Sandvik Mining and Construction Australia

UGM Customer Forum 2011

Loaders
Sandvik Mining and Construction

Contents
Loaders - Safety & Ergonomics

Loaders - Operational Efficiency

Loaders - Maintenance

Appendix

Prevent Tyre Failures with TPMS (Tyre Pressure Monitoring System)

Monitoring Camera System

Ride Control System for Boom

Reliable Electrics

Wiggins Fill Set - hydraulic, transmission and engine oil

Vehicle Control & Management (VCM) System

10

Automatic Central Lubrication System

11

Loaders
Safety & Ergonomics
Forum Points

Workshop
Rating

Tyre monitoring (press & temp)

1. Real time monitoring
2. TKPH
3. Limit the machine speed

20

Proximity detection
Feedback to operator
Around the corner detection

18

Visibility from cab

Cameras
Cab height

16

Tyre changing / Jacking system

15

Sandvik Mining and Construction

Sandvik Responses
(1) Tyre pressure monitoring systems will be
available as an option for equipment delivered
in Q1 2011. LHDs equipped with the Vehicle
Control Management system have access to this
option. Actual bucket weights are stored in the
Vehicle Control Management system and can be
downloaded via USB. Refer to appendix; Tyre
Pressure Monitoring System.
(2) The TKPH is possible by manual control can be
incorporated into the AutoMine system.
(3) The machine speed limiting capability is only
available in the AutoMine system at this stage.
We presently have a project team investigating
proximity detection systems; an initial
questionnaire has been sent to all Regional
Product Line Managers to collect customer
feedback on existing systems and customer
requirements that align with legislation.
Sandvik with a large global customer base is
looking at future machines being able to interact
and integrate with systems from other suppliers
and manufacturers.
Camera systems have been added to our
offering and are available for main LHD models.
Refer to appendix; Camera System.
To further improve visibility, cabin lift kits (to
adjust the height of the cabin) are available for
LH514, LH517 and LH621 loaders. The LH621s
currently being delivered to Australia have a
cabin lift kit as a standard option. The lift kit
raises the cabin by 150mm.
At present there are no actions planned for the
current range of LHDs, however this option will be
considered on future machines.

Loaders
Operational Efficiency
Forum Points

Workshop
Rating

Efficient operation, eg.

1. Bucket position awareness
(feedback to operation),
2. Bucket design (minimize breakout
force, spillage, penetration, wear
packages),
3. Tramming (machine wear & tear,
vision, accuracy/precision, customise
response of machine to each
operator).

14

Collision avoidance

12

Speed
1. Tramming whilst loaded
2. Response to movement control
3. Power to implement
4. Monitor operators to improve
efficiency

10

Reliability (MTBF) Improvement

Automatic bucket filling

Sandvik Mining and Construction

Sandvik Responses
(1) To improve bucket awareness the bucket angle
indicator design should be checked and adjusted as
needed during scheduled servicing.
(2) There is on-going bucket design improvements
that focus on bucket geometry, strength, wear
protection and efficiency. Bucket design will
continue to evolve and improve.
(3) The investigation of the customised response
of machine to each operator will be included in
the next generation VCM software development
project. Accuracy and feel is handled as part of
continuous improvement.
This feature will be included in the proximity
detection study that is currently underway.
(1) Tramming speed and comfort whilst loaded can
be improved by using the ride control system which
is available as an option. Refer to appendix; Ride
Control System.
(2, 3) Response to movement control and power
to implement will be further improved in the next
generation VCM software. Current large LHDs
have sensors on steering articulation to prevent the
steering cylinders reaching full travel at maximum
speed.
(4) There is a project in the pre-study phase where
cycle time detection will be developed. This will
be in conjunction with the OptiMine product
which provides a means for operator efficiency
monitoring.
MTBF is an area which we focus on as a continuous
improvement process and require field feedback.
As an example, the new range of LHDs have
areas of significantly improved MTBF due to
the improvement in the electrical systems and
components. Refer to appendix; Reliable Electrics.
Conceptual studies have been performed. A
development project is estimated to begin at the
end of 2011.

