting components with cracks must be replaced!

Check of brakes
Inspect regularly as well as wear of brake system parts.

In case of signs of excessive heating, consult a brake specialist or the

manufacturer.

Service instructions
Assembly and disassembly may be carried out only by trained specialists.

Repair welding is permissible only after consulting

Kessler Co GmbH & Co.KG!

To remove the axle from the vehicle, read the instructions in the vehicle
manufacture’s manuals. The following descriptions assume that the axle has
been removed and mounted on a jig for further processing.

Always comply with the safety regulations for your country. There is no guarantee
that they correspond to the instructions in this manual.

Instructions for ordering spare parts

Warranty
Kessler & Co. GmbH & Co.KG provides a warranty only for the original delivered replacement parts.
Please be aware that the use of other than original replacement parts can have a negative effect on the
design properties of the axle, therefore making it unsafe.

Kessler & Co. GmbH & Co.KG will not be liable for any damages resulting from the use of other than original
replacement parts and accessories. Please be aware that special production and delivery specifications
exist for proprietary or third-party parts and that our replacement parts comply with the most recent
standards as prescribed by law.

Ordering

When ordering original Kessler replacement parts, please provide the following information:

1. Part number (no. on the installation drawing) see identification plate

2. Serial see identification plate

3. Vehicle manufacturer

4. Name of the spare part

5. Spare part number (drawing or DIN no.)

6. Quantity

7. Mode of dispatch

Identification plate

¾ The position of the identification plate on the axle is mostly next to the drive assemly on the
same side as the oil fill plug.

¾ Close to the identification plate, you will also find the axle serial number of the axle stamped into
the axle housing.

Necessary to contact Kessler & Co. GmbH & Co.KG.

¾ In case of questions, contact Kessler Co. GmbH & Co.KG.

¾ In case of major repairs or overhaul, it is advisable to send the entire axle to

Kessler & Co. GmbH & Co.KG.

All rights reserved Copyright © Sandvik 993
Revised (1146)
05/06/2013
ID: BG00398452 en-US A.001.1 2015-10-19
Chapter
Service and Repair Manualspecifications and maintenance instructions
Lubrication LH204 2
2.43

Table of contents of lubrication intervals and

maintenance instructions

Table of contents of lubrication intervals and maintenance instructions ................................................. 1

General lubrication instructions .............................................................................................................. 2

Filling quantities .............................................................................................................................................................................. 2

Oil change ....................................................................................................................................................................................... 2

Lubrication for storage.................................................................................................................................................................... 2

Prior to operation of the axle .......................................................................................................................................................... 2

Lubrication points ........................................................................................................................................................................... 3

Lubrication points ........................................................................................................................................................................... 4

Lubricants – lubrication intervals .................................................................................................................................................... 5

Recommendable hypoid transmission oil grades ............................................................................................................................ 6

General maintenance instructions .................................................................................................................................................. 7

Chapter
Service and Lubrication
Repair Manual
specifications and maintenance instructions LH204 2
2.43

General lubrication instructions

Filling quantities

¾ Result from the overflow at the oil level checking screws.

Oil change

1. Make sure vehicle is level.

2. Drain oil only when warm. Clean all lubricating points prior to opening screws. Open oil drain
plugs on the axle. Open the drain holes on the carrier assembly, on the wheel assemblies.
On the hub assemblies, the drain plug should be turned downward.

3. Drain oil.

4. Re-insert oil drain plugs.

5. Open oil filler screws and oil level checking screw on the axle.

6. Fill with oil.

7. Watch all level at checking screw (to prevent overflow).

Wait several minutes.
If the oil level drops, add oil until the oil level is constant.

Lubrication for storage

¾ Replace breather with a screw plug with a sealant to prevent oil from leaking and water from
entering the transmission.

¾ Fill the components completely with oil, the same applies to wet disc brakes.

¾ Bare surfaces (e.g.: rim surface, flange mounts,…) must be additionally treated with corrosion
protection.

Prior to operation of the axle

¾ Remove storage oil and fill axle with suitable oil to correct oil level.

¾ Check sealing contact surfaces for corrosion. Check the seals immediately after start-up for
leakage and renew them if leaking.

¾ The corrosion protection on bare surfaces (e.g. rim surface, flange mounts,…) must be
completely removed when the transmission is put into operation.

¾ Check supporting components for corrosion, especially if stored for several years.
The rim face must be cleaned from rust or grease in order to secure a correct friction tight with
the rim and to prevent loosening of the rim

Chapter
Service and Repair Manualspecifications and maintenance instructions
Lubrication LH204 2
2.43

Lubrication points

Axle 72.7097.3g

I = Oil fill plug II Oil level control plug III = Oil drain plug

Axle must to be oil filled by the customer according to WN58601.

Chapter
Service and Lubrication
Repair Manual
specifications and maintenance instructions LH204 2
2.43

Lubrication points

Axle 72.7098.3h

I = Oil fill plug II Oil level control plug III = Oil drain plug

Axle must to be oil filled by the customer according to WN58601.

Chapter
Service and Repair Manualspecifications and maintenance instructions
Lubrication LH204 2
2.43

Lubricants – lubrication intervals

Axle and gearbox

operation
Lubrications
Lubrication point at ambient Lubricant Remarks
intervals 1.)
(outside)
temperatures
at
after every least
125 1000
hours hours 1x per
year

Hypoid – gear oil per

MIL-L2105B/API GL5
Hypoid – gear oil in multi
range characteristic per
Drive assembly MIL-L2105 C/D/API GL5
Oil change
Wheel hub SAE 90
planetary gear from -10°C to +30°C or
drive multi grade oils
Check oil level at
Wheel bearing oil SAE 75 W – 90 control points
continuously under -10°C or
lubricated SAE 75 W - 85 monthly
SAE 140
continuously above +30°C or
multi grade oils

dependent on:
external cooled - tank volume
Wet disc brake See chapter – 7-
oil change - cooling system
- operation conditions
(hours = hours of operation)

1. The value which is reached first always applies.

Chapter
Service and Lubrication
Repair Manual
specifications and maintenance instructions LH204 2
2.43

Recommendable hypoid transmission oil grades

Recommendable hypoid gear oils corresponding

MIL-L 2105 B/API GL 5

alternatively

MIL – L 2105 C/API GL 5

¾ ARAL - Gearoil Hyp 90

¾ AVIA - Gearoil Hypoid 90 EP

¾ BP - Multiuse - Gearoil EP SAE 90

¾ ELF - Tranself Typ B 90 / Tranself Typ B 80 W - 90

¾ ESSO - Gearoil GX - D 90

¾ FINA - Pontonic MP SAE 85 W - 90

¾ FUCHS - Renogear Hypoid 90

¾ MOBIL - HD 90 - A

¾ SHELL - Spirax MB 90 / HD 90

¾ TEXACO - Multigear EP SAE 85 W / 90

¾ AGIP - Rotra MP / Rotra MP DB

Never use „normal“ transmission oils!

Chapter
Service and Repair Manualspecifications and maintenance instructions
Lubrication LH204 2
2.43

General maintenance instructions

Inspection and
Remarks Maintenance intervals 1.)
maintenance points

at
after after after after after every every
least
50 100 1000 4000 8000 500 1000
1x per
hours hours hours hours hours hours hours
year

Inspect, if necessary
Wheel bearing
readjust wheel bearing

Check and tighten with a
torque wrench
Wheel nuts (after tire change after 50km
and 200km)
Screws/drive flange
Nuts/axle mounting Inspect and tighten
(check for tight fit)
bolts
Wet disc brake - spring
load design
Inspect lining wear

Bolted connections
(for example: Check occasionally
drive assembly)

Seals Check occasionally monthly

(hours = Hours of operation)

1. The value which is reached first always applies.

General assembly /disassembly instructions

Section
Service and Repair Manual
service tools
LH204 3

Chapter
Service and Repair Manual
Tools LH204
3.41

Table of contents of general assembly /

disassembly instructions and service tools

Table of contents of general assembly / disassembly instructions and service tools................................. 1

Assembly / disassembly .......................................................................................................................... 2

Disassembly .................................................................................................................................................................................... 2

Assembly ......................................................................................................................................................................................... 2

Use of Loctite and auxiliary materials ..................................................................................................... 3

Handling of Loctite and auxiliary materials .................................................................................................................................... 3

Use of Loctite and auxiliary materials ............................................................................................................................................. 4

Use of Loctite and auxiliary materials on hub assembly ................................................................................................................. 5

Use of Loctite and auxiliary materials of wet disc brake spring load design .................................................................................. 6

Use of Loctite and auxiliary material of drive assembly axle 72.7097.3 ......................................................................................... 7

Use of Loctite and auxiliary material of drive assembly axle 72.7098.3 ......................................................................................... 8

Units ...................................................................................................................................................... 9
Comparison table for units .............................................................................................................................................................. 9

Names of the legal units ................................................................................................................................................................. 9

Torques (Nm) ....................................................................................................................................... 10

Metric coarse-pitch thread............................................................................................................................................................ 10

Metric fine-pitch thread ................................................................................................................................................................ 10

Approximate value of screwing of screw plugs ............................................................................................................................. 11

Wheel nut with thrust collar (for rims with centering).................................................................................................................. 11

Adjusting nut or slotted nuts on drive flanges, gearwheels, etc. .................................................................................................. 11

Tools .................................................................................................................................................... 12
Tools of the hub assembly ............................................................................................................................................................. 12

Tools of the wet disc brake spring load design ............................................................................................................................. 12

Tools for drive assembly axle 72.7097.3 ....................................................................................................................................... 13

Tools for drive assembly axle 72.7098.3 ....................................................................................................................................... 14

Assembly / disassembly
3

Chapter
Service and Tools
Repair Manual LH204
3.41

Assembly / disassembly
Disassembly
Disassembly is the same as the assembly procedure in reverse order.

Prior to disassembly, drain oil and check for abrasion.

Mark matching parts prior to disassembly.

Never use force to separate parts, which fit tightly together. Use suitable pull-off devices for
disassembly of roller bearings, drive flanges and similar components.

For proper disassembly, the use of special tools is recommended.

Prior to disassembly, destruction of bearings and other components, always check whether
the disassembly, destruction of bearings and other components is necessary.

In case of disassembly, always replace worn shaft seal rings, O-rings and roller bearings, if
necessary.

Clean or replace corroded components.

Do not place parts on dirty surface.

Assembly
Clean parts prior to installing.

Bearing points, which run in oil, must be oiled prior to assembly.

During the assembly of radial seal rings, make sure there is sufficient overlapping in the
housing bore. Make sure the radial seal ring is seated flatly. Do not allow Loctite to get onto
the sealing lips!

Radial seal rings, especially sealing rings with a dust lip, must be filled with grease.

The axle shafts must forcibly mounted (they must slide).

Sealing ring-running surfaces on flanges, shafts, etc. must be protected with Castrol Rustilo
DWX 32 prior to installing.

Fill with oil after assembly!

Assembly / disassembly
3

Chapter
Service and Repair Manual
Tools LH204
3.41

Use of Loctite and auxiliary materials

Handling of Loctite and auxiliary materials

¾ The surfaces or screws and threaded holes to be bonded must be free of paint, grease and oil
(washed). The Loctite adhesives used harden under following conditions:
¾ Exclusion of air
¾ Metal-to-metal contact
¾ Warmth

¾ Only a very short time (5 - 10 min.) can be allowed between pre-assembly and controlled
tightening.

¾ Parts prepared with Loctite for bonding can be exposed to air for up to 1 hour.
Exception: Parts made of non-ferrous metal may be exposed only for 1 minute.

¾ Connections subjected to mechanical loads must be allowed to harden at least 24 hours.

¾ Quantity of Loctite:

For screws: For parting surfaces:

1 bead Make sure parts are coated
sufficiently!

Figure1

Assembly / disassembly
3

Chapter
Service and Tools
Repair Manual LH204
3.41

Use of Loctite and auxiliary materials

Type colour Use

1. LOCTITE 243 blue Lightly locked screws

262 red Middle locked screws

270 green Highly locked screws

270 green Increased coefficient of friction in contact surfaces

510 orange Surface gasket

572 white Special gasket

638 light-green Gluing with big width of slit

5926 and
blue Surface gasket
209 125

2. EPPLE 33 grey Surface gasket

3. DIRKO grey Elastic gasket

Figure 2

Assembly / disassembly
3

Chapter
Service and Repair Manual
Tools LH204
3.41

Use of Loctite and auxiliary materials on hub assembly

Securing parts Connection Loctite Auxiliary material

Spacer ring Contact surface 572 -

in planetary-
Grommet 270 -
housing

Thrust ring in axle spindle 270 -

Hexagon-socket- in planetary-
262 -
head cap screw housing
Ring gear
Screws 270
retainer

Wheel safety nut see chapter 5 page 5.7.1

Figure 3

Figure 4

Assembly / disassembly
3

Chapter
Service and Tools
Repair Manual LH204
3.41

Use of Loctite and auxiliary materials of wet disc brake spring load design

Securing parts Connection Loctite Auxiliary material

Thread bushing thread 262 -

Figure 5

Figure 6

Assembly / disassembly
3

Chapter
Service and Repair Manual
Tools LH204
3.41

Use of Loctite and auxiliary material of drive assembly axle 72.7097.3

Securing parts Connection Loctite Auxiliary material

Epple 33 alternative
Drive flange Nut surface -
Dirko grey

Drive pinion Nut thread assembly paste with MoS2

Differential carrier Contact surface 209125 and 5926

Ring gear Contact surface 270 -

Bearing flange screw 262 -

Support bolt cap for support bolt 270 -

Bolt thread / Epple 33 alternative

Support bolt -
nut surface Dirko grey

Differential carrier Screw 262 -

Differential housing Screw 262 -

Ring gear Screw 262 -

Retaining clip Screw 262 -

Lock plate /
Screw 262 -
setting ring

Figure 7

Figure 8

Assembly / disassembly
3

Chapter
Service and Tools
Repair Manual LH204
3.41

Use of Loctite and auxiliary material of drive assembly axle 72.7098.3

Securing parts Connection Loctite Auxiliary material

Epple 33 alternative
Drive flange Nut surface -
Dirko grey

Drive pinion Nut thread assembly paste with MoS2

Differential carrier Contact surface 209125 and 5926

Ring gear Contact surface 270 -

Drive housing Screw 262 -

Differential housing Screw 262 -

Retaining clip Screw 262 -

Lock plate /
Screw 262 -
setting ring
Figure 9

Figure 10

Assembly / disassembly
3

Chapter
Service and Repair Manual
Tools LH204
3.41

Units
Comparison table for units

25,40 mm = 1 in (inch)

1 mm = 0,0394 in (inch)

1 kg (kilogram) = 2,205 lb (pounds)

9.81.Nm (1 kpm) = 7,233 lbf x ft (pound force foot)

1,356 Nm (0,138 kpm) = 1 lbf x ft (pound force foot)

1 bar (1,02kp/cm2) = 14,5 psi (pound force per square inch lbf/in2)

0,070 bar (0,071 kp/cm2) = 1 psi (lbf/in2)

1 Litre = 0,264 Gallon (Imp.)

4,456 Litre = 1 Gallon (Imp.)

