EJC 245

FOR SERIAL NUMBER: 245-3729

OPERATOR’S
MANUAL
Operator’s Manual - English
© 2004 EJC Mining Equipment Inc.
Technical Publications Department
4445 Fairview Street
Burlington, Ontario
Canada L7L 2A4
Tel: (905) 632-4940
Fax: (905) 632-2172
E-mail: tech.pubs@sandvik.com
 Table of Contents
Introduction .............................................................................2-1
Intended Use of Operator’s Manual ........................................................................... 2-1
Intended Use of Machine ........................................................................................... 2-1
Machine Identification ................................................................................................ 2-2
Safety Notations in Operator’s Manual ...................................................................... 2-2
Loader Components .................................................................................................. 2-3
Loader Orientation ..................................................................................................... 2-4
General Safety Procedures ....................................................3-1
Important .................................................................................................................... 3-1
Typical Work Cycle .................................................................................................... 3-1
Correct Operation ...................................................................................................... 3-2
Incorrect Operation .................................................................................................... 3-3
Fire Prevention .......................................................................................................... 3-4
Optional Fire Extinguisher ......................................................................................... 3-4
Optional Fire Suppression System ............................................................................ 3-4
Optional ROPS/FOPS Canopy .................................................................................. 3-5
Back-Up Alarm ........................................................................................................... 3-5
Controls ....................................................................................4-1
Important .................................................................................................................... 4-1
Operator’s Seat ......................................................................................................... 4-2
Steer Control Lever.................................................................................................... 4-3
Boom/Bucket Control Lever....................................................................................... 4-3
Transmission Control Levers ..................................................................................... 4-3
Emergency Stop Button ............................................................................................. 4-4
Fire Suppression Button (If fitted) .............................................................................. 4-5
Instrument Panel........................................................................................................ 4-5
Master Disconnect Switch (Not Shown) .................................................................... 4-5
Accelerator Pedal (Not Shown) ................................................................................. 4-6
Service Brakes Pedal (Not Shown) ........................................................................... 4-6
Instruments ..............................................................................5-1
Important .................................................................................................................... 5-1
Tow Switch................................................................................................................. 5-2
Brake Impending Light............................................................................................... 5-2
Engine Coolant Temperature Gauge ......................................................................... 5-4
Engine Oil Pressure Gauge ....................................................................................... 5-4
Voltmeter.................................................................................................................... 5-4
Front Lights Switch .................................................................................................... 5-4
Check Engine Light.................................................................................................... 5-6
Rear Lights Switch..................................................................................................... 5-6
Park/Emergency Brake Light/Button.......................................................................... 5-6
Audible Alarm ............................................................................................................ 5-8
Dimmer Switch........................................................................................................... 5-8
Brake Fault Light/Button ............................................................................................ 5-8
Converter Oil Temperature Gauge........................................................................... 5-10
Converter Oil Pressure Gauge ................................................................................ 5-10
Hourmeter................................................................................................................ 5-10
Stop Engine Light/Button ......................................................................................... 5-12

I
 Table of Contents

Horn Button.............................................................................................................. 5-12

Ignition Switch.......................................................................................................... 5-14
Diagnostic Port ........................................................................................................ 5-14
Starting the Engine/Motor ......................................................6-1
Stopping the Engine/Motor ....................................................7-1
Brake Tests ..............................................................................8-1
Service Brakes Test ................................................................................................... 8-1
Park Brake Test ......................................................................................................... 8-2
Operating the Bucket/Dump Box ...........................................9-1
Important .................................................................................................................... 9-1
Boom/Bucket Control Lever ....................................................................................... 9-1
Work Cycle .............................................................................10-1
Tramming ................................................................................................................. 10-1
Braking ..................................................................................................................... 10-2
Loading .................................................................................................................... 10-3
Dumping .................................................................................................................. 10-3
Parking ..................................................................................................................... 10-4
Operating Hints .....................................................................11-1
Maintenance and Check Points ...........................................12-1
Introduction .............................................................................................................. 12-1
Engine Off ................................................................................................................ 12-1
Engine On ................................................................................................................ 12-5
Greasing the Machine ...........................................................13-1
Automatic Greasing System .................................................................................... 13-1
Troubleshooting ....................................................................14-1
Important .................................................................................................................. 14-1
Engine Will Not Crank Over ..................................................................................... 14-1
Engine Will Crank Over But Not Start ...................................................................... 14-2
Engine Stalls During Operation ................................................................................ 14-2
Excessive Exhaust Smoke ...................................................................................... 14-2
Engine Misfiring ....................................................................................................... 14-3
Engine Knocking ...................................................................................................... 14-3
Engine Oil Pressure Low ......................................................................................... 14-3
Engine Overheats .................................................................................................... 14-3
Hydraulic Oil Foams ................................................................................................ 14-4
Torque Converter/Transmission Overheats ............................................................. 14-4
Machine Will Not Move ............................................................................................ 14-4
Loss of Power .......................................................................................................... 14-4
Machine Will Not Turn .............................................................................................. 14-5
Little or No Dump Box/Bucket Action ....................................................................... 14-5
Defective Lighting System ....................................................................................... 14-5
Air Venting the Fuel System .................................................................................... 14-6

II
 Introduction

Intended Use of Operator’s Manual

1. Only trained, authorized personnel shall operate and service this machine.
2. The Operator’s Manual is intended as a guide for the correct use and daily maintenance of
this machine. For periodical maintenance, see Service Manual. For parts, see Parts Manual.
3. The Operator’s Manual is an important part of the machine, and should be available to the
operator at all times.
4. The Operator’s Manual shall be read carefully before starting and operating the machine, or
before carrying out any preventive maintenance.
5. The Operator’s Manual should be replaced immediately if lost or unreadable.
6. If any part of this manual is not clearly understood, contact the original equipment
manufacturer. Always quote model number and serial number to request information. Each
individual machine is custom built to satisfy requirements of the mine site, and to comply
with the laws of the country in which the mine site is located.
EJC Mining Equipment Inc.
Technical Publications Department
4445 Fairview Street
Burlington, Ontario
Canada L7L 2A4
Tel: (905) 632-4940
Fax: (905) 632-2172
E-mail: tech.pubs@sandvik.com

Intended Use of Machine

1. EJC loaders are designed to load, haul, and dump rock material exclusively. EJC trucks are
designed to transport and dump rock material exclusively. Intended use also includes
following all operating, inspection, and maintenance instructions in this manual.
2. This machine shall only be used:
• for its intended use
• when it is in proper technical condition
• by an operator aware of safe operating procedures and possible danger
• in strict notice and use of the operator’s manual.
3. Unintended and careless use of this machine may adversely affect the health of the operator
or third persons, or prejudice the machine and other properties. The operator must exercise
care and common sense when operating this machine.
4. Always obey local safety rules related to accident prevention and environmental protection.

S01001/07/00-A 2-1
 Introduction

Machine Identification
Each machine is identified by model number and serial number. The machine model and serial
number are displayed on the name plate, and on the front cover of all manuals.
The name plate is located in the operator’s compartment.

Figure 1: Name Plate

Safety Notations in Operator’s Manual

1. Throughout the Operator's Manual, the following safety notations appear. Follow these
notations, and local government regulations at all times.
2. NOTES will always appear in italics.
NOTE: Indicates a procedure or condition that is essential for the operator to know.
3. CAUTIONS will always appear in bold italics.
CAUTION: Indicates an action or condition that, if not followed, could cause damage to the
machine or other equipment.
4. WARNINGS will always appear in bold preceded by a warning triangle. This symbol, with
a warning statement, means “Warning, be alert! Your safety is involved!” Carefully read the
message that follows.
This indicates an action or procedure that, if not followed, could cause personal injury
or death.

