Rad 04264

EJC 116E
FOR SERIAL NUMBER: 116-3757 REVISION 02
OPERATOR'S
MANUAL
Operator’s Manual - English
© 2004 EJC Mining Equipment Inc.
Technical Publications Department
4445 Fairview Street
Burlington, Ontario
Canada L7L 2A4
Tel: (905) 632-4940
Fax: (905) 632-2172
E-mail: tech.pubs@sandvik.com
Table of Contents
Introduction .............................................................................1-1
Intended Use of Operator’s Manual ........................................................................... 1-1
Intended Use of Machine ........................................................................................... 1-1
Machine Identification ................................................................................................ 1-2
Safety Notations in Operator’s Manual ...................................................................... 1-2
Loader Components .................................................................................................. 1-3
Loader Orientation ..................................................................................................... 1-4
General Safety Procedures ....................................................2-1
Important .................................................................................................................... 2-1
Typical Work Cycle .................................................................................................... 2-1
Correct Operation ...................................................................................................... 2-2
Incorrect Operation .................................................................................................... 2-3
Fire Prevention .......................................................................................................... 2-4
Optional Fire Extinguisher ......................................................................................... 2-4
Optional Fire Suppression System ............................................................................ 2-4
Optional ROPS/FOPS Canopy .................................................................................. 2-5
Back-Up Alarm ........................................................................................................... 2-5
Controls ....................................................................................3-1
Important .................................................................................................................... 3-1
Steer Control Lever.................................................................................................... 3-2
Operator’s Seat ......................................................................................................... 3-4
Accelerator Pedal ...................................................................................................... 3-6
Service Brakes Pedal ................................................................................................ 3-6
Boom/Bucket Control Lever....................................................................................... 3-6
Transmission Control Levers ..................................................................................... 3-8
Master Disconnect Switch ....................................................................................... 3-10
Instruments ..............................................................................4-1
Tow Switch................................................................................................................. 4-2
Motor Run Light ......................................................................................................... 4-2
Motor 150% Load Light.............................................................................................. 4-2
Motor Overloaded Light ............................................................................................. 4-2
Converter Oil Pressure Gauge .................................................................................. 4-4
Converter Oil Temperature Gauge............................................................................. 4-4
Voltmeter.................................................................................................................... 4-6
Brake Impending Light............................................................................................... 4-6
Front Lights Switch .................................................................................................... 4-6
Rear Lights Switch..................................................................................................... 4-6
Audible Alarm ............................................................................................................ 4-8
Horn Button................................................................................................................ 4-8
Motor Fault Light/Button ............................................................................................ 4-8
Cable Reel Limit Override Button ............................................................................ 4-10
Cable Reel Empty Light ........................................................................................... 4-10
Cable Reel Limit Light.............................................................................................. 4-10
Circuit Breaker Lights .............................................................................................. 4-12
Hourmeter................................................................................................................ 4-12
Brake Fault Light/Button .......................................................................................... 4-14
Park/Emergency Brake Light/Button........................................................................ 4-16
I
Table of Contents
Ignition Switch.......................................................................................................... 4-16

Starting the Motor ...................................................................5-1
Installing a New Machine ........................................................................................... 5-1
Starting the Electric Motor .......................................................................................... 5-2
Stopping the Motor .................................................................6-1
Brake Tests ..............................................................................7-1
Service Brakes Test ................................................................................................... 7-1
Park Brake Test ......................................................................................................... 7-2
Operating the Bucket/Dump Box ...........................................8-1
Important .................................................................................................................... 8-1
Boom/Bucket Control Lever ....................................................................................... 8-1
Work Cycle ...............................................................................9-1
Tramming ................................................................................................................... 9-1
Braking ....................................................................................................................... 9-2
Loading ...................................................................................................................... 9-3
Dumping .................................................................................................................... 9-3
Parking ....................................................................................................................... 9-4
Tramming the Machine .........................................................10-1
Important .................................................................................................................. 10-1
Tramming the Machine ............................................................................................ 10-2
Operating Hints .....................................................................11-1
Maintenance and Check Points ...........................................12-1
Introduction .............................................................................................................. 12-1
Engine Off ................................................................................................................ 12-1
Motor On .................................................................................................................. 12-6
Greasing the Machine ...........................................................13-1
Automatic Lubrication System ................................................................................. 13-1
Manual Lubrication .................................................................................................. 13-3
Troubleshooting ....................................................................14-1
Important .................................................................................................................. 14-1
Motor Will Not Start.................................................................................................. 14-1
Motor Overheats ...................................................................................................... 14-2
Motor Overloaded .................................................................................................... 14-2
Voltage Drop ............................................................................................................ 14-2
Cable Reel Inoperable ............................................................................................. 14-3
Control Box Circuit Breaker Tripped ........................................................................ 14-3
Hydraulic Oil Foams ................................................................................................ 14-3
Torque Converter/Transmission Overheats ............................................................. 14-3
Machine Will Not Move ............................................................................................ 14-4
Machine Will Not Turn.............................................................................................. 14-4
Little or No Bucket Action ........................................................................................ 14-4
Defective Lighting System ....................................................................................... 14-4
II
Introduction
Intended Use of Operator’s Manual