1 Litre = 0,220 Gallon (US)

3,785 Litre = 1 Gallon (US)

1609,344 m = 1Mile (land mile)

0°C (Celsius) = +32°F (Fahrenheit)

1°C (Celsius) = +33,8°F (Fahrenheit)

0°C (Celsius) = 273,15 Kelvin

1°C (Celsius) = 274,15 Kelvin

Figure 11

Names of the legal units

Term Symbol New Old Conversion Comment

Nm (Newton T (Nm) =
Torque T kpm 1 kpm = 9,81 Nm
meter) F (N) x r (m)
Moment of Nm (Newton M (Nm) =
M kpm 1 kpm = 9,81 Nm
force meter) F (N) x r (m)
2
1,02 atü = 1,02 kp/cm =
Pressure pü bar atü
1 bar = 750 torr
Figure 12

Assembly / disassembly
3

Chapter
Service and Tools
Repair Manual LH204
3.41

Torques (Nm)
= 0,14

Metric coarse-pitch thread

screw nut screw nut screw nut

thread
8.8 8 10.9 10 12.9 12
M4 3,0 4,4 5,1
M5 5,9 8,7 10
M6 10 15 18
M8 25 36 43
M 10 49 72 84
M 12 85 125 145
M 14 135 200 235
M 16 210 310 365
M 18 300 430 500
M 20 425 610 710
M 22 580 830 970
M 24 730 1050 1220
M 27 1100 1550 1800
M 30 1450 2100 2450
Figure 13

Metric fine-pitch thread

screw nut screw nut screw nut

thread
8.8 8 10.9 10 12.9 12
M8x1 27 39 46
M 10 x 1 55 81 95
M 10 x 1,25 52 76 90
M 12 x 1,25 93 135 160
M 12 x 1,5 89 130 155
M 14 x 1,5 145 215 255
M 16 x 1,5 225 330 390
M 18 x 1,5 340 485 570
M 20 x 1,5 475 680 790
M 22 x 1,5 650 920 1050
Figure 14

Assembly / disassembly
3

Chapter
Service and Repair Manual
Tools LH204
3.41

Approximate value of screwing of screw plugs

tightening torques tightening torques

thread (approximate value) (screw plugs with o-ring)
M14x1,5 ca. 45 -
M16x1,5 ca. 60 -
M24x1,5 ca. 120 -
M30x1,5 ca. 160 -
M42x1,5 ca. 260
Figure 15

Wheel nut with thrust collar

(for rims with centering)

dimensions Phosphorus darkened

M 22 x 1,5 650 Nm
Figure 16

Adjusting nut or slotted nuts on drive flanges, gearwheels, etc.

thread Tightening torque

d1 (mm) (Nm)

M 45 x 1,5 850
Figure 17

Figure 18

Assembly / disassembly
3

Chapter
Service and Tools
Repair Manual LH204
3.41

Tools
When ordering maintenance tools, pleas provide

¾ Part number (no. of installation drawing number)

and

¾ Serial number see identification plate

(The illustrations are not binding for the design)

Tools of the hub assembly

Spanner for wheel safety nut

Order number 031.209.0-3

Figure 19

Tools of the wet disc brake spring load design

Installation tool for face seal

Order number 056.010.0-4

Figure 20

Assembly / disassembly
3

Chapter
Service and Repair Manual
Tools LH204
3.41

Tools for drive assembly axle 72.7097.3

Seal ring sleeve driver

Order number 031.147.0-3

(seal ring dimension 90x130x12)

Figure 21

Spanner for thread rings (Differential bearing)

Order Number 031.167.0-3 (thread M112)

Order Number 031.168.0-3 (thread M132)

Figure 22

Assembly / disassembly
3

Chapter
Service and Tools
Repair Manual LH204
3.41

Tools for drive assembly axle 72.7098.3

Seal ring sleeve driver

Order number 031.067.0-3

(seal ring dimension 90x120x12)

Figure 23

Spanner for thread rings (Differential bearing)

Order Number 031.168.0-3 (thread M132)

Figure 24

Section
Service and Repair
Assembly Manual
of differential and carrier assembly LH204

1016 (1146)
All rights reserved Copyright © Sandvik
Service
Revised 23/07/2012
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service and
Assembly Repair Manualand carrier assembly
of differential LH204
4.0.1

Adjustment of contact pattern of bevel gear teeth

NOTICE: search for the production numbers

of the drive pinion and the ring gear.

It is only possible to achieve an optimal contact pattern, if:

Version 1 Version 2

Production numbers No production numbers

x on drive pinion (marked on the end face) x on drive pinion
x on ring gear (marked on the face of the ring x on ring gear
gear)

¾ The production numbers of the drive pinion ¾ indiscriminate use of drive pinion and ring
and ring gear must match – gear is possible –
only mount in pairs! no pairing necessary!

page 1 of 2
Section
Service and Repair
Assembly Manual
of differential and carrier assembly LH204
4.0.1

Checking the contact pattern of the gear teeth

1. Coat the teeth of the ring gear with spotting paste and then
turn it several times until you can see pressure marks from
the drive pinion on the coated teeth.

2. Check the contact pattern / pressure marks and compare

them with the illustrations in the following table.

3. If necessary, make adjustments as shown in the table.

Optimal contact pattern

Contact pattern too high.

Reduce drive pinion distance by

correcting thickness of the
adjustment disk.
Adjust the backlash by moving the
ring gear out.

Contact pattern too low.

Increase drive pinion distance by

correcting thickness of the
adjustment disk.
Adjust the backlash by moving the
ring gear in.

page 2 of 2
Section
Service and
Assembly Repair Manualand carrier assembly
of differential LH204
4.0.2
4
Securing of the striking nut

NOTICE: The brim of the striking nut has to

be sheared only along the slot flank and the
corner has to be bended on the slot ground.

Figure 1
Figure 2

Use of Loctite and other operating supplies

Striking nut at drive flange

¾ In thread: assembly paste with MoS2 (exception: through drive pinion see enumeration 2)
¾ Front side contact surface: sealing compound (Epple 33 or equivalent)

Striking nut at through drive nut

¾ On thread: Loctite 262

Striking nut at gear wheels, bearings and so on

¾ On thread: assembly paste with MoS2

page 1 of 2
Section
Service and Repair
Assembly Manual
of differential and carrier assembly LH204
4.0.2
4
Removing of the striking nut

NOTICE: Bend away the nose completely.

Otherwise, the thread of the of the drive
pinion will be damaged.
Screw the nut off.

1. The secured striking nut.

Figure 3

2. Applying an applicable flat chisel in the slot

between drive pinion and securing and removing
the securing of the striking nut.

Figure 4

3. The loosened striking nut.

Figure 5

page 2 of 2
Section
Service
Drive and Repair
assembly D Manual
108 LH204
4.4

All rights reserved Copyright © Sandvik
Service
1021 (1146)
Revised 23/07/2012
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service and Repair
Assembly Manual
of differential and carrier assembly A108 LH204
4.4.1
4
Adjustment of drive pinion distance

To obtain the proper tooth flank contact, adjust the

axial position of the drive pinion with the thickness
of the adjustment disc. The necessary thickness of
the adjustment disc for first time assembly can be
obtained by measurement (see calculation
example).

The final thickness of the adjustment disc can be

fixed during the checking of gear meshing at the
assembled drive assembly (see page „Checking
the contact pattern of the gear teeth” – 4.0.1).

Drive assembly A108

theoretical S 3

theoretical B 33,5

theoretical C 13,5

B = Measured width of the taper roller bearing.

C = Distance measured from the contact surface

of the adjustment disc to the contact surface of the
pininion housing.

Page 1 of 2
Section
Service and
Assembly Repair Manualand carrier assembly A108
of differential LH204
4.4.1
4
Version 1 Version 2

Adjustment dimension – A Adjustment dimension – A

Deviating dimension (defined Without inscription on the

during production) is marked on locating face of the pinion, the
the locating face of the pinion. deviating from the specified
It indicates the deviation from dimension is 0.
the specified dimension.

Example: Deviation +0,1 Example: Deviation 0

Sample calculations (dimensions in mm):

Theortical Required
Measured Tolerance at Measured
adjust ment adjustment
disk
bearing width drive pinion distance Calculation of the required adjustment disk thickness disk
B A C
thickness thickness

Version 1

C= deviation
theortical deviation deviation required
from
13,45 disk - from + from +
theoretical
= disk
mm thickness bearing pinion thickness
dimension

deviation
deviation from the deviation from the
from the
theoretical theoretical
theoretical
dimension dimension
dimension 3,0 + 0,10 - 0,10 + 0,05 = 3,05
-0,10 +0,10 -0,05

Version 1

C= deviation
theortical deviation deviation required
from
13,55 disk + from + from -
theoretical
= disk
mm thickness bearing pinion thickness
dimension

deviation
deviation from the deviation from the
from the
theoretical theoretical
theoretical
dimension dimension
dimension 3,0 + 0,20 + 0,15 - 0,05 = 3,30
-0,20 -0,15 +0,05

Version 1

C= deviation
theortical deviation deviation required
from
13,40 disk - from - from +
theoretical
= disk
mm thickness bearing pinion thickness
dimension

deviation
deviation from the deviation from the
from the
theoretical theoretical
theoretical
dimension dimension
dimension 3,0 - 0,1 - 0,1 + 0,1 = 2,90
+0,10 +0,10 -0,10

Fit corresponding disk and outer rings of the taper roller bearings.

Page 2 of 2
Section
Service and Repair
Assembly of theManual
drive pinion bearing LH204
4.4.2

1. Heat the cylindrical roller bearing inner ring to

about 100°C and install it on the stud of the drive
pinion. (Drive on completely after it cools). Press
the cylindrical roller bearing outer ring into the
differential carrier.

2. Insert the two outer rings of the taper roller

bearings into the pinion housing.

3. Calculate the thickness C of the spacer bushing.

a. Place the two inner rings of the taper roller

bearings in their outer rings. Measure A or C.

b. Measure the dimension B of the taper roller

bearing.

c. Thickness of spacer bushing C= A – B.

4. Heat the drive pinion side taper roller bearing to

about 100°C and install it on the drive pinion
shaft. (Drive on completely after it cools):

5. Install the spacer bushing on the pinion shaft.

6. Install the pinion housing onto the drive pinion.

Heat the taper roller bearing inner ring at
undersize to about 100°C and install it with a
tube onto the drive pinion shaft.

7. Install the drive flange onto the drive pinion

shaft. Tighten the safety nut by turning the
pinion housing according sheet 3.5. For
tightening, place the drive pinion in a vice using
soft jaws or clamp the drive flange with the fork
support in the vice.

1024 (1146)
All rights reserved Copyright © Sandvik
Service
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service and
Assembly of Repair Manual
the drive pinion bearing LH204
4.4.3

8. Measure the roll resistance of the bearings by using a torque wrench. If the measured value is
not prescribed 1,0 to 1,5 Nm, adjust the resistance by modification of the thickness of the spacer
bushing. After arriving at the adjustment of the bearing, back - off the safety nut and draw off the
drive flange.

9. Install the radial seal ring with Loctite 572 applied into the pinion housing. Place the O-ring into
the slot of the pinion housing and install the pinion housing on the differential carrier. Fill the
radial seal ring with bearing grease. Fit the carrier of the parking brake (if present) on the pinion
housing resp. the differential carrier and tighten the screws. Slip on the drive flange, together
with the dimensionally stable assembled disk, screw on the safety nut with sealing compound
between the contact surfaces. Tighten the safety nut according to sheet 3.5. Lock the nut by
striking the nut brim into the slot of the pinion.

Before assembly all of the bevel gears and the

thrust rings should be well oiled.

1. Place one differential side gear with the side

gear thrust washer in the differential case.

2. Install the spider with differential gears and

differential pinion thrust washers in the
differential case.

3. Install the other differential side gear and side

gear thrust washer. (At variants with Nospin
differential install the Nospin diff. instead of the
differential gears)

4. Install the other half of the differential case over

the assembly and observe the alignment marks,
tighten the differential case bolts. Secure with
Loctite 262.

5. Check that all differential pinions can rotate

easily.

6. Coat the contact surface of the ring gear with

Loctite 270 and install the ring gear on the
differential case by tapping lightly on the
circumference. Tighten the ring gear bolts.
Secure with Loctite 262.

7. Heat the two taper roller bearings to about 100°C

and install them by using a sleeve.

1026
Al rights(1146)
reserved Copyright © Sandvik
Service
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service of
Assembly anddifferential
Repair Manual
and carrier assembly A108 LH204
4.1.4-108

Dimension of backlash

Place the differential with the outer rings of the taper

roller bearings on the differential carrier which is in a
vertical position, with mounted drive pinion.

Mount the differential straps and align them with the

thread rings.

During this operation be careful of the alignment

marks on the differential straps with respect to the
differential carrier. (Do not interchange the
differential straps.)