S01001/07/00-A 2-2
 Introduction

Loader Components

4 5 3 1
8 9 2

6 7

Figure 2: Loader Components (Side View)

No. Item Purpose

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

2. Lift Arms Raise and lower the bucket.
3. Front Frame Supports the bucket, lift arms, and components
required to run the machine.
4. Rear Frame Supports engine, transmission, and other components
required to run the machine.
5. Center Hinge Connects the front and rear frames. The front and rear
frames pivot around the center hinge to steer the
machine right and left.
6. Outrigger Contains engine components. The outrigger is also
known as skirt.
7. Tires Tires carry the weight of the machine and its load.
8. Operator’s Compartment The operator sits in the operator’s compartment to
(standard location) control the machine.
9. Operator’s Compartment
(EJC 115 LP location)

S01001/07/00-A 2-3
 Introduction

Loader Orientation
1. The front end of the loader is the bucket end.
2. The rear end of the loader is the engine end.
3. Left and right of the machine are referred to by standing at the rear of the machine and
looking towards the bucket.
4. The operator’s compartment where the operator sits, is on the left side of the machine.

LEFT

REAR FRONT

RIGHT

Figure 3: Loader Orientation

S01001/07/00-A 2-4
 General Safety Procedures

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

! WARNING!

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

! WARNING!

Only trained authorized personnel shall operate this machine.

To operate this machine safely:
1. Carefully review and understand the contents of this manual before operating this machine.
2. Know all of the machine's capabilities and functions.
3. Follow all safety and operational procedures contained in this manual.
4. Keep the machine in a clean, well maintained condition.
5. Immediately report any faults for immediate corrective action.

Typical Work Cycle

1. Inspect the machine and perform any required maintenance the operator is authorized to do
while the engine is off.
2. Start the engine.
3. Inspect the machine and perform any required maintenance the operator is authorized to do
while the engine is on.
4. Raise and lower the main implement.
5. Test the park and service brakes according to the brake test procedures in this manual.
6. If the machine is functioning normally, begin operating the machine.
7. If the machine is not functioning normally, shut it down and report the faults immediately.
8. Do not operate the machine again until the faults have been corrected.

S02001/11/03 3-1
 General Safety Procedures

Correct Operation
1. ALWAYS keep all decals on the machine in legible condition. Observe and follow them at
all times.
2. ALWAYS make sure that all gauges, the horn, and indicator lights function properly.
3. ALWAYS report any damage or faulty operation immediately. DO NOT operate the
machine until the faults are corrected.
4. ALWAYS tag the steer control lever to alert other personnel when any machine component
has been disconnected.
5. ALWAYS disconnect the frame lock in the center hinge area before operating the machine.
6. ALWAYS be seated and wear the seat belt (if fitted) when operating the machine.
7. ALWAYS make sure that the transmission is in neutral before starting the engine. During
idle periods, shift the transmission to neutral and apply the park brake.
8. ALWAYS sound the horn for a few seconds before starting the engine/motor to alert other
personnel in the area. Sound the horn frequently during the shift if visibility is reduced.
9. ALWAYS start the engine while sitting in the operator’s seat.
10. ALWAYS test all brakes before starting the shift, and before operating the machine on
grades.
11. ALWAYS keep hands, arms, head, etc. inside the operator's compartment.
12. ALWAYS drive carefully, observe traffic rules and be in full control of the machine.
13. ALWAYS use extreme caution when moving the machine with the main implement (bucket
or dump box) raised. Whenever possible, lower the main implement to the “carry” position
before driving.
14. ALWAYS park on level ground, if possible.
15. ALWAYS turn the machine into a side wall, or block all wheels on both sides of each wheel
if parking on a grade.
16. Except in case of emergency, ALWAYS shut off the engine before turning the master
disconnect switch to the “OFF” position.
17. ALWAYS turn the master disconnect switch to the “OFF” position before working on or
around electrical connections.
18. ALWAYS install the frame lock before working in the centre hinge area or transporting the
machine.
19. ALWAYS stop the engine before filling the fuel tank!
20. ALWAYS refill the fuel tank at the end of each operating period to prevent condensation
from contaminating the fuel.
21. ALWAYS maintain three points of contact when climbing on the machine. For example, one
hand and both feet, or both hands and one foot.

S02001/11/03 3-2
 General Safety Procedures

Incorrect Operation
1. NEVER use the machine for anything other than its intended purpose. EJC trucks are
designed to transport and dump rock material exclusively. EJC loaders are designed to load,
haul and dump rock material exclusively.
2. NEVER use the steer control lever as a hand hold when mounting or dismounting the
machine. The machine may turn even when the engine/motor is stopped.
3. NEVER operate the machine unless all required preventive maintenance has been
performed.
4. NEVER operate the machine unless all electrical boxes are closed tight.
5. NEVER start the machine unless:
• area near the machine is clear
• all covers are installed
• park brake is applied
• transmission control lever is in the NEUTRAL position.
6. NEVER attempt to start the machine by towing.
7. NEVER allow riders in the operator's compartment, in the main implement (bucket or dump
box), or on any other part of the machine.
8. NEVER raise the dump box on a dump truck, if the dump truck is on a slope and the dump
truck is turned.
9. NEVER allow the machine to roll backward with the transmission in forward while working
on steep grades.
10. NEVER drive near or beside a walking person.
11. NEVER leave the machine unattended unless:
• main implement (bucket or dump box) is fully lowered
• transmission control lever is in the NEUTRAL position
• park brake is applied
• engine/motor is switched off and has stopped.
12. NEVER service or adjust the machine when it is in motion. NEVER service or adjust
hydraulic components under pressure.
13. NEVER stand or allow other personnel to stand in the centre articulation area unless the
frame lock is installed and the steer pressure has been bled off to zero.
14. NEVER service electrical parts on an electric-powered machine, unless the trailing cable
has been disconnected. It must not be connected again unless all parts are properly
connected. Use only EJC service parts to ensure that they are identical to parts originally
fitted.

S02001/11/03 3-3
 General Safety Procedures

Fire Prevention
1. Keep the machine clean.
2. Keep all electrical wiring and components in good working order.
3. Ensure that the engine air intake, fuel and exhaust systems in diesel machines are
maintained properly.
4. Keep fire fighting equipment in working order. Know where it is located, and how to use it.
This may require training beyond the scope of this manual.

Optional Fire Extinguisher

NOTE: The location of the optional fire extinguisher is determined by the customer.
In case of fire, do the following.
1. Stop the machine and shut the engine off.
2. Move to a safe distance away from the fire. Determine the location and size of the fire.
3. Remove fire extinguisher from the machine.
4. Hold fire extinguisher upright.
5. Follow instructions on fire extinguisher for correct use.
6. Aim the spray of the fire fighting chemical at the base of the fire until the fire is out.
7. Make sure the fire is out and can not start again.
8. Report the fire immediately.
9. The fire extinguisher must be refilled by trained authorized personnel.
10. The machine must be cleaned and serviced by trained authorized personnel before it is put to
work again.

Optional Fire Suppression System

The optional fire suppression system is activated by two large red buttons. One button is located
in the operator’s compartment. The other button is located on the frame of the machine. Each
button is fitted with a safety lockout ring to prevent accidental activation of the fire suppression
system.
In case of fire, do the following.
1. Stop the machine and shut the engine off.
2. Grasp the ring pull and pull it hard away from the button. This removes the safety lockout
device.
3. Strike the top of the red button, hard. This causes fire suppressing chemicals to be expelled
into various areas of the machine to suppress the fire.

S02001/11/03 3-4
 General Safety Procedures

! WARNING!

The fire suppression system is designed to suppress fires in their early stages. Do not
hesitate-if you detect a fire on the machine, activate the fire suppression system
immediately. The earlier you do this, the more effective the system will be.
4. Move to a safe distance away from the fire. Report the fire immediately.
5. The machine must be cleaned and serviced by trained authorized personnel before it is put to
work again.

Optional ROPS/FOPS Canopy

Description
Roll Over Protective Structures (ROPS) are overhead structures designed to reduce the possibility
of operators from being crushed if the machine they are operating should roll over.
Fall Over Protective Structures (FOPS) are overhead structures that protect operators from falling
objects such as loose rock.

! WARNING!

Always wear seat belt.

Certification
Each new ROPS/FOPS has a certification plate that lists the standards to which it was certified.
The certification plate should be displayed on the ROPS/FOPS at all times.
NOTE: Replace the certification plate as soon as possible if it is missing or illegible. Contact the
original equipment manufacturer if a replacement is required.

