Instructions GIA 10HR07 PDF

INSTRUCTIONS MANUAL
HGGLOADER 10HR07
Vietnam
GIA Industri AB Phone: +46 240 797 00

P.O. Box 59 Fax: +46 240 797 25
SE-772 22 Grngesberg E-mail: info@gia.se
Sweden Internet: www.gia.se
CONTACT
GIA industri ab Phone: +46 240 797 00

Street address: Kopparbergsvgen 39 Fax: +46 240 797 25
Postal (mailing) address: Box 59 E-mail: info@gia.se
SE-772 22 Grngesberg
Sweden
Managing Director
Roger Karlsson
Phone: +46 240 797 05
Mobil: +46 70 837 97 05
E-mail roger.karlsson@gia.se
Sales Department
Per Ek (Sales Manager) Gran Nilsson (Area Manager)

Phone: +46 240 797 30 Phone: +46 240 797 09
Mobil: +46 70 347 97 30 Mobil: +46 70 347 97 30
E-mail per.ek@gia.se E-mail goran.nilsson@gia.se
Hans Ramstrm (Area Manager) Bo Strmsholm (Product Manager GIA SwedVent)

Phone: +46 240 797 33 Phone: +46 31 845 300
Cell phone: +46 70 259 97 33 Mobil: +46 70 5253 327
E-mail hans.ramstrom@gia.se E-mail bo.stromsholm@swedvent.se
Mari Johansson (Area Manager) Jan Josefsson (Area Manager)

Phone: +46 240 797 28 Phone: +46 240 797 09
Mobil: +46 70 83 79 752 Mobil: +46 73 274 67 55
E-mail mari.johansson.@gia.se E-mail jan.josefsson@gia.se
Spare Parts Service E-mail: spareparts@gia.se
Seija Liimatainen Mari Laine

Phone: +46 240 797 13 Phone +46 240 797 44
Mobil: +46 70 19 19 713
Shipping E-mail: shipping@gia.se
Pirjo Honkanen
Phone: +46 240 79737
Service and After market E-mail: aftersale@gia.se
Per Gransell Ragnar Eriksson Christian Kromm

Phone: +46 240 797 21 Phone: +46 240 797 04 Phone: +46 240 797 00
Mobil: +46 70 19 19 718 Mobil: +46 70 83 797 04 Mobil: +46 70 51 95 708
Design
Thger Olesen
Phone: +46 240 797 19
Mobil: +46 70 837 9719
E-mail: thoger.olesen@gia.se
Quality
Sten Jansson
Phone: +46 240 797 07
Mobil: +46 70 191 97 07
E-mail: sten.jansson@gia.se
Finance
Jrgen Bolander
Phone: +46 240 797 20
Mobil: +46 70 191 57 20
E-mail: jorgen.bolander@gia.se
10HR07
WARRANTY AND SERVICE INFO.
Warranty and service information
Instruction
Your new GIA industri ab product has limited warranty according to the conditions and instructions in
this Warranty and service information. In other cases see
Orgalime S2000
Read the Manual and maintenance instructions before starting or using the product for the first time.
Production design
GIA industri ab reserves the right to make changes in the products manufactured / sold by GIA indus-
tri ab at any time without prior notice and without any obligation to make the same or similar changes
on products previously manufactured or sold.
Warranty period, general

The warranty period is normally 12 months otherwise definite in the contract. The warranty period
starts at the date of delivery from GIA industri ab to the first owner/user or start up date.
All components or parts replaced or repaired under warranty will receive the remaining
warranty of the original part or component.
What the warranty covers

The warranty covers the cost of replacing defective parts or of having such parts repaired. A defec-
tive part or product in the sense of this warranty is a part or product that is found to have an inherent
defect which existed at the time of delivery. All warranty repairs must be carried out by GIA industri
ab or authorized workshop.
What the warranty does not cover

The warranty does not cover parts or products damaged during transportation, incorrect installation
or repair, abnormal use, carelessness, overloading, insufficient maintenance or use of spare parts not
authorized or delivered by GIA industri ab. The warranty is void if the user has taken abnormal risks or
if modifications have been performed which in the judgement of GIA industri ab have caused or made
the damage worse, or if seals have broken or settings altered or if the part or product has been used
for a clearly unintended purpose.
Owners obligations
The operation, maintenance and care of your GIA industri ab product, in accordance with the instruc-
tions and requirements listed in your owners manual and this Warranty and service information is
your responsibility. Records should be kept of all maintenance services performed, including all oil and
filter changes. This record of proper maintenance is required for the purpose of determining warranty
coverage at repairs.
Report of a defect
It is the responsibility of the owner of a product to report any defect in the indicated product to GIA
industri ab. Such a report must be made as soon as possible and no later than fourteen (14) days
from the date when the user first observed the defect or ought to have observed it and consequently
in no case later than fourteen (14) days after warranty period expired. The report must include at
least a very brief description of the defect. A Claim report can be found in GIA industri ab Internet
homepage with address: www.gia.se
GIA industri ab
Kopparbergsvgen 39, Box 59, SE-77222 Grngesberg, Sweden
Phone +46 240-79700 Fax +46 240-79725 email info@gia.se Internet www.gia.se
10HR07
HEALTH AND SAFETY
Health and Safety
Personnel
On employment, new employees who are to use the machine ought to undergo a medical examina-
tion, and we even recommend regular medicals thereafter.
The employers liability for safety even encompasses assigning a safety officer responsible for each
work task. Users must know who the responsible safety officer is, as well as be acquainted with the
safety rules that apply to that particular task.
Users are also required to cooperate with the safety officer and follow instructions given by said officer.
The machine may only be used and repaired by personnel with the necessary training.
The employer shall clearly define the obligation of users to follow the safety instructions.
New employees or personnel undergoing training may only use, service or repair the machine under
the constant supervision of experienced personnel.
Users shall be familiar with the characteristics of the machine and with the instruction book provided
by the manufacturer.
Moreover, all users ought to have any necessary official permits or licences to use the machine.
The employer ought to clearly define the knowledge needed to use, adjust, service and repair the
machine.
Only trained and experienced hydraulic mechanics may repair, adjust and inspect hydraulic compo-
nents.
Repairs, adjustments and inspections of electrical equipment may only be conducted by qualified elec-
tricians or persons instructed and supervised by qualified electricians in compliance with the safety
rules for electrical work.
Training and experience

Users shall be trained how to use and service the machine. Users shall familiarise themselves with the
instruction book provided by the manufacturer and the characteristics of the machine.
Accident prevention
Accidents in the workplace generally occur in unusual situations. This makes it important to take into
account all possible, even unlikely, situations that could arise during a work task.
When working in the engine compartment or under the machine, the battery isolating switch and
main power switch must be turned off.
If work that requires the engine to be running is to be conducted, it must be conducted with the
greatest caution for moving parts, such as drive shafts, engine fans and V-belts, and hot engine parts.
Before starting work

Plan the work to avoid accidents, personal injury and material damage.
In case of an accident or fire, act quickly and use the equipment at hand.
Learn to use the first aid and fire-fighting equipment. You should also know where and how on-site
help can be obtained. Nothing should to be left to chance.
Always perform the daily inspection of the machine before starting work.
When a new shift takes over, always inform the personnel of any faults or malfunctions.
10HR07
HEALTH AND SAFETY
Protective equipment, safety devices and safety procedures

Always use personal protective equipment, such as protective clothing, protective shoes, protective
eyewear, ear protectors and a hard hat.
Always follow local safety rules.
Always keep the workplace as clean as possible to avoid accidents due to slipping or stumbling.
The machine may not be used by persons under the influence of alcohol or drugs.
A faulty or malfunctioning machine may not be used until the fault or malfunction has been rectified.
Keep tools in their places.
The appropriate safety procedures must always be followed when working with the machine.
The machine may not be used for anything but its intended purpose.
IMPORTANT: Always keep the workplace clean and tidy to eliminate the risk of accidents.
Oils, greases and fuels

Always use only the lubricants recommended by the manufacturer. Neglecting these recommenda-
tions can negatively affect machine functionality or service life and result in personal injury or material
damage.
Always check the fuel level, oil levels and coolant level before starting.
Different types of oil or fluid must not be mixed.
Cold-start agents and other highly flammable substances may not be stored in the cab.
Highly flammable substances must be kept protected from heat, sparks and naked flames.
Storage containers must not be punctured or destroyed by incineration as there is a risk of explosion.
Smoking is strictly forbidden when refuelling.
Electrical equipment
To avoid personal injury and material damage caused by electricity, there are a number of regulations
and rules that govern the design, installation and use of electrical equipment. Actions must always be
governed by local legislation and electrical safety regulations, which must always be followed without
exception.
Work on electrical equipment may only be conducted by persons with the necessary training.
Always use original spare parts.
All power must be cut to electrical devices that are to be inspected, checked or repaired.
In case of an accident
All personnel working with the machine should be trained in first aid so that injured persons can be
properly treated.
10HR07
PREFACE
Preface
This manual comprises of nine principal sections, as listed in the flyleaf at the front of the manual. The
manual contains descriptions of the design and function of the HGGLOADER, instructions for opera-
tion, maintenance and service work, and a complete spare parts catalogue.
In order to locate a particular item of information in the manual, the flyleaf is first consulted and a
section chosen. The wanted section can then easily be found with the aid of the number tabs on the
index pages. The index page for each section is followed immediately by a table of contents which
makes reference to publication numbers. The publication number is stated on the top edge of each
individual page. The first digit of the publication number indicates the section to which the page
belongs. Other number runs from 001 and upwards through each section.
Minor variation in the equipment of the machine may occur. We therefore reserve the right to intro-
duce amendments to the instructions given in the manual without prior notice, and to otherwise take
such steps as we deem necessary. Amended pages will be provided with an amendment note, which
among other things indicates the date of publication.
The manual is intended to provide all the information and advice that can be needed in order to facilitate
operation and maintenance of the machine. It can, therefore, also be used for internal training of
operators and service personnel
10 HR07
Contents
1 General
Contains a presentation of the next generation HGGLOADER 10 HR
and its varying application.
2 Technical description
Contains description of a standard machine as well as available
optional equipment and includes also a summary of the machine
dimensions and data.
3 Function
Contains descriptions of the electrical and hydraulic functions of
the machine. The descriptions are supplemented by circuit
diagrams. The section also includes description of the function of
the conveyor.
4 Operation
Contains a check list and operating instructions, along with
instructions for loading and transport. This section also includes
instructions for operating the diesel engine.
5 Maintenance
Contains instructions for the regular care and maintenance of the
machine. The maintenance is divided in four different time
intervals, dealing with tasks as cleaning, inspection, oil changing
and lubrication of the equipment.
6 Service
Contains advice and instructions for the maintenance work and
repair of the machine. The section is divided into four sub-
sections, dealing with trouble-shooting, setting of pressures,
component adjustment and component replacement.
7 Miscellaneous
Contains information about optional equipment which is not
normally included on a standard machine.
8 Appendices
Contains in certain cases diagrams, tables, and circuit diagrams,
etc., which forms a complement to the preceding section.
9 Spare parts
Contains a catalogue of spare parts for the machine type specified
on the flyleaf.
10HR07
GENERAL
Modern demands for high output and efficiency,

together with an increased awareness of the
importance of the working environment, impose
rigorous specifications on underground mining
machinery. With these considerations in mind,
GIA industri ab have developed a new generation
of loader, based on the loading principle applied so
successfully in the earlier HGGLOADERS. The control
system with display, camera, controllers, joysticks,
sensors, valves, pumps and motors are supplied
by Sauer Danfoss.
This loader, known as the HGGLOADER

1OHR07, runs on rubber wheels and is designed
for loading operations in drifts and tunnels and Fig. 1. HGGLOADER 10HR is designed for
for loading are in mining applications. operations in drifts, tunnels and for
loading ore in mining applications
Used in conjunction with a dumper, or similar
haulage equipment, the machine forms a trackless
mucking system for operations in underground
rock chambers and other trackless drifting and
tunnelling locations with areas ranging from 10
m and upwards. The machine is able to load in
both uphill and downhill slopes with gradients up
to 1:7.
Significant differences set the HGGLOADER

1O HR07 apart from conventional, bucket-type
loaders. The basic difference lies in the use of
gathering arms, digging blades and a conveyor
frame to replace the conventional bucket. The
gathering arms operate sideways and down-
wards on the floor to push the muck together
in front of the leading edge of the machine. The
digging blades then push the muck onto a conveyor
frame, which carries it over the loader and down Fig. 2. The loader is equipped with garaging
in to the haulage equipment behind the machine. arms, digging blades and conveyor
Moving the muck, instead of throwing it, is the frames.
basic loading principle on which the machine
operates. Muck is loaded smoothly and con-
tinuously, eliminating the intermittent and jerky
character of conventional loading methods and
drastically reducing wear and tear on men and
machines. In the long term, this will provide a
valuable boost for productivity and permit the
production process to be scheduled with a higher
degree of precision.
The HGGLOADER 10HR07 is diesel-electric

four-wheel driven, with a 75 kW electric motor.
The motor torque is transmitted to the wheel via
a pump and a hydraulic motor, from which the
transmitting force takes place over a gear box
and two universal shafts connected to steering
drive shafts.
Fig. 3. The digging blade operation is normally
The electro-hydraulic drive gives the machine synchronized, but each blade can also
a total traction effort of 9 kN giving an excellent be operated individually.
10HR07
GENERAL
penetration performance as it advances into the

ground. The hydraulic motor delivers maximum
torque on start-up.
The HGGLOADER 10HR07 is equipped with an

arm system for a digging width of 4,0 metres.
Normally, digging blade operation is synchronized,
but each blade can be operated individually
where so required. This feature ensures that the
machine operates at maximum efficiency when
clearing the floor or loading and clearing close to
the rock wall. The machine is also ideally suited
for clearing tunnel faces, scaling and trenching
and for handling large boulders which the digging
blades simply move aside for breaking. The machine
can also be used for clearing up the tunnel after
Fig. 4. The driving compartment is ergonomically
drifting operations, as well as for lifting roof arch
designed for increased comfort and
reinforcements and similar equipment.
safety.
The machine is equipped with four-wheel
steering, thus providing additional manoeuvre
when operating in confined spaces. The turning
radius is only 2 metres. The digging components,
which are subjected to the greatest wear, have
been generously over- dimensioned to withstand
the wear and tear of operation. Standard plate
grades can be used to repair digging blades and
gathering arms.
The electro-hydraulic drive gives the machine

an excellent manoeuvrability and at the same
time a high degree of driver comfort. The drivers
compartment is ergonomically designed with
easy-to-reach controls and an almost unlimited
view of the workplace. The drivers comfort and Fig. 5. The gathering arms push the muck in
safety are well satisfied, by fitting a special pro- front of the machine, simultaneously
tective roof over the drivers compartment and clearing the floor.
installing an adjustable drivers seat. The driver
sits during work in a comfortable posture well
out of range of falling rock and collapsing rounds.
The machine is simple and easy to operate and
does not call for physical strength. Drivers can be
quickly trained to maximum operating capacity.
The electro-hydraulic drive system assures a sig-
nificantly lower energy cost per m of rock than
equivalent diesel or air-powered equipment. The
working environment is far better and ventilation
requirements are kept at a minimum. The cabin
has a closed air conditioned system.
The HGGLOADER 10HR07 consists of a chassis on

which the arm system with digging blades and a
conveyor frame with gathering arms are carried.
When in operation, the loader eats continuously
into the round with extended gathering arms and
pushes the muck in front of it, clearing and level- Fig. 6. The length and discharge height of the
ling the floor. As the muck builds up in front of the conveyor frame can be varied to suit
gathering arms, it falls onto the front end of the different haulage vehicles.
10HR07
GENERAL
conveyor frame and is shovelled onto the frame

by the digging blades. The muck is then carried
to the rear by the flights on the chain running
on the bottom of the conveyor frame and loaded
into the haulage vehicle which moves forward
in pace with the loader. The load is discharged
from a lower height into the vehicle which is filled
evenly and quickly without overspill -otherwise a
frequent problem with conventional throw-type
loaders.
The conveyor frame can be adjusted upwards
or downwards to the desired discharge height
and the frame can be extended (when ordered
as new conveyor) with 1500 mm, alt. 2000 mm,
in accordance with customer specifications. The
loader is therefore easy to adapt to the majority
of transport systems with load capacities of up to
25-30 tonnes. Fig. 7. Built-in sprinkler system reduces the air
The examples below illustrate the productivity of pollution
the machine when working with different types
of haulage vehicles:
1. A 10-tonne dumper can be loaded in 2-3
minutes.
2. A 16-tonne dumper can be loaded in 3-4
minutes.
3. An 18-tonne dumper, which may require an
extended conveyor, can be loaded in 4-5
minutes.
4. A 25-tonne off-road truck, which requires
an extended conveyor, can be loaded in 5-7
minutes.
The mode of operation of the loader, which is

based on a combination of gathering arms - digging
blades -conveyor, offers continuous high loading
capacity at the rate of a full 180 m/ hour.
A sprinkler system is installed above the blade

and arm system to supply a continuous spray of
water onto the muck when loading. This sup-
presses dust and explosive gases emanating
from the round, making a valuable contribution
towards reduction of air pollution.
The machine is equipped with a diesel engine

as prime mover for on-site travel. The diesel-drive
gives the loader a top speed of 12 km/hour.
The diesel engine, as well as 2 batteries, are
fitted on all standard equipped machines.
Fig. 8. The cable drum holds the feed cable
The HGGLOADER 10HR07 is equipped with a tight while relocating the loader on the
hydraulically powered cable drum, which auto- work.
matically holds the feed cable tight while relocat-
ing the loader on the work site.
The arm system may also, on the customers

request, be replaced by a back-hoe digging unit
for a greater versatility when using the machine.
10HR07
GENERAL
The HGGLOADER 10HR07 is not only a loader

with a remarkably high capacity. It can also be
adapted to a trackless loading system in combi-
nation with haulage vehicles as lorry trucks and
dumpers. The need of niches is reduced, because
no extra rock blasting needs for the actual load-
ing, and considerable time and money can be
saved.
Further improvements to the working envi-

ronment can be made if the site is prepared for
electro-hydraulic drilling equipment. Equipment
installation and operating costs may be further
reduced as loader power requirements and con-
Fig. 9. HGGLOADER 10 HR07 forms in
nections are adapted for electro-hydraulic drilling
conjunction with suitable transport
operations.
vehicles a trackless loading system
The design and highly praised loading method
of the HGGLOADER 1OHR07 offer many practical
and financial advantages, which; taken together,
result in significant reductions in costs. The main
advantages offered can be summarized in the
following ten points:
Continuous muck loading operation

directly at the face, without moving to
and fro, increases safety and reduces tyre
wear.
Optimum loading capacity and haulage
rates ensure uniform transport operations.
Haulage vehicles are filled at low height
to achieve optimum utilization of payload,
prevent overspill and reduce wear and
tear on vehicles.
Effective floor cleaning by the machine
renders subsequent manual cleaning
unnecessary.
The versatile movement pattern of the dig-
ging blades enables the machine to be
used for trenching and lifting.
The loading height of the conveyor can
be
varied to suit the transport vehicle.
Electro-hydraulic operation reduces ven-
tilation requirements and enables the
loader to be used in conjunction with elec-
tro-hydraulic drilling equipment.
First-class working environment, with full
driver protection that has an excellent
view of the workplace. Integrated sprin-
kler to suppress stone dust.
Standard grade steel plates can be used to
repair digging parts which are subjected
to the most wear and tear.
Quick and accurate production scheduling.
Low operating costs.
10HR07
GENERAL
In closing, it should be noted that the

HGGLOADER 10HR07 is a specialty loader which
in conjunction with suitable transport vehicles
forms a trackless loading system for drifting,
tunnelling and muck loading in mines. The loader
conforms to the most stringent specifications
for continuous operation, manoeuvrability and
capacity when loading in confined tunnels, and
covers a far wider area than any previous com-
parable equipment. At the same time, the equip-
ment offers the driver an outstanding degree of
safety and comfort. Research and development
work designed to combine high productivity with
a first-class working environment have been suc-
cessfully embodied in the unique HGGLOADER
10HR07.
10HR07
TECHNICAL DESCRIPTION 2.000
Contents
Dimension sketch 2.001

Specifications 2.002
General 2.003
Chassis 2.004
Arm system 2.005
Conveyor frame assembly 2.006
Drivers compartment 2.007
Pump unit 2.008
Cable drum 2.009
Sprinkler system 2.009
Batteries 2.010
Diesel-hydraulic drive for self-propulsion 2.011
Motor specification 2.012
Transmission unit 2.013
Steering 2.014
Hydraulic system 2.015
Hydrostatic operation 2.016
Central lubrication (option) 2.017
Fogmaker 2.017

10HR07
TECHNICAL DESCRIPTION
10HR07
Dimension sketch
10HR07
Specifications
Technical data
Load capacity on plane ground 3 m/min
Total weight, standard equipment 16500 kg
Maximum travelling speed with cable 3 km/h
Maximum travelling speed with diesel engine 12,0 km/h
Total tractive pull 90 kN
Tyres 12,00x20
Service brake at all four wheels hydr. multiple disc brake
Parking brake multiple disc brake
Conveyor chai with steel flights
Main electric motor 75 kW at 1000V/50Hz
Maximum inclination when loading, upwards 1:5
Downwards 1:7