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

1. EJC loaders are designed to load, haul, and dump rock material exclusively. EJC trucks are
designed to transport and dump rock material exclusively. Intended use also includes
following all operating, inspection, and maintenance instructions in this manual.
2. This machine shall only be used:
• for its intended use
• when it is in proper technical condition
• by an operator aware of safe operating procedures and possible danger
• in strict notice and use of the operator’s manual.
3. Unintended and careless use of this machine may adversely affect the health of the operator
or third persons, or prejudice the machine and other properties. The operator must exercise
care and common sense when operating this machine.
4. Always obey local safety rules related to accident prevention and environmental protection.
S01001/07/00-A 1-1
Introduction
Machine Identification
Each machine is identified by model number and serial number. The machine model and serial
number are displayed on the name plate, and on the front cover of all manuals.
The name plate is located in the operator’s compartment.
Figure 1: Name Plate
Safety Notations in Operator’s Manual

1. Throughout the Operator's Manual, the following safety notations appear. Follow these
notations, and local government regulations at all times.
2. NOTES will always appear in italics.
NOTE: Indicates a procedure or condition that is essential for the operator to know.
3. CAUTIONS will always appear in bold italics.
CAUTION: Indicates an action or condition that, if not followed, could cause damage to the
machine or other equipment.
4. WARNINGS will always appear in bold preceded by a warning triangle. This symbol, with
a warning statement, means “Warning, be alert! Your safety is involved!” Carefully read the
message that follows.
This indicates an action or procedure that, if not followed, could cause personal injury
or death.
S01001/07/00-A 1-2
Introduction
Loader Components
4 5 3 1
8 9 2
6 7
Figure 2: Loader Components (Side View)
No. Item Purpose
1. Bucket Loads, contains, and dumps broken rock.

2. Lift Arms Raise and lower the bucket.
3. Front Frame Supports the bucket, lift arms, and components
required to run the machine.
4. Rear Frame Supports engine, transmission, and other components
required to run the machine.
5. Center Hinge Connects the front and rear frames. The front and rear
frames pivot around the center hinge to steer the
machine right and left.
6. Outrigger Contains engine components. The outrigger is also
known as skirt.
7. Tires Tires carry the weight of the machine and its load.
8. Operator’s Compartment The operator sits in the operator’s compartment to
(standard location) control the machine.
9. Operator’s Compartment
(EJC 115 LP location)
S01001/07/00-A 1-3
Introduction
Loader Orientation
1. The front end of the loader is the bucket end.
2. The rear end of the loader is the engine end.
3. Left and right of the machine are referred to by standing at the rear of the machine and
looking towards the bucket.
4. The operator’s compartment where the operator sits, is on the left side of the machine.
LEFT
REAR FRONT
RIGHT
Figure 3: Loader Orientation
S01001/07/00-A 1-4
General Safety Procedures
Important
This section contains safety procedures which apply to all trucks and loaders.
! WARNING!
Each machine is custom built. Read entire manual for safety instructions specific to the
individual machine.
! WARNING!
Only trained authorized personnel shall operate this machine.