! WARNING!

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

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

Back-Up Alarm
If the machine is equipped with an optional back-up alarm, an audible alarm sounds when the
transmission is engaged in reverse direction.

S02001/11/03 3-5
 General Safety Procedures

Notes

S02001/11/03 3-6
 Controls

Important
This section contains a description, the location, and the function of the various controls used to
operate the machine The operator must know the location and function of all of them.
NOTE: The numbers on the illustration refer specifically to the item described in each paragraph.

7
3

2 6

Figure 1: Operator’s Compartment

S03008/05/03 4-1
 Controls

1. Operator’s Seat
The operator’s seat is adjustable for comfort.
1. To adjust the lower back support, turn dial (1) to the desired position.
2. To adjust suspension, turn dial (2) until the operator’s approximate weight appears in the red
zone.
3. To adjust the position of the back rest, pull the lever (3) up.
4. To slide the entire seat backwards or forwards, pull up and hold lever (4).
5. Lower arm rests (if fitted) until they are horizontal. To tilt the arm rests up, turn knob
underneath the arm rest towards you. To tilt the arm rest down, turn the knob away from
you.
6. When the entire seat is in the desired position, fasten the seat belt. Adjust length through
plastic slide so that it fits low around the waist and snug across the lap.
NOTE: The seat belt is available only on machines equipped with ROPS or FOPS canopy.

! WARNING!

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

Figure 2 : Operator’s Seat - ISRI6000 Model

S03008/05/03 4-2
 Controls

2. Steer Control Lever

The steer control lever controls the direction of the machine as it travels. When the lever is moved
to the left or right, the steer cylinder extends or retracts causing the machine to turn on the center
pivot.
To steer the machine, move the lever in the direction you want the machine to turn.
1. To turn the machine right while the machine is moving forward, push the steer control lever
away from you.
2. To turn the machine left, pull the steer control lever toward you.

3. Boom/Bucket Control Lever

Moving the boom/bucket control lever causes the lift cylinders or the dump cylinders to extend or
retract. The lever moves in four directions as seen from the operator’s seat: right, left, forward and
backward.
1. To raise the lift arms, move the lever to the right.
2. To lower the lift arms, move the lever to the left.
3. To dump (tip) the bucket, move the lever forward, away from the operator’s seat.
4. To roll back the bucket, move the lever backward, toward the operator’s seat.

Figure 3 : Boom/Bucket Control Lever

4. Transmission Control Levers

Direction Control Lever (A)

The right lever is the direction control lever, and has three positions: forward (F), neutral (N), and
reverse (R).
1. To select forward direction, move the direction control lever to the “F” position.
2. To select reverse direction, move the direction control lever to the “R” position.

S03008/05/03 4-3
 Controls

3. To select neutral, move the direction control lever to the “N” position.
CAUTION: Stop the machine before changing direction.

! WARNING!

Although the machine is fitted with a safety device to prevent start up of the engine while
forward or reverse direction is selected, always physically check that the direction control
lever is in the neutral (N) position before starting the engine.
Gear Selection Lever (B)
The left lever is the gear selection lever and will have 1 to 4 positions: first gear (1) at the bottom,
then up to second gear (2), then up to third gear (3), and fourth gear (4) at the top of the gate.

Figure 4 : Transmission Control Levers

5. Emergency Stop Button

The emergency stop button disconnects power to the engine when pressed. This button should be
used if an emergency arises.

! WARNING!

The emergency parking brakes will automatically apply when the emergency stop button is
pressed. Be prepared for a sudden stop.

S03008/05/03 4-4
 Controls

6. Fire Suppression Button (If fitted)

This is a RED button mounted in the operator’s compartment. It has a safety lockout device to
prevent accidental activation of the fire suppression system.
To activate the system in event of a fire on the machine, do the following.
1. Grasp the ring pull and pull it hard away from the button. This will remove the safety
locking ring.
2. Strike hard the top of the red button. This will cause fire suppressing chemicals to be
dumped in various areas of the machine to extinguish the fire.

! WARNING!

The fire suppression system is designed to extinguish fires in their early stages. Do not
hesitate! If you detect a fire on the machine, activate the fire suppression system
immediately. The earlier you do this, the more effective the system will be.

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

8. Master Disconnect Switch (Not Shown)

The master disconnect switch has two positions: “ON” and “OFF”.
1. To operate the machine, first turn the master disconnect switch to the “ON” position.
NOTE: Turn the engine off before turning the master disconnect switch to the “OFF” position.
2. Turn the master disconnect switch to the “OFF” position before leaving the machine
unattended or performing electrical repairs.

Figure 5 : Master Disconnect Switch

S03008/05/03 4-5
 Controls

9. Accelerator Pedal (Not Shown)

This is the right pedal on the floor of the operator’s compartment.
1. To increase the speed of the engine, press the pedal.
2. To decrease the speed of the engine, release the pedal.

10. Service Brakes Pedal (Not Shown)

This is the left pedal on the floor of the operator’s compartment.
1. Press the service brakes pedal to apply the service brakes during normal operations.The
further down the pedal is pressed, the greater the braking effort.
2. Release the pedal to release the service brakes.
NOTE: Wherever possible, use the deceleration of the engine to slow the machine down, finally
stopping it with the service brakes. Avoid resting your foot on the service brakes pedal, as
this will cause a light application of the brakes, with resulting excessive heat and wear on
brake components.

S03008/05/03 4-6
 Instruments

Important
This section contains a description, location and function of the various controls used to operate
the machine. The operator must know the location and function of all of them.
NOTE: The numbers on the illustration refer specifically to the item described in each paragraph.

Figure 1: Instrument Panel

S04091/12/03 5-1
 Instruments

1. Tow Switch
The tow switch is a key operated switch used during the tow procedure to energize the front and
rear solenoids. When the solenoids are energized, maintenance personnel are able to pump oil to
the brakes and release them.
1. After inserting the proper key, turn the key switch to the right to energize the solenoids.
NOTE: For more information, refer to “Towing the Machine” in the Service Manual.

! WARNING!

Only release the brakes under the strict supervision of the mechanical supervisor. The
park/emergency brake will not work while the machine is in tow mode. Ensure that the
machine is securely blocked with wheel chocks or is securely connected to a towing vehicle
before releasing the brakes.

2. Brake Impending Light

When illuminated, this yellow light indicates that the brakes are about to apply automatically.
The following conditions will cause the light to illuminate:
• clutch oil pressure drops to 150 PSI (10 Bar)
• engine oil pressure drops below 12 PSI (0.8 Bar)
• brake accumulator pressure drops to 1600 PSI (110 Bar)
NOTE: The brake fault light will also illuminate if brake accumulator pressure drops to 1600 PSI
(110 Bar).
NOTE: The light will remain on while pressures are low.

! WARNING!

If this light illuminates during normal operations, be prepared for a sudden stop. Observe
the instrument panel frequently.

S04091/12/03 5-2
 Instruments

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

Figure 2 : Instrument Panel

1. Tow Switch 11. Dimmer Switch

2. Brake Impending Light 12. Brake Fault Light/Button
3. Engine Coolant Temperature Gauge 13. Converter Oil Temperature Gauge
4. Engine Oil Pressure Gauge 14. Converter Oil Pressure Gauge
5. Voltmeter 15. Hourmeter
6. Front Lights Switch 16. Stop Engine Light/Button
7. Check Engine Light 17. Horn Button
8. Rear Lights Switch 18. Ignition Switch
9. Park/Emergency Brake Light/Button 19. Diagnostic Data Link
10. Audible Alarm

S04091/12/03 5-3
 Instruments

3. Engine Coolant Temperature Gauge

The engine coolant temperature gauge indicates the operating temperature of the engine coolant.
Normal operating temperature for the DDEC engine should be 190° to 210° F (88° to 99° C). The
maximum allowable temperature is 235° F (113° C). Should the engine temperature rise above
210° F (99° C) for an extended period of time, the engine will shut down automatically.
NOTE: Normal operating ranges may be represented on the gauge dial as a green zone. Unsafe
operating range may be represented as a red zone.