Loaders
Maintenance
Forum Points

Workshop
Rating

Machine jacking stands

16

Components
1. Match component life
2. Commonality of oils
3. Less electrical connections
4. Oil evacuation & fill points
centralised
5. Live oil sampling from OEM from
one point
6. CAT style bucket pins
7. On-board kidney looping
8. Quality & reliability

14

Sandvik Mining and Construction

Sandvik Responses
This item will be reviewed in conjunction with the
LHD jacking systems as part of the operational
review. Current restraints exist in the envelope size
of the LHD.
(1) Sandvik see matched component life as a
continuous improvement issue and will also be
further developed and enhanced in the new LHD
types which take into account various influences.
The current range of LHDs are utilizing drive train
components from Kessler, Volvo and Cummins
along with our current offering of Detroit and
DANA.
(2) This very much depends on the component
suppliers oil requirements. However, this will be
investigated together with suppliers to minimize the
number of oils required on the mine site.
(3) Recognised and completed in the LH series. The
LHD series has over 200 less electrical terminations
by using the CanBus open system.
(4) Very challenging with present LHDs as we have
achieved what we can with Wiggins connections
for filling and draining of the engine, transmission
and hydraulic oil. Further work and potential
improvements will be included in the new model
LHDs. Refer to appendix; Wiggins Hydraulic Oil
Fill
(5) Sandvik are currently working with the OEM
suppliers as to the correct placement of live
oil sampling points that do not interfere with
lubrication circuits. Kidney looping is also being
considered. Again this is very challenging with
present LHDs, but will be included in requirement
specification for new LHDs.
(6) New style floating pins with coated bushing
have been implemented to make the pins easier to
remove.
(7) Currently under investigation.
(8) Sandvik are constantly looking for the most
suitable products that not only offer longer service
life but are reusable/recyclable and environmentally
friendly as key considerations. We see the use of
fixed steel piping, as an example, becoming more
common in Sandvik loaders and trucks. Ongoing
dialogue with our users and their feedback
continues to assist in these areas.

Loaders
Maintenance (cont.)
Forum Points

Workshop
Rating

Diagnostic tools (onboard & offboard)

1. Easy to understand
2. Easy to use
3. Access online to latest service
bulletins model specific (to deal with
fitter turnover)

12

Working at heights issues/access

1. Hand rails (self raising)
2. Equipment design (remove need to
get up on machine)
3. Greasing

Parts ordering
1. Verification of the correct part
2. Stock management
3. Programmed parts supply
(maintenance schedule)

Sandvik Mining and Construction

Sandvik Responses
(1) The VCM controller allows maintenance
personnel to diagnose and action repairs to their
machine in the comfort of the cabin. Refer to
appendix; Vehicle Control & Management.
(2) The use of colour coded symbols and warning
functions on the VCM screen allows the operator
or maintainer to analyse problems quickly and safely.
(3) We are presently looking to develop a central
web portal for customers to have access to full
manuals.
(1) Hydraulically aided hand rail system are
presently under design.
(2) Ground level daily maintenance functionality has
been implemented with further improvements are
on going.
(3) Autolube is an option that is in our current
offering. Refer to appendix; Automatic Central
Lube System
(1) Sandvik has identified this as a key concern and
is currently finalising a new global parts library to
address this issue. The global library removes the
duplication of part numbers, and will alleviate and
future confusion in parts ordering. The system will
also include a process to verify that parts ordered
actually meet customers requirements.
(2) Sandvik Supply has an on going project based
around customer-focused distribution. We expect
to see results in the near term.
(3) By combining the improved life cycle costing
information and the focus on the maintenance
strategies (which are highly dependant on individual
operating conditions) programmed parts supply can
be improved. Our customer services are actively
working on both.

Appendix
Prevent Tyre Failures with
TPMS (Tyre Pressure Monitoring System)
This system informs the operator
with warnings and alarms of air
leakage, incorrect pressure or
over temperature. This system
can prevent tyre failures, when
corrective actions are done on time.
Save time in daily maintenance
as the operator can see the tyre
pressures from the cabin display.