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

1. Inspect the machine and perform any required maintenance the operator is authorized to do
while the engine is off.
2. Start the engine.
3. Inspect the machine and perform any required maintenance the operator is authorized to do
while the engine is on.
4. Raise and lower the main implement.
5. Test the park and service brakes according to the brake test procedures in this manual.
6. If the machine is functioning normally, begin operating the machine.
7. If the machine is not functioning normally, shut it down and report the faults immediately.
8. Do not operate the machine again until the faults have been corrected.
S02001/11/03 2-1
Correct Operation
1. ALWAYS keep all decals on the machine in legible condition. Observe and follow them at
all times.
2. ALWAYS make sure that all gauges, the horn, and indicator lights function properly.
3. ALWAYS report any damage or faulty operation immediately. DO NOT operate the
machine until the faults are corrected.
4. ALWAYS tag the steer control lever to alert other personnel when any machine component
has been disconnected.
5. ALWAYS disconnect the frame lock in the center hinge area before operating the machine.
6. ALWAYS be seated and wear the seat belt (if fitted) when operating the machine.
7. ALWAYS make sure that the transmission is in neutral before starting the engine. During
idle periods, shift the transmission to neutral and apply the park brake.
8. ALWAYS sound the horn for a few seconds before starting the engine/motor to alert other
personnel in the area. Sound the horn frequently during the shift if visibility is reduced.
9. ALWAYS start the engine while sitting in the operator’s seat.
10. ALWAYS test all brakes before starting the shift, and before operating the machine on
grades.
11. ALWAYS keep hands, arms, head, etc. inside the operator's compartment.
12. ALWAYS drive carefully, observe traffic rules and be in full control of the machine.
13. ALWAYS use extreme caution when moving the machine with the main implement (bucket
or dump box) raised. Whenever possible, lower the main implement to the “carry” position
before driving.
14. ALWAYS park on level ground, if possible.
15. ALWAYS turn the machine into a side wall, or block all wheels on both sides of each wheel
if parking on a grade.
16. Except in case of emergency, ALWAYS shut off the engine before turning the master
disconnect switch to the “OFF” position.
17. ALWAYS turn the master disconnect switch to the “OFF” position before working on or
around electrical connections.
18. ALWAYS install the frame lock before working in the centre hinge area or transporting the
machine.
19. ALWAYS stop the engine before filling the fuel tank!
20. ALWAYS refill the fuel tank at the end of each operating period to prevent condensation
from contaminating the fuel.
21. ALWAYS maintain three points of contact when climbing on the machine. For example, one
hand and both feet, or both hands and one foot.
S02001/11/03 2-2
Incorrect Operation
1. NEVER use the machine for anything other than its intended purpose. EJC trucks are
designed to transport and dump rock material exclusively. EJC loaders are designed to load,
haul and dump rock material exclusively.
2. NEVER use the steer control lever as a hand hold when mounting or dismounting the
machine. The machine may turn even when the engine/motor is stopped.
3. NEVER operate the machine unless all required preventive maintenance has been
performed.
4. NEVER operate the machine unless all electrical boxes are closed tight.
5. NEVER start the machine unless:
• area near the machine is clear
• all covers are installed
• park brake is applied
• transmission control lever is in the NEUTRAL position.
6. NEVER attempt to start the machine by towing.
7. NEVER allow riders in the operator's compartment, in the main implement (bucket or dump
box), or on any other part of the machine.
8. NEVER raise the dump box on a dump truck, if the dump truck is on a slope and the dump
truck is turned.
9. NEVER allow the machine to roll backward with the transmission in forward while working
on steep grades.
10. NEVER drive near or beside a walking person.
11. NEVER leave the machine unattended unless:
• main implement (bucket or dump box) is fully lowered
• transmission control lever is in the NEUTRAL position
• park brake is applied
• engine/motor is switched off and has stopped.
12. NEVER service or adjust the machine when it is in motion. NEVER service or adjust
hydraulic components under pressure.
13. NEVER stand or allow other personnel to stand in the centre articulation area unless the
frame lock is installed and the steer pressure has been bled off to zero.
14. NEVER service electrical parts on an electric-powered machine, unless the trailing cable
has been disconnected. It must not be connected again unless all parts are properly
connected. Use only EJC service parts to ensure that they are identical to parts originally
fitted.
S02001/11/03 2-3
Fire Prevention
1. Keep the machine clean.
2. Keep all electrical wiring and components in good working order.
3. Ensure that the engine air intake, fuel and exhaust systems in diesel machines are
maintained properly.
4. Keep fire fighting equipment in working order. Know where it is located, and how to use it.
This may require training beyond the scope of this manual.
Optional Fire Extinguisher