4. Engine Oil Pressure Gauge

The engine oil pressure gauge monitors the oil pressure in the lube site of the DDEC engine.
Normal oil pressure at operating temperature should be 50 PSI (3.45 bar). Minimum
recommended pressure at low idle is 12 PSI (0.8 Bar).
NOTE: Normal operating range is represented on the gauge dial as a green zone. Unsafe
operating range is represented as a red zone.
CAUTION: If the stop engine light/button illuminates, check the oil pressure gauge. If the oil
pressure is below 7 PSI (0.5 bar), shut down the engine immediately to prevent internal
damage. Do not operate the machine until corrective action has been taken.
The brakes will automatically apply if the engine oil pressure drops below 7 PSI (0.5 bar).
Be prepared for a sudden stop.

5. Voltmeter
The voltmeter indicates the system voltage when the electrical system is switched on. The normal
operating range is between 26V and 30V.

6. Front Lights Switch

Use this switch to turn the front lights on and off.
1. To turn the front lights on, turn the switch clockwise.
2. To turn the front lights off, turn the switch counter-clockwise.

S04091/12/03 5-4
 Instruments

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

Figure 3 : Instrument Panel

1. Tow Switch 11. Dimmer Switch

2. Brake Impending Light 12. Brake Fault Light/Button
3. Engine Coolant Temperature Gauge 13. Converter Oil Temperature Gauge
4. Engine Oil Pressure Gauge 14. Converter Oil Pressure Gauge
5. Voltmeter 15. Hourmeter
6. Front Lights Switch 16. Stop Engine Light/Button
7. Check Engine Light 17. Horn Button
8. Rear Lights Switch 18. Ignition Switch
9. Park/Emergency Brake Light/Button 19. Diagnostic Data Link
10. Audible Alarm

S04091/12/03 5-5
 Instruments

7. Check Engine Light

When illuminated, this light indicates that there is a fault in the engine’s ability to communicate
with fluid, pressure, temperature, and/or engine speed sensors. This light will remain illuminated
until the problem has been corrected.
NOTE: Both the check engine light and the stop engine light will come on at start up, indicating
that the system is connected and functioning. Both lights will go out if the DDEC engine’s
Electronic Control Module does not find a fault.

8. Rear Lights Switch

Use this switch to turn the rear lights on and off.
1. To turn the rear lights on, turn the switch clockwise.
2. To turn the rear lights off, turn the switch counter-clockwise.

9. Park/Emergency Brake Light/Button

The large red park brake light/button is used to apply or release the park brake. The light is on
when the park brake is applied.
1. To apply the park brake, press the button. The light will go on.
2. To release the park brake, pull the button out fully. When the button is released, it will
spring back to the middle position and the light will go out.

! WARNING!

The fact that the light is on is not proof that the park brake is functioning effectively. Test
the park brake at the beginning and end of each operation period, before operating on an
incline, and before leaving the machine unattended. See park brake test procedure.

S04091/12/03 5-6
 Instruments

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

Figure 4 : Instrument Panel

1. Tow Switch 11. Dimmer Switch

2. Brake Impending Light 12. Brake Fault Light/Button
3. Engine Coolant Temperature Gauge 13. Converter Oil Temperature Gauge
4. Engine Oil Pressure Gauge 14. Converter Oil Pressure Gauge
5. Voltmeter 15. Hourmeter
6. Front Lights Switch 16. Stop Engine Light/Button
7. Check Engine Light 17. Horn Button
8. Rear Lights Switch 18. Ignition Switch
9. Park/Emergency Brake Light/Button 19. Diagnostic Data Link
10. Audible Alarm

! WARNING!

S04091/12/03 5-7
 Instruments

10. Audible Alarm

The audible alarm sounds under two possible situations.
Brake Fault
The audible alarm sounds if accumulator pressure falls below 1600 PSI (110 Bar).
To acknowledge the alarm and stop the alarm from sounding, press the brake fault light/button.
After a delay of 32 seconds, the alarm will sound again if the fault has not been corrected.
CAUTION: If the audible alarm sounds, bring the machine to a controlled stop and shut down the
engine immediately.
CAUTION: Press the brake fault light/button to silence the alarm only if corrective action is being
taken.

Controller Fault
The audible alarm will sound if a fault in the IQAN controller occurs.
CAUTION: If the audible alarm sounds as a result of a controller fault, bring the machine to a
controlled stop and shut down the engine immediately. Do not operate the machine
until corrective action is taken.

11. Dimmer Switch

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

12. Brake Fault Light/Button

The red brake fault light/button indicates a fault in the brake hydraulic circuit and provides a
means to silence the audible alarm while troubleshooting is being performed.
CAUTION: If this light illuminates, bring the machine to a controlled stop immediately. Do not
operate the machine until the cause of the warning has been determined and corrective
action is being taken.
An alarm will sound shortly after the light illuminates. The alarm will continue to sound until the
fault is corrected or acknowledged.
To acknowledge the fault and silence the alarm, press the light/button in. If the condition that
caused the alarm still exists, the light will remain on and the alarm will sound again.
The brakes will apply automatically if the brake system accumulator pressure falls below
1400 PSI (97 Bar). Be prepared for a sudden stop.

S04091/12/03 5-8
 Instruments

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

Figure 5 : Instrument Panel

1. Tow Switch 11. Dimmer Switch

2. Brake Impending Light 12. Brake Fault Light/Button
3. Engine Coolant Temperature Gauge 13. Converter Oil Temperature Gauge
4. Engine Oil Pressure Gauge 14. Converter Oil Pressure Gauge
5. Voltmeter 15. Hourmeter
6. Front Lights Switch 16. Stop Engine Light/Button
7. Check Engine Light 17. Horn Button
8. Rear Lights Switch 18. Ignition Switch
9. Park/Emergency Brake Light/Button 19. Diagnostic Data Link
10. Audible Alarm

S04091/12/03 5-9
 Instruments

13. Converter Oil Temperature Gauge

The converter oil temperature gauge indicates the temperature of the oil in the torque converter
and transmission.
NOTE: Normal temperature range is from 180° F (82° C) to 200° F (93° C). This may be
represented as a green zone on the gauge dial. Unsafe temperature range is from 225° F
(107° C) to 250° F (121° C). This may be represented by a red zone on the gauge dial.
If the converter oil temperature rises above 225° F (107° C), do the following.
1. Bring the machine to a controlled stop, then apply park brake.
2. Put the transmission in neutral and rev the engine to approximately half throttle (1000
RPM).
3. Observe the converter oil temperature gauge.
CAUTION: Shut down the engine if the temperature does not begin to fall within two minutes.
Corrective action must be taken.
4. Run the engine at half throttle until the gauge needle has fallen well into the green zone, or
the normal operating range of 180° F (82° C) to 200° F (93° C).
NOTE: An overheating torque converter can be caused by poor maintenance, such as a dirty
cooler, low oil level, or by poor operating habits, such as using too high or too low a gear
during loading or tramming. Ensure the fault is not poor operating habits.

14. Converter Oil Pressure Gauge

The Converter oil pressure gauge indicates the clutch pressure in the transmission. The normal
operating pressure is between 240 PSI (17 Bar) and 300 PSI (21 Bar).
CAUTION: Do not operate the machine with a clutch pressure gauge of 210 PSI (15 Bar) or less.
Corrective action must be taken.

! WARNING!

Brakes will automatically apply if the clutch pressure drops below 60 PSI (4 Bar). Be
prepared for a sudden stop. Check the instrument panel frequently.

15. Hourmeter
The hourmeter registers the total running hours of the machine. If the hourmeter stops working,
inform supervisor.