Main dimension
Maximum length in transport position 10900 mm
Maximum width in transport position, flaps in 2800 mm
Maximum height protection roof 3000 mm
Maximum height in transport position 3000 mm
Ground clearance in transport 350 mm
Digging width, standard arms 4000 mm
Digging dept below ground level 250 mm
Digging width, back-hoe 6200 mm
Digging dept below ground level 900 mm
Track width 2130 mm
Wheel base 2500 mm
Turning radius 2000 mm
Further
Track driven 3500 mm
Skidd steering
Drivers compartment with protection roof,
air condition, stereo and comfortable seat.
Conveyor of standard type, overhang 2 x 12 V, 2 x 135Ah
Cable drum with cable 74Kw
Hose drum with hose
Hydraulic hammer for scaling for back-hoe
Batteries Perkins Diesel 1104C-44T
10HR07
General
The HGGLOADER 10HR07 can be described

in purely general terms as a rubber wheel borne
loader for underground work in mines and tun-
nels.
The machine consists of three main components,
viz. a chassis, an arm system and a conveyor
frame. A sturdy roof protects the drivers
compartment from falling rocks (Fig.1).
The loader is available in a standard version
and in several special versions with extra equip-
ment.
In case of optimal equipment there is a special
description for each version under section
MISCELLANEOUS.
All units are four-wheel driven. The drive is
electro-hydraulic with a pump unit and a hydraulic
motor which gives the machine a total tractive
effort of 90 kN.
The chassis is manufactured in only one ver-
sion, and is equipped with four-wheel steering -
i.e. steering on both pairs of wheels. The turning
radius is only 2 metres and gives the machine
a great mobility in confined spaces. The chassis
rests on four rubber wheels which are steered
hydraulically with cylinder-operated steering
arms.
The arm system consists of a lifting arm
with swing arms, two gathering arms and two
digging blades. The lifting arm is articulated in
the conveyor frame for operation of the digging
blades in the vertical plane. The gathering arms
are attached to the front end of the conveyor
frame and are used to gather the muck in front of
the machine and to clean the floor. The digging
blades are carried in swing arms on the lifting
arm, enabling them to be turned in various direc-
tions as the muck is being loaded onto the con-
veyor. In the standard version, the arm system
permits a digging width of 4000 mm.
The maximum digging depth is 250 mm below
ground level. The loading capacity is 3 m/min.
The arm system is operated by means of double-
acting hydraulic cylinders.
The conveyor frame carries the muck from the
front end of the machine, over the machine and
down into a haulage vehicle stationed behind the
machine.
The frame is articulated above the chassis to
enable the discharge height to be varied according to
the loading height of different types of haulage
vehicles. In the standard version, the conveyor
frame is built with 3500 mm overhang and is
suitable for loading many types of haulage vehi-
cles. If desired, the conveyor frame can also be
lengthened when ordering a new one.
A diesel engine is mounted on the machine
10HR07
for self propulsion (can also be used for digging

with lower speed) in plants where the length
of the supply cable is insufficient for transpor-
tation between the working sites. The machine
is equipped with two batteries for power supply
when starting the diesel motor.
In the following texts, separate and more
detailed descriptions are presented of previously
mentioned components, together with descrip-
tions of the design of the electrical and hydraulic
systems.
10HR07
Chassis
The chassis consists of an undercarriage (7)
mounted on four rubber wheels. The under-car-
riage carries a transmission unit (6) together with
the necessary operating equipment for digging,
driving and steering the machine (Fig.1).
The actual undercarriage consists of three
parts. One welded centre framework of steel with
attachment devices for the two steering drive
shafts and the link which connects the conveyor
frame to the chassis. On the left hand side under-
carriage is the cable-drum (2) with the supply
cable as well as the cabin mounted. On the right
hand side undercarriage is the diesel engine (1),
electric motor (4), pump unit (5) and hydraulic
tank (3) mounted. Optionally, the machine can Fig. 1 Chassi
be equipped with a combined cable and water
hose drum.
The hydraulic oil tank is provided with one
return filter for filtration of the oil in the hydrau-
lic system. An electric pump is connected to the
tank for filling the system via the return filter. The
pump unit (5) , also shown in Fig 2., is mounted
to the electric motor (4) on the chassis for diesel-
and electro-hydraulic drive and operation of the
machine. The machine is equipped with a diesel-
engine (1) for self-propulsion over longer dis-
tances.
Most of the operating controls are positioned
at both arm rests on the chair and on a special
control panel (display) in the drivers cabin. The
roof is FOPS-approved to provide additional safety
for the driver in the event of falling rocks.
The wheel base is 2500 mm and the track
width 2130 mm. Fig. 2 Pump unit
10HR07
Arm system
The standard machine is equipped with a system
of arms adapted for a digging width of 4.0 metres.
The arm system consists of two gathering arms
mounted on the conveyor frame and two digging
blades mounted on a lifting arm (Fig.1).
The gathering arms are mounted one on each
side of the front end of the conveyor frame and
fold back for transport. While working, the gath-
ering arms are turned forwards to an extended
position in order to gather the muck into the con-
veyor as the machine advances into the round,
cleaning the floor in the same manner as a bull-
dozer.
The lifting arm is able to move up and down
around its point of attachment to the conveyor
frame and is used to raise and lower the digging
blades in the vertical plane (Fig.1).
Each digging blade is carried in a swing arm
above the lifting arm. The swing arms can be
turned forwards and rearwards and are used to
swing the digging blades in various directions in
the horizontal plane (Fig.2).
The digging blades can thus be moved verti-
cally by means of the lifting arm and sideways
in various directions within a range of 180 by
means of the swing arms.
The inward and outward movements of the
digging blades are controlled hydraulically with
the aid of double-acting hydraulic cylinder
(Fig.3). The movements of the gathering arms,
lifting arm and swing arms are also controlled in
a similar manner.
As a rule, the digging blades work synchro-
nously, but for special work operations, they may
also be operated individually.
Optional equipment is handled under under
chapter 7, MISCELLANEOUS.
10HR07
Conveyor frame assembly

The conveyor frame assembly consists princi-
pally of a sturdy, welded conveyor frame. Two
gathering arms are mounted in the front end of
the conveyor frame, in the bottom of which a
conveyor chain runs (Fig. 1). The material is car-
ried with the aid of this chain from the front end
of the conveyor frame, over the machine and to
the rear end, where it is loaded onto the haulage
vehicle.
In principle, the conveyor chain is a scrape
conveyor, consisting of an endless roller chain
to which a number of flights are attached. The
chain is powered by a hydraulic motor at a speed
adjusted between 35 and 60 m/min (Fig. 2).
The drive shaft (Fig. 3) is equipped with a chain
wheel over which the roller chain runs. During
operation, the chain wheel pulls the conveyor
chain through the conveyor frame and around
the guide roller at the front end of the conveyor
frame. The guide roller serves as a steering for
the conveyor chain.
The sides of the conveyor frame are made of
steel plates with a thickness of 8 mm, the insides
being lined with wear plates at the lower edge.
The bottom comprises a number of crosswise
steel beams and a bottom plate 8 mm thick, on
top of which a wear layer of special steel with
a thickness of 12 mm is welded to increase the
service life of the conveyor frame and simplify
maintenance.
The unloading height of the conveyor frame
can be varied with the aid of hydraulic cylinders,
which raise or lower the frame to match with the
loading height of the haulage vehicle. The length
of the conveyor frame can be extended 1500
mm, alternatively even longer, when ordered as
new by special agreement with the customer.
10HR07
Drivers cabin
The drivers cabin is located on the left hand
side of the machine, above the front wheel hous-
ing. It consists mainly of a operators seat (3) 1
with joysticks (2) and steering paddles (4) in the
armrests, a front mounted dashboard (1) (dis-
play), a ceiling mounted CD player and an air
condition system. 2 2
The operator sits on a seat with all controls
within easy reach and with a virtually unlimited
view of the working area (Fig.1). The seat is indi-
vidually adjustable for any operator. 4
For security purposes the drivers cabin is 3
equipped with a FOPS-approved roof in order
to protect the driver against falling rock, and all
the glasses are hardened. For emergency exit, a
hammer is provided. Fig. 1 All controls are reached from the
All necessary controls to operate the machine drivers seat
are located in the dashboard (display), in the
armrests of the seat or on the cabin floor, except
control switch (S) for starting the electrical unit
which is located on the electrical cabinet below
the cabin (Fig.2).
Fig. 2 Starting equipment for the electric

unit.
10HR07
Pump unit 1 2
The pump unit is a diesel-electro-hydraulic

drive unit (Fig 1.) which supplies the separate
circuits of the hydraulic system with a flow of oil.
The unit is bolted to the top of the chassis on the
right hand side.
The pump unit (2) is connected to an electric
motor (1) which drives two axial piston pumps
and one gear wheel pump via an intermediate
shaft (Fig. 1).
One axial piston pump (3) supplies the digging
unit, steering, cable wheel and hose wheel with Fig. 1
oil in the first circuit. The system is a load sensing
system (LS-system).
The second axial piston pump (4) supplies the
second circuit with a variable oil flow which pro-
vides working pressure for the conveyor motor, 4 5
propulsion motor and brake system
The gear wheel pumps (5) supplies a constant
flow for the hydraulic oil cooling circuit.
Fig. 2 Pump unit

10HR07
Cable drum and water hose

drum
To improve the on-site mobility of the loader, 1
it is equipped with a cable drum and hose drum
(option) to carry the supply cable/hose (Fig.1). 2
The drums are driven by hydraulic motors
which, while the loader is in motion, automati-
cally keep the cable/hose tight to prevent them 3
from being damaged.
The drums can be set in automatic mode
or be operated manually from the display. It is
also possible to operate the drums through the
switches on the electric box (3) Fig. 1. Fig. 1 Cable drum (1), Hose
During reversing, the drum winds the supply drum (2) and the electric
cable/hose up onto the drum. When driving for- box (3)
wards, the cable is pulled out against the skid
brake built into the cable drum. The outgoing
torque is regulated as necessary with the aid of
a special setting wrench, at the same time as
the drum is rotated in either direction until the
required torque is obtained. The cable drum is
standard equipment on the machine, but the
hose drum is provided as optional equipment.
Optional equipment is handled under chapter
7, MISCELLANEOUS.
Sprinkler system
The machine is equipped with a sprinkler
system which showers water over the muck so as
to reduce dust formation and keep down explo-
sive gases while loading is taking place (Fig.2).
Watering takes place directly above the dig-
ging blades and the front end of the conveyor
frame, which is where the most dust is usually Fig. 2 Sprinkler system
formed. It is appropriate for the machine to be
equipped with the same type of water-connec-
tion as that used for the drilling equipment on
the work site.
10HR07
Batteries
All machines are equipped with two batter-
ies, connected in series (Fig.1). The batteries,
installed beneath the drivers cabin, give necessary
power to start the diesel drive unit.
Specifications:
Battery voltage: 2 x 12 V
Battery capacity: 2 x 135 Ah
Battery isolator
Turn on the main current with the battery isolator
key clockwise before starting the engine (Fig 2).
The isolator is located immediately above the
batteries and is actuated by turning the lever in
clock-wise direction. If operations are to be discon-
tinued for any length of time, or when the run is Fig. 1 Batteries
over, switch off the main current by turning the
key in counter clock-wise direction.
The main switch must not be disconnected

when the engine is running.
Fig. 2 A: Main circuit breaker

10HR07
Diesel-hydraulic drive for 4 3 1 2

self-propulsion and digging
function.
The machine is equipped with a Diesel-engine
(4) for self-propulsion over farther distances than
what is possible via cable. The maximum speed
is also higher than with electro-hydraulic drive.
In this case, the Diesel-engine drives an electric
motor (1) which in turn is connected to the pump
unit (2) supplying the hydraulic system with an oil
flow in the ordinary manner. The Diesel-hydraulic
drive gives the machine a traveling speed of max.
12,0 km/h.
Diesel engine is connected to the electric motor Fig. 1
via an automatic clutch coupling (3) When diesel
engine is running at idle speed the electric motor
stands still and also the pump unit. When engine
rpm are raised up to approx 1200 rpm the clutch
will automatically connect engine with electric
motor and pump unit so hydraulic pumps can
supply oil to the hydraulic system. When pumps
are working then digging can also be performed
in diesel mode, but with lower capacity.
The engine rests on vibration dampers on top
of one side of the chassis (Fig.1) The engine is a
Perkins type 1104C-E44T, EU Step II (Fig.2). The
engine is built to satisfy the high demands made
today in respect of satisfactory working condi-
tions and, for example, the demand for a maxi-
mum permitted CO level of 0.05% by volume in
the case of underground work.
Due to the double vortex combustion chamber
Fig. 2 Diesel engine
in the pistons intensive vertex formation takes
place with excess oxygen, the result being the
complete combustion of the carbon monoxide,
carbonisation remaining below the permitted
level. The engine produces less waste gases and
as a result requires less ventilation than any other
engine used in this field.
10HR07
Engine specification
Engine: PERKINS Diesel
Type: 1104C-E44T EU Step II, 4-cyl
4,4 L
Power: 74,5 kW at 2200 rpm.
Torque: 412 Nm at 1400 rpm (DIN ef
fect)
Equipped as follows:
Oil sump with dipstick
Electronically controlled injection pump
2300 rpm
Automatic advance unit
Oil filler
Hydraulic oil cooler
Cooling air fan
Lubricating oil cooler
Shut down device
Alternator 28V, 75A
Starter motor 24V
Flywheel
Flywheel casing SAE 3
Vibration damper
Silencer
Air intake pipe
Pre-cleaner
Air cleaner
Rubber tube
Rubber connecting piece
Loops for lifting the engine
Oil filter
Fuel filter
Oil pressure switch
Cold start equipment 24 V
The Diesel engine specifics can be found on

the enclosed compact disc (CD). The engine
speed is regulated by a foot throttle.
The engine will be started and stopped with

buttons on the dashboard (display).
10HR07
Transmission unit
The machine is driven and steered hydrostati-
cally through a four-wheeled transmission unit.
The transmission unit consists of two steer-
ing drive axles carrying rubber-tired wheels and
driven by a hydraulic motor via a gear box and
two propeller shafts (Fig.1).
Both steering drive axles are directly bolted on
the undercarriage. The rear axle is attached to a
pivot bearing, thus enabling the rear wheels to
be rotated through 7 in the vertical plane to
absorb irregularities on the ground. The axels are
fitted with a slip differential and final drive (hub
reduction). Both pair of wheels are operated by
the same hydraulic circuit.
A multi disc brake is installed on each side of
the differential in the drive axles and acts as a
parking brake for the machine, but can also, if
necessary, be used as an emergency brake, the
brake is released by hydraulic pressure by lifting
up the push button on the parking control on the
left hand side arm rest.
1
Driving
During propulsion the machine is driven with
the aid of a hydraulic motor (Fig.1), which in turn
acts through hydraulic pressure from a diesel-
electric driven pump. The hydraulic motor output
is varied by changing the displacement of the
motor by the foot throttle.
The power is mechanically transmitted from
the hydraulic motor to the wheels via the gear 2
box, propeller shafts and steering drive axles.
Reversal of the flow direction to the hydrau-
lic motor results accordingly in opposite direc-
tion of rotation of the wheels. Changing the flow
at diesel or electric drive is done by moving the
switch (1) forward or reverse for desired direc-
tion of travel (Fig.2).
The hydraulic motor develops its maximum
torque right from the start. At most the machine
develops a tractive force of 90 kN. Loading can
thus take place even in steep gradients, under Fig 2. Direction switch (1) and
favourable conditions up to a gradient of 1:7. Parking brake (2)
Specifications:
Hydraulic motor: SAUER: Series 51V160
Gear box: Clark Hurth 305.284
Gear ratio: 1:3,27
Steering drive shafts: Dana: 213/ TA6770
Tyres: 12.00 x 20
Travelling speed with electro-hydraulic drive: Max 3 km / h
Travelling speed with diesel drive: Max 12 km / h
10HR07
Steering
The drivers cabin is equipped with two joy-
sticks in the joystick consoles of the drivers seat
and two steering paddles on the right joystick
console upper side. (Fig.1). Each steering paddle
is electrically connected to a magnetic operated
valve. The valves are via hydraulic hoses con-
nected to the steering cylinders, which turn the
wheels on the axles (Fig.2). Thus the steering
system requires no direct mechanical connec-
tion between the steering manipulators and the
steering arm.
The valves are ordinary directional valves,
connected to one axle each. When the steering
paddle is moved, the valve opens accordingly
and releases an oil flow to the steering cylinder. Fig. 1. The driving compartment is
When the paddle is released, the valve is closed, equipped with two joysticks and
leaving the axle in its current position. one drivers seat
Both pair of wheels can be operated individu-
A: Left joystick
ally thus facilitating manoeuvring in severely con-
B: Right joystick
fined spaces. This possibility may be desirable if
C: Steering paddles
the machine for some reason has to be moved
diagonally sideways for example when parallel
parking or when mowing to the machine after a
puncture.
In the display the operator can see the posi-
tion of wheel and also correct them to straight
position automatically
The double-acting cylinders convert the
hydraulic energy to a steering movement by turn-
ing the machine wheels. The turning is restricted
by a mechanical stop on the steering cylinder.
Through a movable centre bearing, the rear
pair of wheels can move 7 in the vertical plane
to absorb irregularities in the ground.
B B
D C C
D
A A
A: Mechanical stop
E
B: Steering cylinder
C: Steering arm
Fig. 2. Steering drive axle D: Steering drive axle
10HR07
Hydraulic system
The hydraulic system consists of three sepa-
rate circuits with different functions. One circuit
is used for ordinary production loading. Second
circuit is used for self-propulsion of the machine
between the working sites. The last circuit is
used for cooling of the hydraulic oil. Return oil
from all 3 circuits flow through a common filter
mounted into the hydraulic tank. The oil tank is
also equipped with a breather, level indicator and
a temperature sensor.
Production loading
During normal production loading, the hydrau-
lic system is mainly supplied with a flow of oil
from one pump in the pump-unit. The flow pro-
vides the requisite hydraulic pressure for posi-
tioning, digging and steering.
First circuit (pump 1)

The circuit is used for operating the digging
unit, (lifting arm, digging blades and swing arms).
Alternatively: (breaker, arm, boom, boom swing, 2 3
rake swing and bucket) gathering arms, conveyer
frame, wheel drums and hammer (option). The axial
piston pump supplies the circuits with a variable
flow of oil; which is distributed into the direc-
tional valve. The hydraulic cylinders are operated 1
by means of magnetic operated valves with joy-
sticks. Turning the gathering arms, like operat-
ing the conveyor frame and hydraulic motor for
cable/hose drum are also done in the circuit.
Second circuit (pump 2)

The second circuit is supplied with a variable
flow of oil by axial piston pump (2), witch pro-
vides working pressure for the hydraulic motor
driving the conveyor chain when loading and also Fig 1. Pump unit
for the hydraulic motor that drives the machine
on working site (self propulsion).
Third circuit (pump 3)

The third circuit is supplied with a constant
flow of oil by a gear pump for cooling of the
hydraulic oil in the complete system.
10HR07
Hydrostatic operation
Diesel-hydraulic operation can work with dig-
ging and transport (self-propulsion).
When transport mode (self propulsion ) is
chosen the throttle pedal (D) is regulating the D
diesel engine rpm as a normal car engine. Higher A
rpm on diesel engine will give more revolutions
on the hydraulic pumps which in turn give more
revs on hydraulic motor and then more speed on
machine.
When digging mode is chosen the diesel engine
will get constant revolution level at 1800 rpm and
the throttle pedal regulates the hydraulic valves
for digging and self-propulsion. (This rpm level is
settled at the factory.)
Speed direction Fig 1

The speed direction will be changed with a
switch (A). (Fig. 1).
See also Fig 3.
Changing the direction of travel

The direction of travel is changed by chang-
ing the direction of flow into the hydraulic motor,
which via the transmission and propeller shafts
drives the wheels on the machine. Reversal of
flow is accomplished with a switch (1) on the left
hand side joy stick. (Fig. 3). Depending on the
position of the switch (1) Fig 3 the flow of oil is
directed to either side of the hydraulic motor
and a corresponding driving direction FORWARD
- REVERSE is obtained. The switch is used in both
diesel and electric mode of operation.

NOTE!
The machine must stand completely still
before changing the direction of travel

Stop control for diesel engine
The engine will be stopped from the display
(see section 4.000).
With regards to use of the diesel engine, see
Perkins driving instructions on the enclosed com-
pact disc (CD). Fig 2: Hydraulic m ot o r (A),
Transmi ssion (B),
Service brakes Propeller shaft (C).
The advantage of hydrostatic operation is that
the throttle pedal (D) is used for self-propulsion
and braking. When no throttle is used the oil flow
to the wheels is blocked and the machine stands
still.
When pressing the throttle pedal, a flow of oil
is conducted to the propulsion motor acting on
the transmission unit which via propeller shafts
affect the drive axles.
10HR07
1
Parking brake
The parking brake as a SAHR disc brake acting
on both output shafts of each drive axle. The
brake is actuated electro hydraulically by the
push button switch on the left hand arm rest
(Fig.3).
When the parking control button is lifted up
to the brake release position, a flow of oil is
led into the parking brake cylinder. The built-in 2
spring brake force working on the both sides of
each differential on both axles is counteracted by
hydraulic pressure and the wheels are released
and can rotate freely.
When the red button is pushed down to parking
position, the built-in spring brake force locks all
drive axle output shafts and all wheel are braked
simultaneously. If necessary, the parking brake
works also as an emergency brake.
When travel direction switch (1) is put in neutral
position parking brake will apply automatically Fig 3. Direction switch (1) and
after a while, shorter time in work mode than in Parking brake (2)
travel mode.
10HR07
Central lubrication system

(option)
The machine may be equipped with an auto-
matic central lubrication system (fig. 1).
The system consists of a lubrication pump with
a grease container, a flow divider and hoses for
the lubrication points.
See the central lubrication system instruction
manual for further information (chapter 8,
APPENDICES).
Fire extinguishing system

The machine is equipped with a manual fire
extinguishing system.
The system consists of 2 pressurized fluid
reservoir, two trigger handles, line pipes and
nozzles.
The nozzles are situated in the engine room Fig 1. Central lubrication system
and by the pump unit.
The placement of the trigger handles are
marked with E. They are situated one under
the drivers cabin and one on the opposite side
of the machine.
See the fire extinguishing system instruction
manual (on the enclosed compact disc (CD)) for
further information.
Fig 2. Fire extinguishing system

10HR07
FUNCTION 3.000
Electrical system 3.001

Electrical circuit diagram 3.001
Electrical circuit diagram - diesel operation 3.001
Hydraulic system 3.002
Hydraulic circuit diagram 3.002
Hydraulic equipment 3.002
Conveyor 3.003
10HR07
FUNCTION
10HR07
FUNCTION 3.001
Electrical system
The following functional description and circuit
diagram describe the design principle of the elec-
trical system of the machine. In the event of any
deviations, a separate circuit diagram is drawn
up for each individual version.
The electrical system is supplied by a trailing
cable which is wound up on the cable drum and
connected to contactor in the apparatus control
and distribution box. The cross-section cable area
may normally not be less than 3x50 mm at 400V
or 3 x 25 mm at 1000V AC.
Bild 1. Mains voltage lamp