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

The optional fire suppression system is activated by two large red buttons. One button is located
in the operator’s compartment. The other button is located on the frame of the machine. Each
button is fitted with a safety lockout ring to prevent accidental activation of the fire suppression
system.
In case of fire, do the following.
1. Stop the machine and shut the engine off.
2. Grasp the ring pull and pull it hard away from the button. This removes the safety lockout
device.
3. Strike the top of the red button, hard. This causes fire suppressing chemicals to be expelled
into various areas of the machine to suppress the fire.
S02001/11/03 2-4
! WARNING!
The fire suppression system is designed to suppress fires in their early stages. Do not
hesitate-if you detect a fire on the machine, activate the fire suppression system
immediately. The earlier you do this, the more effective the system will be.
4. Move to a safe distance away from the fire. Report the fire immediately.
5. The machine must be cleaned and serviced by trained authorized personnel before it is put to
work again.
Optional ROPS/FOPS Canopy
Description
Roll Over Protective Structures (ROPS) are overhead structures designed to reduce the possibility
of operators from being crushed if the machine they are operating should roll over.
Fall Over Protective Structures (FOPS) are overhead structures that protect operators from falling
objects such as loose rock.
! WARNING!
Always wear seat belt.

Certification
Each new ROPS/FOPS has a certification plate that lists the standards to which it was certified.
The certification plate should be displayed on the ROPS/FOPS at all times.
NOTE: Replace the certification plate as soon as possible if it is missing or illegible. Contact the
original equipment manufacturer if a replacement is required.
! WARNING!
Welding, drilling, cutting, or any addition of attachments, including fire extinguisher

brackets, voids certification. To assure the safety of the operator, the ROPS/FOPS must be
replaced if it has been damaged or altered in any way.
Back-Up Alarm
If the machine is equipped with an optional back-up alarm, an audible alarm sounds when the
transmission is engaged in reverse direction.
S02001/11/03 2-5
Notes
S02001/11/03 2-6
Controls
Important
This section contains a description, location and function of the various controls used to operate
the machine. The operator must know the location and function of all of them.
NOTE: The numbers on the illustration refer specifically to the item described in each paragraph.
1 5
6
2
1. Steer Control Lever 5. Boom/Bucket Control Lever

2. Operator’s Seat 6. Transmission Control Levers
3. Accelerator Pedal 7. Master Disconnect Switch
4. Service Brakes Pedal
Figure 1: Operator’s Compartment
S03076/11/04 3-1
Controls
1. Steer Control Lever

The steer control lever operates a valve which directs hydraulic oil to the steer cylinder. As the
cylinder extends or retracts, the machine articulates either to the left or to the right around the
center pivot.
1. To steer the machine, move the lever in the direction you want the machine to turn.
2. To turn the machine right while the machine is moving forward, push the steer control lever
away from you.
3. To turn the machine left, pull the steer control lever toward you.
S03076/11/04 2
Controls
1 5
6
2

S03076/11/04 3
Controls
2. Operator’s Seat
The operator’s seat is adjustable for comfort.
1. To adjust lower back support, turn dial (1) to desired position.
2. To adjust suspension, turn dial (2) until operator’s approximate weight appears in red zone.
3. To adjust position of back rest, pull up lever (3).
4. To slide entire seat backwards or forwards, pull up and hold lever (4), then slide seat to
desired position.
5. Lower arm rests (if fitted) until they are horizontal. To tilt the arm rests up, turn knob
underneath the arm rest towards you. To tilt arm rest down, turn the knob away from you.
6. When entire seat is in desired position, fasten seat belt. Adjust length through plastic slide so
that it fits low and snug across lap.
NOTE: Seat belt is available only on machines equipped with ROPS or FOPS canopy.
! WARNING!
Always wear seat belt while operating machine equipped with optional ROPS or FOPS
canopy.
Figure 3 : Operator’s Seat - ISRI 6000 Model
S03076/11/04 4
Controls
1 5
6
2

S03076/11/04 5
Controls
3. Accelerator Pedal
This is the right pedal on the floor of the operator’s compartment.
1. To increase the speed of the engine, press the pedal.
2. To decrease the speed of the engine, release the pedal.