S04091/12/03 5-10
 Instruments

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

Figure 6 : Instrument Panel

1. Tow Switch 11. Dimmer Switch

2. Brake Impending Light 12. Brake Fault Light/Button
3. Engine Coolant Temperature Gauge 13. Converter Oil Temperature Gauge
4. Engine Oil Pressure Gauge 14. Converter Oil Pressure Gauge
5. Voltmeter 15. Hourmeter
6. Front Lights Switch 16. Stop Engine Light/Button
7. Check Engine Light 17. Horn Button
8. Rear Lights Switch 18. Ignition Switch
9. Park/Emergency Brake Light/Button 19. Diagnostic Data Link
10. Audible Alarm

S04091/12/03 5-11
 Instruments

16. Stop Engine Light/Button

Light
When the engine starts, this light will come on for 5 seconds.
When this light comes on during normal operations, it indicates that there is a fault in engine fluid
levels, pressures or temperatures. This fault may damage the engine.
CAUTION: If the stop engine light remains on, or comes on during operations, shut down the
engine immediately. Do not operate the machine until corrective action has been taken.
The following conditions will trigger the warning light and audible alarm:
• engine oil pressure gauge needle at or below 7 PSI (0.5 Bar);
• engine coolant temperature gauge needle at or above 210° F (99° C);
• engine coolant level too low;
• converter and transmission oil pressure gauge needle in at or below 60 PSI (4 Bar).
Button
To acknowledge the engine fault warning, press the button.
NOTE: To troubleshoot an engine fault, press in the button. The light will flash a code which
identifies the cause of the engine fault. If everything is normal, the stop engine light will
flash two (2) times slowly, then five (5) times quickly. This code is 25. Other codes are
located in the Detroit Diesel Engine Operator’s Manual and Detroit Diesel
Troubleshooting Manual. To correct the engine fault, consult the Diagnostic Data Link
and the Detroit Diesel Troubleshooting Manual.

! WARNING!

Brakes will automatically apply if engine oil pressure falls below 7 PSI (0.5 bar). Be
prepared for a sudden stop.

17. Horn Button

Always sound the horn before starting the engine/motor. Sound the horn frequently in areas of
low visibility and/or frequent traffic.
1. Press the horn button to sound the horn.
2. Release the horn button to stop the horn from sounding.

S04091/12/03 5-12
 Instruments

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

Figure 7 : Instrument Panel

1. Tow Switch 11. Dimmer Switch

2. Brake Impending Light 12. Brake Fault Light/Button
3. Engine Coolant Temperature Gauge 13. Converter Oil Temperature Gauge
4. Engine Oil Pressure Gauge 14. Converter Oil Pressure Gauge
5. Voltmeter 15. Hourmeter
6. Front Lights Switch 16. Stop Engine Light/Button
7. Check Engine Light 17. Horn Button
8. Rear Lights Switch 18. Ignition Switch
9. Park/Emergency Brake Light/Button 19. Diagnostic Data Link
10. Audible Alarm

S04091/12/03 5-13
 Instruments

18. Ignition Switch

This rotary switch has three positions: ON, OFF and START. Turned fully clockwise to the left is
the OFF position.
1. Turn the switch one position clockwise to switch the electrical system on.
2. Turn and hold the switch to the extreme clockwise position to start the engine/motor.

! WARNING!

Never leave the machine (except in case of emergency) unless the ignition switch is turned to
the OFF position, as the steering pressure will not bleed off until the switch is off.

19. Diagnostic Port

The diagnostic port is for the Diagnostic Data Link (DDL), which executes precise tests on the
engine and the Electronic Control Module. Use the DDL in conjunction with the test outlined in
your Detroit Diesel Troubleshooting Manual.
NOTE: The Diagnostic Data Link (DDL) can be purchased from your local EJC representative.

S04091/12/03 5-14
 Starting the Engine/Motor

! WARNING!

Never attempt to start the engine/motor without first knowing how to shut it off.
CAUTION: Check the engine for correct oil level before starting the engine.
CAUTION: Check the transmission for presence of oil before starting the engine/motor.

! WARNING!

Before starting the engine/motor, sound the horn and make sure that the area is clear,
especially between the front and rear frames.
1. Make sure that the frame lock is in the storage position.
2. Turn the master disconnect switch to the “ON” position.
3. Sit in the operator's seat. Adjust seat as desired. Wear seat belt if machine is equipped with a
canopy.
4. Make sure that the park brake is applied.
5. Make sure that the transmission is in neutral.
6. If the instrument panel is equipped with a main circuit breaker, turn the main circuit breaker
to the “ON” position.
7. Turn the ignition switch to the “ON” position.
NOTE: The check engine warning light and the stop engine warning light will come on. This is
the Electronic Control Module (ECM) diagnosing the system to ensure everything is
functional. If all conditions are normal, the warning lights should go out after
approximately 5 seconds. If the warning lights do not go out, consult Detroit Diesel
Service Manual for diagnostic procedures.
8. After the warning lights go out, and with your foot OFF the accelerator pedal, turn and hold
the ignition switch in the start position and crank the engine. As soon as the engine starts,
release the switch. If it does not start immediately, continue to crank for up to 10 or 15
seconds. If the engine still doesn't start, allow the starter motor to cool for one minute, then
try again. If it still won't start, refer to Operator Troubleshooting or Detroit Diesel
Troubleshooting Manual for diagnostic procedures.
CAUTION: Do not engage the starter motor when the engine is running.
9. Check all gauges and indicators to make sure that systems are functioning properly.
NOTE: Check the instrument panel frequently during operations.
10. As soon as the engine starts and is running smoothly, increase the engine speed to 1/4
throttle.

S05002/01/01 6-1
 Starting the Engine/Motor

11. Release the park brake only when the check engine light and stop engine light have both
gone out.
12. When the engine is running normally, reduce engine speed to low idle.
13. Reapply the park brake.

! WARNING!

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

S05002/01/01 6-2
 Stopping the Engine/Motor
To stop the engine/motor, do the following:
1. Bring the machine to a controlled stop. Apply the brakes if necessary.
2. Lower the boom/bucket until the bucket is in firm contact with the ground.
3. When the machine is completely stopped, put the transmission in neutral.
4. Apply the park brake.
5. Let the engine idle for 2 to 5 minutes. This allows critical components to cool gradually.
6. Turn the ignition switch to the “OFF” position. The engine/motor should stop within 30
seconds of turning the switch.
NOTE: If the machine is fitted with a delayed shut down device, the engine/motor will not stop
immediately.

! WARNING!

Do not leave the operator's compartment until the engine/motor has stopped.
7. If the machine is equipped with a main circuit breaker on the instrument panel, turn the main
circuit breaker to the “OFF” position.
8. Dismount from the machine and turn the master disconnect switch to the “OFF” position.

! WARNING!

Do not leave the operator's compartment unless the park brake is applied and the bucket is
in firm contact with the ground.

S06001/04/01 7-1
 Stopping the Engine/Motor

Notes

S06001/04/01 7-2
 Brake Tests

Service Brakes Test

! WARNING!

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

! WARNING!

You must always be certain that the service brakes and park brake are working properly at
all times. Test the service and park brake at the beginning of each shift.
PERFORM THE SERVICE BRAKE TEST EXACTLY AS SET FORTH BELOW:
1. Start the engine/motor as normal.
2. Roll back the bucket.
3. Release the park brake.
4. Apply the service brakes with the service brakes pedal.
5. Select second (2nd) gear and forward direction. Rev the engine to full power.
CAUTION: The machine must not move at all!
CAUTION: Do not hold the engine at full power for more than five (5) seconds, as the torque
converter will quickly overheat.
6. Repeat the test in reverse direction.
7. Select neutral and shut down the engine/motor.

! WARNING!

If the machine fails the service brake test, tip the bucket into firm contact with the ground.
Apply the park brake, shut down the engine and dismount from the machine. Block all four
wheels. (If blocks are not available, turn the machine into a sidewall or bank). Do not
operate the machine again until corrective action has been taken!

S07003/02/01 8-1
 Brake Tests

Park Brake Test

CAUTION: Maintenance is vital if serious injury is to be avoided. No machine can endure the harsh
conditions present at any mine without maintenance of the machine. Failure to report a
minor problem will often mean a more serious problem later. A problem or suspected
problem which can threaten injury to the operator or others should be given the highest
priority.

! WARNING!

It is essential that the park brake and the service brakes be maintained properly at all times.
If one is to go near any part of the machine for refuelling or any other reason, the machine
wheels must be blocked and all brakes must be set as even slight movement of the machine
when a person is in a vulnerable position can cause death or serious injury.

! WARNING!