Warnings and alarms

Tyre leak detected

Extreme over pressure (38% over)
Over pressure (28% over)
Under pressure (12,5 % under)
Extreme under pressure (25% under)
Over temperature (85OC)
Low battery in sensor

Features

TPMS is an option for all Sandvik LHDs with colour display and trucks with a display.
TPMS is fully integrated into Sandvik control system.
It includes four pressure sensors integrated into tyre vent caps, wiring adapter and radio receiver.
Sensors and their positions (FL, FR, RL, RR) are taught one by one to the system during the first
time installation. Follow instructions on the display.
If a sensor is broken, follow the display
instructions on how to change it to a new one.
Sensor includes battery. Replace the sensor,
when you receive low battery warning.
All TPMS sensors are similar and have the same
part number.

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Sandvik Mining and Construction

Monitoring
Camera System

Monitoring Camera System

2 cameras one facing in each direction
2 monitors ergonomically positioned in the cab
Improves visibility by reducing blind spots

Available on LH209L->LH621

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Ride Control System

for Boom
Makes ride smoother
Two accumulators are used to empty and load the lift cylinders on LHDs
Accumulators provide pressure to boom cylinders and lift boom up slightly
from the stoppers
Allows boom to move according to the road conditions
Avoids shock to the frame

* Options vary according to machine type please see the availability from
the specifications or the price list

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Sandvik Mining and Construction

Reliable Electrics
Industrially fabricated wiring harnesses
High industrial level quality
Reliability
Fast and easy repair

Enhanced solutions

Stainless steel junction boxes

Accurate and robust temperature and pressure sensors

All information on one 5.7 LCD display

No analogue gauges needed

Less components -> Less spare parts
Integrated warnings and alarms
Built-in tools for diagnostics

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Wiggins Fill Set

Hydraulic, transmission and engine oil

Reduces fill time by 2/3rds.

Safe and fast oil filling from ground level.
Reduces spillage because the nozzle automatically shuts off when the tank is full.
The nosepiece of the refuelling device also has to be Wiggins type (not supplied).

* Options vary according to machine type please see the availability from the specifications or the
price list

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Sandvik Mining and Construction

Vehicle Control & Management

VCM System
LHD Features - Electrics / VCM System

Features
All information on one 5.7 LCD display,
Excellent new diagnostics, built-in tools for troubleshooting
Same user interface with all Sandvik LH-series machines
Less components = Less spare parts
Compatible with AutoMine, Can-open RRC, Monitoring
Benefits
Less machine stopping failures
Easy operation & maintenance
Fast & easy troubleshooting
High level of operator comfort
No analogue gauges needed

LHD Features - Easy Troubleshooting

Interlocks

Function chain

2,50

Troubleshooting without electrical schematics and

multimeter
Hydraulic and electrical faults quickly isolated
Entire function chain in one window
No special tools needed
Warnings and alarms for:
Engine alarms from Engine Control Module (ECM)
Temperatures and pressures
Oil levels
Central lubrication failures

VCM system component failures

Connection failures
Sensor failures
Filter blocking

Warning pop up at 105

All stored in log file

Browsing on display
Downloading with standard laptop

Alarm pop up at 110

VCM module
CAN bus
J1939

Display
Front

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Rear
Dashboard
Chair
Middle

Sandvik Mining and Construction

ECM

Automatic Central
Lubrication System
Automatic central lubrication system carries out the required lubrication work
automatically throughout the shift.
The hydraulically driven pump feeds lubricant to grease loader units through
two main grease channels .
Adjustable lubrication for each point ensures sufficient lubrication for current
application.

* Options vary according to machine type please see the availability from the
specifications or the price list
Example of lubrication points in TORO 0010 (total 28 points):
Oscillation

2 pcs
Drive shaft

1 pcs
Steering cylinders 4 pcs
Middle hinges
2pcs
Boom

8 pcs
Lift cylinder

4 pcs
Tilt cylinder

2 pcs
Swing lever

2 pcs
Support axle

2 pcs
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Sandvik Mining and Construction