10HR07
FUNCTION
Partlist
GIA 2704257801 301118 AS1
Item Designation Megacon No. GIA No. Qty. Description Data Manufacture Type Order Number Sheet ref. Note
AS1
AS1 981520 Enclosures
+AS1-F1 901002 Miniature Circuit Braker 10A Merlin Gerin C60N-1-10C /10.1D
+AS1-F12 901111 Miniature Circuit Braker 3A ABB S503HV-K3 1SFE164503-102 /1.3B
+AS1-F13 901135 Miniature Circuit Braker 3A ABB S502HV-K3 1SFE164502-102 /2.3C
+AS1-F14 901047 Miniature Circuit Braker 2A Merlin Gerin C60N-1-2C
+AS1-F16 901047 Miniature Circuit Braker 2A Merlin Gerin C60N-1-2C 24306 /2.2E
+AS1-F04 901007 C60N-2-6C Miniature Circuit Braker 6A Merlin Gerin C60N-2-6C /2.3B
+AS1-K1 934027 Relay 2vxl 115VAC Schneider RSB2A08F7 /1.6E GROUND FAULT
+AS1-K2 934027 Relay 2vxl 115VAC Schneider RSB2A08F7 /1.8E PHASE SEQVENCE SUPERVISION
+AS1-K6 921060 1 Contactor 110V 50/60Hz ABB A50-30-00 110V AC
+AS1-K3, -K5 921063 2 Contactor 110V 50/60Hz ABB A75-30-00 110/50
+AS1-K3, -K5, -K6 921041 3 CA5-10 aux contakt 1sl 1NO ABB CA5-10 32 322 18
+AS1-K3, -K5, -K6 921042 3 CA5-10 aux contakt 1sl 1NC ABB CA5-01
+AS1-K3, -K5, -K6 921043 3 RV5/250 Varistor A9-A110 ABB
+AS1-K21 932001 1 TE-5S 115V Tiddon Y/D kopplare
+AS1-K4 934024+934021 Relay 2vxl 8A 24VDC RSB2A080BD /5.4G MOTOR START
+AS1-K7 933067 Safety Relays 24V AC/DC Omron G9SB-301B /6.8D E-STOP RELAY
+AS1-K50 933005 Phase control relay 24VAC/DC DOLD MK9059.11 0035833 /1.5D PHASE SEQVENCE SUPERVISION
+AS1-K51 933014 Ground fault / earth leakage relay110-380V Megacon ELR-3C 110-380V 604030 /1.2E
+AS1-M1 /3.3F HYDRALIC MOTOR
+AS1-Q7 922041 Over voltage relay 110V Allen-Bradley CEFB1-12 110V 32 856 42 /3.3D HYDRAULIC MOTOR 75kW
+AS1-Q01 911257+911238+911241+911246 /1.8A MAIN SWITCH
911245 1 Circuit breaker 250A 20kA ABB T3N-250 R200
911239 1 Handle /Tmax T4-T5 ABB
911241 1 T-max auxilary contact T1-T6 1NO + 1NC ABB 1SDA051368R1
911240 1 T-max Under-voltage T4-T5 UVR110-127 VAC ABB UVR-C 110...127VAC 1SDA054883R1 /1.9E MAIN SWITCH
+AS1-Q10 913205 Motor protective circuit breaker 0.63 - 1A Telemecanique GV2ME05 31 165 08 /1.4C
+AS1-R1 Thermistor /5.4G Thermistor M1
+AS1-S23 833258 Limit switch A10 Saia Burgess DS3 65004100 /1.7D
+AS1-T01 961124 Transformer, Control 25VA Nordtrafo TT91/99-41 50 VA 400-690//110/24V /1.4F
+AS1-T03 961051 Transformer, Control 250VA Nordtrafo TT201/96-56 250VA 400-690//2x110/24 /2.2D
+AS1-T10 961073 Transformer, Current CT-1/60 601033 /1.2B
+AS1-Z2 931167 Suppressors 110-240 VAC Telemecanique LA4DA2U 32 375 05 /4.7C
+AS1-X24 996301 1 Chassihouse
+AS1-X24 996342 1 40-pol femal holder
A_301118_GIA AS1 400V 2704257801 301118 AS1 10HR 1000V 1(1) 2008-05-14
Partlist
GIA 2704239801 301084 AS2
AS2
AS2 981533 1 Enclosures

X2 990406 90 Terminal ZDK 2,5/1,5 2 Weidmller
S1 943333 1 Emergency stop actuator

S1 943320 1 Fixing adaptor
S1 943322 1 Contact element
S1 922097 1 Label E3733512
+AS2-K21 934023+934025+934028 1 Relay + socket RSB1A160BD 1vxl 16A 24VDC /4.7A HEADLIGHT FRONT (RELAY)
+AS2-K22 934023+934025+934028 1 Relay + socket RSB1A160BD 1vxl 16A 24VDC /4.7B HEADLIGHT REAR (RELAY)
+AS2-K23 934023+934025+934028 1 Relay + socket RSB1A160BD 1vxl 16A 24VDC /4.7B WIPERS (RELAY)
+AS2-K24 934023+934025+934028 1 Relay + socket RSB1A160BD 1vxl 16A 24VDC /4.7C FLUSHING WINDSCREEN (RELAY)
+AS2-K25 934023+934025+934028 1 Relay + socket RSB1A160BD 1vxl 16A 24VDC /4.7D SIGNAL HORN
+AS2-K26 934023+934025+934028 1 Relay + socket RSB1A160BD 1vxl 16A 24VDC /4.7D
+AS2-D1 994387 1 Saur MC050-010 10100900 /1.2G

+AS2-D2 994387 1 Saur MC050-010 10100900 /2.2G
D1-D2 994388 2 Contact 10100946
+AS2-V20 974020 2 Plint + Diod
Y1 920359 1 Water valve
X20, X55 996301 2 HDC

X20, X55 996342 2 HDC 40-pol female
X50 996401 1 HDC

X50 996441 1 HDC 64-pol female
X25 996301 1 HDC

X25 996332 1 HDC 40-pol male
X10-17 130010 8 Connector 4-pol UTG0104SH Souriau Female Chassi

CAN2A, XC2 130010 2 Connector 4-pol UTG0104SH Souriau Female Chassi
CAN2B, CAN2F 130024 2 Connector 8-pol UTG0128SH Souriau Female Chassi
X30 130100 1 Connector 12-pol UTG01412SH Souriau Female Chassi
X-- 130682 50 Contact female SC16ML11S6 Souriau
X10-17 130155+130159 8 Connector 4-pol UTG6104PN+UTG10AC Souriau Male Cable

CAN2A, XC2 130155+130159 2 Connector 4-pol UTG6104PN+UTG10AC Souriau Male Cable
CAN2B, CAN2F 130156+130142 2 Connector 8-pol UTG6128PN+UTG12PG Souriau Male Cable
X30 130614+130613 1 Connector 12-pol UTG61412PN+UTG14PG Souriau Male Cable
X-- 130702 50 Contact male SM16ML11S6 Souriau
X35 974239 1 Dsub
+AS2-B27 /12.6G
+AS2-B27 /12.6G
A_301084_GIA AS2 2704239801 301084 AS2 10HR 1000V 1(1) 2008-05-14

Partlist
GIA 2704240801 301085 AS3
AS3
AS3 981534 1 Encloser

X3 990406 33 Terminal ZDK 2,5/1,5 2 Weidmller
+AS3-B32 984410 1 /1.7F TEMPSENSOR HYDARULIC TANK

+AS3-B33 994087 1 /3.5F FILTER SWITCH
+AS3-B34 1 VR2 C-O /3.5G LEVEL SWITCH HYDRAULIC
+AS3-K31 934023+934025 1 Relay + socket /2.7B HEADLIGHT FRONT (RELAY)

+AS3-K32 934023+934025 1 Relay + socket /2.7B HEADLIGHT REAR (RELAY)
+AS3-R30, R31 100749 2 Power resistance 24v/330ohm/2W 60-033-47 /3.3G
+AS3-Y31 923059 1 /3.5B BRAKE VALVE

+AS3-Y32 923059 1 /3.5C LS DUMP VALVE 1
+AS3-Y33 923059 1 /3.5C LS DUMP VALVE 2
+AS3-Y34 923059 1 /3.5D PCOR
+AS3-Y35 923059 1 /3.5E BPD
X21 996301 1 HDC

X21 996332 1 HDC 40-pol male
X21 996905 23 HDC crimp male
A_301085_GIA AS3 2704240801 301085 AS3 10HR 1000V 1(1) 2008-05-14

Partlist
GIA 2704241801 301086 AS4
AS4
AS4 981535 1 Encloser

+AS4-S41 943364 1 Selector switch actor ZB5-AJ5 3-lges /1.3B SWITCH CABLE IN/OUT
+AS4-S42 943364 1 Selector switch actor ZB5-AJ5 3-lges /1.3C SWITCH HOSE IN/OUT
S41-42 923321 4 Contact element
S41-42 943320 2 Fixing adaptor
X4 990406 14 Terminal ZDK 2,5/1,5 2-vning Weidmller
4 Cable entries NW7 156196
4 Nut M12*1,5 120974
A_301086_GIA AS4 2704241801 301086 AS4 10HR 1000V 1(1) 2008-05-14

Partlist
GIA HYTT
Postbeteckning Megacon Art.nr. GIA Art.nr. Antal Beskrivning Elektriska data Fabrikat Typnummer Bestllningsnummer Bladreferens Anmrkning
Hytt
+DISPLAY-C4 994391 1 Panel Sauer Panel Sauer 10100890 /16.8C

Display 922999 1 Kabel+Kontaktsats panel Panel Cable + Connection kit 10100868
A21 1 Stereo Stereo 4709999801
B20 994394 1 Gaspedal Gas throttle 791681N

B20 922998 1 Kontakt Contact
B21-22 994384 2 Styrpaddel Control paddle 11019605
B21-22 994385 2 Kontakter+kabel Connector + cable 162U2099
B23 994386 1 Joystick H Joystick R
B24 994407 1 Joystick V Joystick L
B23-24 994408 2 Kontakt Joystick Joystick connector 10101551
B28 922915 1 Torkarmotor Wiper motor S1122
B28 K1536218 1 Kpa Torkarmotor Wiper motor cover S700298
H25 922428 1 Innebelysning Internal lighting 2JA007373071 /14.6E CABIN LIGHT
S04 922401 1 Ndstopptrycke Emergency stop mushroom E3732835

S04 922060 1 Hllare Holder E3732255
S04 922592 1 Kontaktblock Contact 2NO E3733197
S04 922097 1 Skylt Sign E3733512
S21 922727 1 P-bromstrycke P-brake mushroom E3732840
S21 922497 1 Hllare+Kontaktblock Holder + contact 1NC E3732710
S22 1 FNR Switch FNR Switch M077696
S22 1 Htta Hood M077404
S25 922798 1 Ddmansbrytare DMC switch ZCP28.
S25 922799 1 Rulle Ddmansbrytare Roller DMC switch ZCE21.
Engelska A_301118_GIA AS1 400V Hytt HYTT 10HR 1000V 1(1) 2008-05-15
Partlist
GIA MASKIN
Postbeteckning Megacon Art.nr. GIA Art.nr. Antal Beskrivning Elektriska data Fabrikat Typnummer Bestllningsnummer Bladreferens Anmrkning
MASKIN
922938 8 Xenon Belysning Xenon lightning 0030022822-001

H21 K17334318 1 Backvarning ljud Backup warning sound 986334001
H21-1 922183 1 Backvarning ljus Backup warning light E5377026
H21-1 922184 1 Fste H21-1 Holder H21-1 E5377092
A26-27 2 Orlaco kamera med kabel Orlaco camera + cable
B1-2 923027 2 Induktivagivare Inductive sensor 650.2701.001
B1-2 923130 2 Slanghllare till givare Tube holder for sensor 155405
B27 994027 1 Tankgivare disel Diesel level sensor 224082007035
B29 929240 1 Spolarmotor Flusher motor 246082008012
S03 923131 1 Ndstopp Emergency stop E3734723
S03 923132 1 Genomfring pg13 NW12 Cable gland PG13/NW12 155136
S03 923133 1 Mutter pg13 Nut PG13 121048
B25-26 923000 2 Givare Styr/Fram,Bak Sensor Steering/Front,Back 424A16A045B
B25-26 2 Kontakt Styr givare Contact steering sensor Wurth 3 pol
S1 922310 1 Batterifrnskiljare Battery switch 6EK246100001
G1 K1684927 2 Batteri Battery
921658 2 Polsko + Battery connector +
921659 2 Polsko - Battery connector -
921826 2 Polskydd + Connector cover +
921827 2 Polskydd - Connector cover -
B31 922394 1 Kontakt giv hydmotor sauer Connector hydraulic motor sauer 500724
S05 922401 1 Ndstopptrycke Emergency stop mushroom E3732835
S05 922060 1 Hllare Holder E3732255
S05 922592 1 Kontaktblock Contact 2NO E3733197
S05 922097 1 Skylt Sign E3733512
P31-32 990821 2 Kontakt tryckgiv sauer Contact pressur sensor sauer 162U9990
994409 4 Gr kontakt sauer Grey contact sauer 157B4992
923129 2 Svart kontakt sauer Black contact sauer 157B4993
923059 3 Ventilkabel 10M Valve connector 10M 7000-18021-6361000
B34 994087 1 Hyd,niv vakt Guard hydraulic level FSK-254-2.4/0/12
B32 994410 1 Hyd,temp vakt Guard hydraulic temp 1090173
B32 994411 1 Kontakt Contact K23436
B33 1 Hyd,filter vakt Guard hydraulic filter VR2C.0
M31 993837 1 Pfyllnadspump,Hyd Refill pump hydr. Oil
1 Generator Generator 100A2871A901
H22 921162 1 Signalhorn Horn 3BA002768-382
994392 14 Byglingar till elmodul Daisy chain cable
2 Genomfringar Elmotor Cable gland electrical motor
923110 5 NW 7 NW 7 156196
922311 5 NW 7 mutter NW 7 nut 120974
Engelska A_301118_GIA AS1 400V MASKIN 10HR 1000V 1(1) 2008-05-15

10HR07
FUNCTION 3.002
Hydraulic system
General
The hydraulic system can be operated either
by electric or diesel power. The systems are inte-
grated in each other, the electric power must be
used when loading, while diesel power is used
mainly for longer transport distances, and when
electric power is not available for service work.
The electric hydraulic system may be consid-
ered as three different circuits with entirely sepa-
rate functions. The circuits are supplied with a
flow of oil from the pump unit, consisting of three
hydraulic pumps.
All circuits are used for ordinary production
loading.
During production loading, the main hydraulic Fig 1. Pump unit
system is supplied with an oil flow from three
pumps in a diesel-electro-hydraulic pump unit.
From the pumps (1) and (2) the flow of oil is con-
ducted to directional valves in the system, with
the aid of which a number of hydraulic cylinders
and motors are operated. Pump (3) circulates
and cools the hydraulic oil from tank through the
cooler and back again into tank.
All hydraulic cylinders are double-acting,
with alternatively pushing or pulling functions,
depending on the operation performed with the
machine.
The movement of the cylinders are controlled
by two chair mounted joysticks, one on each
side. When a joystick is moved, an electric signal
is transferred to the solenoid mounted on a direc-
tional valve. All the directional valves are electri-
cally controlled.
During production loading, a hydraulic motor is
used for driving the conveyor chain and another
hydraulic motor, is driving the wheels in the trans-
mission unit. Additional option motors are driving
the cable drum on which the feed cable is wound
up and water hose drum on which the water spay
hose is wound up
The control pressure in the system is set
directly on the LS-pumps. The gear pump has no
pressure regulating valve.
All oil in the system (except the drainage oil)
returns through the same return filter into the
tank.
During production loading; the water, which is
led to the front end of the conveyor frame for
spraying the round during loading, binds the dust
and significantly reduces the air pollution.
The parking brake consists of two disc brakes,
one on each side of the differential housing in
the steering drive axle. When needed the park-
ing brake works also as an emergency brake.
Brake releasing is done by lifting the park brake
button, where upon the hydraulic pressure coun-
10HR07
FUNCTION 3.002
teracts the spring force in each brake cylinder

acting on the output shaft to the wheel, and the
wheels are released.
When pushing the button for parking brake,
the oil from the parking brake cylinders is evacu-
ated and the built-in spring force locks the output
shaft of the drive axle and all wheels are braked
simultaneously.
Production loading
The oil flow from pump (1) is divided into 2
valve group circuits. One circuit (digging valve cir-
cuit) is used for operating the swing arms, digging
blades and lifting arm. Another circuit (position-
ing valve circuit) is used for steering, operating
cable and hose wheels, conveyer front and rear,
catch arms and support legs. Axial piston pump
(1) supplies these circuits with the required pres-
sure and oil flow. The oil circuit from pump (2)
(conveyer and propel circuit) is used for conveyer
chain movement, propulsion and parking brake.
The oil flow from pump(3) is a cooling circuit for
hydraulic oil.
Digging valve circuit

This circuit is a LS-system (load sensing
system), which means that when the pump is Fig 1. Pump unit
running without any operation being performed
no oil is carried into the system, the pump is just
maintaining a stand-by pressure in the circuit.
The swing arms, the digging blades, lift arm,
quick tool and optional hammer are positioned in
this valve unit
When the (right hand side) SWING ARM joy-
stick is moved to the IN or OUT position the
piston in one of the slide sections of directional
valve is moved to an alternatively pressed-in or
withdrawn position. The oil is then directed to
the appropriate side of the hydraulic cylinder by
means of which the right-hand swing arm with
digging blade is turned IN or OUT from centre of
the machine.
When the DIGGING BLADE/ STICK joystick
is moved to the IN or OUT position the piston
in the other slide section of directional valve is
moved to an alternatively pressed-in or with-
drawn position. The oil flow is then directed to
means of which the right-hand digging blade is
moved in and out.
When the (left hand side) SWING ARM joy-
stick is moved to the IN or OUT position the
piston in one of the slide sections of directional
valve is moved to an alternatively pressed-in or
withdrawn position. The oil is then directed to
means of which the left-hand swing arm with
digging blade is turned IN or OUT from centre
10HR07
FUNCTION 3.002
of machine. The left-hand and right-hand swing

arm can be operated individually or together.
When the DIGGING BLADE/ STICK joystick is
moved to the IN or OUT the piston in the other
slide section of directional valve is moved to an
alternatively pressed-in or withdrawn position.
The oil flow is then directed to the appropriate
side of the hydraulic cylinder by means of which
the left-hand digging blade is moved in and out.
The digging blades can be operated individu-
ally or together. This is regulated electronically in
the hydraulic screen on the display.
When the LIFTING ARM joystick is moved to
the UP or DOWN position the piston in one slide
section of directional valve is moved to an alter-
natively pressed-in or withdrawn position. The oil
is then directed to either side of the hydraulic cyl-
inders by means of which the lifting arm is raised
and lowered. In the directional valve there is a
built-in check valve, with which the force in the
lifting arm is regulated, as it moves downwards.
Non-return and throttling valve limits the speed
when the lifting arm moves downwards.
Positioning valve circuit

This circuit use the same pump as digging valve
group and have also the same LS system.
Steering, gathering arms, conveyor frame
position, optional cable wheel, optional hose
wheel and optional support jacks are controlled
in this valve group.
When the STEERING wheel is moved in either
direction the valve connected to the wheel shaft
is effected. From there the oil flow is directed to
the hydraulic cylinders by means of which the
front and rear wheels respectively, are steered,
independently of each other.
When the GATHERING ARMS joystick is moved
to the OUT or IN position the piston in slide sec-
tion of directional valve is moved to an alterna-
tively pressed-in or withdrawn position. The oil
flow is then directed to either side of the hydraulic
cylinders, by means of which the gathering arms
are turned towards and away from the machine.
When the CONVEYOR FRAME REAR joystick is
moved to the UP or DOWN position, the piston in
the slide section of directional valve is moved to
an alternatively pressed-in or withdrawn position.
The oil flow is then directed to either side of the
hydraulic cylinders, by means of which the rear
end of the conveyor frame is raised and lowered.
The slide section is operated electrically with the
right hand side joystick.
When the CONVEYOR FRAME FRONT joystick
is moved to the UP or DOWN position, the piston
in the slide section of directional valve is moved
to an alternatively pressed-in or withdrawn posi-
tion. The oil flow is then directed to either side
10HR07
FUNCTION 3.002
of the hydraulic cylinders, by means of which the

front end of the conveyor frame is raised and
lowered. The slide section is operated electrically
with the left hand side joystick.
Conveyer and propel circuit

This circuit is supplied with a variable oil flow
from axial piston pump (2), which provides work-
ing pressure for the two hydraulic motors, driving
the conveyor chain and propulsion motor when
loading.
When diesel engine or electric motor is started
and pump (2) is running without any opera-
tion being performed, no oil is conducted to the
hydraulic motor. Simultaneously, a circular pump-
ing takes place of the flow from the feed pump
inside the main pump, which builds up a feed
pressure in the closed circuit.
When the CONVEYOR CHAIN button is pushed
to LOADING or REVERSING position on the dis-
play, the oil flow is directed from the main pump
to inlet duct on the hydraulic motor. The motor
torque is transmitted to the conveyor chain drive
shaft via a coupling and a worm gear. A change
in the flow direction to the motor gives conse-
quently a corresponding reversing of the con-
veyor chain direction of rotation, which is done
manually with push buttons on the display.
The flow from pump (2) also provides working
pressure for the hydraulic motor that drives the
machine wheels for transports in the plant or by
just moving the machine in production.
When driving direction switch is chosen and
when pressing the foot pedal for DRIVING FOR-
WARD or REVERSE an oil flow is directed from the
main pump to inlet duct on the hydraulic motor.
The motor torque is transmitted to the wheels via
gear box, two propeller shafts and two steering
drive shafts
The driving direction is selected by putting
the direction switch to desired position, FOR-
WARD, NEUTRAL or REVERSE. When changing
the direction of flow to the motor, there is a cor-
responding change of the direction of rotation of
the wheels and in that way also the direction of
the machine.
NOTE!
The driving direction may only be changed
while the machine is at a standstill.
Valve (13) in hydraulic system is a subsequent

filling valve for the propulsion motor so it always
will have enough oil also when changing direction.
The valve is adjusted to a pressure of 15 bar.
The PARKING BRAKE is released by lifting the
button on parking control. Then the oil flow is
conducted into the brake piston and the hydraulic
10HR07
FUNCTION 3.002
pressure counteracts the spring brake force work-

ing on the output shaft brake piston in the drive
axle differential so that the wheels are released
and can rotate freely.
When pushing the button for parking, the oil
is evacuated behind the brake piston and the
built-in spring brake force locks the output shaft
on each side of the differential and the wheels
are braked.
10HR07
FUNCTION 3.003
Conveyor
The muck is loaded into the haulage vehicle (A)
by means of a conveyor chain which runs in the
bottom of the conveyor casing (C). (B)
The conveyor chain consists of a roller chain to
which there is a number of flights connected.
The drive shaft (A) of the chain is mounted at
the discharge end of the loader and the shaft is
driven by one hydraulic motor (B).
The hydraulic motor is mounted directly on
one side of the drive shaft (Fig. 1).
Operation of the conveyor chain is effected by
means of buttons on the control panel (display).
The conveyor chain can be driven both for-
ward and reverse.
When preparing the machine before transpor-
tation, lower the frame and lifting arm, retract
the gathering arms (D) and digging blades to the
tramming position.
(C)
(D)
10HR07
OPERATION 4.000
Contents
Check-list 4.001
Operating instructions 4.002
Control panel (display) 4.003
Digging controls 4.004
Steering paddle control 4.005
Function of wheel direction indicators 4.006
Digging controls Backhoe 4.007
Starting a new machine 4.008
Lifting the machine 4.009
Operating instructions for Perkins diesel engine 4.010

10HR07
OPERATION
10HR07
OPERATION 4.001
Check list
BEFORE STARTING REMARKS
1. Grease machine and check oil levels
according to lubricating instructions.
2. Carry out inspection and maintenance Check also that the 3 emergency stop buttons
according to INSPECTION and MAINTENANCE outside the machine are pulled out.
CHART (see MAINTENANCE, chapter 5)
3. Connect the trailing cable to the machine.
4. Place machine in loading position and place
the transport vehicle under the conveyor
frame.
5. Remove any obstacles from working area.
6. Make sure that nobody except the operator
remains within the working area during
loading.
10HR07
OPERATION 4.002
Operating instructions
Start: electro hydraulic power pack
1. Switch on the main 24V circuit-breaker