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

Moving the boom/bucket control lever causes the lift cylinders or the dump cylinders to extend or
retract. The lever moves in four directions as seen from the operator’s seat: right, left, forward and
backward.
1. To raise the lift arms, move the lever to the right.
2. To lower the lift arms, move the lever to the left.
3. To dump (tip) the bucket, move the lever forward, away from the operator’s seat.
4. To roll back the bucket, move the lever backward, toward the operator’s seat.
Figure 5 : Boom/Bucket Control Lever
S03076/11/04 6
Controls
1 5
6
2

S03076/11/04 7
Controls
6. Transmission Control Levers
1. Direction Control Lever

2. Gear Selection Lever
Figure 7 : Transmission Control Levers
Direction Control Lever

The right lever is the direction control lever, and has three positions: forward (F), neutral (N), and
reverse (R).
1. To select forward direction, move the direction control lever to the “F” position.
2. To select reverse direction, move the direction control lever to the “R” position.
3. To select neutral, move the direction control lever to the “N” position.
CAUTION: Stop the machine before changing direction.
! WARNING!
Although the machine is fitted with a safety device to prevent start up of the engine while
forward or reverse direction is selected, always physically check that the direction control
lever is in the neutral (N) position before starting the engine.
Gear Selection Lever
The left lever is the gear selection lever and will have one to four positions: first gear (1) at the
bottom, then up to second gear (2), then up to third gear (3), and fourth gear (4) at the top of the
gate.
NOTE: Fourth gear (4) is locked out at the transmission at the customer’s request.
S03076/11/04 8
Controls
1 5
6
2

S03076/11/04 9
Controls
7. Master Disconnect Switch

The master disconnect switch has two positions: “ON” and “OFF”.
1. To operate the machine, first turn the master disconnect switch to the “ON” position.
NOTE: Turn the engine off before turning the master disconnect switch to the “OFF” position.
2. Turn the master disconnect switch to the “OFF” position before leaving the machine
unattended or performing electrical repairs.
Figure 9 : Master Disconnect Switch
S03076/11/04 10
Instruments
This section contains a description of the various controls and instruments on the instrument panel
that are used to operate the machine. The operator must know the the function of each in order to
operate the machine safely.
NOTE: The numbers on the illustration refer specifically to the item described in each paragraph.
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
13 12
000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21
1. Tow Switch 12. Horn Button

2. Motor Normal Light 13. Motor Fault Light
3. Motor 150% Load Light 14. Cable Reel Limit Override Button
4. Motor Overloaded Light 15. Cable Reel Empty Light
5. Converter Oil Pressure Gauge 16. Cable Reel Limit Light
6. Converter Oil Temperature Gauge 17. Circuit Breakers
7. Voltmeter 18. Hourmeter
8. Brake Impending Light 19. Brake Fault Light/Button
9. Front Lights Switch 20. Park/Emergency Brake Light/Button
10. Rear Lights Switch 21. Ignition Switch
11. Audible Alarm
Figure 1: Instrument Panel
S04096/11/04 4-1
Instruments
1. Tow Switch
The tow switch is used by authorised service personnel during the tow procedure to energize the
front and rear brake solenoid valves. Refer to the tow procedure in the Service Manual for more
information.
2. Motor Run Light

The motor run light indicates that the motor is on and working normally.
3. Motor 150% Load Light

This light indicates that the motor is working between 100% and 150 % of its maximum load.
Horsepower will be limited if this light illuminates during operation.
CAUTION: If this light illuminates during normal operation, bring the machine to a controlled stop
and contact service personnel. Do not operate the machine until correction action has
been taken.
4. Motor Overloaded Light

This light indicates that the motor is overloaded. If the motor overheats or if a phase reversal in
the supply voltage to the motor occurs, the motor overload light will illuminate, the motor will
shut down, and the park/emergency brake will apply automatically. Approximately 32 seconds
after the light comes on, an alarm will sound. To silence the alarm, press the motor fault button.
CAUTION: Never press and hold the button to silence the alarm unless corrective action is being
taken.
CAUTION: Contact service personnel immediatley if this light illuminates during operation. Do not
operate the machine until corrective action has been taken.
! WARNING!
Be prepared for a sudden stop.
S04096/11/04 4-2
Instruments
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
12
13 000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21

11. Audible Alarm
S04096/11/04 4-3
Instruments
5. Converter Oil Pressure Gauge

The converter oil pressure gauge indicates the clutch pressure in the transmission. Normal
operating pressure is between 240 and 280 PSI (16.5 and 19 Bar).
CAUTION: If converter oil pressure falls below 100 PSI (7 Bar), shut down the engine immediately
to prevent internal damage. Do not operate the machine again until corrective action
has been taken.
! WARNING!
Brakes will apply automatically if clutch pressure drops below 60 PSI (4 Bar). Be prepared
for a sudden stop. Observe the instrument panel frequently.
6. Converter Oil Temperature Gauge