Backlash
Version 1 Version 2

The smallest admissible value at the closest Is no value marked on the circumference of the ring
place is marked on the circumference of the ring gear, the backlash is depend on the ring gear
gear. diameter (see following table).

Drive Ring gear

Backlash
description diameter
Drive
< 390 0,35
assembly 108

Page 1 of 2
Section
Service and of
Assembly Repair Manual and carrier assembly A108
differential LH204
4.1.4-108

Adjustment of backlash

Version 1 Version 2
Tighten the differential strap bolts by hand. By a
counter rotation of the two thread rings, move the
differential until the backlash is correct.

Therefore hold the drive pinion at the drive flange.

Check the backlash by careful forwards and
rearwards rotating the ring gear. Use a dial indicator.

Measure the backlash during a few times turns of

the ring gear and if need correct the backlash,
because of the smallest admissible value at the
closest place must not be fall short of.

Adjust the backlash according to sheet “Adjustment

of contact pattern of bevel gear teeth”.
Tighten screws of the differential straps and lock
them with Loctite 262.

Adjust the bearing roll resistance trough tightening

of the thread rings. Set value: 2,0 to 3,0 Nm. Check
the value with a torque wrench. If measuring at the
drive pinion / drive flange, take the ratio of the bevel
wheel set into account.

Screw the lock plates for the thread rings and

secure with Loctite 270, if need bend the lock plates.

Page 2 of 2
Section
Serviceyand
Assembl of Repair Manual
the ring gear support bolt LH204
4.2.3

1. Glue the cap with Loctite 270 onto the support bolt.

2. Coat the support bolt with Epple 33.

3. Screw the support bolt with cap by hand to contact to the ring gear, without exerting pressure.

4. Screw the counter nut onto the support bolt.

5. Turn back the support bolt max. 15°.

6. Tighten the counter nut, during this operation the support bolt must not move.

In tightened condition the clearance between the ring gear surface and the contact surface of the
support bolt amounts about 0,1 mm.

Attention:

The support bolt has to be sealed again when adjusting timely.

All rights reserved Copyright © Sandvik
Service
1029 (1146)
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service and Repair
Assembly Manual
of differential and carrier assembly LH204

1030 (1146)
All rights reserved Copyright © Sandvik
Service
Revised 27/07/2012
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service and
Assembly Repair Manualand carrier assembly
of differential LH204
4.0.1

Adjustment of contact pattern of bevel gear teeth

NOTICE: search for the production numbers

of the drive pinion and the ring gear.

It is only possible to achieve an optimal contact pattern, if:

Version 1 Version 2

Production numbers No production numbers

x on drive pinion (marked on the end face) x on drive pinion
x on ring gear (marked on the face of the ring x on ring gear
gear)

¾ The production numbers of the drive pinion ¾ indiscriminate use of drive pinion and ring
and ring gear must match – gear is possible –
only mount in pairs! no pairing necessary!

page 1 of 2
Section
Service and Repair
Assembly Manual
of differential and carrier assembly LH204
4.0.1

Checking the contact pattern of the gear teeth

1. Coat the teeth of the ring gear with spotting paste and then
turn it several times until you can see pressure marks from
the drive pinion on the coated teeth.

2. Check the contact pattern / pressure marks and compare

them with the illustrations in the following table.

3. If necessary, make adjustments as shown in the table.

Optimal contact pattern

Contact pattern too high.

Reduce drive pinion distance by

correcting thickness of the
adjustment disk.
Adjust the backlash by moving the
ring gear out.

Contact pattern too low.

Increase drive pinion distance by

correcting thickness of the
adjustment disk.
Adjust the backlash by moving the
ring gear in.

page 2 of 2
Section
Service and
Assembly Repair Manualand carrier assembly
of differential LH204
4.0.2
4
Securing of the striking nut

NOTICE: The brim of the striking nut has to

be sheared only along the slot flank and the
corner has to be bended on the slot ground.

Figure 1
Figure 2

Use of Loctite and other operating supplies

Striking nut at drive flange

¾ In thread: assembly paste with MoS2 (exception: through drive pinion see enumeration 2)
¾ Front side contact surface: sealing compound (Epple 33 or equivalent)

Striking nut at through drive nut

¾ On thread: Loctite 262

Striking nut at gear wheels, bearings and so on

¾ On thread: assembly paste with MoS2

page 1 of 2
Section
Service and Repair
Assembly Manual
of differential and carrier assembly LH204
4.0.2
4
Removing of the striking nut

NOTICE: Bend away the nose completely.

Otherwise, the thread of the of the drive
pinion will be damaged.
Screw the nut off.

1. The secured striking nut.

Figure 3

2. Applying an applicable flat chisel in the slot

between drive pinion and securing and removing
the securing of the striking nut.

Figure 4

3. The loosened striking nut.

Figure 5

page 2 of 2
Section
Service
Drive and Repair
assembly A Manual
51 LH204
4.1

All rights reserved Copyright © Sandvik
Service
1035 (1146)
Revised 27/07/2012
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service and Repair
Assembly Manual
of differential and carrier assembly A51 LH204
4.1.1-51
4
Adjustment of drive pinion distance

To obtain the proper tooth flank contact, adjust the

The final thickness of the adjustment disc can be

Drive assembly A 51 fixed during the checking of gear meshing at the
assembled drive assembly (see page „Checking
theoretical S 3
the contact pattern of the gear teeth” – 4.0.1).
theoretical B 38

B = Measured width of the taper roller bearing.

Page 1 of 2
Section
Service and
Assembly Repair Manualand carrier assembly A51
of differential LH204
4.1.1-51
4
Version 1 Version 2

Adjustment dimension – A Adjustment dimension – A

Deviating dimension (defined Without inscription on the

during production) is marked on locating face of the pinion, the
the locating face of the pinion. deviating from the specified
It indicates the deviation from dimension is 0.
the specified dimension.

Example: Deviation +0,1 Example: Deviation 0

Sample calculations (dimensions in mm):

Theor. Required
adjustment Measured bearing Tolerance at drive adjustment
Calculation of the required adjustment disk thickness
disk width pinion disk
thickness thickness

Version 1

theor. deviation deviation

required disk
disk - from + from =
thickness
thickness bearing pinion

deviation from the deviation from the

theoretical dimension theoretical dimension
3,0 - 0,15 + 0,15 = 3,0
+0,15 -0,15
Version 1

theor. deviation deviation

required disk
disk + from + from =
thickness
thickness bearing pinion

deviation from the deviation from the

theoretical dimension theoretical dimension
3,0 + 0,20 + 0,15 = 3,35
-0,20 -0,15
Version 1

theor. deviation deviation

required disk
disk - from - from =
thickness
thickness bearing pinion

deviation from the deviation from the

theoretical dimension theoretical dimension
3,0 - 0,1 - 0,1 = 2,8
+0,10 +0,10

Fit corresponding disc and outer rings of the taper roller bearings.

Page 2 of 2
Section
Service and Repair
Assembly Manual
of drive pinion bearing LH204
4.1.2

1. Insert the two outer rings of the taper roller

bearings into the differential carrier.

2. Calculate the thickness C of the spacer ring.

a. Place the two inner rings of the taper

roller bearings in their outer rings.
Measure A.

b. Measure the dimension B of the drive

pinion.

c. Thickness of the spacer ring C = A - B.

3. Heat the drive pinion side taper roller bearing to

about 100°C and install it on the drive pinion
shaft. (Drive on completely after it cools).

4. Install the spacer ring on the pinion shaft.

5. Install the drive pinion into the differential

carrier. Heat the taper roller bearing inner ring at
undersize to about 100°C and install it with a
tube onto the drive pinion shaft.

6. Install the drive flange onto the drive pinion

shaft. Tighten the safety nut according sheet
3.5. For tightening fix the differential carrier and
block the drive flange.

7. Measure the resistance of the bearings by using a torque wrench. If the measured value is not
the prescribed 0,8 to 1,2 Nm, adjust the resistance by modification of the thickness of the spacer
ring. After arriving at the adjustment of the bearing, back - off the safety nut and draw off the
drive flange.

8. Install the radial seal ring with Loctite 572 applied. Fill the radial seal ring with bearing grease.
Fit the carrier of the parking brake (if present) on the differential carrier and tighten the screws.
Slip on the drive flange together with the dimesionelly stable assembled disk (if present), screw
on the safety nut with sealing compound between the contact surfaces. Tighten the safety nut
according sheet 3.5. Lock the nut by striking the nut brim into the slot of the pinion.

Before assembly all of the bevel gears and the

thrust rings should be well oiled.

1. Place one differential side gear with the side

gear thrust washer in the differential case.

2. Install the spider with differential gears and

differential pinion thrust washers in the
differential case.

3. Install the other differential side gear and side

gear thrust washer. (At variants with Nospin
differential install the Nospin diff. instead of the
differential gears)

4. Install the other half of the differential case over

the assembly and observe the alignment marks,
tighten the differential case bolts. Secure with
Loctite 262.

5. Check that all differential pinions can rotate

easily.

6. Coat the contact surface of the ring gear with

Loctite 270 and install the ring gear on the
differential case by tapping lightly on the
circumference. Tighten the ring gear bolts.
Secure with Loctite 262.

7. Heat the two taper roller bearings to about 100°C

and install them by using a sleeve.

Al rights reserved Copyright © Sandvik
Service
1039 (1146)
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Service and Repair
Assembly Manual
of differential and carrier assembly A51 LH204
4.1.4-51

Dimension of backlash

Place the differential with the outer rings of the taper

roller bearings on the differential carrier which is in a
vertical position, with mounted drive pinion.

Mount the differential straps and align them with the

thread rings.

During this operation be careful of the alignment

marks on the differential straps with respect to the
differential carrier. (Do not interchange the
differential straps.)

Backlash
Version 1 Version 2

Drive Ring gear

Backlash
description diameter
Drive
< 325 0,30
assembly 51

Page 1 of 2
Section
Service and
Assembly Repair Manualand carrier assembly A51
of differential LH204
4.1.4-51

Adjustment of backlash

Version 1 Version 2
Tighten the differential strap bolts by hand. By a
counter rotation of the two thread rings, move the
differential until the backlash is correct.

Therefore hold the drive pinion at the drive flange.

Check the backlash by careful forwards and
rearwards rotating the ring gear. Use a dial indicator.

Measure the backlash during a few times turns of

the ring gear and if need correct the backlash,
because of the smallest admissible value at the
closest place must not be fall short of.

Adjust the backlash according to sheet “Adjustment

of contact pattern of bevel gear teeth”.
Tighten screws of the differential straps and lock
them with Loctite 262.

Adjust the bearing roll resistance trough tightening

of the thread rings. Set value: 2,0 to 3,0 Nm. Check
the value with a torque wrench. If measuring at the
drive pinion / drive flange, take the ratio of the bevel
wheel set into account.

Screw the lock plates for the thread rings and

secure with Loctite 270, if need bend the lock plates.

Page 2 of 2
Section
Service and Repair
Assembly of theManual
hub assembly LH204

Hub assembly drive axle

Coat the seat of the spacer ring on the steering knuckle resp. axle spindle with Loctite 572. Heat the
spacer ring to about 100°C and push it by gently striking onto the steering knuckle resp. axle
spindle. (The steering knuckle resp. axle spindle must be free of corrosion). Oil the seal ring tread
onto the spacer ring.

1044 (1146)
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Service
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Serviceyand
Assembl of Repair Manual
the drive axle onto the axle housing LH204
5.3.1

Coat the contact surface of the axle housing with Epple 33 (at version through drive with Loctite
510), and mount the complete drive assembly. The axle housing being placed in a horizontal
position, secure the screws with Loctite 262. Mount the pol wheel (if present) onto the axle shaft
(see 5.1.7).

Engage the axle shaft into the axle housing.

The axle shaft should be able to be moved easily (by hand) in the toothing of the differential side
gear.

At version with differential lock on the outside (D 71/ D 109) the differential lock must always be
actuated when assemble or disassemble the axle shaft.

Direction:

Actuating of the differential lock is necessary to prevent the sliding sleeve to drop out of the shifter
fork into the axle housing when pulling out or sliding in the axle shaft. This would entail disassembly
of the axle.

Assembly of the spacer ring (if present) see sheet 5.1.6.

Install the brake onto the axle spindle, be careful of the brake control position and bolt it.
At version with disc brake install the brake carrier (if present), then mount the wheel hub with the
brake disc, and after this operation install the brake.

Prepare and mount the wheel hub see chapter 5.5.

Attention: Hold the wheel hub with a hoist until the outer bearing with ring gear carrier is
mounted.

Assembly of the planetary gear drive see chapter 6.

At version with drum brake mount the brake drum.

Assembly of the ABS - sensor installation (if present) see 5.1.7.

Attention:

At version with ABS resp. ABS - preparation (the pol wheel is mounted onto the axle shaft) the
thrust ring of the sun gear in the axle spindle must be dismounted for disassembly the axle shaft.

1046 (1146)
All rights reserved Copyright © Sandvik
Service
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Serviceand
Prepare and Repair
mount Manual
wheel hub LH204
5.5.108
5
Prepare wheel hub

Install the wheel studs (1), standout (A) according to the axle installation drawing. Attach shims (6),
screw on the nuts (7) and tighten them by hand.

Press in outer rings of taper roller bearings (2 + 3), do not hammer them. Install inner ring of taper
roller bearing (3).

Install the face seal (4) into the wheel hub (5) (see 5.8).

Mount wheel hub

Push the pre - assembled wheel hub (5) parallel onto the axle spindle resp. steering knuckle.

Tightening torque of the wheel safety nut

axle series readjustment used bearings (Nm) new bearings (Nm)

D 71 400 460

Adjusting of wheel bearings

The temperature of the axle parts should be between 0 and + 20°C at the bearing adjustment.

Screw on the wheel safety nut (Loctite- resp. Molykote- using see below) and adjust and secure as
following described:

Screw on the wheel safety nut and tighten it with a 1,5 - 2 times higher tightening torque than the
finish tightening torque. During the tightening, turn the wheel hub a few times and knock it with a
plastic hammer. Untighten the wheel safety nut (about 180° back rotation), then tighten the wheel
safety nut to the tightening torque according to the table. At this tightening turn the wheel hub also a
few times, if there is no possibility for securing, the wheel safety nut has to be turned back to next
securing possibility.