(A) Fig 1.
2. Check that any emergency stop push
button is not pressed.
3. Switch on the main high voltage circuit
breaker Fig 1 (B).
The main high voltage circuit breaker

Fig. 1 Electrical cabinet
(B) has 3 positions:
Power ON in vertical position .
Power OFF in horizontal position (as
shown in Fig.1)
Power Tripped when handle stopped in
45 degree position. To restart the handle
has to be turned to OFF position before
turned into ON position again.
Parking/emergency brake
The parking brake push button is located on
the left hand side arm rest in the drivers cabin
Fig.4.
Push the button to lock the brake and pull up
to reset. Parking brake indicator lamp is shown in
the bottom part of the display.
In digging position the parking brake will auto-
matically apply in approx 3 seconds.
Parking brake must also be applied before it is
possible to stop the diesel engine.
Towing the machine in the event of

possibly breakdown.
Before towing the parking brake and the
hydrostatic system must be disconnected. Park-
ing brake must be disengaged with hydraulic oil
pressure, if that is not possible, the parking brake
must be disengaged manually by the 4 special
A
release screws, two on each axle.
For more information : see drive axle manual
(enclosed compact disc).
WARNING! Fig. 4. Main circuit breaker

By disengaging the parking brake there is
nothing that can keep the machine from
creeping away, so secure the wheels by
putting wheel blocks behind them.
Hydrostatic system is disengaged by discon-

necting the propeller shafts from the drive axles
Before towing the gathering arms and digging
10HR07
OPERATION 4.002
blades must be retracted to the transport posi-

tion. The front end conveyor frame must be
raised slightly above ground level and the rear
end must rest in the parking position.
Manual control of cable drum

The cable drums can be operated manually
from the panel on the outside or from the display
panel inside the drivers cabin.
This manual control box will overrun the set-
tings in the display mode.
Cable / Hose OUT = turn the switch clockwise

Cable / Hose IN = turn the switch anti clockwise
Note! Fig. 5. Cable drum control panel on the

To be able to pull out the cable or hose by outside
hand, the automatic mode must be cho-
sen. (See further 4.003 cable and hose A: Cable, IN / OUT
wheel screen for more information) B: Hose, IN / OUT
Button no 4, in Fig. 6, will guide the operator

to the cable and hose wheel screen, (See fur-
ther 4.003 cable and hose wheel screen for more
information)
H = hose drum and C = cable drum
Red colour = manual mode

Green colour = automatic mode
Loading with conveyor

Change the direction of the conveyor chain
with button no 5 or no 6 (Fig.7). Push button no
6 for loading or button no 5 for reversing.
Green colour is operating position for the chain. Fig. 6

Red colour is stopped position for the chain Button number 4 get you to the cable and
hose wheel screen
If rock jams in the conveyor frame
Change the direction of the conveyor chain
until the rock is free and continue loading.
During brief stoppage

Lower the digging blades to the floor. Stop the
conveyor chain; see section Loading with con-
veyor above. Stop the electric motor with the
button no 3 in the display, see Fig. 7 above.
Stop during longer stoppage / Stop

after completed loading
1. Stop the conveyor chain.
2. Retract the gathering arms and digging
blades to tramming position.
3. Raise the front end of the conveyor frame Fig. 7
above ground level and lower the rear end Button (6): conveyer forward for loading
to the parking position. Button (5): conveyer reverse for rock jams
4. Stop the electrical motor with the stop
10HR07
OPERATION 4.002
button.
5. Apply the parking brake. C
6. Turn off the main high voltage circuit-
breakers and the 24V and high voltage . A E
7. Disconnect the main cable from the distri-
bution box.
B
Air condition unit D
A. Recirculation or air from outside
B. Temperature regulator air condition
C. Fan speed
D. Cabin Heat ON / OFF
E. Air condition ON / OFF Fig. 8 Air condition unit
Start the air condition unit with switch (E)
CLOSE cabin door and window.
For starting set thermostat (B) and fan
speed (C) at maximum.
After initial cool down period adjust the ther-
mostat (B) and fan control (C) to a comfortable
setting.
During winter time, start the unit ones a month
to lubricate the system.
Webasto cabin heater (option). For further
information about Webasto see chapter 8,
APPENDICES.
10HR07
OPERATION 4.003
Control panel (Display)
Start screen (Fig. 1)

Start screen is shown until OK button is
pressed
Main menu screen (Fig. 2)

In this menu the operator can choose driver
setting button no (5), transport button no (2),
digging diesel button no (3) or digging electric
button no (4).
Setting screen (Fig. 3) Fig. 1 Start screen

When going to driver setting screen the driver
is allowed to change, without password, conveyer
speed, speed of digging function (reducing joy-
stick operations in the different directions x, y).
From setting screen it is possible to enter ser-
vice screen with button no (5), but that requires
a password.
Press button (A) or (B) to move between fields

Press button (C) or (D) to change the values
Service screen (Fig.5)
Time and date setting screen (Fig. 4)

Fig. 2 Main menu screen
Fig.3 Setting screen
Fig. 4 Time and date setting screen

10HR07
OPERATION 4.003
Service screen (Fig. 5)

Password is required to enter into the service
screen below Fig.5
In the service screen it is possible to check if
a sensor calibration is ok (The sensors are steering
joysticks, steering sensors, pedal). Here it is also
possible to set the identification of a new PVED.
NOTE!
When changing a new PVED it is only allowed
to change and identify one module at the time. If
several modules are changed at the same time,
all modules will get the same identification and
act at the same command. See section 6
When auto cal is OK these

feilds are green.
If a new PVED is detected during start up this is shown and with the arrow up and down it
is possible to choose the right id. The right procedure is described in section 6.
Pressure on the proportional reducing vale Pressure on the proportional reducing vale for cable wheel.
Setting of the diesel rpm in digging mode. Setting of the reduced steering speed in transport mode
Fig. 5
10HR07
OPERATION 4.003
Transport screen (Fig.6)

When entering this screen the hydraulic motor
goes into min displacement and the machine can
go to full speed.
The conveyer chain is stopped when entering
this screen. The front and/ or the rear of the con-
veyor however can be lifted and lowered.
Camera view
F forward Choosing left hand side or

N neutral right hand side rear camera
R reverse
ON/OFF ON/OFF
Head lights front Green = on Red = off Head lights rear Green = on Red = off
Start/ stop Diesel engine Hose and Cable wheel indication.
Green= on Red= off Green = on Red = off Press 4 = Wheel screen
To Main menu
To hydraulic screen To diesel screen
Fig. 6
10HR07
OPERATION 4.003
Digging diesel screen (Fig.7)

Similar to electric but only diesel engine is
used.
Camera view
F forward Choosing left hand side or

N neutral right hand side rear camera
R reverse
Head light front Head light Rear

Start/ stop Diesel engine Hose and Cable wheel indication.
Green=on Red=off Green = on Red = off Press 4 = Wheel screen
Conveyor reversing.
Conveyor loading.
Green=On Red= Off
Green=On Red= Off
Fig. 7
10HR07
OPERATION 4.003
Digging electric screen (Fig.8)
Camera view
F forward Choosing left or right

N neutral hand side camera
R reverse
Head light front Head light rear

Start/ stop Electric motor Hose and Cable wheel indication.
Green= on Red= off Green = on Red = off Press 4 = Wheel screen
Conveyor reversing. Conveyor loading.
Green=On Red= Off Green=On Red= Off
Fig. 8
10HR07
OPERATION 4.003
Diesel screen (Fig.9)

This screen shows engine rpm, engine temp,
diesel volume and engine operating hours.
Hydraulic screen (Fig.10)

This screen shows hydraulic pressure for
pumps P1 and P2, hydraulic oil temperature and
choosing possibilities of digging blades.
Digging with both blades = push button (5) and

(6) to green colour.
Digging with only left blade = push button (5)
to green colour.
Digging with only right blade = push button (6) Fig.9 Diesel engine screen
to green colour.
In the bottom also the electric operating hours
are visual.
Hydraulic screen (Fig. 10A)

This screen shows additionally the total
operating hours on the top (electric motor plus
diesel engine operation) and is only available
from Transport screen-hydraulic button or
Digging diesel screen- hydraulic button.
Cable and hose wheel screen (Fig.11)

The cable and hose wheels can be operated
manually by push buttons (5), (6) respectively Fig. 10 Hydraulic screen
push buttons (1), (2) or in automatic mode by
push buttons (7) and (3).
The values for IN and OUT forces in automatic
mode for the cable and the hose has been
adjusted on the service screen.
Automatic mode is normally used when driv-
ing the machine forward or reverse.
Manual mode is normally used when machine
is standing still and then using cable or hose.
Water on is operated by push button 4 and is
indicated with green colour when the sprinkler
system is watering the digging area in front of
the conveyor.
Fig. 10A Hydraulic screen
Fig. 11 Cable and hose wheel screen

10HR07
OPERATION 4.004
Digging controls
Left hand side joystick Right hand side joystick
The left joystick controls the conveyor and The right joystick controls the digging
gathering arm movements. arm and lifting arm.
10HR07
OPERATION 4.005
Steering paddle control

By moving both steering paddles to the right or
left at the same time; the front and rear wheels
will move in the same directions. See position A
and B (Fig 12).
A: Wheel position when both steering

paddles moved to the left
B: Wheel position when both steering

paddles moved to the right
C. Wheel position when front paddle is

moved to the left and rear paddle to
right
Fig. 12. Steering paddles for
A. Front wheels
B. Rear wheels
Fig. 13 Wheel position

10HR07
OPERATION 4.006
Function of wheel direction

indicators
When front wheels or rear wheels are in
straight forward direction, the direction indicators
A and B are positioned as shown in Fig 14.
When the indicators are in other positions the
wheels also have another direction than straight
forward. See Fig 12. When pushing on top of
steering paddle (A) for front wheels and/or (B)
for rear wheels the wheels will automatically
correct themselves in straight forward position.
10HR07
OPERATION 4.007
Digging controls Backhoe

Left hand side joystick
The left joystick controls the conveyer and
gathering arm movements (fig 18).
Right hand side joystick

The right joystick controls the lifting arm,
boom and bucket (fig 19).
Fig. 18
Fig. 19
10HR07
OPERATION 4.008
Starting a new machine

Measures before using a new machine
1. Thoroughly inspect the new machine and
make sure that it has not been damaged
during transport.
2. Dismantle the machine if it is to be trans-
ported in such confined spaces that it
cannot be moved intact without difficulty.
Then transport the parts to the assembly
site and reassemble the machine in the
previous manner.
3. Check the oil level in the hydraulic oil tank,
motor oil in diesel engine, gear housing
cable drum, gear box in pump unit, gear
box transmission, drive shaft differential
housing and planetary gearing. If the
machine has been dismantled for trans-
portation, the affected bearings must be
re lubricated after assembly. See the lubri-
cating instructions in the MAINTENANCE
section - sheet 5.009
4. Check the air pressure in all tyres. See
sheet 5.004 in the MAINTENANCE section.
5. Check that the machine is properly
grounded by making sure that no earth
connections on the machine are loose.
6. Check that the fuses on the feed side in
the plant distribution box are correctly
dimensioned in accordance with the local
electrical safety regulations.
7. Connect the supply cable from the cable
drum to the plant distribution box.
8. Switch on the main switch in the plant.
9. Start the machine in accordance with direc-
tions. See operating instructions sheet
4.002. Do not start the machine before
having checked the main fuses in the
plant and in the apparatus cubicle on the
machine. Then check, if necessary, that
the phase sequence is correct.Check that
there is no oil leakage at the machine. If
necessary, reroute any incorrectly connected
hydraulic hoses.
10. Check that the parking brake works
satisfactory.
11. Perform a test of the machine on the work
site and check all the functions. Make sure
that there are no malfunctions that may
obstruct operation.
12. Run the machine in accordance with the
directions given in the operating instruc-
tions. If possible, avoid reversing the con-
veyor chain while loading is taking place.
Breaking-in control
A special breaking-in control is to be carried
out after 40 - 50 operating hours. The control is
10HR07
OPERATION 4.008
done according to the following points and given

pages in the section MAINTENANCE.
1. Tighten all electric cable connections in

the apparatus cubicle, cable drum collec-
tor and plug. See 5.005.
2. Tighten all bolt and screw joints e.g. at
jointing plates on the conveyor frame, the
cover over the swing arm bearings, retain-
ing screws on the cylinder pins and lifting
arm attachment, see 5.005.
3. Tighten all coupling on the hydraulic
hoses. See 5.005.
4. Check the oil level at all places as well as
lubricating instructions 5.007.
5. Change all filter inserts and also the valid
lubricating instructions 5.007.
10HR07
OPERATION 4.009
Lifting the machine

Procedure for lifting the machine
If the Hggloader has to be raised from the
ground for one reason or another, proceed in
accordance with the following directions:
1. Raise the front end of the conveyor frame

assembly to the top position and lower the
rear end to the parking position.
2. Lock the conveyor frame assembly to the
chassis by means of temporary welded on
steel plates.
3. Attach suitable lifting equipment to the
holes in the conveyor frame assembly.
Hole diameter = 55 mm.
4. Place wooden beams or similar supports
between the conveyor frame assembly
side plates if short straps are used for lift-
ing. By this means, the frame assembly is
protected from deformation. If long straps
are used, this measure is not necessary.
5. Raise the machine very cautiously with
the available lifting equipment and put
it down again equally cautiously. The
machine weight varies slightly, depending
on the version, but is in the order of 16-18
tonnes.
6. Remove the lifting equipment and any
supports from the machine. Release the
conveyor frame assembly from the chas-
sis by cutting off the temporary welded on
plates.
10HR07
OPERATION 4.010
diesel engine
Pre operation checks
1. Check the engine oil level using the
dipstick (A). If necessary, top up with
recommended oil to the correct level at
(B) in accordance with the directions
issued by the engine manufacturer. See
the separate instruction manual (enclosed
compact disc) for the diesel engine.
2. Check the fuel level on the instrument
panel, Fig 2. If necessary, top up with fuel
in accordance with the directions issued
by the engine manufacturer in the sepa-
rate instruction manual.
3. Engine filter indicator is electronic visual in the
bottom of the display when engine filter has to
be changed, Fig.3
Fig. 3 Engine filter indicator

10HR07
OPERATION 4.010
Starting the engine

The engine which is equipped with a glow plug
system is started in the following manner:
1. Turn on the main current, by moving the
lever on the battery isolator in clock-wise
direction.
NOTE!
Do not switch off the main current, while
the diesel-engine is running.
2. Check that the switch (2) in Fig 5 is in

neutral (N) position and that the park-
ing brake is applied = button (1) pushed
down.
3. Push the starting button and hold it there
until the engine starts and the red diesel
sign turn to green colour.
4. Release the button directly when the
engine starts firing. The starter motor
must not rotate with the engine.
5. Do not keep the starter motor running for
more than 30 seconds at a time. If the B
engine fails to start.
6. Reduce revs as soon as engine starts. Run
engine under medium load and at chang-
ing speeds until it reaches normal operat-
ing temperature. Do not rev engine up to
high speed after cold start. Do not either
let the engine idle for more than 5 min-
A
utes.
7. Release the brakes by pulling up the knob
on the parking control.
8. Drive the machine with care.
NOTE!
The driving direction can be changed only
while the machine is at a standstill.
9. Change the driving direction when neces- Fig 5 Driving direction switch (A)
sary, by means of the switch (2). Parking brake push button (B)
10. Increase the diesel-engine speed to at
least 1100 rpm, before driving the machine
in either direction.
11. Slow down the speed of the machine by
decreasing the foot pressure from throttle
pedal, or decrease the engine speed to
idle.
WARNING!
APPLY PARKING BRAKE EVERY TIME THE
DRIVERS SEAT IS LEFT UN-MANNED.
Starting at low temperature

10HR07
OPERATION 4.010
Start the engine in accordance with the above

instructions. In low temperatures give full throttle
and the glow heating will go on for approximately
6 seconds before engine starts to turn around.
Switching off the engine

Apply parking brake (fig. 5). Bring the motor
down to idle and allow the engine to continue
to idle for 2 minutes, to lower temperatures in
the unit. Turn off the engine by pushing the start
button (fig. 6) so the green disel sign turns to
red colour. Break the main circuit with the battery
isolator for long stops.
10HR07
MAINTENANCE 5.000
Contents
Maintenance chart 5.001

Introduction - general 5.002
General (every 10 hours) 5.003
Lubricating instructions 5.007
Lubrication chart 5.008
First 50 hours service 5.009
BIO OIL 5.010
10HR07
MAINTENANCE
10HR07
MAINTENANCE 5.001
C=Change
MAINTENANCE CHART Cl=Cleaning
I=Inspection
L=Lubrication
HGGLOADER 10 HRC07
MAINTENANCE TIME INTERVALS AND MEASURES PAGE

Every Every Every Every
10 hours 50 hours 500 hours 1000 hours
General 5.002
Digging blade joints, lifting arm L 5.003
bearings and swing arm bearings
Hydraulic cylinders for swing arms, L
lifting arm and digging blades
Bearing for drive shaft with chain L
wheel
Hydraulic oil tank I
Automatic lubrication system (op- I
tion)
Fire Extinguisher system I
Engine I
Engine coolant level I
Engine oil level I
Engine air filter indicator I
AC compressor/ Generator belt I
Cleaning the machine Cl 5.004
Lubrication L
Cabin filter I/C
Hydraulic oil cooler and AC con- Cl
denser
Cable wheel L/I
Hose wheel L/I
Tyres I
Conveyor chain I/C/L
Chain wheel on conveyor drive I
shaft
Conveyor chain speed adjustment I
Coupling engine-motor I
Guide roller I
Digging blade teeth I/C
Hydraulic cylinders I/C
Drive shafts, tie rods, steering arm I
Hydraulic hoses I/C
Cylinder pins on hydraulic cylinders I/C
for digging blades and swing arms
10HR07
MAINTENANCE 5.001
Electric cables I
Lighting and light signal I
Return filter indicator I
Lubrication L 5.005
Drive chain for cable wheel / hose I/L
wheel
Wear plates (Conveyor frame) I/C
Digging blade bearings I
Digging blade- and swing arm I
cylinders
Wear on conveyor chain I
Hydraulic motor for conveyor I
Lifting arm I/L
Link I
Batteries I
Main motor I
Apparatus cubicle Cl/I
Earth connection Cl/I
Cable drum collector Cl/I/C
Cable/ Hose drum chain I/ L
Cable/ Hose drum length indicator I/ L
Return filter Cl/C
Propeller shaft I/L
Bearing for pendulum axle I
Chain wheel on conv. drive shaft I
Gearbox (traction) I
Swing arm bearing I
Air Condition unit I
Engine oil filter I/ CL/ C
Engine oil C
Engine fuel filter, primary C
Engine fuel filter, secondary C
Engine radiator I/CL
Wheel axle differential oil level I
Wheel axle planetary oil level I
Hydraulic tank return filter I/CL/C 5.006
Lubrication L
Breather filter hydraulic tank Cl
Engine valve lash I
Differential housing on drive shafts C
oil
Final drive on steering drive shafts C
oil
Gearbox (traction) oil C
Gear housing for cable drum C
Lubricating instructions 5.007
10HR07
MAINTENANCE 5.002
Introduction
General
How long your Hggloader 10HR07 will last
between overhauls will depend on how carefully
you look after it. Meticulously performed periodi-
cal maintenance undoubtedly prolongs the ser-
vice life of the machine and at the same time
results in lower repair costs. Obviously it is of
vital importance for the Hggloader to be looked
after in a systematically manner in order to avoid
trouble and so as to reduce the overall running
costs.
Periodical maintenance of the machine is per-
formed at four different intervals of time, enabling
possible defects to be discovered and remedied
at an early stage, thus eliminating costly and pro-
longed standstills. Temporary cease of operations,
for instance in conjunction with shift changing,
can be usefully employed for simple overhauls on
the machine, whereas the more comprehensive
maintenance work should be performed during
specially allocated time.
The maintenance intervals proposed here may
obviously be slightly modified to suit conditions
prevailing on different work-sites. To the greatest
extent possible, the maintenance should never-
theless be performed in accordance with our rec-
ommendations and at the intervals listed below.
Every 10 hours Section 5.003

Lubrication chart Section 5.008
Care and maintenance of the Hggloader and

its accessories will assure:
That the necessary lubrication is per-
formed
That the material is kept intact and in per-
fect working order
That the loader and associated equipment
is prepared in the prescribed manner for
every run.
Reporting faults
A report should be filed immediately after a
fault is detected or suspected while the machine is
being operated or in conjunction with mainte-
nance. Faults should be reported to the mechanic
responsible for repairs. A service card should be
drawn up for each individual loader. Informa-
tion such as the dates of regular maintenance,
oil changes, repairs, etc. should be noted on the
service card. These notes not only facilitate main-
tenance, but also highlight any part of the loader
to which particular attention should be devoted.
10HR07
MAINTENANCE 5.002
Lubrication at high working temperature

The ambient working temperature is usually
between +5 and +20C while the machine is
running. The lubricants specified in the lubricat-
ing instructions have been chosen for operation
within this temperature range.
If the working temperature is abnormally
high, e.g. when working at great depth below
ground, the specified lubricants should therefore
be replaced by more suitable grease and oils.
In a situation of this nature, it is advisable
to get in touch with GIA industri ab in order to
decide which lubricants should be used at the
work site concerned.
Maintenance of Diesel engine

Please consult the operating and maintenance
instructions issued by the engine manufacturer
for maintenance and limited service work on the
Diesel engine, These are contained in a special
instruction manual (see enclosed compact disc).
Maintenance of steering drive shafts

The first oil change in the differential case and
final drives is also to be done after 50 operating
hours. Oil changing is performed according to
1000 hrs service, section 5.006.
Maintenance of gear box

In addition to the periodical oil changing in the
gear box, the very first oil change is to be done
after 50 operating hours. Oil changing is carried
out in accordance with 1000hrs service, section
5.006.
10HR07
MAINTENANCE 5.003
Every 10 hours or daily

A B B
General
Maintenance every 10 hours should be carried
out in conjunction with shift changing and com-
prises of attendance to the machine to the extent
required to assure trouble-free operation. The
maintenance work at this juncture is concerned
with simple inspection of the equipment and
lubrication of the moving parts which are most C
subject to wear, as well as checking of the oil
level in the hydraulic oil tank and in the gear box
on the pump unit. The maintenance work should
be carried out in accordance with the directions Fig. 1. Digging blades, lifting arm and
given below and in compliance with the lubricat- swing arms
ing instructions. A: Swing arm bearing
B: Digging blades joint
C: Lifting arm bearing
Digging blade joints, lifting arm bearings
and swing arm bearings
Lubricate all bearings in accordance with the
A
lubricating instructions - Code B. Clean all the dirt
off the lubrication point before lubricating and
check that nipples are provided at all lubrication
points (Fig.1). Replace any damaged nipples.
Any surplus grease remaining on the outside of
the nipple may be left behind to facilitate clean-
ing of the lubrication point in conjunction with
subsequent lubrication.
B
Hydraulic cylinder for swing arms, lifting Fig. 2. Drive shaft bearing
arm and digging blade
Lubricate all bearings on the hydraulic cylin- A: Drive shaft
ders in accordance with the lubricating instruc- B: Lubricant nipple
tions - Code B. Clean and check the lubrication
points in the same manner as described above.
Bearing for conveyor drive shaft with

chain wheel
Lubricate the drive shaft bearing in accor-
dance with the directions given in the lubricating
instructions - Code B.
Clean and inspect the lubrication point in the
same manner as described above (Fig.2).
10HR07
MAINTENANCE 5.003
Hydraulic oil tank