You must always be certain that the park brake and service brakes are working at all times.
PERFORM THE PARK BRAKE TEST EXACTLY AS SET FORTH BELOW:
1. Start the engine/motor and check all instruments and gauges.
2. Make sure that the park brake is applied.
3. Observe instrument panel to check that park brake light is on.
4. Roll back the bucket to the carry position.
5. Select second (2nd) gear and forward direction. Rev the engine to full power.
CAUTION: The machine must not move!
6. Repeat the test in reverse direction.
CAUTION: If the machine does not move, do not keep the engine at full power for more than five (5)
seconds.
CAUTION: If the machine does move, do not move it more than a few feet. If the machine moves
there is a problem with the brakes and the machine should be immediately shut down
for maintenance.

! WARNING!

If the machine fails any part of the park brake test, push the park brake light/button, shut
down the engine and dismount the machine. Block the front and rear wheels. If blocks are
not available, turn the wheel into sidewall or bank. Do not operate the machine again until
corrective action is taken.

S07003/02/01 8-2
 Operating the Bucket/Dump Box

Important
With practice and experience the bucket can be rolled back and lowered at the same time by
moving the lever to the left and toward you simultaneously. Moving the lever to the right and
away from you will raise and tip the bucket. The ability to become a more efficient operator will
come with practice and experience.

! WARNING!

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

! WARNING!

Always use extreme caution when moving the machine with a raised bucket. Where
possible, always lower the lift arms on the stops in the carry position before moving.

Boom/Bucket Control Lever

This machine is equipped with a single boom/bucket control lever which moves in four directions.
NOTE: Right and left refer to the lever, NOT the machine’s right and left.
1. To raise the lift arms, move the lever to the right.
2. To lower the lift arms, move the lever to the left.
3. To dump (tip) the bucket, move the lever forward.
4. To roll back the bucket, move the lever backward.

S08001/02/02 9-1
 Operating the Bucket/Dump Box

Notes

S08001/02/02 9-2
 Work Cycle

Tramming

! WARNING!

Inspect the machine and test the brakes before putting the machine to work.
NOTE: This machine is designed to travel in forward and reverse direction.
1. Ensure that the engine is running, and the bucket is rolled back to the carry position.

! WARNING!

Always travel up and down grades with the bucket facing downhill. It could be used to stop
the machine in case of an emergency.
2. Select forward (F) or reverse (R) direction of travel, and first gear.
3. Release the park brake by pulling out fully.
NOTE: Refer to the Instrument Panel chapter for more information.
4. Apply light pressure to the accelerator pedal until the machine is travelling at a controlled
speed.

! WARNING!

Practise steering while the machine is travelling slowly. After completing a turn, new
operators may make the machine wander back and forth before travelling in a straight line.
CAUTION: Do not rest your foot on the service brake pedal during tramming, unless braking is
required. Excessive use of the service brakes, even slight pressures, will reduce the
machine’s ability over time to stop effectively.
5. Shifting from one gear to another can be done at any time conditions permit. When shifting
down, apply slightly more pressure to the accelerator pedal.
6. Do not shift to a lower gear unless the machine is moving at a speed low enough to permit
this.
NOTE: Always shift one gear at a time.
7. Use the transmission to slow the machine down, finally stopping it with the brake pedal.
This will reduce wear and extend the life of brake components.

S09001/10/03 10-1
 Work Cycle

! WARNING!

Test the park brake before operating the machine on an incline.

! WARNING!

Never move the gear shift lever into neutral while tramming, especially while travelling on
an incline. The brakes will automatically apply.
Tramming Up a Grade Without a Load
When tramming up a grade with an empty bucket, choose a gear that will allow you to travel at a
safe speed. When possible, avoid severe grades.
Tramming Down a Grade Without a Load
When descending down a grade with an empty bucket, choose a gear that allows you to drive
without any unnecessary braking.
Tramming Up a Grade With a Load
When carrying a load, travel up grades in second (2nd) gear. If engine performance and vehicle
speed decrease, shift the transmission to first (1st) gear. When possible, avoid severe grades.
Tramming Down a Grade With a Load
When descending down a grade with a load, select a gear which provides a controlled descent. As
you approach the downgrade, release the accelerator pedal to allow the machine to slow, and
choose a suitable gear.
CAUTION: Do not put the machine into motion when it has a load until the engine and torque
converter have warmed to normal operating temperatures. All gauges should be
displaying normal readings.

Braking
The machine can be brought to a full stop during tramming by pressing the brake pedal, located at
the operator’s feet.
NOTE: Refer to the Controls chapter for more information.
When pressed, the brake pedal operates the service brakes in each wheel end. The amount of
braking force is equal to how far down the brake pedal is pushed by the operator.
1. To bring the machine to a full stop immediately, press the brake pedal down fully.
2. To slow the speed of the machine, apply the necessary pressure to the brake.
CAUTION: Do not rest your foot on the service brake pedal during tramming, unless braking is
required. Over time, excessive use of the service brakes, even slight pressures, will
reduce the machine’s ability over time to stop effectively.

S09001/10/03 10-2
 Work Cycle

! WARNING!

Always wear a seat belt, if equipped on the machine. If the machine is equipped with a
ROPS/FOPS canopy, wear the seat belt and a hard hat. Be prepared for a sudden stop.

Loading
NOTE: Obtain maximum loading efficiency by adjusting the loading cycle to operating
conditions.
NOTE: If possible, work the outer edges of the muck pile first and then the centre. This will
prevent spreading of loose material in the loading area.
CAUTION: If the machine is equipped with an ejector plate, make sure that the ejector plate is fully
retracted before mucking.
1. Lower the lift arms on the stop blocks and tip the bucket to the desired digging angle.
2. Drive the machine in first (1st) gear, forward direction and full power, forcing the bucket
cutting lip into the muck pile. Alternate dump and roll back movements will assist in good
penetration.
CAUTION: Avoid spinning or lifting the wheels off the ground while loading the bucket. This will
accelerate tire wear and cause premature structural problems.
3. As the bucket achieves maximum penetration, gradually roll back the bucket to fill it
completely.
4. Shake any excess load off the bucket. This will assist in keeping roadways clean and
prevents spillage.
5. Select reverse direction and slowly withdraw from the muck pile. Keep the bucket low and
rolled back. Drive to the dumping area.
6. Always carry a loaded bucket as low as possible, to ensure good stability, and unobstructed
vision of the roadway.

Dumping
1. When approaching the dumping area, release the accelerator pedal and bring the machine to
a controlled stop with the service brakes. Shift the direction control lever to the neutral
position. The park/emergency brake system should apply automatically, after approximately
10 seconds.
2. Accelerate the engine to full speed.
3. Raise the bucket to the maximum height required to clear the object being loaded. Tip the
bucket to dump the load. If the machine is equipped with an eject plate, extend the plate o
push out the load.
CAUTION: Do not allow the bucket to contact the “back” (ceiling).

S09001/10/03 10-3
 Work Cycle

4. Roll back the bucket and lower it to the carry position. If equipped, fully retract the ejector
plate.

Parking
1. Stop the machine on flat ground, if possible.
2. When the machine is completely stopped, put the transmission directional control lever in
neutral.
3. Lower the lift arms and roll the bucket forward until the bucket is resting on the ground.
4. Apply the park brake.
5. Let the engine idle for 2 to 5 minutes to cool gradually.
6. Turn the ignition switch to the OFF position. The engine should stop within 10 seconds.
7. Slowly move the steer control lever back and forth. The machine should not move.
8. Exit the operator’s compartment, then turn the master disconnect switch to the OFF
position.

! WARNING!

Do not leave the operator’s compartment unless the engine is stopped, the park brake is
applied, and the bucket is resting on the ground.
9. Report any faults or damage immediately.