Designation Version Security/ Remarks

Shaft nut with cheese Cheese head screw

head screw Loctite 270

1. Seal ring

2. Rubber toric ring

3. Housing retaining lip

4. Housing ramp

5. Seal ring housing

Seal rings, torics, and housings must be clean and free of any oil film, dust, or other foreign matter.
Use a solvent that evaporates quickly, leaves no residue, and is compatible with the rubber toric
rings. The recommended solvent is Isopropanol. Ring and housings should be wiped with a solvent
- soaked lint free cloth or paper towel.

After all components have been wiped clean, the torics should be installed on the metal seal rings
so that they rest in the radius on the tail of the metal ring. Insure that the torics are not twisted by
inspecting the mold flash line on the outside diameter of the toric for true circumferential tracking
around the seal. Twisted torics will cause nonuniform face load that can result in leckage of lubricant
and pumping of debris past the toric. If a twist is apparent, it can be eliminated by gently pulling a
section of the toric radially away from the metal seal ring and letting it “snap” back. Repeating this in
several places around the ring will eliminate any twist in the toric ring.

Put the toric ring (2) on The toric ring (2) can twist if it is not Eliminate toric twist by gently
seal ring (1), at the wet all around during installation or if pulling a section of the toric (2)
bottom of the seal ring there are burrs of fins on the retaining rapidly away from the seal ring (1)
ramp (7) and against lip (3) of the housing (5). and letting it “snap” back.
the retaining lip (8).

Place the installation tool around the seal ring and dip the seal ring into a pan of Isopropanol solvent
to lubricate the toric ring. It is essential to lubricate the toric with Isopropanol so that the toric will slip
past the housing retaining lip and seal uniformly in the housing nose radius. Insufficient lubrication
can cause poor seal performance due to nonuniform loading (twisted torics or cocked seals). Use of
solvents other than Isopropanol can leave a residue on the toric or ramps and allow the toric to slide
rather than roll in seat. This can also result in poor seal performance due to nonuniform loading.

Put the installation tool (9) onto the seal ring (1)
with toric ring (2). Lower the rings into a container
with Isopropanol until all surfaces of the toric (2)
are wet.

Toric sliding on retainer ramp.

Toric caught on housing retainer lip.

Toric sliding on seal ramp.

After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly and
immediately “pop” the seal into the housing with a firm push of the installation tool. Remove the
installation tool and check the seal stantout height at several places around the circumference of the
ring to verify an accurate installation. If the seal does not meet the height specification, inspect the
toric for twists or obvious bulges.

With all surfaces of the toric ring (2) wet with

Isopropanol, use the installation tool (9) to position
the seal ring (1) and the toric ring (2) squarely
against the housing (5) as shown. Use sudden
and even pressure to pop (push) the toric ring (2)
under the retaining lip (3) of the housing (5).

The seal can be adjusted by gently pushing the toric into position by hand or by using a fabricated
adjustment hook.

If small adjustments are necessary, do not

push directly on the seal ring (1); use the
installation tool (9) to push down or the
adjustment tool (11) to pull up.

A thin film of light oil should be applied to the seal faces prior to
assembly. Use an applicator, a disposable tissue or a clean finger to
distribute the oil evenly. Be careful not to get any oil on the rubber toric
rings.

Be sure there is no visible debris on either of the seal faces - even a small
piece of lint can hold the seal faces apart and cause leakage.

After successful installation, wait one minute for the Isopropanol to dry before assembling the two seal
halves in the final loaded position. This delay is to allow any excess solvent to dry so that the torics roll,
rather than slide, in the housing as the faceload is increased. If the torics slide, this can produce a
nonuniform load that can result in poor seal performance.

Results of incorrect assembly :

Point “A” and point “B” remain stationary.

Points “X” and “Y” rotate 180°.
This causes high pressure at “A”/ “Y” and possible
galling.
When rotated, points “B”/ “X” has low pressure and
possible leakage.

Original assembled position Rotated 180°

After the unit to be sealed is assembled, a post - assembly leakage test can be performed to insure
the seal is properly installed. A vacuum check is recommended rather than a pressure check as
vacuum checks are more sensitive. Many users find this an easy check to combine with a vacuum
fill technique for the lubricant. It is recommended the compartment be filled to the correct level with
lubricant and then rotated slowly several revolutions to seat the seals. A vacuum test will catch big
seal damage such as broken seal rings or cut torics that may be caused in the last phases of
assembly. The Duo - Cone seal is not designed to seal air, so some leakage can be expect using
such a procedure.

Following these guidelines and recommendations should insure optimum performance from the Duo
- Cone - seals.

1054 (1146)
All rights reserved Copyright © Sandvik
Service
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Assembly of the
Service and ring
Repair gear and ring gear carrier
Manual LH204
Assembly of the sun gear 6.1.1

Prepare the ring gear and the ring gear

carrier

Heat the taper roller bearing inner ring with cage (1) to
about 100°C and install it onto the ring gear carrier (2).
Place the ring gear (3) onto the ring gear carrier. Bolt
the retainer (5) with the screws (4), secure the screws
with Loctite 270.

Assembly of the ring gear carrier

Install the ring gear carrier (2) with ring gear (3) into the wheel hub resp. onto the steering knuckle
resp. axle spindle. The oil compensating hole in the ring gear carrier must be on the bottom.
Subsequent adjust wheel bearings (see chapter 5.7).

Assembly of the thrust ring

Press the thrust ring (6) into the steering knuckle

resp. axle spindle. Secure with Loctite 270.

Assembly of the sun gear

Slip the sun gear (7) onto the universal joint resp.
axle shaft, install the circlip (9) and push the
universal joint resp. axle shaft towards the inside
until the circlip contacts to the sun gear and the sun
gear contacts to the thrust ring.

Prepare planetary gear:

Install the needle bearing (10 resp. 11) into the planetary
gear (12 resp. 13).

Insert the preassembled planetary gears (12 resp. 13)

with needle bearings (10 resp. 11), rings (16) (if present)
and thrust discs (14 resp. 15) into the planetary housing
(22 resp. 23) (planetary housing in horizontal position).

Place o - ring (19) into the slot of the planetary housing

(22). Because of the difference of diameter of 0,1 mm
press the planetary pin (17 resp. 18) in direction of arrow.
Be sure, that the bore hole of the locking pin in the
planetary pin and planetary housing are aligned. After
inserting, secure the planetary pin with the locking pin (20
resp. 21).

1056 (1146)
All rights reserved Copyright © Sandvik
Service
Revised 01.09.2007
ID: BG00398452 en-US A.001.1 2015-10-19
Section
Adjustment
Service and of theManual
Repair axial clearance LH204
Assembly of the planetary housing 6.1.3

Adjustment of the axial clearance

The axial clearance between axle shaft resp.

universal joint and thrust disc (27) in the planetary
housing must be 0,3 - 0,7 mm.

Measure distances :

Dimension A =

Dimension B =

Required disc thickness =

A - B - axial clearance (0,3 - 0,7 mm)

Mount the correctly dimensioned thrust disc (if

necessary, make final correction on a lathe) into the
planetary housing. Secure with Loctite 270.

Assembly of the planetary housing

Place o - ring (30) into the slot of the planetary housing.

Install the planetary housing and bolt it.

Knock the locking pin (20 resp. 21) completely to the inner
side of the planetary pin.

Press the planetary pin in direction of arrow out of the

planetary housing.

Attention:

Because of the difference of diameter of 0,1 mm do not

press the planetary pin against the direction of arrow out
of the planetary housing, to prevent damaging the bore.

Remove the planetary gears with the thrust discs and

needle bearings.

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

General information about this service

manual

The representations of the parts on the drawings

do not necessarily correspond to parts of this statement.

Chapter
Assembly / Disassembly of service brake
Service and wet
Repair Manual
disc brake – spring load design - 4340 LH204
7.91

7 Table of contents of assembly/disassembly

of the wet disc brake spring load design with
piston adjustment screws for air gap setting

General information about this service manual ....................................................................................... 1

7 Table of contents of assembly/disassembly of the wet disc brake spring load design with piston
adjustment screws for air gap setting ..................................................................................................... 2

Overview of parts ................................................................................................................................... 4

Overview of parts ................................................................................................................................... 5

Safety notes ........................................................................................................................................... 6

7.91.1 WARNING! ........................................................................................................................................................................... 6

7.91.2 DANGER! .............................................................................................................................................................................. 6

7.91.3 WARNING LABEL .................................................................................................................................................................. 6

7.91.4 Important remarks ............................................................................................................................................................... 6

7.91.5 General remarks ................................................................................................................................................................... 6

Assembly of the wet disk brake .............................................................................................................. 7

7.91.6 Assembly of the piston seals ................................................................................................................................................ 7

7.91.7 Prepare the brake housing ................................................................................................................................................... 7

7.91.8 Assembly intermediate piece ............................................................................................................................................... 8

7.91.9 Assembly piston ................................................................................................................................................................... 8

7.91.10 Assembly springs ................................................................................................................................................................ 8

7.91.11 Assembly of the brake carrier ............................................................................................................................................ 9

7.91.12 Final assembly .................................................................................................................................................................. 10

Check the air gap (pressurized) ............................................................................................................. 10

7.91.13 Check the air gap (pressurized) without wear indicator .................................................................................................. 10

7.91.14 Check the air gap (pressurized) with piston adjustment .................................................................................................. 11

7.91.15 Centring of the discs ......................................................................................................................................................... 12

7.91.16 Check brake hydraulic system for leaks ........................................................................................................................... 12

7.91.17 Check cooling oil room for leaks....................................................................................................................................... 12

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

Disassembly of brake ............................................................................................................................ 13

7.91.18 Disassembly of brake ....................................................................................................................................................... 13

Remarks to the wet disc brake .............................................................................................................. 14

7.91.19 Permissible oil for brake without external cooling (oil sump = cooling fluid) .................................................................. 14

7.91.20 Check - measure lining wear without lining wear indicator ............................................................................................. 14

7.91.21 Installation and basic setting of the lining wear indicator ............................................................................................... 15

7.91.22 Check lining wear with a installed lining wear indicator.................................................................................................. 15

Chapter
Assembly / Disassembly of service brake
Service and wet
Repair Manual
disc brake – spring load design - 4340 LH204
7.91

Overview of parts

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

Overview of parts

1. Brake carrier 20. Thread bushing

2. Brake housing 21. O-Ring
3. Intermediate piece 22. Face seal
4. piston 23. Hexagon socket screw
5. Inner disc 24. Warning label
6. Outer disk 25. Hexagon nut
7. O-Ring 26. Bolt
8. 27. Nut cap
9. Hexagon screw 28. O-Ring
10. Screw plug 29. O-Ring
11. 30. Pin
12. 31. O-Ring
13. Compression spring set 32. circlip
14. Bleeding socket 33. O-Ring
15. Sealing ring
16. Bleeder valve
17. Gasket
18. Gasket
19. Piston guide ring

Chapter
Assembly / Disassembly of service brake
Service and wet
Repair Manual
disc brake – spring load design - 4340 LH204
7.91

Safety notes
7.91.1 WARNING!

Before commencing work on the brake, ensure that no unintended machine movement can happen
when the braking effect is removed.
- Danger to life! -

7.91.2 DANGER!

The brake is under spring tension. Parts could become loose and fly out suddenly if improper brake
assembly resp. disassembly.
- Danger to life! -
The loading resp. unloading of the springs must not be realized by the brake housing screws, it has to
be made with a suitable press and device.

Preferably the assembly / disassembly should be done by Kessler & Co.

.91.3 WARNING LABEL

7.91.4 Important remarks

Do not contact or expose inner and outer disks to water!

7.91.5 General remarks

During the assembly and disassembly of a wet disk brake, dirt and abraison particles must not
get into the brake or into the grooves of sealing. All parts which are subject to assembly or
disassembly, e.g. brake carrier (1) or brake housing (2), need also to be cleaned on their outside.

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

Assembly of the wet disk brake

7.91.6 Assembly of the piston seals

1. Install the o - rings (1) into the slots of the intermediate piece (4)

2. Install the profile seal rings (2) with stepped side to the piston showing into the slots of the intermediate piece (4)

3. Install the guide ring (3) into the slot of the intermediate piece (4)

7.91.7 Prepare the brake housing

1. Lay the discs (1 + 2) alternately into the brake housing (3)

Hint: The upper disc always has to be an outer disc!

Chapter
Assembly / Disassembly of service brake
Service and wet
Repair Manual
disc brake – spring load design - 4340 LH204
7.91

7.91.8 Assembly intermediate piece

1. Fit o-ring (1) onto the brake housing (2)

2. Place on the intermediate piece (3)
3. Take the screw holes position into consideration
4. It is recommendable to use 2 thread bolts (4)
(longer screws without screw head) for fixation

7.91.9 Assembly piston

1. Check the piston treads for intactness.

2. Wet the piston treads with oil.
3. Install the piston (1) into the intermediate piece,
take the position of the spring holes and screw
holes into consideration.

Hint: The piston must not tilt (danger of seal

tread damage!)

7.91.10 Assembly springs

1. Place the springs (1) and the spring sets (1) as

shown in the spring arrangement,
into the piston (2).

16 outer springs / 0 inner springs

Spring arrangement:

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

7.91.11 Assembly of the brake carrier

1. Fit the o - ring (1) onto the brake carrier (2).

2. Place the brake carrier onto the springs (3), thereby note the position of the brake
connections.

3. Squeeze together the brake carrier and brake housing (5) by using a press and device,
which is suitable for the brake be load.

4. Detach the thread bolts and screw in and tighten the screws (6).

5. Lift the press ram slowly.

6. Install the warning label on the brake and stamp in the corresponding preload.

DANGER!