Check the oil level in the hydraulic oil tank.
While this is being done, the loader must be
standing in a level position and the pump motor
must be switched off. The oil level can be checked
through the sight glass on the side of the oil tank
(Fig.3). The oil level must never be permitted to
fall below the minimum level in the glass.
WARNING!
Push the emergency stop button before starting
to fill the hydraulic tank with the 24V electrical
pump, this to prevent someone from starting
the diesel engine or electric high voltage(400V-
1000V) motor during filling procedure.
If necessary, top up with hydraulic oil, but not

more than up to the upper part of the sight glass.
To top up oil with the electric pump unit (D), pro-
ceed in accordance with the lubricating instruc-
tions - Code B. Connect a filler hose to quick
connection (F), then fill the tank with oil, using
the electric pump. Remember to clean the hose
and connection (F) before connecting them. Con-
nection (F) will automatically close when sepa-
rated from the filler hose. Pull out the emergency
button when oil filling is kompleted
Central lubrication system (optional)

Check every lubrication point. See chapter 7,
MISCELLANEOUS, for more information about
optional equipment.
Fire extinguishing system

Check the manometer pressure.
Fig. 4. Filler pump button for hydraulic oil

10HR07
MAINTENANCE 5.003
Manual checks on the machine

Cooling system coolant level check (see
Fig 1, A)
Engine oil level check (see Fig 1, B)
Engine air cleaner service indicator check
(see Fig 2, B)
Alternator and air condition compressor
fan belt check. Adjustment is made by the
alternator adjuster arm (C) Fig 3.
Fig 1 Oil level dip stick (B)

Coolant level in expansion tank (A)
Fig 2 Air cleaner indicator
Fig 3 Belt Check / adjusting

10HR07
MAINTENANCE 5.004
Every 50 hours
General
Maintenance at intervals of 50 hours is appro-
priately carried out at specially allocated times
by repair mechanics or other qualified repairmen.
This maintenance work comprises of thorough
cleaning of the loader, lubrication, inspection and
any necessary adjustment of the equipment. The
maintenance work is carried out with the guid-
ance of the following directions, the inspection
chart and the lubricating instructions.
Cleaning
Hose the loader down to remove all the dirt.
NOTE!
Do not aim the high pressure water jet
direct on the electrical AMP connections
on the hydraulic valves.
Run the conveyor chain while hosing down the

loader and clean the conveyor frame, chain, drive
shaft and guide roller, making sure that all dirt is
removed.
Lubrication
Lubricate the loader in accordance with the
directions given in the lubricating instructions -
Code C. Check that lube nipples are fitted at all
lubrication points. Replace damaged nipples.
Cabin filters
The cabin filters are situated behind the cabin
wall. The two filters together must be changed at
the same occasion. The intervals for filter change
my vary depending on operation. Must be tested
at site. Check also at the same occasion that the
cabin ventilation hoses are not damaged.
Air hydraulic oil cooler/ AC condenser

Cleaning the air cooler is most important since
accumulation of dust on the cooling fins is liable
to reduce cooling efficiency. The inspection inter-
val is given for normal operating conditions but
has to be adjusted for each site.
Clean the cooler as follows:

1. Stop the cooling fan and pump motor.
2. Undo the locking bolt and turn the cooler
out from the chassis to increase the acces-
sibility.
3. Blow compressed air from both side of the
cooler until all dust is removed.
4. Check also the fan blades and clean them
if necessary to avoid unbalance during
operation.
10HR07
MAINTENANCE 5.004
Sometimes it can be necessary to use cold

cleansing agent to remove dust retained by a film
of oil or fuel. Spray it on the cooling fins and fan
blades, wait a moment before washing it off with
cold water.
Cable wheel (C)

Lubricate and check that the drive chain, fig. 2
(E), between motor and cable drum is tight.
Hose wheel (D) (optional)

Lubricate and check that the drive chain. fig. 2
(F), between motor and hose drum is tight.
Alternator / AC compressor belt

Check belt tension. See section 5.003 Fig. 2 Cable drum (C) and Hose drum (D)
Tyres
Check the air pressure in the tyres and inflate
them if necessary to the correct pressure. At the
same time, check the tyres for wear and make
sure that they are undamaged. If tyre damage
is detected, this should be reported to the acting
supervisor so that the necessary action can be taken.
Tyre pressure:
Tyres 12,00 20XRA = 8,5 bar (0,85 MPa)
Conveyor chain
Run the conveyor chain a little at a time and
examine it very thoroughly for wear on the flights
and links. Replace any links showing signs of frac-
turing and check that all locking pins in the chain
are in position. Insert new locking pins where
necessary. Lubricate the links with waste oil if Fig. 3. Conveyor frame
the chain tends to bind. If the conveyor chain is A: Conveyor chain
heavily worn, it must be discarded and replaced B: Flight
by a new one. The procedure for chain replace- C: Conveyor frame
ment is described in the SERVICE section.
Check that the conveyor chain is sufficiently
tensioned. If the chain displaces an excessive
tendency to climb onto the teeth of the drive
shaft in conjunction with reversing, tighten it as
follows:
1. Back off the cam unit retaining screws on

both sides of the machine (Fig.4).
2. Tighten the chain by tightening the tension-
ing screws equally, but not so hard as to
cause the chain to bind while running.
Then lock the tensioning screws with the
nuts. Fig. 4. Tension device for conveyor
3. Tighten the cam unit retaining screws. chain
A: Cam unit
Test run the conveyor chain and repeats the B: Locking nut
procedure described above until it is properly C: Tensioning screw
tensioned and the chain can be seen just under D:
Bild 4. Spnnanordning Retaining screw
fr conveyorkedja
the conveyor frame. E: Conveyor chain
10HR07
MAINTENANCE 5.004
Chain wheel on conveyor drive shaft

The chain wheel (Fig.5) on which the chain
runs is subject to continuous wear through abra-
sion by the muck. For this reason, the wear
should be checked at regular intervals. The chain
wheel is divided into two halves, attached to the
drive shaft with hollow pins. If necessary, the
chain wheel can therefore be changed without
any major difficulty in accordance with the direc-
tions, see the SERVICE section.
Conveyor chain speed adjustment

Conveyer chain speed is normally adjusted
Fig. 5. Drive shaft
from factory for good performance and long life
A: Chain wheel
time. When problem occurs check the speed of
B: Drive shaft
the conveyor chain and adjust it if necessary, by
regulating the displacement of the axial piston
pump. It is adjusted according to the material
type and flow. Try to keep the speed as slow as
possible, without the chain jamming, which will
result in the best economy and less wear on the
chain and plates.
When the speed is correctly adjusted the
working pressure during mucking should never
be higher then app. 75 % of max. pressure in the
circuit. This is to avoid over loading and frequent
stops of the chain
The adjustment is done in accordance with the
following instructions enl. Fig 4.:
1. Chose the correct field with buttons (A)
or (B)
2. Chose direction with button no (1) or (2) Fig. 4. Conveyor chain speed adjustment
3. Press buttons (C) or (D) to change the
value
4. Start the electrical motor and switch in
position LOADING, and check the speed
by counting the flights for one minute.
(Can be adjusted between 80 -135 flights/
minute).
5. Save the adjusting values.
6. Check the working pressure during muck-
ing and readjust if necessary.
10HR07
MAINTENANCE 5.004
Guide roller
Check the wear on the guide roller teeth and
hub (Fig.1). If these parts are heavily worn, the
entire guide roller should be replaced, along with
its bearings and sealing rings. Replacement is
carried out as described in the description found
in the SERVICE section.
Digging blade teeth

Check the attachment of the teeth and exam-
ine the teeth for wear. Worn out teeth should be
replaced in accordance with the following direc-
tions:
Tap the dowel out of the tooth with a mallet
and mandrel, thus releasing the tip of the tooth Fig. 1. Guide roller
from the tooth holder (Fig.2). Insert the new tip A: Guide roller
in the holder and strike the dowel in with the
mallet. The dowel is symmetrical and can be
fitted from either side of the tooth tip. Worn
tooth holders should be replaced by new ones
in accordance with the instructions found in the
SERVICE section.
Hydraulic cylinders
Check all the hydraulic cylinders for oil leak-
age and mechanical damage on the piston rods.
Re-tighten hydraulic couplings and replace defec-
tive O-rings and seals where necessary. Replace
damaged cylinders or cylinder parts in accor-
dance with the instructions found in the SERVICE Fig. 2. Fitting the digging teeth
section. When fitting the cylinders on the loader,
drive the cylinder pins in with a mandrel and a A: Tooth tip
mallet. B: Dowel
C: Tooth holder
D: Digging blade
Drive shafts, tie rods and steering arm
Check that the toe-in is correct for both pairs
of wheels. This is appropriately done by measur-
ing the parallelism of the wheels in a suitable
way. The maximum permissible deviation is 5
mm.
Hydraulic hoses
Check all hydraulic hoses for wear and for
leakage from the couplings. If necessary, replace
packing and O-rings and tighten couplings.
Cylinder pins on hydraulic cylinders

for digging blades and swing arms
Check the locking of the cylinder pins on the
hydraulic cylinders (Fig.1). If necessary, tighten
the retaining screws on the cylinder pins to a
torque of 78 Nm. Fig. 1. Digging blade and swing arm
cylinder
A: Swing arm cylinder
Electric cables
B: Digging blade cylinder
Check that all electric cables are in good shape
C: Retaining screw
and that they are properly secured. Make sure
that gaskets and cable grommets seal properly.
10HR07
MAINTENANCE 5.004
If possible, visually inspect the supply cable and

check that the plug has not been damaged.
Lighting
Check that all the head lamps on the loader
function satisfactory.
Light signal
Check that the light signal works properly.
Return filter
An electric filter indicator (C) is mounted on the
filter housing (A) (Fig.1). The indicator will give
a warning in the display screen when the filter Fig 1 Return filter Housing (A)
element gets dirty. Change the filter insert for the El- warning sensor for clogged
first time after 50 operating hours, and then at filter (C)
intervals of every 1000 hours or more frequently
if the indicator shows that this is necessary. To
change the filter insert, proceed in accordance
with the special directions for maintenance every
1000 hrs.
10HR07
MAINTENANCE 5.005
Every 500 hours

General
Unnecessary work interruptions and machine
breakdowns can be avoided by regular inspection
of and attendance to the loader. Maintenance
every 500 hours therefore entails thorough care
and maintenance of the equipment in its entirety.
Always cut off the power supply by turning off
the main switch in the plant before commencing
maintenance work on the machine. Maintenance
is carried out in accordance with the directions
given below with the backing of the inspection
chart and lubricating instructions.
Lubrication
Lubricate the loader in accordance with the
directions given in the lubricating instructions -
Code D. The loader must be thoroughly cleaned
prior to lubrication.
Fig 1 Cable / Hose drum unit.
Drive chain for cable drum / hose Cable position sensor (A)
drum Hose position sensor (B)
Check the chain condition, adjust if necessary.
Also check the function of the position indica-
tors/ sensors for cable and hose positions. Code
D. Sensors (A) and (B) must stop and warn the
driver via the display that the cable or hose have
reached their maximum allowed OUT position.
Fig. 1.
Wear plates (conveyor frame)

Check the wear of the upper wear plates inside
the conveyor frame. If necessary, replace worn
plates in accordance with the separate instructions.
See the instructions on page 6.004, found in the
section headed SERVICE.
Digging blade bearing

Raise the digging blades slightly above the
ground and aim them straight down while the
check is being performed (Fig. 2). Check the
bearing play in the digging blade bearings by tilt- A: Digging blade
ing one digging blade at the time in the longitu- B: Digging blade bearing
dinal direction of the bearing pin, while noting
the play between the pin and the bearing bush. Fig. 2. Checking the play in digging blade bear-
If play is excessive, the bearing bushes in both ings
bearings should be replaced. The bearing bushes
are fitted with the aid of a mallet and a mandrel.
Digging blade and swing arm cylinders

Check the bearing play in the ball joints of the
hydraulic cylinders. Replace any worn ball joints
by new ones, proceeding in accordance with the
special directions. See the instructions on page
6.004, found in the section headed SERVICE.
10HR07
MAINTENANCE 5.005
Wear of conveyor chain

Check the wear of the conveyor chain. If neces-
sary, replace worn sections according to previous
measurements.
Hydraulic motor for conveyor (Poclain)

Check the condition of the conveyor motor by
measuring the drain flow rate. This can be done
without it being necessary to disconnect the
motor (Fig. 3) from the hydraulic system. The
check is best carried out by two operators, one of
whom drives the loader at certain stages of the
check, while the other performs the actual mea-
surement of the flow rate. Checking is performed
in accordance with the following directions:
1. Disconnect the end of the drain hose from
the connection of the hydraulic motor,
(Fig. 3) and collect the escaping oil in a A: Drain hose
suitable vessel. Plug the released free end B: Pressure gauge socket
of the drain hose. C: Shaft motor
2. Position a beam as a stop at the front end (max drain pressure = 1,5 bar (0,15
of the conveyor frame. Position the beam MPa))
in such a manner that the conveyor chain
is locked as soon as a flight is advanced so Fig. 3. Conveyor motor
far that it encounters the beam.
3. Start the loader and drive carefully the
chain towards the beam by setting the
lever in the position for REVERSING. At
the same time, hold a suitable vessel
under the hose connection on the motor
and measure the drain flow rate for a
period of one minute. This flow rate gives
a good indication of the extent of wear
of the included components and directly
reveals the condition of the motor.
Normal drain flow per motor = 1,0 l/min

Maximum drain flow per motor = 3,0 l/min
A: Lifting arm
B: Fastening screw, tightening torque 1000
Relief valves in the pump are set at a pressure
Nm
of 350 bar (35 MPa).
Fig. 3. Lifting arm fastening
4. Stop the loader when the check has been
completed and remove the stop from the
front end of the conveyor frame.
5. Remove the plug from the drain hose
and reconnect the hose on the motor as
before.If the maximum permissible drain
flow rate is exceeded the motor must be
dismantled and overhauled. For this purpose,
the motor can either be sent to the nearest
distributor for repair or else be overhauled
in accordance with the special directions
issued by the sub-supplier (included in the
enclosed compact disc). A: Link bearing
B: Link
Lifting arm
Check the play in the two attachment points of Fig. 1. Link
10HR07
MAINTENANCE 5.005
the lifting arm. Check that the play between the

lifting arm and the conveyor frame doesnt exceed
0,5-1 mm. Tighten all retaining screws to a torque
of 1000 Nm at both bearings. Lubricate the screws
with molybdenum disulphide, e.g. MOLYKOTE, or
similar grease. Put the digging blades in a verti-
cal position and lower them to the ground. Lift
and lower the arm slowly so that the cylinders
are pushing and pulling alternatively. At the same
time, check the play. If the play is excessive, the
bearing bush must be replaced by a new one.
See the instructions on page 6.004, found in the
section headed SERVICE.
Link
Check the bearing play in the link which connects
the undercarriage to the conveyor frame (Fig.1).
Start off by turning one of the digging blades A: Batteries 2 x 12V
out from the machine and lowering its tip to
the ground. Then tilt the digging blade to and Fig. 2. Top up with battery water if the electrolyte
fro by making small IN - OUT movements with level is too low
the lever. At the same time, note the amount
of play by observing the sideways movement
of the conveyor frame. A small amount of play
in the bearing gives moderate movement of the
frame, whereas a larger amount of play results
in an excessive movement which is a sign of worn
out link bearings. Excessive bearing play is best
adjusted in connection with a total renovation of
the machine. The work is carried out in accor-
dance with the instructions on page 6.004, found
in the section headed SERVICE.
Batteries
Unscrew the caps on the cells and check the
electrolyte level in the batteries. The level should A: Main motor
normally be approx. 10 mm above the upper (direction of rotation = clockwise)
edge of the plates. Top up with battery water Fig. 1. Main Electric motor
(distilled, de-ionised water) if necessary. Never
use ordinary tap water or so called improvement
electrolyte (Fig.2). Screw the caps back on.
Check that the batteries are firmly secured,
but do not tighten the nuts too much as to cause
damage. Make sure that end terminals and connection
clips are firmly tightened and lubricated with
acid-free Vaseline as protection against oxidation
and poor contact.
If the batteries have tilted and electrolyte has
escaped, they must be topped up with battery
water. The acidity should then be adjusted to the
correct value by a qualified repair man. This can
only be done in conjunction with charging the
battery.
Main Electric motor

Examine the motor cables for damage and Fig 2. Turning direction of diesel engine (A)
make sure that they are securely connected in Turning direction of electric motor (B)
the electrical cabinet. Check that the motor is
10HR07
MAINTENANCE 5.005
firmly secured to the undercarriage. Then start

the motor and check that it functions properly.
After any intervention with the main power
supply - e.g. for maintenance work, when moving
the machine to a new plant or when changing
the motor - check that the electric motor has the
correct direction of rotation and the correct phase
sequence. The motor must never be permitted to
run in reverse because damage to the hydraulic
pumps is likely to result.
To check the direction of rotation, press the
START and STOP buttons alternately, while
Fig 3. Electrical cabinet
observing the rotation through the motor fan
casing. The correct direction of rotation is clockwise
as viewed through the fan casing (Fig.1).
Electric motor and Diesel engine must turn in
the same direction. See Fig 2.
Electrical cabinet
Inspect the electrical equipment in the electri-
cal cabinet and clean the contactors and relays.
Wipe away moisture and dirt from the compo-
nents in order to avoid short-circuiting. If the
components show signs of abnormal wear, the
cause of this should be investigated. Do not lubri-
cate the moving parts of contactors. Do not file
burnt contacts. Instead, they should be discarded
and replaced by new ones.
Check: A: Cable drum
that all nuts and screws are firmly tight- B: Collector Cover
ened. Tighten loose screws and nuts.
that all components function satisfactory. Fig. 1. Cable drum collector
Change defective parts.
that no dirt or rust is present inside the
cubicle. Clean and vacuum the cubicle if
necessary.
that cable connections are clean and firmly
fitted and that the insulation is intact.
Make sure that the earth connection is
properly made.
that cable grommets and the gasket on
the door seal effectively. Replace dam-
aged parts.
Earth connection
Check that all earth connections are properly
made. Clean the contact surfaces if necessary
and replace any defective components.
Cable wheel collector

Open the cable wheel collector and clean
the equipment in accordance with the following
instructions:
1. Back off screws and remove the cover
from the collector (Fig.1).
2. Tighten all electric cable connections. Fig 2. Chain lubrication (C) and (D)
3. Clean collector, either with a vacuum Chain length indicator lubrication
cleaner or using a brush and a lint-free (E) and (F).
10HR07
MAINTENANCE 5.005
cloth. Do not use water for cleaning.

4. Check positively that slip rings are dry,
clean and completely free of oil or dirt.
Clean slip rings if necessary.
5. Check all components for wear. Replace
damaged parts.
6. After cleaning, check that the sealing strip
is intact and that it seals effectively.
7. Finally, fit the cover on the collector and
tighten the screws firmly.