S09001/10/03 10-4
 Operating Hints

NOTE: Always report any faults or problems with the machine as soon as possible. Minor
malfunctions can quickly grow to major faults if ignored.
1. ALWAYS sound the horn before starting the engine/motor. Sound the horn frequently,
especially in areas of limited visibility and congestion.
2. ALWAYS keep the loading and dumping areas as clean and level as possible to ensure equal
distribution of weight and improve stability.
3. If possible, work the outer edges of the muck pile first and then the centre. This will prevent
spreading of loose material in the loading area.
4. When loading the bucket, shake any excess load off the bucket before moving to the dump
area. This will assist in keeping roadways clean and prevent spillage.
5. Avoid spinning or lifting the wheels off the ground while loading the bucket. This will
accelerate tire wear and cause premature structural problems.
6. ALWAYS carry a loaded bucket as low as possible to ensure good stability and visibility.
7. ALWAYS test the park brake before operating on an incline.
8. ALWAYS travel in first (1st) gear and avoid excessive use of the brakes when carrying a
loaded bucket down an incline.
9. When dumping, only lift the bucket high enough to clear the object being loaded.
CAUTION: Never contact the roof with the bucket.
NOTE: On machines equipped with a catalytic exhaust purifier, avoid running the engine at idle
for long periods. This can cause “masking” of the catalyst and reduce the efficiency of the
purifier.

S11001/02/02 11-1
 Operating Hints

Notes

S11001/02/02 11-2
 Maintenance and Check Points

Introduction
This section contains a checklist of items to be checked and/or serviced before the machine is put
to work. For more information regarding these procedures, or for maintenance other than required
on a daily basis, refer to the Service Manual.
NOTE: The correct type and quantities of various lubricants used in the different systems on this
machine are specified in the Service Manual.

! WARNING!

Report all damage and faulty operations immediately. Do not operate a faulty machine.
Ensure the frame lock is fitted before working in the central articulation area. Never service
or adjust the machine while it is motion. Do not work around the loader end of the machine
with the lift arms and bucket raised, unless the lift arms are properly supported.

Engine Off
NOTE: Inspect the following points before starting the engine/motor.
General Inspection
1. Walk around the entire machine to make sure it is in good condition.
2. Report any damage or faults immediately.
Operator’s Compartment
1. Make sure the operator’s compartment is clean.
2. Remove all debris which could interfere with the correct operation of the pedals.
Batteries
1. Check the condition of the battery cable, terminals, and connections.
2. Check that the batteries are clean and secure.

! WARNING!

Batteries emit toxic hydrogen gas when charging. Do not smoke and keep area well
ventilated when inspecting the batteries.

S13005/04/02 12-1
 Maintenance and Check Points

Fire Extinguisher (If Fitted)

1. Verify that pressure is in the safe zone.
2. Check condition of trigger handle and hose. Ensure that the fire extinguisher is securely
mounted, but easily removable.
.

Figure 1: Fire Extinguisher

Fire Suppression System (If Fitted)

1. Check that the dry chemical tank and gas expellant tanks are installed, hoses and fittings are
in good condition, and that both actuators are fitted with safety lockout rings.
NOTE: One actuator is located in the operator’s compartment; the other is located on the rear
frame.

Figure 2 : Fire Suppression System

Bucket Cutting Lip and Dump Stops

1. Check the condition of the bucket cutting lip (1), corners and sidesheet welds for cracks.
Check condition of dump stops (2) and lift arm stops (3).
CAUTION: Poor lip condition can greatly reduce loading efficiency.

S13005/04/02 12-2
 Maintenance and Check Points

2
Figure 3 : Bucket Cutting Lip and Dump Stops

Fuel Tank
1. Check fuel level in the tank and refill it if necessary.
2. Check for cracks and leaks.
NOTE: Do not allow the machine to run out of fuel. Fill up the machine as often as possible to
prevent condensation inside the tank(s). If the machine is equipped with two fuel tanks, the
fuel level in both tanks should be the same. If the fuel level in both tanks is not the same,
the crossover pipe is probably blocked. Report this to your supervisor.

! WARNING!

Avoid overfilling the fuel tank. Use extreme caution when filling the fuel tank and avoid
splashing fuel on the exhaust manifold. Fire Hazard.
Dry Type Air Cleaner(s)

! WARNING!

Do not attempt to service the air cleaner(s) while the engine is running.
CAUTION: It is vitally important that the air cleaner(s) be properly maintained at all times. A
defective air cleaner can dramatically reduce the life on the engine.
1. Check all joints for loose, missing, or damaged clamps. Check rubber connectors for
fraying and cracks.
2. Empty and clean the pre-cleaner (if equipped).
3. Check the service indicator. When the red flag appears in the window, the primary element
is dirty and must be cleaned or replaced.
4. Empty and clean the dust cup if the air cleaner is not equipped with a vacuator valve.

S13005/04/02 12-3
 Maintenance and Check Points

Exhaust System
1. Check the condition of the exhaust pipes, manifolds, joints and purifiers. The exhaust must
be in good condition at all times.

! WARNING!

Do not operate a machine with a defective exhaust system.

(DDEC) Engine Oil
1. New engines usually have a slightly higher oil consumption during the first 200 hours of
operation. Check the engine oil level twice per day; once per day is sufficient after this
period. Always check the oil while the machine is parked on level ground.
2. To allow the oil level to be accurately checked at low idle as well as stopped, the oil dipstick
is provided with marks on both sides.
3. When the engine is at low idle, the dipstick should be coated with oil between the FULL (F)
and LOW (L) marks on the “running” side of the dipstick.
4. When the engine is stopped, the dipstick should be coated with oil up to the FULL (F) mark
on the “stopped” side of the dipstick.
5. Add oil as necessary to maintain oil level.
CAUTION: Do not operate the machine unless the oil level is correct. Severe engine damage could
result.

Figure 4 : DDEC Engine

S13005/04/02 12-4
 Maintenance and Check Points

Engine Coolant Level

1. Remove the cap slowly when it is cool.
2. Add coolant slowly (to prevent air pockets from forming) to a level within 1/2 inch (1 cm)
of the bottom of the fill pipe.
3. Start the engine with the expansion tank cap off and add coolant when the level stabilizes.
Allow for the expansion of coolant as it heats up.
4. Stop the engine and re-install the cap. Check the condition of the cap seal. If it is damaged,
replace it.
CAUTION: Never add coolant to an overheated engine. Allow the engine to cool first.

Wheels, Tires, and Wheel Nuts

1. Check the condition and pressure of all four tires. The tire pressure for all four tires must be
80 psi (552 kPa).

! WARNING!

Operators and service personnel must be alerted to the risk involved when working on
multi-piece rim wheels. Refer to Occupational Safety and Health Administration (OSHA)
Regulation 29 CFR Part 1910.177.
NOTE: OSHA is affiliated with the U.S. government.
2. Check wheel nuts for proper torque setting. On a new machine or a machine that has had a
wheel replaced, check the wheel nuts every 10 hours for the first 50 hours of operation, and
thereafter every 50 hours. The setting for all wheel nuts is 400 pounds feet (542 Nm).
Greasing
1. Apply grease to points described in “Section 14: Greasing the Machine”.
Frame Lock
1. Make sure that the frame lock is NOT installed in the center hinge area.

Engine On
NOTE: Inspect the following items after inspecting the engine/motor.
Operator’s Compartment
1. Operate levers and pedals to make sure they are working properly.
2. Make sure gauge needles rise to normal levels.
3. Make sure warning lights go out.
Hourmeter

S13005/04/02 12-5
 Maintenance and Check Points

1. Make sure hourmeter is working. If the hourmeter stops working, inform supervisor or
mechanic.
2. Make sure that the preventive maintenance schedule is performed according to the
Preventive Maintenance Schedule in the Service Manual.

Figure 5 : Hourmeter

Lights
1. Check for damage to wiring and mountings.
2. Switch all lights on and verify that they are working.

Figure 6 : Lights

Hydraulic Oil Level

1. Run the engine at half throttle until hydraulic oil reaches normal working temperature.
2. Make sure the main implement is fully lowered.
3. The level must be at the top of the lower sight glass.

! WARNING!

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

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

S13005/04/02 12-6
 Maintenance and Check Points

FILL
DIRTY FILTER INDICATOR

CHECK LEVEL

Figure 7 : Hydraulic Tank

Transmission Oil Level

1. Run the engine at half throttle until the transmission reaches normal operating temperature.
2. With the engine running at low idle, remove the dipstick and wipe it clean with a clean shop
cloth.
3. Insert the dipstick into the tube fully. Remove it again and read the level.
4. Add oil as necessary to bring the oil level to the full mark on the dipstick.
Hydraulics and Steering
1. With the engine running at half speed, raise the lift arms, roll back the bucket and lower the
lift arms. This ensure that the bucket controls are working correctly.
2. Sound the horn and articulate the machine from left to right.
3. Have an assistant look for oil leaks from the steer, hoist and dump cylinders while they are
being operated.