Preferably the assembly/ disassembly should be done by Kessler & Co. GmbH & Co.KG

Chapter
Assembly / Disassembly of service brake
Service and wet
Repair Manual
disc brake – spring load design - 4340 LH204
7.91

7.91.12 Final assembly

1. Screw in the bleeder with connection piece and seal ring as well as the screw plugs with seal ring.

2. Check brake hydraulic system for leaks (see page 12).

Check the air gap (pressurized)

with wear indicator

without wear indicator

7.91.13 Check the air gap (pressurized) without wear indicator

1. While none actuated brake (piston room pressurized).

2. Measure through the wear inspection hole the distance from the brake carrier to the piston end face – write
down the measure = measure A.
3. Actuate the brake (piston room none pressurized).
4. Measure again through the wear inspection hole the distance from the brake carrier to the piston end face –
write down the measure = measure B.
5. The difference of the measured distances A and B gives the air gap sL (pressurized).
6. Rated size sL see table.
7. Actuate the brake (piston room none pressurized).
8. Measure through the check hole the distance from brake carrier to the end face and stamp the now
ascertained dimension into the brake carrier near by the wear inspection hole.

air gap and wear dimension

air gap sL new (pressurized) wear dimension

brake type
mm mm

Wet disc brake 4340

1,12 +1,46 2,0
spring load design

Hint: with increased disc wear and hence it resulting less spring tension the brake torque will be reduced

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

9. Install o - ring (brake carrier/ axle spindle resp. steering knuckle) free of torsion and loops (inapplicable at one-
piece design brake carrier).
10. Install the complete brake on the axle (coat the contact surface with Loctite 270) (inapplicable at one-piece
design brake carrier).
11. Mount face seal see chapter 5.8.

7.91.14 Check the air gap (pressurized) with piston adjustment

piston adjustment

Prepare and installation of the piston adjustment screws:

Assembly of the brake as described, before brake carrier assembly the piston adjustment screws have
to be installed with the o-rings already fitted and lightly greased fully into the brake carrier.

Air gap setting:

1. Actuate the brake

2. screw in the piston adjustment screws to contact at the piston
3. Subsequently screw out the piston adjustment screws according to the nominal air gap and release
the brake
4. Screw on and tighten the counternuts, during thism, the piston adjustment screws must not be
turned
5. Attach the o-rings
6. screw on and tighten the cap nuts to a low torque

air gap and wear dimension

air gap sL new (pressurized) wear dimension

brake type
mm mm

Wet disc brake 4340

1,12 +1,46 2,0
spring load design

Chapter
Assembly / Disassembly of service brake
Service and wet
Repair Manual
disc brake – spring load design - 4340 LH204
7.91

Inspection and adjustment of the air gap:

1. detach cap nuts and counter nuts

2. Actuate the brake
3. screw in the piston adjustment screws to contact at the piston
4. Subsequently screw out the piston adjustment screws according to the nominal air gap and release
the brake
5. screw on and tighten the counternuts, during this the piston adjustment screws must not be turned.
6. attach the o-rings
7. screw on and tighten the cap nuts to a low torque

7.91.15 Centring of the discs

1. The centring of the inner discs at wet disc brake has to be realized at wheel hub mounting by the wheel hub
itself.
2. To this the disc set has to be released by hydraulic pressure.
3. After centring clamp the disc set by releasing the hydraulic pressure (spring load effect).

Hint: To save the centering of the disc set in case of disassembly the wheel hub, the hydraulic pressure
should be released, so the disc set will be clamped (spring load effect).

7.91.16 Check brake hydraulic system for leaks

1. Before conducting the test, bleed the brake hydraulic system.

2. The pressure drop after applying pressure corresponding to the working pressure of the brake for a period of
15 minutes must not exceed 2%.

Test medium: Motor oil SAE 10 W corresponding to MIL - L 2104.

.91.17 Check cooling oil room for leaks

Brake with external cooling:

After assembly of the wheel hub with the face seal and adjusting
of the wheel bearings check the tightness of the cooling oil room.

1. Install an air pressure gauge with shutoff valve.

2. Be load the hub assembly with 1,5 bar pressure air.
3. Turn the hub assembly several times.

The pressure drop after a period of 10 minutes must not exceed 0,1 bar.
Copyright © Sandvik 1071 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
© Kessler & Co. GmbH & Co.KG
All rights reserved - 12 - 05/06/2013
7

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

Disassembly of brake
7.91.18 Disassembly of brake

WARNING!

Before commencing work on the brake, ensure that no unintended machine movement can happen
when the braking effect is removed.
- Danger to life! -

The complete brake can be removed from the axle spindle after unscrewing of the screws (1)

Hint: To safe the centring of the disc set in case of disassembly the wheel hub, the hydraulic
pressure should be released, so the disc set will be clamped (spring load effect).

The disassembly of the brake has to be realized in reverse sequence.

DANGER!

Preferably the assembly/ disassembly should be done by Kessler & Co. GmbH & Co.KG.

Before unscrewing the screws (2) of the brake, the brake has to squeeze together by using a press
and device (3), which are suitable for the brake preload (see warning label). After removing of all
screws lift the press ram slowly till the springs are released.

Chapter
Assembly / Disassembly of service brake
Service and wet
Repair Manual
disc brake – spring load design - 4340 LH204
7.91

Remarks to the wet disc brake

7.91.19 Permissible oil for brake without external cooling
(oil sump = cooling fluid)

Actuation fluid: Do not use brake fluid at any time!

Use a mineral oil base hydraulic oil type fluid only!

1) Motor oil API SE/ CD

MIL - L - 46152C/ MIL - L - 2104 C o. D
2) ATF C - 3 or Dexron

3) Hydraulic oil HLP DIN 51524 Part 2

Viscosity:

For moderate climate ISO VG 22 - 32

For extremely cold climate ISO VG 15
For extremely warm climate ISO VG 46

Cooling fluid: Hypoid gear oil like specification on installation drawing:

SAE 90 per MIL - L - 2105 B , API GL 5
Important: It is necessary to use oils with LS - additives (Limited Slip),
according to the recommendation of the oil supplier.
For example: 3 - 6% Lubrizol LZ 6178

7.91.20 Check - measure lining wear without lining wear indicator

Check measure: It is measured through the check hole, while actuating the brake.
The check measure, new, is marked in the housing below the hole.

Is the measured dimension bigger than the marked dimension and maximum
wear dimension, unconditional consult Kessler & Co. GmbH & Co.KG.

After working at the brake, bleed the brake hydraulic system and check for tightness!

Chapter
Assembly / Disassembly of service brake
Service and Repair
wet Manual
disc brake – spring load design - 4340 LH204
7.91

7.91.21 Installation and basic setting of the lining wear indicator

1. Install the o-rings (13) and the circlip (15) onto the indicator pin (14)

2. Push the indicator pin (14) lightly greased, into the thread bushing (12)

3. Actuate the brake and screw in and adjust the thread bushing (12) (Loctite

262 in thread) to a standout x (see below) of the indicator pin (14) according

to the respective wear dimension

4. Nominal dimension

Brake type Wear dimension X mm

Wet disc brake 4340 spring load design 2,0

5. Wet the thread and the mounting flange of the cap nut (10) with Molykote

6. Attach the seal ring (11)

7. Screw on and tighten the cap nut (10) with 8 Nm

7.91.22 Check lining wear with a installed lining wear indicator

1. The check must realize then the indicator pin (14) is assembled

2. Actuate the brake

3. Detach the cap nut (10) and push the indicator pin (14) to the inside

4. The standout x of the indicator pin (14) shows the maximum allowed

residual lining wear

5. If the end face of the indicator pin (14) is flush with the end face of the

thread bushing (12), the maximum lining wear has been reached and a

brake check is necessary,

unconditional consult Kessler & Co. GmbH&Co.KG

17.11 Dana cardan shafts

Installation and Maintenance

for Driveshafts / Industrial Applications
Important Product Information and
Safety Instructions

ID: BG00398452 en-US A.001.1 2015-10-19
Service and Repair Manual LH204

Table of Contents

3 Safety instructions
4 Transport and storage
5 Installation • Dismantling
· Installation
· Disassembly
· Flange bolting
· Companion flanges
14 Maintenance
· Maintenance intervals
· Inspection
· Lubrication
· Recommended regreasing intervals
16 Repair
17 Additional information and ordering instructions
18 After-sales service

2 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204

Safety instructions Our products have been developed

and tested according to the latest state-of-the-art engineering.

The characteristic features of the property. Additional safety be performed by trained and
products which are described in information is incorporated qualified personnel who are
our information material or which throughout this manual. familiar with these instruc-
we specified in writing were sub- tions, general safety stan-
jected to proper and careful in- dards, and EC Regulation for
WARNING
spection. machinery, if applicable.
Rotating Driveshafts

Other features are possible but • Rotating driveshafts are dan- • The operating data of the
they are subject to our written gerous. You can snag clothes, driveshafts, such as speed,
confirmation. gloves skin, hair hands etc, deflection angles, lengths,
which can cause serious inju- etc., must never be exceeded.
Knowledge of the various de- ry or death.
mands on GWBTM products for a • Do not alter driveshafts in
• Do not work on an exposed
particular application lies with the any way without our written
drive shaft when it is running
purchaser. The selection of shaft consent. If you do so, you
and be sure the power source
types and the specification of may be creating a safety
is off.
sizes on our part shall in all cases hazard and you are no longer
be considered only as a recom- • Exposed driveshaft must be covered by our warranty.
mendation. Purchaser is required guarded. Suitable safety de-
to verify the drawings and docu- vices (e.g. catch bows, solid
• The balanced state of a drive-
ments submitted by GWB based safety guards) must be provi-
shaft must not be altered.
on the data submitted by pur- ded to prevent possible se-
An out-of-balance driveshaft
chaser. It is the purchaser’s rious injury or death, or dama-
may result in uneven run-
responsibility to determine the fit- ge to property from thrown
ning and premature wear
ness of the product for its inten- parts in the event of a separa-
of the joints and bearings of
ded use. ted shaft
the units to which the drive-
shaft is connected. In extre-
When using, handling, installing,
WARNING me cases of imbalance, the
and maintaining driveshafts the Other Important Safety driveshaft could break and
following safety instruction must Information components could be thrown
be strictly observed to prevent • Installation, assembly and from the vehicle or machine.
injury to persons or damage to maintenance work should only

ID: BG00398452 en-US A.001.1 2015-10-19 3

Service and Repair Manual LH204
Transport and storage

joint range joint range

CAUTION
To prevent injuries of persons and damage
to the driveshafts always make sure
that the shafts are safely transported and
stored.

Please consider the following must be taken to prevent the • Avoid bumps and knocks
precautions: splined parts from separating. during transport and storage.
Danger of injury!
• Use strong nylon ropes or • Do not store or handle the
lifting belts. When using steel • When lifting or putting down shaft with any stress or load
cords, protect the edges. the shaft, the moving parts on the spline protection (1) or
(flange yoke and journal cross) the seal (2).
• Driveshafts should be may tilt and lead to injuries.
transported in a horizontal Keep hands away from the
position (see illustration). joint!
For non-horizontal transporta- Danger of crushed hands!
tion additional precautions

1 2 2 1

Series 587, 687, 688 Series 390, 392, 393

• Use appropriate frames or • Use chocks or blocks to • Secure shaft against falling
racks for storage, so that the prevent driveshaft from over if it is stored in a vertical
flange yokes are not loaded. rolling. position.

• Keep driveshafts in a dry

place.

4 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204
Installation/dismantling
Installation • The faces and the centering • Check the axial and radial run-
diameter of the shaft flanges out as well as the spigot fit
and companion flanges must of the mounted flanges and
WARNING be free of dust, grease or paint the connected units (see Com-
See Rotating Shafts warning to guarantee a safe connec- panion flanges on page 12).
on Page 3. tion.
• Do not turn the joints of the
Important Product Installation
• Be careful when handling the driveshafts with assembly
Information
driveshaft. Freely moving levers because this may da-
flange yokes may cause mage the grease nipples or
• In order to maintain the pro-
perties of the driveshaft as injury. relief valves.
described in the information
• Check position of yokes (1) • Use nuts and bolts of the
brochure, they must not be
of the shaft. Observe the prescribed quality (strength)
altered from their as delivered
arrow markings (2). They must (see Flange bolting on page 7).
state.
be in alignment. The splines
are fitted to one another and • Only use nuts and bolts in
• Driveshafts are elastic and
must not be exchanged or accordance with the supp-
flexural bodies. Their flexural
distorted. lier’s specification.
vibration and their critical ben-
ding speed must be calculated.
• Protection caps should be re- • The bolts should be evenly
The maximum permissible
moved from the regreasing- tightened crosswise with a
operating speed must be suf-
and ventilation valve before torque wrench (see Flange
ficiently below the critical ben-
use. bolting on page 7).
ding speed of the first order.

• For the smooth running and • Before installation remove the

safety of the shaft the n x b transport retainer device, if
present. In case of doubt
value (speed x deflection ang-
please contact the supplier.
le) of the relevant shaft size
must not be exceeded.
Please contact us.

ID: BG00398452 en-US A.001.1 2015-10-19 5

Service and Repair Manual LH204
Installation/dismantling
• When using driveshafts • For spray-painting the shaft • When cleaning driveshafts,
without length compen- we recommend our paint stan- do not use aggressive che-
sation, one of the connecting dards (Please ask for them). mical detergents or pressu-
units must be flexible in order rized water or steam jets
to be fitted over the flange • Protect rilsan-coated splines because the seals may be
pilot. Variations in length (sleeve muff or sleeve yoke) damaged and dirt or water
which may be caused by against may penetrate.
temperature changes must – heat
be allowed for by a suitable – solvents • Driveshafts can be used in
connecting bearing. – mechanical damage. a temperature range between
Visible rilsancoated areas –25°C (–13°F) and +80°C
• If driveshafts with length should not be painted after (+176°F), up to +120°C
compensation are used, the installation in the driveline. (+248°F) but only for limited
companion flanges must be Danger of sealing damage! periods and not on a frequent
firmly fitted on the shafts of basis. Please contact us if the
the connected units. operating temperature deviates
from these values.