Lubrication
Cable /Hose wheel chains (C) / (D) Fig 2. must
be lubricated according to code D. Also cable/
hose drum length indicators (E) / (F) must be Fig 1 Return filter Housing (A)
lubricated according to code D. Filler cap / Breather (B)
El- warning sensor for clogged filter (C)
Return filter
The return filter incorporates a filter insert
which has to be changed at regular intervals.
Normally, the inserts should be changed at
intervals of 500 running hours, but more frequent
changes may be necessary under extremely
heavy duty conditions. Inspection, cleaning and
replacement of insert take place with the engine
switched off, using the following procedure:
1. Remove the cover from the filter (Fig.1,
(A)) and lift up the filter insert.
2. Inspect the insert thoroughly to check for
dirt. Normally, no dirt will be visible on
the insert. But if there is a considerable
amount of dirt or particles this may be an
early warning of component damage in the
system and is thus an indication of a pos-
sible malfunction. The filter insert cannot
be cleaned. Replace both the insert and
the O-rings.
3. NOTE! Never attempt to clean or reuse
the old filter insert. Always use a new
filter insert. Any attempt to clean the filter
insert will have a detrimental effect on the
filter paper and thus permit a contami-
nated flow to pass through the filter.
4. Check the cover parts for damage. If Fig 2 Filter element / insert (D)
any damage is detected, the entire cover
assembly must be replaced. Remove col-
lected dirt and take great pains to prevent
dirt form entering the tank. Check that the
O-ring between the cover and filter head
is undamaged.
5. Coat the sealing surfaces on the filter
head and cover with clean hydraulic fluid.
Do the same thing with the O-rings on the
insert. Place the new filter insert inside
the bowl. When doing so, take care not to
scratch the insert against the filter head.
6. Fit the cover on the filter head and tighten
the retaining screws firmly.
10HR07
MAINTENANCE 5.005
Propeller shafts
Check the attachment of the propeller shafts
(Fig.1) to the gearbox and steering drive shafts.
Tighten the bolts if necessary. Also check the
play in the spider. If the play is excessive, worn
parts must be replaced.
Bearing for pendulum axle

Relieve the load on the rear axle by raising the
rear end of the machine. Move the axle attach-
ment up and down with a suitable tool, checking
the bearing play in both bearings at the same
time (Fig.1). Excessive play in the bearings is a
sign of worn bearing bushes. Change the bushes
if necessary when repairing other parts of the
rear axle.
Chain wheel on conveyor drive shaft

The teeth of the chain wheel are subject to
constant wear on one side of the conveyor chain.
Check tooth wear at regular intervals and turn
the wheel the other way round when deemed
necessary. To turn the chain wheel over, proceed
as follows: A: Front axle
1. Part the conveyor chain at the drive shaft B: Propeller shafts
and remove the chain wheel (Fig.2). C: Rear pendulum axle
See instructions sheet 6.004 in the sec- D: Bearing for pendulum axle
tion SERVICE, Removal of chain wheel, Fig. 1. Propeller shafts and pendulum axle
points 1 - 4.
2. Turn the wheel halves in the opposite
direction to that in which they were previ-
ously fitted and secure them to the drive
shaft with the hollow pins.
3. Reconnect the conveyor chain. See direc-
tions page 6.004, Fitting the chain wheel,
points 1 - 6.
A: Chain wheel
B: Hollow pin
C: Collar
Fig. 2. Chain wheel on drive shaft
10HR07
MAINTENANCE 5.005
Gearbox
Check the oil level in the gearbox every 500
hours. It is best carried out immediately after
operating at normal oil temperature for a while.
The pump motor must be switched off and the
machine must be level while this check is being
performed.
Unscrew the combined filler/level plug (Fig.1).
If the amount of oil is correct the oil run out of
the gearbox.
If necessary, top up with oil until it reaches the
level plug opening. Use the grade of oil specified
in the relevant lubricating instructions - Code D.
Close the plug properly after having topped up.
NOTE!
Never check the oil level while the oil is cold. Fig. 1. Gearbox.
A: Filler/level plug
Swing arm bearings B: Drain plug
Check the radial clearance in both swing arm
bearings as follows:
1. Raise the digging blade slightly above the
ground, and aim it straight down during
the check (Fig.2).
2. Remove the upper and lower covers from
the bearing. Tighten the Nyloc nut on the
clamping bolt to a torque of 520 Nm, as
well as screws holding upper and lower
bushings to 296 Nm (Fig.3).
3. Lift the arm up and down in small move-
ments so that the swing arm bearing load Fig. 2. Checking the radial clearance
varies (Fig.2), checking at the same time A: Swing arm bearing, nominal
the amount of radial clearance between radial clearance for unworn
the pins and bushings at both ends of the parts: 0.17 0.30
bearing.
If the radial clearance is excessive, the bushings
should be replaced by new ones as should the
conical pivots and sockets if necessary. See the
special directions in the section headed SERVICE.
Check the axial clearance in both swing arm

bearings as follows:
1. Measure the distance between the upper
edge of the upper bushings and the end
of the conical pivot, with the digging blade
hanging straight down. Make a note of this
measurement.
2. Place a suitable support under the bearing
and lower the lifting arm so that the bearing Fig. 3. Swing arm bearing
rests completely unloaded on the support A: Conical socket B: Conical pivot
and the digging blade hangs freely in the C: Sleeve D: Conical pivot
air. E: Conical socket F: V-ring
3. Measure the distance between the upper G: Bolt, hardened washer H: Cover
edge of the bushing and the conical pivot I: Bushing K: Not greased surfaces
once again and take a note of this L: Lifting arm M: Swing arm
measurement also. N: Bushing O: Cover
4. Calculate the difference between the two P: Locknut
Tightening torque 520 Nm
10HR07
MAINTENANCE 5.005
measurements: this comprises the existing

axial clearance. The correct clearance is
approx. 0,2 mm.
If the clearance is correct, remove the support

from the bearing and refit the two covers as
before. If, on the other hand, the clearance is
incorrect it must be adjusted. The procedure is
as follows:
1. Back off the 8 screws holding the lower
bushings. Remove the bushing by screwing
3 screws (MC6S 16x75 full-threaded) into
the puller holes and withdraw the bushing
with the shims.
2. Remove a number of shims corresponding
to the difference between the existing and
correct clearance.
3. Fit the new set of shims and the bushing
on the bearing and tighten the 8 screws to
a torque of 296 Nm. Check the V-ring on
top and replace it if necessary, put back
both covers and tighten the bolts firmly.
4. Remove the support and check the operation
of machine.
Air Condition/Cabin heating unit

(Additional equipment)
See chapter 7, MISCELLANEOUS, for information
about additional equipment. For further information
about the Webasto cabin heater see chapter 8,
APPENDICES.
Engine oil filter (Spin on filter) change

See fig 1 (C). For more details see Perkins manual
(enlosed compact disc).
Primary Fuel filter (water separator)

The fuel filter, fig 1(B), is fitted on the line between
the tank and the Diesel engine, for separation of
water and sludge in the fuel (Fig.1). The bowl is
emptied by unscrewing the plug in the bottom
of the reservoir a little bit, so that the impurities
can run out. Drain the bowl when water is visible
inside the glass.
Note!
Tighten the bottom plug after drainage to
prevent air enter into the fuel system.The
bowl is on the fuel suction line.
Secondary fuel filter See Fig 1 (A)

Change the filter insert regularly every 500
operating hours. See Perkins manual
(enclosed compact disc) Fig. 1. Engine oil and fuel filters
A: Secondary Fuel filter
Engine radiator B: Primary fuel filter (water
Inspect the radiator for damaged fins, corro- separator)
sion, dirt, grease, inects, leaves, oil and other C: Engine oil filter
10HR07
MAINTENANCE 5.005
debris. Clean the radiator if necessary.
Steering drive shafts shaft oil level

check
Differential housing
Unscrew the combined filler/level plug from
the shaft and check the amount of oil in the dif-
ferential housing (Fig.2). If the amount of oil is
correct the oil level should just reach the plug
hole. If necessary, top up with oil to the correct
level and then tighten the plug firmly. Use oil as
directed in the lubricating instructions - Code C.
Final drive
Position the machine in such a way that the
word OIL LEVEL can be read horizontally on the
wheel hub. Unscrew the plug from the final drive
(Fig.2). If the amount of oil is correct, the oil
Fig. 2. Steering drive shaft
should run out. Tighten the plug immediately if
1: Oil fill plug
the amount of oil is correct. If necessary, fill up
2: Oil drain plug
with fresh oil until it just reaches the plug open-
3: Check level plug
ing. After topping up, tighten the plug firmly. Use
the oil recommended in the lubricating instructions
- Code C.
NOTE!
Check after a few minutes that the oil level
is correct. If the oil level has dropped,
fill up to the correct level until the level
remains constant. The oil level should be
checked once a week, which is especially
important before starting a vehicle with
new or repaired axles.
In addition to these instructions, see also the

directions of the producer for the steering drive
shafts (enclosed compact disc)
10HR07
MAINTENANCE 5.006
Every 1000 hours
General
Maintenance every 1000 hours comprises
of lubrication of the electric motor bearings,
changing oil in the gearbox and replacement of
filter inserts. The maintenance work should be
performed by qualified repair men or specially
appointed personnel. The work is to be carried
out in accordance with the following directions
and with the backing of the inspection chart and Fig. 1. Hydraulic tank filler cap /
lubricating instructions. breather (A)
Lubrication
Lubricate the two bearings of the electric motor
with grease in accordance with the directions in
the lubricating instructions - Code E. Replace
damaged lubricating nipples if necessary.
Return filter
The return filter incorporates a filter insert which
has to be changed at regular intervals. Normally,
the inserts should be changed at intervals of 500
running hours, but more frequent changes may
be necessary under extremely heavy duty con-
ditions. Inspection, cleaning and replacement of
insert take place with the engine switched off,
using the following procedure:
1. Remove the cover from the filter (Fig.1, (A))
and lift up the filter insert.
2. Inspect the insert thoroughly to check for
dirt. Normally, no dirt will be visible on the insert.
But if there is a considerable amount of dirt
or particles this may be an early warning of
Fig. 2. Steering drive shaft
component damage in the system and is thus
1: Oil fill plug
an indication of a possible malfunction. The
2: Oil drain plug
filter insert cannot be cleaned. Replace both
3: Check level plug
the insert and the O-rings.
3. NOTE! Never attempt to clean or reuse the
old filter insert. Always use a new filter insert.
Any attempt to clean the filter insert will
have a detrimental effect on the filter paper
and thus permit a contaminated flow to pass
through the filter.
4. Check the cover parts for damage. If any
damage is detected, the entire cover assembly
must be replaced. Remove collected dirt and
take great pains to prevent dirt form entering
the tank. Check that the O-ring between the
cover and filter head is undamaged.
5. Coat the sealing surfaces on the filter head
and cover with clean hydraulic fluid. Do the
same thing with the O-rings on the insert.
Place the new filter insert inside the bowl.
When doing so, take care not to scratch the
insert against the filter head. Fig. 3 Steering drive shaft
6. Fit the cover on the filter head and tighten 4: Grease nipples
the retaining screws firmly.
10HR07
MAINTENANCE 5.006
Filler cap (Breather)

Unscrew the filler cap by hand and check for
damage. (Fig.1).
Engine valve lash

Inspect and adjust if necessary. For more details
see Perkins manual (see enlosed compact disc).
Oil change in differential housing in steering

drive shafts
Change oil in the differential housing for the
first time after 50 operating hours. Then the oil
changing is to be carried out every 1000 operat-
ing hours, or at least once a year. The oil should
be drained immediately after operation while
still warm. Oil changing should be carried out in
accordance with the lubricating instructions and
the following directions:
Clean the area around the combined filler/ Fig. 4. Gearbox
level plug and around the drain plug (Fig.1).
Remove the plugs from the shaft and drain all the A: Filler/level plug
oil. Clean the drain plug and screw it firmly back B: Drain plug
again. Fill with fresh oil until the level comes up to
the filler plug hole. Use oil specified in the lubri-
cating instructions - Code E. Oil volume approx.
19.2 litres. Clean the filler plug and screw it in
lightly. Check the oil level after running about 10
minutes and top up if necessary until oil starts to
flow out the filler plug hole. After final checking
and topping up, tighten the plug firmly.
Oil change in final drive in steering drive

shafts
Change oil in the final drives the first time after
50 operating hours, then every 1000 operating
hours. Oil changing should be done immediately
after operation while the oil is still warm and
flows out of the hubs more easily when drained.
The procedure for oil changing in the respective
final drive is as follows:
Position the machine in a position in which
the combined level/filler/drain-plug faces straight
down under the wheel centre. Clean the area
around the plug thoroughly. Then remove the
plug and drain the oil from the hub.
Position the machine, or turn the wheel, to a

position where the plug hole is in a horizontal line
with the wheel centre. Fill up with fresh oil until it
flows out from the plug hole. Use oil specified in
the lubricating instructions - Code E. Oil volume
approx. 1,8 litres, in each hub. After having filled
up with oil, tighten the plug properly.
Oil change in gearbox

On a new machine the first oil change takes
place after 50 operating hours. Then the oil
changing is to be carried out every 1000 hours.
10HR07
MAINTENANCE
Oil changing in the gearbox is best carried out

immediately after operation, while the oil is still
warm and flows easily out of the gearbox housing.
Oil changing is carried out with the motor
switched off and in accordance with the following:
Place a low profile container under the gear-
box to collect the old oil. Back off and remove the
filler/lever plug and the drain plug. Drain the old
oil out of the gearbox housing through the hole
in the bottom plate (Fig.4). Then screw the drain
plug back firmly.
Pour ca 6,0 litres of oil into the gearbox, or
until the oil reaches the plug opening. Choose oil
in accordance with the lubricating instructions -
Code E. Screw the filler/lever plug back in. Finally,
make sure that the drain plug seals properly
10HR07
MAINTENANCE 5.007
Prescribed lubricant
Engine oil: Quality: API: CF-4, CG-4, CH-4

ACEA: E1 - E3/96 + E4 - 98
Viscosity: SAE 15W-40
Axle and Gearbox: API GL 5 LS, SAE 85W 90
Lubricating grease: MoS2-grease
Hydraulic oil: ISO VG 46 Alternative BIO OIL See page 5.010
Volume litre:
Engine: 7, 0
Drive axles: 2 x 15,5
Finale gear drive axle: 4 x 1,8
Hydraulic tank: 300,0
Gear box, wheel driving: 6,0
10HR07
MAINTENANCE 5.008
Lubrication chart
No. Code Points Destination Remarks Lubricant
1 B 4 Digging blades bearing Grease nipples Lubricating grease
2 B 4 Swing arm cylinder Grease nipples Lubricating grease
3 B 2 Lifting arm bearing Grease nipples Lubricating grease
4 B 4 Lifting arm cylinder Grease nipples Lubricating grease
5 B 4 Swing arm bearing Grease nipples Lubricating grease
6 B 4 Digging blade cylinder Grease nipples Lubricating grease
7 C 4 Gathering blade cylinder Grease nipples Lubricating grease
8 C 4 Link bearing (The grease Grease nipples Lubricating grease
block is to be found on the
right side of the HGGLOADER)
9 C 4 Front cylinder for frame Grease nipples Lubricating grease
(The grease block is to be
found on the right side of the
HGGLOADERN)
10 C 4 Rear cylinder for frame Grease nipples Lubricating grease
12 C 6 Propeller shaft Grease nipples Lubricating grease
13 D 2 Cable/ Hose wheel chain Chain oil
14 D 2 Cable/ Hose wheel length Chain oil
indicator
15 C 2 Pendulum axle Grease nipples Lubricating grease
16 C 8 Steering spindle Grease nipples Lubricating grease
17 B 1 Bearing for conveyor drive Grease nipple Lubricating grease
shaft
18
19 E 2 Electric motor Grease nipple Lubricating grease
20 C 1 Direction valve Check
21 D 2 Chain stretching equipment Coat with grease Lubricating grease
22
23 B 1 Hydraulic tank Check oil level ISO VG 46
24 B 1 Diesel engine Check oil level Engine oil
25
27 C 1 Hydraulic return filter Check indicator
28 D 1 Gear box, wheel driving Check oil level API GL5 LS SAE 80W - 90
29 C 2 Differential housing Check oil level API GL5 LS SAE 80W - 90
30 C 4 Final gear wheel driving Check oil level API GL5 LS SAE 80W - 90
31 D 1 Gear, cable wheel Check , grease
32
33 D 1 Hydraulic return filter Charge insert
35 D 1 Diesel engine Change oil Engine oil
36 D 1 Diesel engine oil filter Change insert
37 E 1 Gear box, wheel driving Change oil API GL5 LS SAE 80W - 90
38 E 2 Differential housing Change oil API GL5 LS SAE 80W - 90
39 E 4 Final gear wheel driving Change oil API GL5 LS SAE 80W - 90
40 E 1 Gear housing, cable drum Change oil API GL5 LS SAE 80W - 90
41 F 1 Hydraulic tank Change oil ISO VG 46
42 C 2 Rear axel link (The grease Grease nipple Lubricating grease
lubrication point is to be
found beside the fuel tank)
10HR07
MAINTENANCE 5.008
A A
B 4 B
C C
D D
E E
F F
A A
B 1 6 2 5 2 4 3 B
C C
D D
E E
F F
Code
A = Daily
B= Every 10 hours
C= Every 50 hours
D = Every 500 hours
E= Every 1000 hours
F = At renovation
10HR07
MAINTENANCE 5.008
A A
B 17 B
C 7a 7b C
D D
E E
F F
A A
B B
C 30 16 29 15 9 8 30 10 16 30 C
D 28 29 21 D
E 39 38 39 37 38 39 E
F F
Code
A = Daily A A
B B
B= Every 10 hours C 42 C
D 30 D
C= Every 50 hours E 39 E
F F
D = Every 500 hours
E= Every 1000 hours
F = At renovation
10HR07
MAINTENANCE 5.008
A A
B B
C C
D 13a 13b 14b D
E E
F F
A A
B B
C C
D 31 32 14a 32 31 D
E E
F F
Code
A = Daily
B= Every 10 hours
C= Every 50 hours
D = Every 500 hours
E= Every 1000 hours
F = At renovation
10HR07
MAINTENANCE 5.009
First 50 hours service

When the first 50 hours after start up of the machine or after a major repair it is recommended to do
some filter and oil changes like following:
Change the main hydraulic return filter
Change engine oil filter
Change oil in gear box for traction
Change oil in differential housing and final drive
10HR07
MAINTENANCE 5.010
BIO OIL
This machin 10HR07 has been supplied with BIO
OIL ( biodegradable synthetically hydraulic oil) of
the mark Statoil Hydraway Bio SE 46.
Adding bio oil

Adding MUST ABSOLUTELY be made with ABOVE
BRAND, oil type and OIL NOTATION.
Mixing different bio oil types and kinds may damage
pumps, valves and cylinders and make the hydraulic
system difficult to clean.
As the bio oils are relatively new products and for
the first time used in a 10HR machine
hydraulic oil samples must be taken regularly every
500 hours to keep control of the oil quality
Changing bio oil

Changing of bio oil must be made every 2000
hours if the oil samples do not show anything
else. All hydraulic bio oils must be filtrated down
to a particle size of 10m when adding or refilling
the system.
That means that the oil must be filled with the
existing and mounted filling pump.
Installation of hydraulic equipment together

with reparing of the machine.
Extreme cleanliness is absolutely necessary at all
work with the hydraulic system to avoid disruptions
and damages on the components.
All personal that at all have to do with the hydraulic
equipment on the machine must be full aware of
the importance of cleanliness.
A well developed awareness of the cleanliness
when working with hydraulic is necessary if the
equipment
will function satisfactory in the long term. Therefore
below directions must be followed as extensively
as possible.
Pre-assembly must be made in clean room.
Welding and grinding shall in pricipal never be
performed together with hydraulic installation
work. If welding or grinding must be performed
during the mounting the hydraulic components
must be well protected. Only new seal material
may be used in such occasions.
Open adapters and connections are not allowed
to be uncovered at the working place. No component
protection may be unwrapped until just before
the component will be mounted. Protection plugs
on a hydraulic hose must for example not be
removed at the same time from both ends. The
plug may only be removed from that end which
will be mounted.
10HR07
SERVICE 6.000
Contents
General 6.001
Troubleshooting 6.002
Setting of pressure 6.003
Component adjustment 6.004
10HR07
SERVICE
10HR07
SERVICE 6.001
General
The SERVICE-section comprises of advice and
instructions for the regular service on the loader.
If a loader does not operate satisfactory in any
way, the fault must be located and remedied
as soon as possible. The fault may be slight. A
simple adjustment frequently sufficing to restore
the perfect working order of the loader. However,
if any component is found to be damaged it must
be replaced before putting the loader back into
operation. If in doubt, it is wisest to get in touch
with GIA industri ab, for further information, or,
in appropriate cases, asks for assistance.
WARNING!
Always switch-off the main circuit breaker
in the generating plant before commencing
service work on the loader.
The conveyor frame assembly must be
locked with the locking device provided
for this purpose before commencing work
under this assembly.
The service section comprises four main groups:

Trouble shooting Section 6.002
Setting of pressure Section 6.003
Component adjustment Section 6.004
Component replacement Section 6.004
Installation of hydraulic equipment in

conjunction with repairs to the machine
Scrupulous cleanliness is absolutely essential
whenever work is being carried out in the
hydraulic system, in order to avoid malfunctioning
and damage to included components.
Everyone who has anything to do at all with
the hydraulic equipment of the machine should
be fully aware of the importance of cleanliness.
Thorough awareness of the importance of
cleanliness when dealing with hydraulics is in fact
absolutely essential if the equipment is to function
satisfactory in the long-term perspective. Bearing
this in mind, the directions given below should be
observed to the greatest possible extent.
Acceptance inspection
Thoroughly check purchased spare parts for
cleanliness, paying particular attention to hoses,
cylinders and couplings. Also check that the com-
ponents are sealed. If the seal is damaged upon
delivery, the component must be cleaned and
resealed before being placed in the stockroom.
No component may be placed in the stockroom
without being sealed.
10HR07
SERVICE 6.001
Installation
All installation work should be carried out at a
special hydraulic installation station.
Preliminary installation shall be carried out in
a clean room.
In principal, welding and grinding must never
be performed in conjunction with hydraulic installation
work. If welding and grinding are nevertheless
essential in the course of installation, the hydrau-
lic components must be amply protected. Only
new sealing material may be used in this circum-
stance.
Couplings and adapters may not be left lying
around open on the installation site. The protec-
tion for the components may only be removed in
conjunction with fitting. The protective caps on a
hydraulic hose, for example, may not be removed
from both ends at the same time, but only from
the end actually being connected.
All oil must be filtered down to a particle size
of 10m when topping up with oil.
This implies that the oil is to be poured in via
the existing filling pump.
Start-up
Whenever the machine is started up after
major intervention in the hydraulic system, the
system should be connected to an extra high-
pressure filter for further cleaning of the hydrau-
lic oil.
10HR07
SERVICE 6.002
Troubleshooting Hydraulic system

Fault Probable Test / Remedy
Conveyor chain jams repeatedly. Conveyor chain in wrong posi- Slacken the chain and lift back
tion on the chain wheel. in correct position, (tooth in the
centre a flight section).
Chain speed to slow. Adjust chain speed according to
instructions. See page 5.004.
Conveyor chain is to slack. Tighten the chain slightly.
Conveyor chain to tightly ten- Slacken the chain slightly.
sion.
Bearing breakdown in the guide Measure the working pressure
roller in the conveyor circuit. The
pressure should be constant. In
case of a pulsating pressure the
bearing play should be checked
for the guide roller. If excessive
change seals and bearing. See
6.004
Leakage in the closed circuit. Measure the load sensing
pressure from the axial piston
pump. It should be 15-16 bar at
idling. Check also at maximum
working pressure, (350bar) the
feed pressure should never
drop below 10 bar. If so this is
an indication that there is ex-
cessive leakage in the circuit.
Worn hydraulic motor. Measures drain flow as special
instruction. See page 5.005
Shaft seal leaks on hydraulic Housing pressure (drain pres- Measure the drain pressure. See
motor for conveyor chain. sure) too high. page 5.005. Change return filter
insert if found necessary.
The digging blades does not Load sensing pressure low. Check pressure, see page
move equal at unloaded move- 6.003. It should be 22-25 bar.
ment The inner friction in the valves
can also cause minor difference.
Incorrect adjustment of the Adjust the speed by turning
directional valve. the oil flow adjustment screws
until the digging blades move
equally.
10HR07
SERVICE 6.002
One digging blade is weaker Inner leakage in the hydraulic Drive the cylinder to the end,
than the other. cylinders. or locked position. Stop the
motor, unscrew and plug the
return line from the cylinder.
Once again start and drive the
cylinder in the same direction,
if oil is coming out from the
unplugged connection on the
cylinder it is a sign that the pis-
ton seals should be changed.
Leaky shock valve If the pressure check above
shows a lower reading in one
end position, check or replace
relevant shock valve.
Machine action is slow and Main axial piston pump worn. Check max. working pressure
weak for all cylinders hydraulic. on the pump, adjust if neces-
sary. Measure the flow rate
from the pump at max. working
pressure. Replace or repair the
pump if the read-of indicates
too low flow rate from the
pump.
The machine has poor driving Leakage in the closed circuit. Measure the load sensing
torque for the wheels. pressure from the axial piston
pump. It should be 15-16 bar at
idling. Check also at maximum
working pressure, (350 bar)
the feed pressure should never
drop below 10 bar. If so this is
an indication that there is ex-
cessive leakage in the circuit.
Pressure to low in the load Measure the load sensing pres-
sensing lines from the pump. sure. See page 6.003. If correct,
measure the pressure between
the valve and the pump. If the
pressure is lower there, change
or repair the servo valve.
Troubleshooting Electrical system 1000V
Loader fails to start and light No power. Check power supply.
will not illuminate. Blown fuse. Change fuse ( 10 Amp )
Light is on but loader fails to Power in supply cable out of Change position of two cables
start. phase. in the electrical plug.
Over current relay tripped. Reset relay and check the set-
ting.
Micro switch for operating volt- Reset micro switch.
age has tripped.
Overload relay has tripped. Reset overload protector.
10HR07
SERVICE 6.002
Overload relay trips repeatedly. Voltage input on the loader to Measure voltage at contactor
low. under load. Maximum permit-
ted voltage drop is about 7%
of rated voltage. Inspect cross
section area, and cable lengths
from transformer. Check cable
connections.
Overload setting to low. Adjust the overload relay to
rated current for the electrical.
Pressures in the hydraulic sys- Measure all hydraulic pressure
tem is set too high. at all points and adjust if neces-
sary.
A servo valve or a control de- Check that none the control
vice on one of the axial piston lines is under pressure and
pumps may be jammed. verify that the axial piston
pumps is not out of alignment
when starting.
Burnt windings in the electrical Use a megger to check out
motor. windings in the electrical motor.
Troubleshooting Electronical Display system
Red LED blinking See error symbol in the screen
Diesel warning High temperature
Low oil pressure.
Red LED blinking
Over speed of diesel
Broken CAN communication Text message in the middle of

the screen what bus is failing
Steering joysticks A symbol shown in the warning Wrong input to the controller
Red LED blinking area Transport mode not possible
Steering sensor A symbol shown in the warning Wrong input to the controller
Red LED blinking area Transport mode is not possible
Throttle pedal A symbol shown in the warning Wrong input to the controller
Hydraulic motor A symbol shown in the warning PPU signal missing