S13005/04/02 12-7
 Maintenance and Check Points

Figure 8 : Bucket Hydraulics

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

S13005/04/02 12-8
 Maintenance and Check Points

S13005/04/02 12-9
 Maintenance and Check Points

S13005/04/02 12-10
 Greasing the Machine

Automatic Greasing System

S14005/09/00 13-1
 Greasing the Machine

! WARNING!

DO NOT WORK BETWEEN THE FRONT AND REAR FRAMES UNLESS THE
MACHINE IS SHUT DOWN, STEER PRESSURE HAS BLED OFF AND THE FRAME
LOCK IS INSTALLED.
CAUTION: CORRECT AND REGULAR GREASING IS ONE OF THE MOST IMPORTANT ASPECTS
OF SERVICING THIS AND ANY OTHER MACHINE WORKING IN THE MINING
ENVIRONMENT. POOR GREASING WILL LEAD TO PREMATURE FAILURE OF VITAL
BEARINGS, BUSHINGS AND PINS. THIS WILL RESULT IN POOR PERFORMANCE OF
THE MACHINE AND INCREASED MAINTENANCE COSTS.
NOTE: This machine is equipped with a twenty--one point automatic greasing system.
1. Check the grease pump for correct operation at least twice a shift.
2. The following locations are serviced by the automatic greasing system.

QUANTITY DESCRIPTION
1 STEER CYLINDER BASE END

1 TOP HINGE PIN

1 STEER CYLINDER ROD END

1 BOTTOM END HINGE PIN

2 BOOM TO BUCKET LEFT SIDE

2 BOOM TO BUCKET RIGHT SIDE

1 HOIST CYLINDER TO BOOM RIGHT SIDE

1 HOIST CYLINDER TO BOOM LEFT SIDE

1 DUMP CYLINDER PIN AT BASE END

1 BEARING AT FRONT OF CRADLE WELDMENT

1 PILLOW BLOCK DRIVE TRAIN REAR FRAME

1 HOIST CYLINDER/FRAME RIGHT SIDE

1 HOIST CYLINDER/FRAME LEFT SIDE

2 BOOM PIVOT RIGHT SIDE

2 BOOM PIVOT LEFT SIDE

1 PILLOW BLOCK DRIVE TRAIN FRONT FRAME

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

CAUTION: WHEN GREASING DRIVELINE JOINTS, USE A HAND GREASE PUMP TO PREVENT
DAMAGE TO THE SEALS.

S14005/09/00 13-2
 Greasing the Machine

4. Inspect all grease nipples for damage. Inspect all grease hoses for damage, leaking and
fraying. Ensure that grease is actually reaching the bearings and bushings. Have an assistant
look for grease coming out between bearings and bushings while grease is being applied.

S14005/09/00 13-3
 Greasing the Machine

Notes

S14005/09/00 13-4
 Troubleshooting

Important
The following tables identify common machine problems and their suggested remedies. If the
operator cannot correct the problem, inform supervisor as soon as possible. Most of the following
problems can be avoided by following operating procedures correctly and carrying out scheduled
maintenance on time.

! WARNING!

Do not operate the machine until any malfunction or problem has been corrected.
NOTE: The following tables are only guides to the simple remedies within the scope of an
operator. Any doubt as to the fault must be referred to maintenance personnel.

Engine Will Not Crank Over

Cause Remedy
Master disconnect switch off Turn master disconnect switch on.

Ignition switch in off position Turn to start position.

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

Weak or dead battery Recharge or replace battery.

Transmission directional control lever not in neutral Shift to neutral.

position.

Any other problem Report to maintenance.

S15005/01/01 14-1
 Troubleshooting

Engine Will Crank Over But Not Start

Cause Remedy
Fuel tank empty Fill fuel tank and vent fuel system.

Air in fuel system Air vent the fuel system.

Severe cold conditions Longer pre-heat.

Fuel tap closed Open fuel tap.

Loose fuel lines Tighten fuel lines and vent fuel system.

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

Any other problem Report to maintenance.

Engine Stalls During Operation

Cause Remedy
Fuel tank empty Refill and vent fuel system.

Loose fuel lines Tighten and air vent the fuel system.

Air in the fuel system Air vent the fuel system.

Sudden air intake restriction Remove cause of restriction.

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

Any other problem Report to maintenance.

Excessive Exhaust Smoke

Cause Remedy
Hot working conditions No remedy on machine.

Machine overloaded Reduce load.

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

Engine oil level excessively high Drain to correct level.

Contaminated fuel Drain, clean, and refill fuel tank.

Air intake restriction Remove source of restriction.

S15005/01/01 14-2
 Troubleshooting

Engine Misfiring

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

Air in fuel system Air vent the fuel system.

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

Engine Knocking
CAUTION: Shut down engine immediately!

Cause Remedy
Insufficient oil Refill to correct level. Report to maintenance.

Engine Oil Pressure Low

Cause Remedy
Incorrect type/amount of oil Check type/level.

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

Any other problem Report to maintenance.

Engine Overheats

Cause Remedy
Machine overloaded Reduce load.

Clogged radiator core Clean radiator.

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

Restricted air intake Remove restriction.

Broken belts Replace belts.

Dirty cooler fins Clean cooler fins.

Operating in wrong gear Shift to correct gear.

S15005/01/01 14-3
 Troubleshooting

Hydraulic Oil Foams

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

Torque Converter/Transmission Overheats

Cause Remedy
Machine overloaded Reduce load.

Transmission oil level low Check oil level and top up.

Low oil pressure Report to maintenance.

Incorrect type Check type, drain, and refill.

Severe oil leaks Check oil level with engine running.

Clogged cooler core. Clean cooler core.

Machine Will Not Move

Cause Remedy
Park or service brake applied Release brakes.

Low clutch oil pressure Report to maintenance.

Transmission in neutral Shift into gear.

Engine/motor stopped Start engine/motor.

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

S15005/01/01 14-4
 Troubleshooting

Machine Will Not Turn

Cause Remedy
Frame lock installed Move frame lock to storage position.

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

Engine/motor stopped Start engine/motor.

Little or No Dump Box/Bucket Action

Cause Remedy
Engine/motor stopped Start engine/motor.

Bucket/dump box overloaded Reduce load.

Low hydraulic oil level Check and top up.

Severe leakages Report to maintenance.

Defective Lighting System

Cause Remedy
Defective light bulb Replace bulb.

Light assembly wiring loose or broken Tighten or replace ground wire.

Defective light control switch Report to maintenance.

Circuit breaker tripped Report to maintenance.

S15005/01/01 14-5
 Troubleshooting

Air Venting the Fuel System

The DDEC engine fuel system is designed to be constantly circulating. This allows air and
contaminants to be purged from the system. If the fuel tank is allowed to run dry, use the
following procedure to restart the engine.
To remove all the air from the fuel circuit, do the following:
NOTE: Never use the starting motor and fuel pump to prime the fuel filter and strainer. Prolonged
use of the starting motor and fuel pump to prime the fuel system can result in damage to
the starting motor, fuel pump, and injectors. It can also cause the engine to run erratically
due to the amount of air in the lines and filters.
1. Fill the fuel tank with the recommended grade of fuel. If only partial filling is available, add
a minimum of 10 gallons (38 liters) of clean fuel to the tank.
2. Remove the fuel filter from its cover, fill it with fuel, and reinstall it.
3. Start the engine. Check fuel filter and strainer for leaks.
4. If the engine fails to start after replacement of the fuel strainer and/or filter, the fuel system
will require priming. See Detroit Diesel manuals.

S15005/01/01 14-6
EJC Mining Equipment Inc.
4445 Fairview Street
Burlington, Ontario
Canada L7L 2A4
Telephone: (905) 632-4940
Fax: (905) 632-2172