The converter oil temperature gauge indicates the temperature of the oil in the torque converter
and transmission.
NOTE: Normal temperature range is from 180° F (82.2° C) to 200° F (93.3° C). This may be
represented as a green zone on the gauge dial. Unsafe temperature range is from 225° F
(107.2° C) to 250° F (121.1° C). This may be represented by a red zone on the gauge dial.
If the converter oil temperature rises above 225° F (107.2° C), do the following.
1. Bring the machine to a controlled stop, then apply park brake.
2. Put the transmission in neutral and rev the engine to approximately half throttle (1000
RPM).
3. Observe the converter oil temperature gauge.
CAUTION: Shut down the engine if the temperature does not begin to fall within two minutes.
Corrective action must be taken.
4. Run the engine at half throttle until the gauge needle has fallen well into the green zone, or
the normal operating range of 180° F (82.2° C) to 200° F (93.3° C).
NOTE: An overheating torque converter can be caused by poor maintenance, such as a dirty
cooler, low oil level, or by poor operating habits, such as using too high or too low a gear
during loading or tramming. Ensure the fault is not poor operating habits.
S04096/11/04 4-4
Instruments
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
12
13 000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21

11. Audible Alarm
S04096/11/04 4-5
Instruments
7. Voltmeter
The voltmeter indicates the system voltage when the electrical system is switched on. The normal
operating range (green zone) is between 26 V and 30 V.
CAUTION: Do not operate the machine if the indicator is in the red zone while the motor is running.
Contact service personnel immediatley. Do not operate the machine until corrective
action is taken.
8. Brake Impending Light

When illuminated, this light indicates that the brakes are about to apply automatically. The
following conditions will cause the impending auto brake light to illuminate:
• brake accumulator pressure drops to 1600 PSI (110 Bar);
• engine oil pressure drops to 12 PSI (0.8 Bar);
• converter accumulator pressure drops to 150 PSI (10 Bar).
NOTE: The brake impending light will remain illuminated while pressures are low.
! WARNING!
If the brake impending light illuminates during operation, be prepared for a sudden stop.
Observe the instrument panel frequently.
9. Front Lights Switch

This switch controls the front lights.
1. To turn the front lights on, turn the switch to the centre position.
2. To have the front lights illuminate automatically when the transmission shifter is put into
forward gear, turn the switch to the far right (clockwise).
3. To turn the front lights off, turn the switch to the far left (counter-clockwise).
10. Rear Lights Switch

This switch controls the rear lights.
1. To turn the rear lights on, turn the switch to the centre position.
2. To have the rear lights illuminate automatically when the transmission shifter is put into
forward gear, turn the switch to the far right (clockwise).
3. To turn the rear lights off, turn the switch to the far left (counter-clockwise).
S04096/11/04 4-6
Instruments
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
12
13 000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21

11. Audible Alarm
S04096/11/04 4-7
Instruments
11. Audible Alarm

The audible alarm sounds if accumulator pressure falls below 1600 PSI (110 Bar) or if there is a
fault in the motor.
To acknowledge the warning and stop the alarm from sounding:
• Press the brake fault light/button if the brake impending light is illuminated.
• Press the motor fault light/button if the motor fault light is illuminated.
After a delay of 32 seconds, the alarm will sound again if the fault has not been corrected.
CAUTION: If the audible alarm sounds, bring the machine to a controlled stop and shut down the
machine immediately.
CAUTION: Silence the alarm only if corrective action is being taken.
12. Horn Button

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

This light will illuminate if the motor overheats or if a phase reversal in the supply voltage to the
motor occurs. At the same time, the motor will shut down automatically and the park/emergency
brake will apply. Approximately 32 seconds after the light illuminates, the audible alarm will
sound.
Press and hold the button to silence the alarm.
CAUTION: Never press and hold the button to silence the alarm unless corrective action is being
taken.
! WARNING!
S04096/11/04 4-8
Instruments
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
12
13 000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21

11. Audible Alarm
S04096/11/04 4-9
Instruments
14. Cable Reel Limit Override Button

The cable reel is equipped with a limit switch that will automatically stop the machine when only
approximately nine wraps of cable remain on the cable reel.
If this occurs during normal operation and it is necessary to start the motor again, do the
following:
! WARNING!
Do not press the cable reel limit override button to increase tramming distance. This may
cause the cable to separate from the machine, resulting in possible electrical shock to the
operator and/or personnel in the area.
1. Press in and hold the cable reel override button.
2. Press in the park/emergency light.button, then pull it all the way out.
3. Restart the motor.
15. Cable Reel Empty Light

The cable reel empty light indicates that only nine wraps of cable remain on the cable reel. If this
light illuminates during operation, the motor will automatically shut down and the park/
emergency brake will apply.
! WARNING!