JS 1000 Joysticks Text message in the middle of Error message from a joystick
the screen with fault number
PVED valve Text message in the middle of Error message from PVED valve
the screen with fault number
Only one PVED is allowed to
change at the time to be recog-
nized at the system
10HR07
SERVICE 6.002
If an error message is detected from a PVED a

text is shown in the middle of the screen with the
fault number whatever screen is active.
When changing PVED only one PVED at the

time is allowed to change. When connecting a
default PVED on the bus the system recognize it
and it is possible from the service screen to set a
new id. It is important to change only one PVED
at the time.
To change a new PVED module in loop

CAN 2B
1. Dismount the incorrect module
2. Disconnect cable CAN 2B from module 7HA
hammer and connect that cable CAN
2B into the new module. Disconnect the
terminating resistance from module 10 and
connect the terminating resistance to the
new module. Let the new module hanging
loose until it is renamed.
The new module must not be mounted
into final position before it is renamed.
3. Turn the power on inside the cabin.
4. Choose driver settings and service in the
display
5. Enter the required password. The status
select identity appears (in red letters) on
the display
6. Press the button with the arrow up to
choose the right PVED id
7. Press the button OK until reboot PVED (in
red letters)appears on the display
8. Turn the power off
9. Mount the new module into final place.
10. Turn the power on and everything is clear
to use
To change a new PVED module in loop

CAN 2F
1. Dismount the incorrect module
2. Disconnect cable CAN 2F from module 17
CAL Catch arm left and connect that cable
CAN 2F into the new module. Disconnect
the terminating resistance from module 12
and connect the terminating resistance to
the new module. Let the new module hang-
ing loose until it is renamed.
The new module must not be mounted
into final position before it is renamed.
3. Turn the power on inside the cabin.
display
5. Enter the required password. The status
select identity appears (in red letters) on
the display
6. Press the button with the arrow up to
choose the right PVED id
10HR07
SERVICE 6.002
7. Press the button OK until reboot PVED (in

red letters)appears on the display
8. Turn the power off
9. Mount the new module into final place.
10. Turn the power on and everything is clear
to use
In case you have to change to a new PVED

module without a spare module
Scenario:
The BLL module blade left stops functioning
and the QT module quick tool is not used on
the machine
1. Turn the power off with the key to the main
circuit-breaker
2. Dismount the QT module
3. Disconnect the CAN 2F cable
4. Disconnect also the terminating resistance
from the STF module
5. 5. Connect the CAN 2F cable and the
terminating resistance to the QT module
(which is not used on the machine) in order
to reset it to basic position from factory
6. Turn the power on inside the cabin
display
8. Enter the required password.
9. Press button No 8 to reset the PVED module
10. If everything is okay according to the mes-
sage press button No 3
11. Recieved Node ID 129 appears. (Re-
cieved Node ID 129 is the Quick Tool Node
ID. Press down OK-button
12. Reboot PVED to set identity appears in
red letters. Turn the power off with the key
to the main circuit-breaker
13. Disconnect the CAN 2F cable and the termi-
nating resistance from the QT module.
14. Reconnect the CAN 2F cable and the termi-
nating resistance to their respective old
places
15. Replace the BLL module with the QT-module
that was just reset
16. See To change a new PVED module in loop
CAN 2B or To change a new PVED module
in loop CAN 2F depending of which module
that shall be changed. See PVED Function to
deside in which loop you are changing the
module.
17. Assemble the BLL module that is incorrect
to the place where the QT module was
mounted (the QT module loop is not used
on the machine)
18. Disconnect cable No 2 from the SWR mod-
ule but let the cabel still be connected to
the QT module
19. Connect cabel No 1 to the SWR module.
10HR07
SERVICE 6.002
Text in display Larm

Emergency Stop Emergency stop is activated
Hydraulicoil Filter Hydraulic oil filter switch is on
Hydraulicoil Level Hydraulic oil level in tank is to low
Emergency Stop Emergency stop is activated
Hydraulicoil Filter Hydraulic oil filter switch is on
Hydraulicoil Level Hydraulic oil level in tank is to low
CAN Bus Controllers PLUS+1 units are not active
Voltage Overload Voltage in cable is to high
CAN Bus Valves 2 No CAN communication from PVED
Joystick JS1000 fault nr. 1-11 Error from Joystick left (1) or
Xx Valve PVED fault nr.xx right (2) Error from PVED nr xx
Voltage Ground Voltage ground is missing
Voltage Phase Voltage phase is wrong
Cable length Cable length sensor is active
Hose length Hose length sensor is active
Fire Fire is detected
PVED Function Node ID

1. Quick Tool 129
2. Swing right ( Bucket) 130
3. Blade Left ( 1st Boom) 132
4. Blade Right ( 2nd Boom) 131
5. Liftarm 133
6. Swing left 134 CAN 2B
7. Hammer 135
8. Steering front 136
9. Steering rear 137
10. Conveyor 138
11. Propel 139
18. Propel 140
12. Cable Wheel 129
13. Hose wheel 130
14. Conveyor rear 131 CAN 2F
15. Conveyor front 132
16. Catcharm right 133
17. Catcharm left 134
10HR07
SERVICE 6.003
Setting of pressures
General
Before setting the pressures, check that the oil
tank contains the correct amount of oil. Normally,
the oil level should reach up to the upper part of
the sight glass and should never be below the
sight glass. If necessary, top up with fresh oil
to the correct level, using oil as recommended
in the lubricating instructions. Pressure settings
are best adjusted immediately after operation,
while the oil is still warm. The machine should
be positioned on even and firm ground with the
conveyor frame assembly in tramming position.
Pressure adjustments can be set in Diesel- or
Electric mode in accordance with the following Bild 1.
instructions:
NOTE!
All pressure settings are noted on the
hydraulic drawing.
Main pressures for the different systems are

adjusted by the two axial piston pumps, (1) and
(2) se Fig1.
PUMP1
Checking and adjusting of pressure for digging
and positioning circuit. See fig 1, Fig 2 and Fig 3.
Load Sensing pressure (LS pressure)

1. Install a pressure gauge in port X1.
2. Start the truck and allow the hydraulic oil
to reach normal operating temperature. Bild 2. LS mtpunkter
3. Run the hydraulics, for example the dig- X1 = Pump 1
ging blade cylinders, slowly. Hold the main X2 = Pump 2
pressure at a medium level. LS pressure
must remain around 25 bar below tha
working pressure.
4. If adjustment is required unscrew the LS
Locking Set Screw (LSL). and adjust using
the LS Adjustment Screw (LSA).
5. When the LS pressure has been obtained,
tighten the locking screw (LSL) to 6.8
Nm.
PUMP1
System pressure (See Fig1 and Fig4)
1. Install a pressure gauge in port M or see
the pressure in the hydraulic menu in dis-
play.
to reach normal operating temperature.
Bild 3. Pump 1
3. Run the hydraulic digging blade cylin-
ders to an end position. Main pressure
(=system pressure) must be 180 bar.
4. If adjustment is required unscrew the PC
Locking Set Screw (PCS)and adjust the
10HR07
SERVICE 6.003
main pressure using the PC Adjustment

Screw (PCA).
5. After completing adjustment tighten the
locking screw (PCS) to 6.8 Nm.
Checking and setting of working pres-

sure for the lifting arm cylinders.
1. Place the digging blades of the machine in
a vertical position resting on the ground.
2. Connect a pressure gauge to the pressure
gauge socket (M) on the directional valve
(Fig.5) or see in the hydraulic menu on
display in cabin.
3. Move the lever in the direction LIFTING
ARM - DOWN. Check that the pressure is
correctly set app. 35-60 bar, depending on
the material. If necessary adjust the pres-
sure as follows. Bild 4. Pump 1
4. Remove the rubber plug above the adjusting
screw for LB. Move again the lever in the
direction LIFTING ARM - DOWN. Note at
the same time the pressure on the pres-
sure gauge, turn the adjusting screw until
correct pressure is obtained.
5. Put the rubber plug back and remove the
pressure gauge from the valve.
Check the pressure setting during operation

and readjust if necessary.
The pressure setting for lifting arm UP is made
with adjusting screw LA in the same way as
above. The lifting arm UP pressure should be 140
- 160 bar.
Checking and adjusting the oil flow for

the digging blades and swing arms
The speed of the digging blades and swing Bild 5.
arms should be equal on both sides of the
machine, to obtain the best loading capacity.
Test: Start the machine and position the
blades up in the air. Move lever DIGGING BLADE
IN and OUT and check that both blades move
with the same speed. Check the swing arms in
the same way. If adjustment is needed this can
only be made with the installation computer.
On the other hand the common speed for both
blades or both digging arms can be adjusted via
the display in drivers screen (see section headed
OPERATION).
PUMP 2
Checking and adjusting of the pressure for the
conveyor circuit. See Fig 1 and Fig 6.
Load Sensing pressure (LS pressure)

1. Install a pressure gauge in port X2.
to reach normal operating temperature.
10HR07
SERVICE 6.003
3. Run the hydraulics, for example the con-

veyor chain, slowly. Hold the main pres-
sure at a medium level. LS pressure must
remain around 15 bar below the working
pressure.
4. If adjustment is required unscrew the LS
Locking Set Screw (LSL). and adjust using
the LS Adjustment Screw (LSA).
5. When the LS pressure has been obtained,
tighten the locking screw (LSL) to 6.8
Nm.
PUMP 2 System pressure

See Fig 1 and Fig 7)
Connect the pressure gauge on the test nip-
ples M2, Fig 7. When testing the conveyor chain
must be blocked with a bar in the front end so
the flights will be stopped when the lever is in the Bild 6. Pump 2
REVERSING position. If the pressure is correct the
high pressure reading should be 250 - 300 bar.
Checking and setting of the pressure

for the traction circuit
The same pump (Pump 2) is also used for the
traction system. The test is done with the electri-
cal motor or the diesel engine running, but the
machine must be able to be stopped somehow.
( The parking cannot be used as the computer
system will bloc forward or reverse driving).Con-
nect the pressure gauge to M2.
The pressure should be max 350 bar, the same
as max pump pressure.
Bild 7. Mtuttag
Conveyor chain speed adjustment
The speed of the conveyor chain can be adjusted
by regulating the oil flow to the conveyor motor.
This is done via the display in the driver setting
screen It is adjusted according to material type
and flow. Try to keep the speed as slow as possi-
ble, without the chain jamming, which will result
in the best economy and less wear on the chain
and plates. When the speed is correctly adjusted
the working pressure during mucking should never
be higher then app. 75 % of maximum pressure
in the circuit. This is to avoid overloading and
frequent stops of the chain.
The adjustment is done in accordance with the
following instructions:
1. Start the electrical motor and move the
lever to position LOADING. Check the
speed by counting the flights for one
minute. (Can be adjusted between 80 -135
flights/minute).
2. Read the working pressure during muck-
ing and readjust if necessary.
10HR07
SERVICE 6.004
Component adjustment
Adjustment of play in link bearing
Play in the link bearing is most easily adjusted
in conjunction with a complete overhaul of the
machine. It is assumed that the conveyor frame
has been removed from the chassis at an earlier
stage.
Excessive bearing play probably originates
from the link bearing in both the chassis and the
conveyor frame, which have probably been worn
roughly an equal amount. The play must thus be
adjusted at both bearings.
Prior to adjustment of the bearing play, worn
components must be discarded and replaced by
new ones. The work is performed in accordance
with the following directions:
Dismantling the link bearing

1. Strap the link to a suitable hoisting device
or place timber beneath it so that it does
not drop down when released from the
bearing bracket (Fig.1).
2. Remove the nut and washer and then
withdraw the clamping bolt from the link
bearing on the chassis (Fig.2).
3. Pass an assembly rod or a bar through the
hole in one stud and remove the opposite
stud from the bearing.
4. Remove the other stud out in a similar
manner, whereupon the link is released
and can be moved aside from the bearing
itself.
5. If required back off the screws and remove
them together with the bushes. At the
same time, collect the shims which may
appropriately be reused when adjusting Bild 2. Lnkens lagring i chassit
the bearing play.
Clean all dismantled parts and check them for

wear. Change defective components.
Similarly inspect the parts included in the link
bearing on the conveyor frame. In this case also
replace worn parts (Fig.3).
Assembly of link bearing

1. Measure the exact width of the link at the
wider bearing bracket.
2. Screw both bushes into the chassis with-
out interlying shims.
3. Measure the exact distance between the
inside of the bushes. Then remove the
bushes from the chassis.
4. Calculate the difference between the two
measurements. Put together a shim packet
corresponding to the calculated difference,
plus an additional 0,1 mm shims.
5. Insert the shim package under one bush-
10HR07
SERVICE 6.004
ing, or split them between both bushings.

Screw the bushings on to the chassis, but
leave them both out a little to make it
easier to mount the link.
6. Place the link in the correct position, and
put one stud in each end of the link.
7. Tighten the screws for the bushings to a
torque of 296 Nm.
8. Insert the clamping bolt through the bear-
ings and link. Tighten the entire bearing
assembly with washer and nut. Tightening
torque = 280 Nm.
9. Move the link from side to side and check
that the adjustment is correctly made (Fig.
2). If the clearance is not correct, adjust
the thickness of the shim package.
When fitting the conveyor frame to the link,

the bearing is assembled and the bearing play
adjusted in accordance with the directions given
above.
NOTE!
After 10 - 20 hours operation, the clamping
bolt, as well as the screws for the bushings
should be re tightened.
10HR07
SERVICE 6.004
Component replacement
Chain wheel on drive shaft
Art. no 270 2069-001
Removal of chain wheel (chain conveyor

only)
1. Back off the cam-unit retaining screws
on both sides of the machine and screw
out the conveyor-chain tensioning screws
flush with the lugs (Fig.1).
2. Slacken the conveyor chain by pulling back
the cam unit, as far as possible. This is
most easily done by locking the lower part
of the roller chain to the conveyor frame in
a suitable manner. Then start the electric
motor and cautiously run the chain for-
ward with the lever to position LOADING
until the cam unit has been pulled back Bild 3. Nockaggregat
the maximum amount. Dismantling and
reconnection of the chain is thus consider-
ably easier. Now stop the motor and turn
off the main switch in the plant. Discon-
nect the lower part of the roller chain from
the conveyor frame assembly.
3. Split the conveyor chain at the unloading
end by removing a connecting link from
the roller chain. Then bend the free ends
of the chain free from the chain wheel
so that the chain wheel can be removed
(Fig.2).
4. Cut away the weld in the joints between
the chain wheel halves.
5. Drive the elastic hollow pins out of the ring
and remove the split chain wheel from
the drive shaft. Check simultaneously the
safety device for wear, see page 2. Bild 4. Kedjehjul p drivaxeln
Fitting the chain wheel

1. Locate the bigger half of the new chain
wheel in the ring on the drive shaft. Then
place the smaller half in the ring and lock
both halves to the drive shaft by driving
hollow pins into the wheel and ring (Fig.2).
Put shims in the joints between the chain
wheel halves and fix them by welding.
2. Place the roller chain over the chain wheel
and connect the ends together.
NOTE!
Always match one of the chain wheel
teeth into one flight section. Following
tooth will then automatically align between
two of the roller links.
3. Tension the chain by tightening the ten-

sioning screws. Do not tighten too firmly
so as to cause the chain to bind during
10HR07
SERVICE 6.004
operation. Measure the distance between

the heads of the tensioning screws and the
lugs into which they are screwed (Fig.1),
and check in this way that the drive shaft
is fixed at a right angle in relation to the
conveyor frame assembly.
4. Tighten the cam-unit retaining screws
slightly.
5. Test run the chain for a while and check
that it is sufficiently tensioned. If the chain
shows an excessive tendency to climb
on the teeth of the chain wheel during
reversing the chain will require further
tensioning. If so, slacken the cam-unit
retaining screws and then turn the ten-
sioning screws until acceptable tensioning
is obtained, i.e. until the chain emerges
slightly under the side plate (Fig.1).
6. When the chain is correctly tensioned,
tighten the cam-unit retaining screws
firmly and, finally, lock the tensioning
screws in the adjusted positions by means
of the nuts.
Safety device between the upper and

lower part of the conveyor chain
The safety device (Fig.3), should be checked
for wear in connection with replacement of the Bild 5. Fastsvetsning av skerhetsanordning
chain wheel. This safety device prevents falling
stones from getting stuck in the lower part of the
chain. Add material, by welding, to the existing
safety device, or make a new one, and weld it to
the cam unit, see measures given in page 3.
10HR07
SERVICE
Guide roller (chain conveyor only)
Before starting to carry out any form of ser-
vice work in the loader, the main switch must be
turned off in the generating plant.
Removal of roller
Undo one link on the roller chain and bend the
free ends of the conveyor chain clear of the roller.
Then back off the roller retaining screws with a
box spanner and remove the roller together with
the brackets from the machine (Fig.1).
Dismantling the roller

1. Unscrew the retaining screws for the hold-
ers from the guide plate (Fig.2).
2. Cut away the weld between the hold-
ers and the wear plate, thus completely
releasing the holders with roller from the
plate.
3. Pull the holders off the ends of the roller.
Change the old guide roller for a new

complete roller (Fig.3).
The new roller is filled with oil upon delivery.
Also change the guide plate and holders if these
items are worn out. If, on the other hand, the
plate and holders are to be reused, the welds
should be completely ground off during disman-
tling.
Assembling the roller

1. Insert the ends of the new roller into their
respective holders.
2. Screw the two holders to the guide plate
(Fig.2). Tighten the retaining screws firmly
with a box spanner.
3. Weld the holders to the wear plate (Fig.2).
After welding, make sure that the seams
cannot get caught by the flight of the con-
veyor chain. If they so the seams must be
ground down.
Refitting the roller

Screw the roller to the conveyor frame assem-
bly in the same position as before. Tighten the
retaining screws firmly with a box spanner. Place
the conveyor chain over the roller with one tooth
placed into the middle of the flight section and
reconnect the ends of the chain. Test run the
machine.
10HR07
SERVICE 6.004
Wear plates in conveyor frame (chain
conveyor)
Removal of upper wear plates

1. Remove the conveyor chain from the
upper side of the conveyor frame assem-
bly. This is most easily done by slackening
the chain and removing a connecting link
from the roller chain at the front end of
the conveyor frame assembly, the upper,
free end of the chain is then run towards
the unloading end until its last link reaches
a position some four inches from the chain
wheel. Then lift the chain off the chain
wheel and allow it to hang down under
the frame assembly from the lower, curved
wear plate. Place the return part of the
chain in a pile on the floor in front of the
conveyor chain assembly.
2. Remove all screws, washers and nuts used
to attach the upper wear plates (Fig.1) or
grind off the plug welds.
3. Remove the worn plates from the con-
veyor frame assembly.
4. Clean the beams and plates on which the
wear plates rest in the conveyor frame.
Fitting the upper wear plates

1. Insert the new upper wear plates on the
beams in the conveyor frame.
2. Secure the wear plates in the same
manner as they were removed, using the
screws, washers and nuts, or plug weld
the plates.
3. Fit the conveyor chain in the opposite
order to that in which it was removed.
At this stage of the work, one man runs the
conveyor while another checks that the chain
does not get caught while being run into the
frame assembly.
NOTE!
teeth into a flight section. Subsequent
teeth will then automatically align be-
tween two of the roller links.
4. Tension the conveyor chain and then lock

the tensioning screws with their respec-
tive lock nuts. When the chain is correctly
tensioned, tighten the cam unit retaining
screws firmly.
5. Test run the machine and check that the
conveyor chain does not get caught in any
of the joints.
10HR07
SERVICE 6.004
Lower wear plates

Check the lower wear plates for wear after
having removed the upper wear plates. If neces-
sary, these lower wear plates (Fig.2) must also
be changed, which in this case is done before
the upper plates are fitted. Replacement involves
simply removing the old plates and replacing
them by new ones assembly. which are screwed
or plug welded into position in the same manner as
before. Before the lower wear plates are changed,
the conveyor chain must, however, be completely
removed from the machine.
10HR07
SERVICE 6.004
Conveyor chain (chain conveyor only)
Conveyor chain replacement is a task that
should preferably be entrusted to two men.
During most stages of the job, one man operates
the loader while the other carries out the neces-
sary work and at the same time directs the oper-
ator. Replacement is carried out in accordance
with the directions given below, with the front
end of the conveyor frame assembly resting on
the ground and the rear end lowered to parking
position.
1. Back off the cam-unit retaining screws
on both sides of the machine and screw
out the conveyor-chain tensioning screws
flush with the lugs (Fig.1).
2. Slacken the conveyor chain by pulling
back the cam unit, as far as possible. This
is most easily done by locking the lower
part of the roller chain to the conveyor
frame in suitable manner. Then start the
conveyor motor and cautiously run the
chain forward with the lever to position
LOADING until the cam unit has been
pulled back the maximum amount. Dis-
mantling and reconnection of the chain is
thus facilitated. Now stop the motor and
disconnect the lower part from the con-
3. Split the conveyor chain at the lower part
midway between the drive shaft and the
wear plate, by removing a connecting link
from the roller link (Fig.2).
4. Roll up the new chain and place it under
the rear end of the conveyor frame assem-
bly.
NOTE !
The conveyor chain must be rolled up so
that the flights are the right way round
when the chain is drawn into the conveyor
frame assembly. This implies that the
flight must slide along the conveyor frame
assembly with the lower pointed edge
facing the unloading end, and the JOY
mark facing upwards (Fig.2).
5. Connect the new chain to the lower, free

end of the old chain (Fig.3).
6. Start the conveyor motor and perform
lever movement for LOADING on the con-
trol panel. Run the new chain slowly into
the conveyor frame assembly while the old
chain is removed and placed in a pile on
the floor. Stop the conveyor motor when
the new chain reaches the chain wheel of
the drive shaft (Fig.3). At this stage, one
man must check that the new chain does
10HR07
SERVICE 6.004
not get caught by the wear plate, giving

directions to the driver meanwhile.
7. Secure the rear end of the new chain in
a suitable manner so that it will not be
drawn inadvertently into the bottom of the
frame assembly.
8. Again run the conveyor motor carefully and
draw the chain forwards until its front end
reaches between the drive shaft and the
wear plate (Fig.2). Then stop the motor.
NOTE!
teeth into one flight section. Following
tooth will then automatically align between
two of the roller links.
9. Release the rear end of the new chain.