• Driveshafts that have been

stored for more than 6 months
must be relubricated before
use (see Maintenance).

• In general we recommend to
relubricated the driveshaft
after setup in the driveline.

• For spray-painting the drive-

shaft, make sure that the
sliding range of the seal
(length compensation L a) is
covered.

6 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204
Installation/dismantling
Disassembly We recommended a bolting set See tables for insertion of bolts.
consisting of: All bolts must be tightened
• Before disassembly protect with the specified torque. The
the driveshaft from Hexagon bolt with short thread tightening torques Ta given in the
spline separation. similar to DIN 931/10.9 table are based on a 90% (80%
(shaft length greater than flange Hirth-serration) utilization of the
thickness) elastic limit and apply to slightly
CAUTION Self-locking nut, similar to oiled bolts.
You must secure the driveshaft DIN 980/934-10.
against falling down before Do not use molycote paste or
pulling it off the companion The bolts allow fitting any other grease on the bolts
flange. The flange yoke may a) partially from the joint side, i.e. and nuts. In case of corrosion
tilt, which could cause injury! the recessed diameter c does not protected bolts and nuts, ple-
prevent the bolt from turning; ase contact us.
• Observe the directions for b) from the companion flange
transport, storage and instal- side. We recommend designing Max. permissible tolerance of
lation of driveshafts. the recessed diameter C1 so as DIN 25202 class B.
locate the bolt head.
Flange bolting

The flange bolting set can be

supplied by GWBTM on request.
The bolt lengths given in the
tables are only suitable if the
dimension 2 x G corresponding
to the double the flange thick-
ness G is not exceeded (see data
sheets). If longer bolts are used,
check whether the bolts can
still be inserted from the joint
side.

ID: BG00398452 en-US A.001.1 2015-10-19 7

Service and Repair Manual LH204
Installation/dismantling
Series 587/687/688

l
Shaft size 587.50 587.55 587.60
2xG v Flange dia. A mm 225 250 250 285 285

Ta Nm 295 405 405 580 580
c mm 158 176 168 202 202
c1 mm 171 189 189 214 214
s

d – M 16 M 18 M 18 M 20 M 20
Hexagon bolt:

l mm 50 60 60 64 64
short model similar to
DIN 931/10.9
v mm 20 24 24 24 24
c1

s mm 24 27 27 30 30
c

Hexagon nut:
similar to DIN 980/10 i1 ) – 8 8 8 8 8
Joint flange Self-locking Bolts inserted from joint side yes yes yes yes yes

Shaft size 687/688.15 687/688.20 687/688.25 687/688.30 687/688.35

Flange dia. A mm 100 120 120 120 150 150 180

Ta Nm 35 69 69 69 120 120 190

c mm 64 76 76 76 100 100 119
c1 mm 69,5 84 84 84 110,3 110,3 132,5
d – M 8 M 10 M 10 M 10 M 12 M 12 M 14

l mm 23 27 27 27 33 33 40

v mm 9 11 11 11 13 13 16

s mm 13 17 17 17 19 19 22
i1 ) – 6 8 8 8 8 8 8

Bolts inserted from joint side
Normal design yes yes yes yes yes yes yes
Bolts inserted from joint side Wide angel design – – – – – – –

Shaft size 687/688.40 687/688.45 687/688.55 687/688.65

Flange dia. A mm 150 180 180 225 180 225 180 225

Ta Nm 120 190 190 295 295 295 295 295

c mm 100 119 119 158 118 158 118 158
c1 mm 110,3 132,5 132,5 171 130,5 171 130,5 171
d – M 12 M 14 M 14 M 16 M 16 M 16 M 16 M 16

l mm 33 40 40 50 50 50 50 50

v mm 13 16 16 20 22 20 20 20

s mm 19 22 22 24 24 24 24 24
i1 ) – 8 8 8 8 10 8 10 8

Bolts inserted from joint side Normal design yes yes yes yes yes yes no yes
Bolts inserted from joint side Wide angel design yes yes yes – yes – – –

1) = Number of bolt holes Ta = Tightening torque of bolting Special torque wrenches supplied on
request

8 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204
Installation/dismantling
Series 390
Standard bolting

l
Shaft size 390.60 390.65 390.70 390.75 390.80
Flange dia. A mm 285 315 350 390 435 2 xG v
Ta Nm 580 780 780 1.000 1.500
c mm 202 230 256 295 332
c1 mm 214 247 277 308 343

d
s
d – M 20 M 22 M 22 M 24 M 27
Hexagon bolt:
l mm 64 70 75 85 95
short model similar to
v mm 24 26 25 29 31 DIN 931/10.9

c1
s mm 30 32 32 36 41

c
Hexagon nut:
i1 ) – 8 8 10 10 10 similar to DIN 980/10
Bolts inserted from joint side yes yes yes yes yes Joint flange Self-locking

Series 587/390
Dowel pin connection

Shaft size 587.50 587.55 390.60 390.65 390.70 390.75 390.80

l
Flange dia. A mm 250 250 285 315 350 390 435
Ta Nm 130 130 200 200 280 280 400 a a v
c mm 176 168 202 230 256 295 332
c12 ) mm 176 176 198 228 254 294 332
2xG
d – M14 M14 M16 M16 M18 M18 M20
l mm 65 65 75 75 90 95 110 Hexagon bolt:
ds mm 25 25 28 30 32 32 35 short model similar to
ds

d
s

ls mm 32 32 36 40 45 50 60 DIN 931/8.8

v mm 17 17 23 19 24 23 30 Hexagon nut:

a mm 6 6 6 6 8 8 8 similar to DIN 980/10
Self-locking
c1

s mm 22 22 24 24 27 27 30

c
i1 ) – 4 4 4 4 4 4 4 Dowel pin: DIN 1481

Bolts inserted yes yes yes yes yes yes yes Joint flange Dowel pin: DIN 7349
from joint side

Series 587/190
Super short designs

l
Shaft size 587.50 190.55 190.60 190.65 190.70
Flange dia. A mm 275 305 348 360 405 2 xG v

Ta Nm 190 295 405 405 580
c mm 213,5 237,5 274 288 324,5
c1 mm 225 250 285 299 338
s

d – M 14 M 16 M 18 M 18 M 20
Hexagon bolt:
l mm 50 50 60 60 65
short model similar to
v mm 15 20 24 24 21 DIN 931/10.9
c1

s mm 22 24 27 27 30
c

Hexagon nut:
i1 ) – 10 10 10 10 10
similar to DIN 980/10
Bolts inserted from joint side yes yes yes yes yes Joint flange Self-locking

1) = Number of bolt holes Ta = Tightening torque of bolting Special torque wrenches supplied on
request
2) = Dowel pin connection without locking

ID: BG00398452 en-US A.001.1 2015-10-19 9

Service and Repair Manual LH204
Installation/dismantling
Series 392/393
Flange connection with face key

l
2 xG v
s

Hexagon bolt:
short model similar to
DIN 931/10.9
c1

Hexagon nut:
similar to DIN 980/10
Joint flange Self-locking

Shaft size 392.50 392.55 392.60 392.65 392.70 393.75 393.80 393.85 393.90
Flange dia. A mm 225 250 285 315 350 390 435 480 550

Ta Nm 295 405 580 780 780 1.000 1.500 2.000 2.000
c mm 152 170 193 224 254 286 315 334 420
c1 mm 171 190 214 247 277 307 342 377 444
d – M 16 M 18 M 20 M 22 M 22 M 24 M 27 M 30 M 30
l mm 60 75 80 90 100 110 120 130 140

v mm 20 25 26 26 30 30 36 36 40

s mm 24 27 30 32 32 36 41 46 46
i1 ) – 8 8 8 10 10 10 16 16 16

Bolts inserted from joint side no no no no no no no no no

1) = Number of bolt holes Ta = Tightening torque of bolting Special torque wrenches supplied on
request

10 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204
Installation/dismantling
Series 492/498/598
Flange connection with Hirth-serration

2xG

d
s
Hexagon bolt:
short model similar to
DIN 931/10.9

Hexagon nut:
similar to
DIN 980/934-10

Series 492 Joint flange Self-locking

Shaft size 492.60 492.65 492.70 492.75 492.80 492.85 492.90

Flange dia. A mm 285 315 350 390 435 480 550
Ta Nm 175 270 270 375 375 525 720
d – M 14 M 16 M 16 M 18 M 18 M 20 M 22
s mm 21 24 24 27 27 30 32
i1 ) – 10 10 12 12 16 16 16
Bolts inserted from joint side
no no no no no no no

Series 498/598

Shaft size 498.00 498.05 498.10 498.15 498.20 498.25 498.30 498.35 498.40 498.45 498.50 498.55 498.60
598.00 598.05 598.10 598.15 598.20 598.25 598.30 598.35 598.40 598.45 598.50 598.55 598.60
Flange dia. A mm 600 650 700 750 800 850 900 950 1.000 1.050 1.100 1.150 1.200

Ta Nm 900 900 900 1.800 1.800 3.150 3.150 3.150 5.400 5.400 5.400 8.200 8.200
d – M 24 M 24 M 24 M 30 M 30 M 36 M 36 M 36 M 42 x 3 M 42 x 3 M 42 x 3 M 48 x 3 M 48 x 3

s mm 36 36 36 46 46 55 55 55 65 65 65 75 75
i1 ) – 20 20 24 24 24 24 24 24 20 20 20 20 20
Bolts inserted from
no no no no no no no no no no no no no
joint side

1) = Number of bolt holes Ta = Tightening torque of bolting Special torque wrenches supplied on
request

ID: BG00398452 en-US A.001.1 2015-10-19 11

Service and Repair Manual LH204
Installation/dismantling
Companion flanges The dimensions of the companion from the companion flange side.
flanges correspond with those of In this case the distance Zmin
In general, driveshafts are con- the same size of driveshafts, ex- must be met between the flange
nected to the driven units by cept for the centring depth FA and and the adjacent housing.
companion flanges. the fit CA , the depth of the keyway
tA and the width bA . They can be If it is not possible to insert the
The accurate running of a drive- taken from the following tables. bolts from the companion flange
shaft requires certain tolerances side, we recommend the use of
for the axial and radial run-out For better bolt locking we recom- stud bolts.
(see tables). mend designing the relief of the
companion flange as a bolt head
surface and inserting the bolt

G Series 587
X = Axial run-out
X Y = Radial run-out
Y Z min = bolt length
(incl. bolt head) Shaft size 587.50 587.55 587.60

A mm 225 250 250 285 285
bA

FA mm 4 -0,2 5 -0,2 5 -0,2 6 -0,5 6 -0,5

∅A
∅ CA

G mm 15 18 18 20 20
tA

X and Y mm 0,05 0,06 0,06 0,06 0,06
CA h6 mm 140 140 140 175 175

FA Zmin

Series 687/688

Shaft size 687/688.15 687/688.20 687/688.25 687/688.30 687/688.35

A mm 100 120 120 120 150 150 180
FA mm 2,3 -0,2 2,3 -0,2 2,3 -0,2 2,3 -0,2 2,3 -0,2 2,3 -0,2 2,3 -0,2

G mm 7 8 8 8 10 10 12

X and Y mm 0,05 0,05 0,05 0,05 0,05 0,05 0,05
CA h6 mm 57 75 75 75 90 90 110

Shaft size 687/688. 40 687/688.45 687/688.55 687/688.65

A mm 150 180 180 225 180 225 180 225
FA mm 2,3 -0,2 2,3 -0,2 2,3 -0,2 4 -0,2 2,3 -0,2 4 -0,2 2,3 -0,2 4 -0,2

G mm 10 12 12 15 14 15 15 15

X and Y mm 0,05 0,05 0,05 0,05 0,05 0,05 0,05 0,05
CA h6 mm 90 110 110 140 110 140 110 140

12 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204
Installation/dismantling
Series 390

Shaft size 390.60 390.65 390.70 390.75 390.80

A mm 285 315 350 390 435
FA mm 6 -0,5 6 -0,5 7-0,5 7-0,5 9 -0,5

G mm 20
22 25
28 32

X and Y mm 0,06 0,06 0,06 0,06 0,06
CA h6 mm 175 175 220 250 280

Series 587/190
Super short designs

Shaft size 587.50 190.55 190.60 190.65 190.70

A mm 275 305 348 360 405
FA mm 4 -0,2 5 -0,3 6 -0,5 6 -0,5 7-0,5

G mm 15 15 18 18 22
X and Y
mm 0,06 0,06 0,06 0,06 0,06
CA h6 mm 140 140 175 175 220

Series 392/393

Shaft size 392.50 392.55 392.60 392.65 392.70 393.75 393.80 393.85 393.90
A mm 225 250 285 315 350 390 435 480 550
FA mm 4 -0,5 5 -0,5 6 -0,5 7-0,5 7-0,5 7-0,5 9 -0,5 11-0,5 11-0,5

G mm 20 25 27 32 35 40 42 47 50

X and Y mm 0,06 0,06 0,06 0,06 0,06 0,06 0,06 0,06 0,06
CA f8 mm 105 105 125 130 155 170 190 205 250
bA K8 mm 32 40 40 40 50 70 80 90 100
t A + 0,2 mm 9 12,5 15 15 16 18 20 22,5 22,5

ID: BG00398452 en-US A.001.1 2015-10-19 13

Service and Repair Manual LH204
Maintenance
Maintenance intervals • Check the flange bolts for • The use of incompatible
tightness and retighten them lubricants or greases can re-
Driveshafts are used in a great with the prescribed torque sult in driveshaft failure and
variety of industrial plants with (see Flange bolting on page 7). possible separation of the
very different operating condi- driveshaft.
tions. We recommend inspec- • Backlash inspection. By lifting
tions at regular intervals and, if the joints and the length com- GWBTM driveshafts are lubrica-
possible, to coordinate them with pensation check the visible ted with grease and ready for
maintenance work on other parts or tangible backlash. installation.
of the equipment. However main-
tenance work should be carried Check the driveshaft for any unu- • For relubrication of driveshafts,
out once a year at least. sual noise, vibration or abnormal use a standard grease ac-
behaviour and repair the damage, cording to STD 4006-000.
Inspection if any. You may use a lithium com-
plex grease ONLY if it meets
WARNING Lubrication the following specification:
Excessive looseness can KP2N-20/DIN 51502 accor-
cause imbalance or vibration
WARNING ding to DIN 51818.
in the driveshaft assembly. Lubrication Warnings
Imbalance or vibration can • Do not use grease with
cause premature component • In adequate lubrication inter- molycote additives!
wear, which can eventually re- vals or improper lubrication Original standard GWB
sult in separation of the shaft can cause journal cross burn grease can be mixed ONLY
resulting in serious injury to up, which can lead to separati- with lithium complex grease
persons or damage to proper- on of the shaft or connecting on mineral oil base.
ty. It is important that you fol- components from the vehicle
low the inspection procedures. or machine, resulting in serious • Clean the grease nipples
injury or damage to property. before relubricating.