NOTE: If the machine shuts down as the result of too few cable wraps, it will be necessary to
override the cable limit switch to the start the machine again. Refer to the Cable Reel
Limit Override Button description for more information.
16. Cable Reel Limit Light

The cable reel limit light indicates that only 14 wraps (approximately 70 feet) of cable remain on
the cable reel.
CAUTION: If this light illuminates during operation, stop the machine and put more cable on the
cable reel.
S04096/11/04 4-10
Instruments
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
12
13 000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21

11. Audible Alarm
S04096/11/04 4-11
Instruments
17. Circuit Breaker Lights

All circuit breaker lights installed on the machine are labelled on the instrument panel and
correspond to circuit breakers installed inside the instrument panel.
Circuit Rated
Description
Breaker Label Amperage (A)
1 5 This light is for the Lube circuit breaker, which controls power to the
optional automatic lubrication system.
2 5 This light is for the Start circuit breaker, which controls power to the
motor.
3 10 This light is for the Monitor circuit breaker, which controls power to
the gauges and the motor fault/light button.
4 10 This light is for the Brake circuit breaker, which controls power to the
park, front, and rear brake solenoids.
5 10 This light is for the Transmission circuit breaker, which controls power
to the transmission solenoids.
6&7 15 These lights are for the Front Lights circuit breakers, which control
power to the front lights.
8&9 15 These lights are for the Rear Lights circuit breakers, which control
power to the rear lights.
NOTE: The “LUBE OPTION” circuit is optional and may not be installed on this machine.
CAUTION: If a circuit breaker light illuminates, immediately bring the machine to a controlled stop
and shut down the engine. The circuit breaker must be reset from inside the instrument
panel. Only authorised personnel shall reset a circuit breaker. Do not reset a circuit
breaker unless the fault which caused it to trip has been corrected.
18. Hourmeter
The hourmeter registers the total running hours of the machine.
CAUTION: If the hourmeter stops working, inform service personnel immediately.
S04096/11/04 4-12
Instruments
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
12
13 000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21

11. Audible Alarm
S04096/11/04 4-13
Instruments
19. Brake Fault Light/Button

The red brake fault light/button indicates a fault in the brake hydraulic circuit and provides a
means to silence the audible alarm while troubleshooting is being performed.
CAUTION: If this light illuminates, bring the machine to a controlled stop immediately. Do not
operate the machine until the cause of the warning has been determined and corrective
action is being taken.
An alarm will sound shortly after the light illuminates. The alarm will continue to sound until the
fault is corrected or acknowledged.
To acknowledge the fault and silence the alarm, press the light/button in. If the condition that
caused the alarm still exists, the light will remain on and the alarm will sound again.
! WARNING!
The brakes will apply automatically if the brake system accumulator pressure falls below
1400 PSI (97 Bar) or if converter oil pressure drops below 60 PSI (4 Bar) - be prepared for a
sudden stop!
S04096/11/04 4-14
Instruments
1 2 3 4 5 6 7 8 9 10
100
200
300
100
200
40
80
F
120
C
260
160
325
22
26
30
A A 11
0 PSI 400 OIL 18
34
TEMP
DRIVE VOLTS
OIL
12
13 000000
HOURMETER
OVERRIDE
STOP
14 15 16 17 18 19 20 21

11. Audible Alarm
S04096/11/04 4-15
Instruments
20. Park/Emergency Brake Light/Button

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

(MOMENTARY)
Figure 9 : Three Position Park/Emergency Brake Button
! WARNING!
The fact that the light is on is not proof that the park brake is functioning effectively. Test
the park brake at the beginning and end of each operation period, before operating on an
incline, and before leaving the machine unattended. See the park brake test procedure in
the Brake Test chapter for more information.
21. Ignition Switch