Detach the old chain from the new one.
10. Connect the new chain together with a
connecting link and pins (Fig.4)
11. Tension the chain by tightening the ten-
sioning screws. Do not tension so firmly as
to cause the chain to bind during opera-
tion. Measure the distance between the
heads of the tensioning screws and the
lugs into which they are screwed and
check in this way that the drive shaft is
fixed at a right angle in relation to the con-
veyor frame assembly (Fig.1).
12. Tighten the cam-unit retaining screws
slightly.
13. Test run the new chain for a while and
check that it is sufficiently tensioned. If
the chain shows an excessive tendency
to climb on the teeth of the chain wheel
during reversing the chain will require fur-
ther tensioning. If so, slacken the cam-unit
retaining screws and then turn the ten-
sioning screws until acceptable tensioning
is obtained, i.e. until the chain emerges
slightly under the side plate.
14. When the chain is correctly tensioned,
tighten the cam-unit retaining screws
firmly and, finally, lock the tensioning
screws in the adjusted positions with the
nuts (Fig.4).
10HR07
SERVICE 6.004
Bushes in lifting arm bearings
Replacement of bushings in the lifting arm
attachment points to the conveyor frame assem-
bly is best carried out with the aid of a suitable
lifting device such as a telpher or the like. The
task is best performed by two men and the pro-
cedure is as follows:
Removal of bushes
1. Attach a suitable lifting device in the lifting
arm with a chain or wire, strapping in such
a way that the arm weighs evenly, i.e. bal-
ances, when lifted.
2. Back off the retaining screws at both
bearings and remove the outer half of
the bearing cover from the shanks of the
lifting arm (Fig.1). The lifting arm is thus
released form its attachment to the con-
3. Hoist the lifting arm up high enough for it
to completely clear the shaft.
4. Remove the lubricating nipples from the
shaft ends and pull the shaft out from the
bearings.
5. Remove the worn bearing bushes from
the ends of the arm bracket (Fig.2).
Fitting the bushes

1. Carefully drive a new bearing bush into
each end of the arm bracket (Fig.2). Use a
mandrel and a mallet to drive the bushes
home.
2. Insert the shaft in the bearings so that the
ends of the shaft protrude 132,5 mm from
the flange of the bearing bushes (Fig.2).
Screw a lubricating nipple into each end of
the shaft. Damaged nipples must be
discarded and replaced by new ones.
3. Lower the lifting arm and fit the ends of
the shanks onto the shaft.
4. Screw the outer halves of the bearing
covers onto their respective bearings.
Tighten the retaining screws 1000 Nm
(Fig.1)*.
5. Lubricate the screws with molybdenum
disulphide, e.g. MOLYKOTE, or similar
grease.
6. Remove the lifting device from the arm.
Lubricate both bearings with grease in
accordance with the lubricating instruc-
tions.
7. Test run the machine and check that the
bushes are correctly fitted.
*Check before tightening the screws that the

total axial play in the lifting-arm bearings does not
exceed 0,5 mm. If necessary undo the retaining
10HR07
SERVICE 6.004
screws on the bearing cover and pull the shanks

of the lifting arm together until the correct axial
play is obtained.
Tooth holders on digging blades
Before worn tooth holders are replaced the dig-
ging blade must be removed from the machine.
Welding the holders is carried out with an unal-
loyed basic electrode, i.e. OK 48.00, OK 55.00 or
similar electrode. Holders and teeth are replaced
as follows:
1. Cut away defective tooth holders and grind
off old welds. Then clean the digging blade
from all rust and dirt.
2. Mark out the positions on the digging
blade according to the previous distances
between the holders.
3. Place the tooth holder, together with the
tooth, in marked position on the digging
blade.
4. Press the holder against the front edge
of the V-plate (Fig.1) and tack weld the
holder in the rear (Fig.2).
5. Preheat the welding zone on the tooth
holder and the digging blade to approx.
150-200 C (423-473 K).
6. Begin welding on the middle holders. Start
welding at the rear edge of the holder, and
weld alternately along both the sides in
direction towards the tooth (Fig.2). Apply
the weld properly along the entire contact
surface of the tooth holder against the
V-plate.Also weld under the front part of
the holder, where it rests against the front
edge of the V-plate. In addition, fix the
holder to the wear plate with a weld bead
in accordance with the adjoining figure.
The weld will become tougher if it is heated
after welding with a gas torch to 500-600 C (
773-873 K). The heating temperature can easily
be checked with temperature chalks.
10HR07
SERVICE 6.004
Hydraulic cylinder
Part-no 470 5320-803 and 804
The cylinder is used for operation of the con-

veyor frame assembly, swing arm and lifting
arm.
Hydraulic cylinder
Part-no 470 5000-802
The cylinder is used for operation of the gath-

ering blades.
Repairs to the hydraulic cylinders are best
carried out by qualified personnel with thorough
knowledge of the function of the cylinders.
Dismantling the hydraulic cylinder

1. Clean the outside of the cylinder after removing
it from the machine.
2. Remove the ball joint (A) and the lock-
ing rings (B) from the piston-rod lug and
barrel (Fig.1).
3. Drain remaining oil out of the cylinder.
4. Secure the cylinder in a vice fitted with
copper jaws.
5. Remove couplings on the cylinder.
6. Loosen the A-cover (E) with the aid of an
assembly key and screw the A-cover from
the barrel (M).
7. Pull the piston rod (H) out of the cylinder.
8. Secure the piston-rod lug in a vice and let
the piston rod rest in a V-shaped support
which should be provided with soft sur-
faces to avoid scratching the piston rod.
9. Back off the stop screw (L) (between
piston and piston rod) with a hexagon
wrench after having drilled out the upset
that locks the screw.
10. Loosen the piston (K) with the aid of an
assembly sleeve and screw it from the
piston rod.
11. Pull the A-cover off the piston-rod.
12. Remove all seals and O-rings from the
piston rod and A-cover. Also remove the
wiper ring. Use a blunt screwdriver or
similar tool to take away seals.
Take great care to avoid damage to the seal

grooves. Clean the parts and examine them very
carefully for wear. Worn or damaged parts must
be discarded and replaced by new ones. Inspect
the cylinder bore (the barrel), the piston rod and
the bearing surface in the A-cover for scratches.
Very fine scorings (discernible to the eye but not
detectable with the finger or fingernail) can be
disregarded. If there are any coarse scratches, the
part concerned must be discarded and replaced
10HR07
SERVICE 6.004
by a new one. In addition, always change the

piston seal, piston-rod seal, wiper ring, O-ring
(which seals between piston and piston rod) and
the O-ring with thrust ring (which seals between
A-cover and barrel).
Assembly of hydraulic cylinder

1. Coat all seals and bearing surfaces with
hydraulic oil.
2. Fit the wiper ring and seals of the A-cover.
Fit the piston-rod seal (D) into its groove
and fit the seal so that the groove for the
white thrust ring faces the wiper ring.
Then fit the thrust ring. The thrust ring
(F), for O-ring (G), must be positioned
closest to the thread.
3. Push the A-cover (E) onto the piston rod
(H).
4. Mount the O-ring (J) on the piston rod.
5. Screw the piston (K) onto the piston rod,
tighten with an assembly sleeve to a
torque of 353 Nm .
6. Drill and tap a hole for the stop screw in
the thread between piston and piston rod.
Hole diameter 4,2 mm, depth 10 mm and
thread M5.
7. Clean thoroughly after having drilled and
tapped the hole.
8. Insert a stop screw in the hole and tighten
with an Allen key.
9. Lock the stop screw with two centre
pops.
10. Fit the piston seal (I).
NOTE !
Coat the dividing points of the piston seal
with grease (Molykote BR2 or the like)
before fitting. Position the dividing points
of the guide rings through 90 and 180
respectively in relation to those of the
piston sealing ring.
11. Slide the piston rod (H) into the barrel

(M).
12. Screw the A-cover onto the barrel and
tighten it with the aid of an assembly
sleeve to a torque of 245 Nm.
13. Fit the ball joint (A) and the locking rings
(B) in the piston-rod lug and barrel. Coat
the ball joints with grease (Molykote BR2
or the like) before fitting.
Testing
1. Fill the cylinder with oil and run the piston
rod in and out a few times so that all air is
expelled from the cylinder. Stop the piston
rod at one end position.
2. Subject the cylinder to a pressure test.
10HR07
SERVICE 6.004
Maximum pressure =300 bar ( 30 MPa ).

3. Test the piston seal by loosening the non
pressurized connection to check for leak-
age.
4. Move the piston rod to the other limit posi-
tion and repeat points 2 and 3.
There must not be any external or internal
leakage.
Swing arm bearings
If the radial clearance in the swing arm bear-
ings is excessive, the bushings must be replaced
together with their attachment screws. At the
same time, worn conical pivots and scored conical
sockets should be replaced if necessary. The pro-
cedure is as follows:
Dismantling the swing arm bearing

5. Strap the swing arm in a suitable manner
to prevent it from falling down when sepa-
rated from the lifting arm.
6. Disconnect the hydraulic hoses from the
digging blade cylinder which accompanies
the swing arm when it is released from
the arm.
7. Detach the swing arm cylinder from its attachment
point on the swing arm.
8. Remove the upper and the lower cover
from the bearing. Collect the screws
(Fig.1).
9. Remove the 8 screws holding the lower
bushing. Remove the bushing by screwing
3 screws (MC6S 16x75 fully-threaded) into
the puller holes and withdraw the bush-
ing.
10. Remove the lock-nut and washer from the
lower end of the bolt and withdraw the
bolt from the bearing.
11. Make a stout puller with a M30 thread
(Fig.2). Screw the puller into the upper
conical pivot and withdraw it from the
bearing.
12. Withdraw the lower conical pivot in the
corresponding manner, thus releasing the
swing arm from the lifting arm.
13. Lift the swing arm off from the bearing.
14. Take the bushes out of the bearing.
15. Drive out the conical sockets from the arm
if they are damaged.
Check the bearing components for wear and
renew any defective components. Also change
the conical sockets in the arm if they are dam-
aged, e.g. scored and cannot be re-used.
Assembling the swing arm bearing

1. Refit the conical sockets in the arm if
they have been removed, together with
10HR07
SERVICE 6.004
the interlaying sleeve. The conical sock-

ets must be fitted symmetrically so that
the ends protrude from the arm an equal
amount.
2. Place the swing arm in position to fit the
lifting arm.
3. Coat the cylindrical bearing surface on the
conical pivots with grease and attach the
swing arm to the lifting arm by driving the
upper conical pivots into the bearing.
NOTE ! Take great care to ensure that

no grease gets onto the conical contact
surface.
4. Fit the lower bushing without shims. Secure

the bushing with new screws, tighten the
bolts lightly.
5. Insert the lower conical pivot into the bearing.
6. Insert the bolt with the washer from above
and tighten the bearing together with the
washer and lock-nut. Tighten the nut to a
torque of approx. 260 Nm, which is half the
final tightening torque.
7. Tighten the screws for the lower bushing
until there is contact between the conical
sockets and the bushings at both top and
bottom of the bearing.
8. Check that the swing arm can be turned by
hand by one man, although it takes a bit of
effort to move.
9. Measure the distance A between the lower
bushing and the swing arm, (Fig.1). Put a
set of shims together corresponding to the
measured distance A, plus an additional 0,2
mm shim, to account for the axial clearance.
10. Fit the set of shims and the lower bushing
on the bearing and secure the bushing with
new attachment screws. Tighten the screws
to a torque of 296 Nm.
11. Pull the bearing together by tightening the
lock-nut to a torque of 520 Nm.
12. Remove the strapping from the swing arm.
13. Check that the work has been correctly
carried out so that the swing arm can be
turned by hand in all directions. Readjust as
necessary.
14. Attach the released swing arm cylinder to
the swing arm.
15. Re-connect detached hydraulic hoses to the
digging blade cylinder.
16. Lubricate both bearings with grease, turning
the swing arm to and fro as you do. Check
that grease oozes out round the entire
bearing race.
17. Fit a new V-ring on the upper conical socket
and put back both covers on the bearing.
Tighten the screws firmly.
10HR07
SERVICE 6.004
18. Test run the machine upon completion of

the work.
NOTE!
The specified tightening torques are valid
for screws lubricated with molybdenum
disulphide ( MoS2 ).
Digging blade bearings

If the bearing play is excessive, the bearing
bushes in both bearings must be replaced. The
work is started with the digging blades pointing
straight downwards and resting lightly against
the floor.
Dismantling the digging blade bearing

19. Remove the cylinder pin and detach the
hydraulic cylinder from the digging blade
(Fig.1).
NOTE!
Do not loose the spacer sleeves.
20. Remove the nuts and lock washer from

the end of the shaft.
21. Remove the screw and washer used to fix
the shaft in the bearing.
22. Tap the shaft out of the bearing, thus
releasing the digging blade from the swing
arm.
23. Remove the digging blade from the
machine.
24. Take the bushes out of the bearing.
Assembling the digging blade bearing

Manufacture a mandrel for fitting the bearing
bushes according to sheet 8.013 E in the section
headed APPENDICES. A holder for the mandrel
can be made as described in sheet 8.010 E.
Tap the bearing bushes into the digging blade
with the aid of mandrel and holder.
Assemble the digging blade bearing in

the opposite order to dismantling.
Tighten the screw used to fix the shaft in the
bearing, applying a torque of 200 Nm.
Test run the machine after having finished the
work.
10HR07
SERVICE 6.004
Hydraulic oil tank

Change oil in the hydraulic system as soon as
it has become contaminated; for instance in the
event of pump or motor failure. Oil changing is
most appropriately performed immediately after
a run while the oil is still warm. While this work
is being carried out, the main engine must be
switched off and the machine must be standing
on level ground. Conditions of scrupulous cleanli-
ness must be observed whenever work is being
carried out on the hydraulic system, since the
presence of even minute impurities in the system
can cause considerable damage. The hydraulic
oil is changed in accordance with the following
instructions and lubrication chart.
Undo the pipes from the return filter. Remove
the screws from the tank cover (H). Remove
the cover together with the return filter and
the breather (C) which is bolted to the top of
the oil tank (Fig.1). Be sure to empty the tank
completely with the aid of a pump. (A pipe plug
is provided under the tank for draining the oil
if more suitable). Scrape off any deposits from
the bottom and sides of the tank, using a rubber
scraper. Flush the tank with white spirit if the
old oil is discoloured, in the same way as after a
pump or hydraulic motor failure. Wipe the inside
of the tank with a clean lint-free cloth. Cotton
waste or similar material must not be used in any
circumstance.
Also clean other parts of the hydraulic system
where impurities may possibly have accumulated
and which vary with the location of the damaged
component. Flush the hoses with white spirit. Fit
the cover on the tank and check at the same
time that the gasket under the cover is undamaged
and forms a good seal. If the gasket is damaged,
it must be discarded and replaced by a new one.
Tighten the screws firmly.
Reconnect the removed hydraulic hose to the
return filter. Fill up with fresh oil until the oil level
reaches the upper part of the sight glass on the
side of the tank. Use the oil quantity and grade
as specified in the lubrication instructions - Code
F. Connect a filler hose to the quick connection,
then fill up with oil using the electric pump and
associated hose. The latter should naturally be
cleaned before it is connected to the oil drum.
Close the shut-off cock when the system has
been filled up (Fig.2).
Check for leakage in the hydraulic

system.
Tighten couplings as well as the pipe plug
under the tank if necessary.Never start the drive
motor if there is no oil in the hydraulic system.
Let the machine run for a while and check the
oil level in the tank once again. If necessary, top
10HR07
SERVICE 6.004
up the oil level until it reaches the upper sight

glass.
Starting the machine after replace-

ment or repair of axial piston pumps
To prevent the pumps from seizing when the
machine is started up, it is essential for all air to
be expelled from the hydraulic system. At this
juncture, it is assumed that the oil has been
changed and the system cleaned in accordance
with the directions mentioned above.
Start-up is accomplished in the following

manner:
1. Lift the machine clear of the ground so
that all the wheels are able to rotate
freely. (It must be possible for the pumps
and hydraulic motors to be started under
low load).
2. Release the brakes, which must be open
during the entire starting-up procedure.
3. Start the main engine in the normal manner
and let it run for approx. 10 seconds. Then
stop the engine. Wait for 2 or 3 minutes to
enable air to be expelled form the pump
casing. (Check that the ventilation lines
from the pump casing are positioned so
that air can easily escape i.e. they should
run upwards without bends).
4. Repeat the above procedure 5 times. In
the mean time, the oil tank should be con-
tinuously topped up.
5. Run the main engine and put the DRIVE
lever alternately to both positions 3 times for
approx. 30 seconds each time, at approx.
1/3 of maximum displacement.
6. Lower the machine to the ground as it is
now ready to work.
NOTE!
The wheels will rotate during this proce-
dure
10HR07
SERVICE 6.004
Changing tyres
Removal of wheel
1. Apply a jack at a suitable point under the
chassis.
2. Loosen the nuts on the wheel bolts
(Fig.1).
3. Raise the wheel completely clear of the
ground.
4. Remove the nuts.
5. Remove the wheel from the machine, with
the aid of available lifting device.
Replace the old tyre by a new one, pumping
this to the right pressure, before fitting it on the
machine.
Tyre pressure in all wheels:

Standard tyres 12.00 x 20 XRA = 8.5 bar (0,85
MPa).
Refitting the wheel

1. Lift the wheel onto the wheel bolts.
2. Tighten the nuts slightly.
3. Lower the wheel onto the ground.
4. Tighten the nuts in pairs to a torque of
500-600 Nm.
5. Take the jack away.
10HR07
MISCELLANEOUS 7.000
Contents
Optional equipment which is not normally included with the standard 10HR07 7.001
Water hose wheel 7.001
Central lubrication system 7.001
Backhoe 7.002
Webasto heater for the cabin 7.003

10HR07
MISCELLANEOUS
10HR07
MISCELLANEOUS 7.000
Information about optional equipment

which is not normally included
with the standard 10HR07
Water hose wheel

The HGGLOADER 10HR07 can be equipped
with a water hose wheel for automatic out- and
in pulling of the water hose.
Water is used for the sprinkler system which

showers water over the muck to reduce dust
formation for better environmental conditions.
The function of the hose wheel is identical to the
cable wheel.
Central lubrication system

10HR07 can be equipped with an automatic
lubrication system as option. The system consists
of lubrication pump with a grease container, flow
dividers and hoses for the lubrication points.
10HR07
MISCELLANEOUS 7.002
Backhoe
Technical Description Boom Joint

This digging unit, by virtue of its design,improves Lifting arm
accessability to muck when loading. Among other
things it enables scaling of walls and roofs, as
well as lifting and track laying, to be carried out.
The backhoe unit, moreover, is highly suitable
for shielding and when loading muck containing
large amounts of water. Bucket
The backhoe unit consists of the following
main components: bucket, rake, boom, articula-
tion joint and lifting arm. Fig 4. The backhoe units main
The bucket is articulated at the end of the rake components
but also rotates 360 around its own axis (Fig.4).
The rake is attached to the boom and both are
articulated at the end. The boom rotates 62 in
either direction on the lifting arm (Fig.5), which is
attached to the conveyor frame in the same way
as the standard arm.
Function Maximum angle 62

The backhoe unit is operated through hydraulic
cylinders just as the standard digging unit, in fact
the loader is identical to the standard loader in
every respect but the digging unit.
Operation
During operation, the loader advances continu-
ously into the muck pile with extended gathering
arms and hence pushes the muck in front of the Fig 5. The boom rotates 62 in either
machine. As the amount of muck in front of the direction on the lifting arm
machine increases its continuously moved by the
bucket onto the conveyor. The conveyor trans-
ports the muck to the back and into the transport
car or shuttle car that follows the machine.
10HR07
MISCELLANEOUS 7.003
Webasto heater for the cabin
As an option the HGGLOADER10HR07 can

be equipped with a Webasto air heater Air Top
2000ST. The Webasto heater belongs to the most
silent air heaters. Air Top 2000ST is a powerful
heater which quickly gives an increased comfort
inside the cabin. During hot summer days the
unit can also be used as ventilation fan.

Instructions GIA 10HR07 PDF

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INSTRUCTIONS MANUAL

GIA Industri AB Phone: +46 240 797 00

GIA industri ab Phone: +46 240 797 00

Per Ek (Sales Manager) Gran Nilsson (Area Manager)

Hans Ramstrm (Area Manager) Bo Strmsholm (Product Manager GIA SwedVent)

Mari Johansson (Area Manager) Jan Josefsson (Area Manager)

Spare Parts Service E-mail: spareparts@gia.se

Seija Liimatainen Mari Laine

Shipping E-mail: shipping@gia.se

Service and After market E-mail: aftersale@gia.se

Per Gransell Ragnar Eriksson Christian Kromm

WARRANTY AND SERVICE INFO.

Warranty and service information

Warranty period, general

What the warranty covers

What the warranty does not cover

HEALTH AND SAFETY

Health and Safety

Training and experience

Before starting work

HEALTH AND SAFETY

Protective equipment, safety devices and safety procedures

Always follow local safety rules.

Keep tools in their places.

Oils, greases and fuels

Different types of oil or fluid must not be mixed.

Smoking is strictly forbidden when refuelling.

Always use original spare parts.

Modern demands for high output and efficiency,

This loader, known as the HGGLOADER

Significant differences set the HGGLOADER

The HGGLOADER 10HR07 is diesel-electric

penetration performance as it advances into the

The HGGLOADER 10HR07 is equipped with an

The electro-hydraulic drive gives the machine

The HGGLOADER 10HR07 consists of a chassis on

conveyor frame and is shovelled onto the frame

The mode of operation of the loader, which is

A sprinkler system is installed above the blade

The machine is equipped with a diesel engine

The arm system may also, on the customers

The HGGLOADER 10HR07 is not only a loader

Further improvements to the working envi-

Continuous muck loading operation

In closing, it should be noted that the

TECHNICAL DESCRIPTION 2.000

Dimension sketch 2.001

TECHNICAL DESCRIPTION 2.001

TECHNICAL DESCRIPTION 2.002

TECHNICAL DESCRIPTION 2.003

The HGGLOADER 10HR07 can be described

TECHNICAL DESCRIPTION 2.003

for self propulsion (can also be used for digging

TECHNICAL DESCRIPTION 2.004

TECHNICAL DESCRIPTION 2.005

TECHNICAL DESCRIPTION 2.006

Conveyor frame assembly

TECHNICAL DESCRIPTION 2.007

Fig. 2 Starting equipment for the electric

TECHNICAL DESCRIPTION 2.008

The pump unit is a diesel-electro-hydraulic

Fig. 2 Pump unit

TECHNICAL DESCRIPTION 2.009