• Use adequate regreasing

devices. For joint relubrication
Central lubrication 4 point lubrication maximal pressure of 15 bar
is required. For the length
compensation it depends on
the design. The regreasing
must be continued until fresh
grease becomes visible from
all four seals.

• Driveshafts that have been

stored for more than 6 months
must be regreased before use.

14 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204
Maintenance
• When cleaning driveshafts, which can result in separation • Grease and air-relief valves
do not use aggressive che- of the driveshaft from the ma- must not be removed or repla-
mical detergents or pressu- chine or vehicle. ced by standard grease nipp-
rized water or steam jets les.
because the seals may be The journal cross assemblies
damaged and dirt or water may be relubricated via a conical • Protection caps should be
may penetrate. After a clean- grease nipple (DIN 71412) located removed from the grease
ing, the driveshaft must be in the middle of the cross or at the nipples before operation.
regreased until the grease bottom of the bush. The journal
escapes out from all four seals. cross assembly has to be repla- • Relubricating should be done
ced before the calculated bearing at the shortest compressed
Journal cross assemblies lifetime is reached. The bearings length L z of the shaft.
of the journal cross must be lubri-
WARNING cated until the grease passes Recommended regreasing
Excessive looseness across the through from all four seals of the intervals
ends of journal cross bearing bearings. Driveshafts of the series
assemblies can cause imbalan- 498/598 (in special cases also the We recommend the following ins-
ce or vibration in the driveshaft series 390, 392, 393, 492) must be pection and regreasing intervals.
assembly. Imbalance or vibrati- lubricated via a flat grease nipple (see table below)
on can cause component wear, according to DIN 3404. The illust-
rated adapter pipe can be used as • Unfavourable effects like
adapter between a conical grease temperature, dirt and water
nipple at the driveshaft (acc. to may necessitate shorter lubri-
DIN 71412) and a flat grease nipple cating intervals. Principally we
connection at the grease pump recommend adapting the lu-
(see illustration). bricating intervals to the indivi-
dual operating conditions.
Length compensation
• For driveshafts with plastic-
The length compensation of coated splines (on request)
the series 390, 392, 393, 492, the relubricating intervals may
Regreasing intervals (standard) 190 and 587 as well as special be extended, dependent on
designs of the series 687/688 is the application, to 12 months.
lubricated via a combined grease
Series Joints Length compensation
and air-relief valve with a conical
587 6 months 6 months 1 )
maintenance-free
grease nipple according to DIN
687/688 6 months
12 months 1 ) 71412 (no self-locking grease
190 6 months 6 months nipple). The length compensation
390 6 months 6 months of the series 498/598 is lubricated
392/393 6 months 6 months via a flat grease nipple according
492/498/598 3 months 3 months
to DIN 3404.
1) for greasable length compensation

ID: BG00398452 en-US A.001.1 2015-10-19 15

Service and Repair Manual LH204
Repair
Safety Information Regarding • The repair of driveshafts by screws of shafts of the series
Repairs the user should only be made with split yokes. Observe our
in emergency cases and only installation and repair instruc-
• For safety reasons driveshafts for such equipment where the tions.
should only be repaired by operating speed of the shaft
GWBTM or by GWB -approved does not exceed 500 rpm. If • Improper repairs can lead to
repair shops. The repair of the speed exceeds 500 rpm, driveshaft failures that can
driveshafts is performed in a the driveshaft must be cause serious injury or damage
professional manner by our rebalanced. to property. Please contact
driveshaft service experts. us if you have questions or
The shafts are overhauled using • If journal cross assemblies need additional information.
original spare parts. are to be replaced, you should
also replace the bearing cap

Dana’s environmental protection

management policy

An important feature of Dana’s environmental protection

management policy is dedication to product responsibility.
Because of this commitment, the effect of driveshafts on the
environment is given considerable attention. GWB drive-
shafts are lubricated with lead-free grease, their paint finishes
are low in solvents and free of heavy metals, and they are
easy to maintain. After use, they can be introduced into the
recycling process.

16 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204

Additional information and ordering instructions

Selection of driveshafts
The selection of a GWBTM driveshaft ist determined not only by the
maximum permissible torque of the shaft and the connections but
also by a variety of other factors.

For the exact determination and transmitted to the track (wheel a) in general: II 3 GDc T6
selection of driveshafts, see the slip or adhesion torque). b) for driveshafts with adapted
Selection of Driveshafts pages in features: II 2 GDc T6
GWB catalogue. Driveshafts in crane travel
drives The driveshaft should not be
Dana engineers can precisely The particular operating condi- used under the following opera-
calculate the correct size of the tions for travel drives of cranes ting conditions:
shaft and joint for your applica- have been taken into conside-
tion with the use of computer ration in the DIN-standard 15 450. • Within the critical bending
programs created specifically As a result, driveshafts for these speed range of the drive
for this purpose. applications can be selected by • Within the critical torsional
using that standard. speed range of the drive
In order to best match your re- • At operating angles which ex-
quirements, you’ll be asked to Driveshafts in marine ceed the specified maximum
provide the following information: transmissions (refer to drawing confirmed
These driveshafts are subject to with order)
• Installation length of the acceptance and must corres- • At dynamic and static opera-
driveshaft pond to the standards of the ting torques which exceed the
• Maximum joint angle respective classification society. specified limit (refer to drawing
requirement confirmed with order)
• Required length compen- Driveshafts for other forms of • At speed x deflection angle
sation passenger conveyance (n x b) conditions which
• Maximum rotation speed of Driveshafts used in amusement exceed the limit (refer to
the shaft park equipment, ski lifts or similar GWB catalogue)
• Shaft end connection details lift systems, elevators, and rail • For usage time which exceeds
• Maximum torque to be vehicles must be in accordance the calculated bearing lifetime
transmitted with the standards and specifica- of the joint bearings
• Nominal torque to be tions of the appropriate licensing
transmitted and supervisory authorities. If you’d like more information
• Load occurrences on GWB driveshafts, or would
• Description of the equipment Driveshafts in explosive envi- like to discuss specific appli-
and working conditions ronments (Atex-outline) cation requirements with an
For the use of driveshafts in are- engineer, please call Dana at
Specific applications as with danger of explosion, an 00 49 (0) 201- 81 24 - 0 or visit
EC-conformity certificate acc. to www.gwbdriveshaft.com,
Driveshafts in railway EC-outline 94/9/EG can be www.dana.com.
transmissions provided.
The selection of driveshafts in the
secondary system of railway The possible categories for the
vehicles must be based on the product „driveshaft“ are:
maximum torque that can be

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Service and Repair Manual LH204

After-sales service Spicer Gelenkwellenbau GmbH

E-mail: industrial @ dana.com, Web: www.gwbdriveshaft.com / www.dana.com
Mailing address: P.O. Box 10 13 62 - 45013 Essen / Germany
Office address: 2. Schnieringstraße 49 - 45329 Essen / Germany
Phone: 00 49 (0) 201- 81 24 - 0, Fax: 00 49 (0) 201- 81 24 - 652

Home Country Belgium Finland

GKN Service Benelux BV Oy UNILINK Ab
GKN Service International GmbH Rue Emile Pathéstraat 410 Vattuniemenkatu 15
D-22525 Hamburg B-1190 Brussel (Vorst-Forest) 00210 Helsinki
Ottensener Str. 150 Phone: 00 32-2-33 49 861 Phone: 00 358-9-68 66 170
Phone: 0 40-540 090-0 Fax: 00 32-2-33 49 888 Fax: 00 358-9-69 40 449
Fax: 0 40-540 090-44 E-mail: unilink@unilink.fi
Brazil
Foreign Country Dana Indústrias Ltda. France
Rua Ricardo Bruno Albarus, 201 GKN Service France
Argentina Gravataí / RS CEP 94045-400 Ecoparc Cettons-Secteur 1 Jaune
Chilicote S.A. Phone: 00 55-51 3489-3775 8 Rue Panhard et Levassor
Avda. Julio A. Roca 546 E-mail: vendas@gwbcardans.com.br 78570 Chanteloup les Vignes, France
C1067ABN - Buenos Aires Web: www.gwbcardans.com.br Phone: 00 33-1-30 068 434
Phone: 00 54-11-43 31-66 10 www.dana.com.br Fax: 00 33-1-30 068 439
Fax: 00 54-11-43 31-42 78 E-mail: serge.campestrini@gkn.com
E-mail: chilicote@chilicote.com.ar China / P.R.C.
Also responsible for Uruguay and Chile. Dana China Shanghai Office Greece
7F, Tower B, Hongwell International Plaza Sokrates Mechanics GmbH
Australia No. 1602 Zhongshan Road West 205, Piraeus Str.
Hardy Spicer Company P/L Xuhui District, Shanghai, China GR-11853 Athens
17-31 Discovery Road Phone: 00 86-21 333 250 00 Phone: 00 30-210-34 71 910
Dandenong South, Victoria 3175 Fax: 00 86-21 648 723 00 Fax: 00 30-210-34 14 554
Phone: 00 61-3-97 941 900 E-mail: shao.cheng@dana.com E-mail: sokrates@enternet.gr
Fax: 00 61-3-97 069 928
E-mail: russell.plowman@hardyspicer.com.au China Hellas Cardan GmbH
Dana (Wuxi) Technology Co., Ltd. Strofi Oreokastrou
Dana Australia Pty Ltd No. 209 Xinzhou Road, Wuxi National GR-56430 Thessaloniki
39- 45 Wedgewood Road Hi-Technology Industrial Phone: 00 30-23 10-682 702
Hallam, Victoria, 3803 Development Zone, P.R. China Fax: 00 30-23 10-692 972
Phone: 00 61-3-92 135 555 Phone: 00 86-510-886 560 00 E-mail: hecardan@otenet.gr
Fax: 00 61-3-92 135 588 Fax: 00 86-510-881 198 66
Web: www.dana.com.au Great Britain
Denmark GKN Driveline Service Ltd.
Austria GKN Service Scandinavia AB Higher Woodcroft Leek,
GKN Service Austria GmbH Baldershöj 11 A+B GB-Staffordshire, ST13 5QF
Slamastraße 32 DK-2635 Ishöj Phone: 00 44-15 38-384 278
A-1230 Wien Phone: 00 45-44 866 844 Fax: 00 44-15 38-371 265
Phone: 00 43-1-61 63 880-0 Fax: 00 45-44 688 822
Fax: 00 43-1-61 63 880-15
Also responsible for Eastern Europe.

18 ID: BG00398452 en-US A.001.1 2015-10-19

Service and Repair Manual LH204

India Norway Spain

Dana India Private Limited GKN Service Scandinavia AB Gelenk Industrial S.A.
Survey No. 278, Raisoni Industrial Park, Phase II, Karihaugveien 102 Balmes, 152
Hinjewadi, Village-Mann, Tal. Mulshi, N-1086 Oslo E-08008 Barcelona
Pune -411 057 (INDIA) Phone: 00 47-23 286 810 Phone: 00 349-3-23 74 245
Phone: 00 91-9948572000 Fax: 00 47-23 286 819 Fax: 00 349-3-23 72 580
E-mail: koteswara.rao@dana.com E-mail: javier.montoya@gelenkindustrial.com
Russia-Ukraine
Indonesia APA-KANDT GmbH South Africa
PT. Tekno Fluida Indonesia Weidestr. 122a Driveline Technologies (Pty) Ltd.
Kawasan Multiguna - Taman Tekno BSD D-22083 Hamburg CNR. Derrick & Newton Roads
Sektor XI Blok H2 No. 3A - BSD City Phone: 00 49-40-48 061 438 Spartan, Kempton Park
Tangerang 15314 Fax: 00 49-40-480 614 938 P.O. Box 2649
Phone: 00 62-21-75876580 E-mail: office@apa-kandt.de Kempton Park 1620
Fax: 00 62-21-75876581 Web: www.apa-kandt.de Phone: 00 27-11-929-56 00
E-mail: info@teknofluida.com Fax: 00 27-11-394-78 46
Web: www.teknofluida.com Sweden E-mail: richard@driveline.co.za
Contact: GKN Service Scandinavia AB
Antoni Sutiono: antoni.sutiono@teknofluida.com Alfred Nobels Allé 110 USA, Canada
Jan Pieter Sinaga: jan.pieter@teknofluida.com SE-14648 Tullinge Dana Spicer Service Parts
Phone: 00 46-86 039 700 P.O. Box 321
Italy Fax: 00 46-86 039 702 Toledo, OH 43697-0321
Uni-Cardan Italia S.p.A. Phone: 001-800-621-80 84
Via G. Ferraris, 125 / C Switzerland Fax: 001-800-332-61 24
I-20021 Ospiate di Bollate (MI) GKN Service International GmbH E-mail: tom.deHaven@dana.com
Phone: 00 39-02-383 381 Althardstraße 141
Fax: 00 39-02-33 010 30 CH-8105 Regensdorf
Phone: 00 41-44-871-60 70
Japan Fax: 00 41-44-871-60 80
Nakamura Jico Co. Ltd.
10-10, Tsukiji, 3-chome
Chuo-Ku, Tokyo
Phone: 00 81-3-35 43-97 72
Fax: 00 81-3-35 43-97 79

Netherlands
GKN Service Benelux BV
Haarlemmerstraatweg 155-159
NL-1165 MK Halfweg
Phone: 00 31-20-40 70 207
Fax: 00 31-20-40 70 217

Copyright by Spicer Gelenkwellenbau GmbH

All rights reserved.
Any reproduction of this publication or parts thereof is subject to the
explicit authorization of the copyright-holder.
This catalogue supersedes all former editions.
We reserve the right to make alterations.
Release 07/2015

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Service and Repair Manual LH204
Dana Holding Corporation About the Dana GWB Products TM

is a world-leading supplier of driveline, Dana produces GWB industrial drive-

sealing, and thermal-management tech- shafts and genuine service parts for
nologies that improve the efficiency and the scrap steel, construction, railway,
performance of passenger, commercial, marine, and paper industries. Manu-
and off-highway vehicles with both con- facturing and assembly operations in
ventional and alternative-energy power- Germany are supported by Dana’s
trains. The company‘s global network global network of R&D and distribution
of engineering, manufacturing, and facilities.
distribution facilities provides original-
equipment and aftermarket customers
with local product and service support.
Based in Maumee, Ohio, Dana employs
approximately 24,500 people in 26
countries and reported 2011 sales of
$7.6 billion.

Trains Industrial plants Ships

Spicer Gelenkwellenbau GmbH

2. Schnieringstraße 49
45329 Essen / Germany

Phone: 00 49 (0) 201- 81 24 - 0
Fax: 00 49 (0) 201- 81 24 - 652

www.gwbdriveshaft.com
www.dana.com

APPLICATION POLICY
Capacity ratings, features, and specifications vary depending upon theCopyright
1094 (1146) model and © type of service. Application approvals must be obtained from Dana. We reserve the right to
Sandvik
change or modify our product specifications, configurations, orID:
dimensions at any
BG00398452 time
en-US without
A.001.1 notice.
2015-10-19

Service and Repair Manual LH204

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17.12 Tank breather filter

Tank Breather Filter

ELF/BF/BL/BLT/LU
Drymicron

Tank breather filters are

designed to filter the air Copyright © Sandvik 1097 (1146)
ID: BG00398452 en-US A.001.1 2015-10-19
entering oil tanks.
1.2. BF (TANK BREATHER FILTER) Non-flam fluids 1.2.1.3 Seals
Service
1.2.1. Technicaland Repair Manual
description Size HFA HFC HFD-R LH204
Polyurethane on the element
1.2.1.1 Filter housing 3 – – – 1.2.1.4 Special models and accessories
Construction 4 – – – – Filter type BF 3 with a check/
Tank breather filters size 3 and 4 bypass valve for improved pump
consist of a housing that can be 5 z z – suction
screwed on to the oil tank, and a 52 z z – – Clogging indicators for filter type
built-in filter element. 7 z z – BF 7 and BF 8
Note: 8 z z z – Tamper proof BF 3 (-DS)
When filters are fitted or removed
1.2.2. General
they must only be tightened or
Rapidly biodegradable fluids Temperature range
unscrewed at the hexagonal nut.
Size HTG HE HPG -30 °C to +100 °C
Sizes 5, 52 and 7 have housings
PAG PEG Weights
that can be screwed onto the tank
3 + + z z BF 3./-RV 0.38 kg
and have one or two
BF 3 0.33 kg
exchangeable filter element(s). 4 + + z z BF 4 0.08 kg
Size 8 consists of a flange for 5 + + z z BF 5 2.00 kg
mounting to the tank, an BF 52 2.60 kg
52 + + z z
exchangeable element and a cap. BF 7 0.40 kg
7 + + z z
1.2.1.2 Filter elements BF 8 12.4 kg
Hydac filter elements fulfil all ISO 8 + + z z
Symbol
test criteria.
Reliable filter operation is only + unlimited suitability
guaranteed for original Hydac - not suitable
filter elements.
z limited suitability
The filter elements are made from
phenolic resin impregnated paper
or from inorganic fibre (only for HFA oil in water emulsion
BF 8) and cannot therefore be ( H2O content ≥ 80%)
cleaned. HFC water polyglycol solution
Fluid compatibility (H2O content 35-55%)
The standard models are suitable HFD-R synthetic, water-free phosphate
for use with mineral and ester
lubrication oils. For use with non-
flam and rapidly biodegradable HTG vegetable oil based hydraulic
fluids, please see table: fluids
HE ester-based synthetic hydraulic Changing intervals
fluids The breather filter elements or
filters must be replaced as
HPG polyglycol-based synthetic
frequently as the fluid filters, but
hydraulic fluids
at least once per year.
PAG sub-group HPG:
polyalkylene glycol
PEG sub-group HPG:
polyethylene glycol

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6
Service and Repair Manual
1.2.3. Model code (also order example)
1.2.3.1 Complete filter
LH204
BF P 3 F 10 W 1. X /-RV

Filter type
BF
Filter material
BN (only BF 8)
BN/AM (only BF 8)
P
Size
3 (housing: steel, zinc-plated / synthetic coating)
4 (housing: steel, zinc-plated / synthetic coating)
5 (housing: steel)
7 (housing: glass fibre reinforced synthetic material)
8 (housing: steel, galvanised)
Type of connection
Type Filter size
BF 3 BF 4 BF 5 BF 52 BF 7 BF 8 G = threaded connection
F z to ISO 228
G¼ z F = flange connection
G½ z
G¾ z
G 3/8 z
G1 z
G2½ z z
Filtration rating in µm
10 = 1µm absolute (for BN, BN/AM, only for BF 8)
3 = 3µm absolute (for P)
10 = 10µm absolute (for P)
Type of clogging indicator
W = no port for clogging indicator
K = pressure gauge, measuring range -1 to +0.6 bar (only for BF 7 and BF 8)
Type code
G F ∆p [bar]
BF 3...1.0 G¾
BF 3...2.0 G 3/8
BF 3...3.0 G½
BF 3...4.0 /-RV G¾ 0.4
BF 3...5.0 /-RV G¾ 0.7
BF 3...6.0 /-RV G¾ 0.2
BF 3...7.0 /-RV G¾ 1.0
BF 4...1.0 G¼
BF 5...1.0 G2½
BF 52...1.0 G2½
BF 7...1.0 G1
BF 8...1.0 z
Modification number
X the latest version is always supplied
Supplementary details
RV check/bypass valve (only BF 3), not 100% air-tight or leakage-free
DS tamper proof (for BF 3 only)

1.2.3.2 Replacement element 0005 L 010 P

Size
0005 (for BF 5 and 52)
0007 (for BF 7)
0008 (for BF 8)
Type
L for air filter element
Filtration rating in µm
003
010
Filter material
P paper (for BF 5, 52 and 7)
BN Betamicron® (for BF 8)
Replacement element not available for size 3 and 4 Copyright © Sandvik 1099 (1146)
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7
1.2.4. Dimensions BF
Service and Repair ManualBF 4 G...
BF 3 G..., BF 3 G.../-RV BF 5 G...
LH204

Type BF 3G..1.0 BF 3G..2.0 Type BF 4 G...1.0 Type BF 5G..1.0

BF 3G.. /-RV d1 44 d1 177
d1 76 76 d2 G¼ d2 G2 ½ ISO 228
d2 G¾ G 3/8 ISO 228 h1 107
ISO 228 ISO 228 d5 8 h4 90
d5 19 12 h1 62
h1 79 72 h3 13,5
h3 16 12 SW 17
SW 36 22

Type BF 3G..3.0
d1 76
d2 G½
ISO 228
d5 15
h1 76
h3 1100 (1146)
14 Copyright © Sandvik
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SW 27
8
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Service and Repair Manual LH204

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Original instructions
Service and Repair Manual LH204
BG00418889 A.001.1 2014-08-05

17.13 Emergency radio Tele Radio Panther Operating Instructions

(option)

Operating instruction
Emergency Radio Tele Radio Panther

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instruction LH204

Copyright
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Table of Contents

1 Introduction ................................................................... 7
1.1 System description and main components ....................................... 7
1.2 Transmitter functions ...........................................................................8

2 System programming and testing ............................... 11

2.1 Programming the system .....................................................................11
2.2 Testing the system operation ..............................................................12

3 Technical specifications ...............................................15

3.1 Transmitter ............................................................................................ 15
3.2 Receiver .................................................................................................15

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1 INTRODUCTION
1.1 System description and main components
System description
The emergency radio system is designed to release the machine brakes
remotely in a rescue situation when machine is operated in a Radio
Remote Mode.
The system operating frequency is 2 405-2 480 MHz.
Note! The system shall not be used for a normal towing procedure!

Main components

1 2

1 Transmitter
2 Receiver; alternatively either 5 (left) or 11 (right) relays depending
on the model

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1.2 Transmitter functions

1 2 3

4 5 6

1110 (1146)
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Buttons
Button (1): Engine / electric motor stop
• Pressing the button stops the engine / electric motor.
Button (2): Releasing the parking brake
• Pressing the button connects the brake system magnetic valve. If the
brake system pressure is at a sufficient level brakes and hydrostatic
power transmission (if equipped) are released.
• NOTE! Brakes are released only as long as the buttons (2 & 4) are kept
pressed.
Button (3): Releasing the parking brake using the brake releasing pump
• Pressing the button connects the electrically driven pump to pressurize
the brake system to a sufficient level and releases the brakes and
hydrostatic power transmission (if equipped).
• NOTE! Brakes are released only as long as the buttons (3 & 4) are kept
pressed.
Button (4): Transmitter lock
• Pressing the button enables the use of buttons 1-3.
Button (5): Not in use
Button (6): Power ON / OFF
• Pressing the button turns the transmitter power ON / OFF.
• The power is turned off automatically if not used for 30 seconds. Power is
restored by pressing the button.

LED lights
The utmost LED light (A) is blinking (green light) when the power in the
transmitter is ON. The LED light is constantly on (green light) when any a
button is pressed. When the power is turned OFF from the transmitter the
upmost LED light blinks (red light) for a while.
The four LED lights between the buttons are not used in this application.

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2 SYSTEM PROGRAMMING AND TESTING

2.1 Programming the system
Safety precautions:

Only trained and authorized personnel may operate the system.

The emergency radio system works only when the engine / electric motor of
the machine is not running.
The emergency radio system is programmed in the factory before it is
delivered to the customer. The customer only needs to reprogram it in a
fault situation.
If the system needs to be reprogrammed, do the following:
1. Press the receiver Function button (A) until red LED (7) lights up.
2. Press the receiver Select button (B) until LEDs (1-5) light.
3. Press any transmitter button, e.g. button (1) until LEDs (1-10) flash 3
times befor going out.

Receiver with 6 relays

5 1 2 3 4 6

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Receiver with 11 relays

5 1 2 3 4 6

Erasing the transmitter

To erase transmitter(s) from the receiver, press the receiver Function
button (A) and Select button (B) at the same time until red LEDs (1-5) go
out.
NOTE! If red LED (7) flashes slowly, one or several transmitters are still
registered in the receiver.

2.2 Testing the system operation

Safety precautions:

Only trained and authorized personnel may operate the system.

The system and its components must be inspected and periodically
maintained. The condition of the system must be taken seriously because
system malfunction may cause the brakes and hydrostatic power
transmission to release abruptly with severe consequenses. If anything
looks suspicious, call a service person.
Make sure that there are no other emergency radio systems in use on the
same site and operating under the same frequency code.
Make sure that the transmitter batteries are kept in good condition for
disturbance-free operations.

1114 (1146)
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Maintain the emergency radio receiver box free of moisture. Condensation

build-up may cause the brakes to release by causing a short-circuit in a key
component in the receiver.
Do not leave the loader energized in the remote mode when not in use. The
remote control key-switch must be in the manual position 1.
The emergency system only works when the engine / electric motor of the
machine is not running.
After every 250 hours of operation the system function must be tested
as follows:
1. Enter the cabin.
2. Make sure the machine is parked on level and safe ground.
3. Start the machine.
4. Let the machine run until the brake pressure has reached a operating
limit.
• Do not release the brakes.
5. Turn the remote control key switch located in the instrument panel to the
position 2 (remote mode).
• Incase the machine shuts down move to the step 7.
6. Push the buttons (4) and (1) on the transmitter.
• The machine should shut down.
7. Push the button (4) constantly and push/release button (2) repeatedly
until low brake pressure indicator turns on.
8. Push the button (4) constantly and push button (3) to start the brake
release pump.
• Let the pump run until the low brake pressure indicator and brake
indicator light turns off and brakes are released.
9. If the system works as described you can turn the remote control key
switch back to the manual mode position (1).
Requirements after task
After testing the system the transmitter must be stored in a safe place
outside the machine. Do not store the transmitter in the operators cabin.
The transmitter must be available if an emergency situation occurs.

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3 TECHNICAL SPECIFICATIONS
3.1 Transmitter
Batteries 3 x 1.5 V AAA / LR03 Alkaline
Buttons 6 x 2-step buttons
Operating frequency 2.4 GHz
Channels 16 (channel 11-26)
Channel separation 5 MHz
Dublex communication No
Antenna 1 internal PCB antenna
Size 65 mm (2.6") x 112 mm (4.4") x 35 mm (1.4")
Weight 100 g (0.2 lbs)

3.2 Receiver
Digital inputs 8
Operating frequency 2405-2480 MHz
Channels 16 (channel 11-26)
Channel separation 5 MHz
Dublex communication No
PN-RX-MN5, PN-RX-MNB5, PN-RX-MD:11: 1
internal PCB antenna
Antenna
PN-RX-MN5E, PN-RX-MD11E: 1 external
antenna, reversed SMA
IP class 66
Operating temperature -20°C to +55°C / -4°F to +130°F
Size 120 mm (4.7") x 117 mm (4.6") x 51 mm (2")
Weight 400 g (0.8 lbs)

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www.sandvik.com

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Service and Repair Manual LH204

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7(/(5$',23$17+(5
Service and Repair Manual LH204

17.14 Emergency Radio Installation and User Instructions (optional)

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ID: BG00398452 en-US A.001.1 2015-10-19

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