This rotary switch has three positions: “ON”, “OFF” and “START”. Turned fully counter-
clockwise to the left is the “OFF” position.
1. Turn the switch one position clockwise to switch the electrical system on.
2. Turn and hold the switch to the extreme clockwise position to start the engine/motor.
! WARNING!
Never leave the machine (except in case of emergency) unless the ignition switch is turned to
the “OFF” position, as the steering pressure will not bleed off until the switch is off.
S04096/11/04 4-16
Starting the Motor
Installing a New Machine
! WARNING!
High voltage. Only trained and authorized personnel shall service the electrical system and
electrical components.
! WARNING!
It is vitally important to provide correct voltage and to maintain it at all times.
! WARNING!
The machine must be grounded through the ground wires contained in the trailing cable.
This ensures the safety of the operator and those who come into contact with the machine.
CAUTION: Do not connect machine to the power source until the available voltage and frequency
have been checked against the nameplate rating of the electric motor. The power
source must be of sufficient capacity to provide energy for the various loads on the
line.
CAUTION: Make sure external power leads L1, L2, and L3 are in the correct sequence with the
terminals in the motor protection box. Looking at the motor’s fan, the motor rotation
should be clockwise. Have an assistant observe the rotation when turning the ignition
switch. If the rotation is counter-clockwise, turn power off and have an electrician
correct the rotation.
S05003/07/01 5-1
Starting the Motor
1 2 3 4
6 7
Figure 1: Typical Installation

1. Electric LHD
2. Trailing Cable
3. Fuse or Circuit Breaker
4. Disconnect Switch
5. From Power Source
6. Transformer
7. Feeder Line
Starting the Electric Motor
! WARNING!
Never attempt to start the motor without first knowing how to shut it off.
! WARNING!
The cable reel will take up any slack in the cable when the electric motor starts.
! WARNING!
The cable reel will take up any slack in the cable when the electric motor starts.
S05003/07/01 5-2
Starting the Motor
1. Make sure that the frame lock is in the storage position.

2. Turn the master disconnect switch to the “ON” position.
3. Sit in the operator’s seat. Adjust seat to a safe and comfortable position. Wear seat belt if
machine is equipped with a canopy.
4. Make sure that the park brake is applied.
5. Make sure that the transmission is in neutral.
6. Turn the main circuit breaker on the motor protection box to the “ON” position.
7. Turn the ignition switch to the “RUN” position.
8. Release the ignition switch when the motor starts.
CAUTION: The circuit breaker will trip if an overload or short circuit exists. Do not reset the circuit
breaker or replace the fuse unless the problem has been corrected.
9. Check all gauges and indicator lights to make sure that systems are functioning properly.
NOTE: Check the instrument panel frequently during operations.
! WARNING!
Do not attempt to move the machine unless all warning lights are out and gauges register
normal pressures and temperatures.
S05003/07/01 5-3
Starting the Motor
Notes
S05003/07/01 5-4
Stopping the Motor
To stop the motor, do the following:
1. Bring the machine to a controlled stop. Apply the brake if necessary.
2. Lower the boom/bucket until the bucket is in firm contact with the ground.
3. When the machine is completely stopped, put the transmission in neutral.
4. Apply the park brake.
5. Turn the ignition switch to the “OFF” position. The engine/motor should stop within 30
seconds of turning the switch.
6. Move the main circuit breaker located on the motor protection box to the “OFF” position.
7. Dismount from the machine and turn the master disconnect switch to the “OFF” position.
! WARNING!
Do not leave the operator’s compartment unless the park brake is applied and bucket is in
firm contact with the ground.
S06006/07/01 6-1
Stopping the Motor
Notes
S06006/07/01 6-2
Brake Tests
Service Brakes Test
! WARNING!
It is essential that the service brakes and park brake be properly maintained at all times.
! WARNING!
You must always be certain that the service brakes and park brake are working properly at
all times. Test the service and park brake at the beginning of each shift.
PERFORM THE SERVICE BRAKE TEST EXACTLY AS SET FORTH BELOW:
1. Start the engine/motor as normal.
2. Roll back the bucket.
3. Release the park brake.
4. Apply the service brakes with the service brakes pedal.
5. Select second (2nd) gear and forward direction. Rev the engine to full power.
CAUTION: The machine must not move at all!
CAUTION: Do not hold the engine at full power for more than five (5) seconds, as the torque
converter will quickly overheat.
6. Repeat the test in reverse direction.
7. Select neutral and shut down the engine/motor.
! WARNING!
If the machine fails the service brake test, tip the bucket into firm contact with the ground.
Apply the park brake, shut down the engine and dismount from the machine. Block all four
wheels. (If blocks are not available, turn the machine into a sidewall or bank). Do not
operate the machine again until corrective action has been taken!
S07003/02/01 7-1
Brake Tests
Park Brake Test

CAUTION: Maintenance is vital if serious injury is to be avoided. No machine can endure the harsh
conditions present at any mine without maintenance of the machine. Failure to report a
minor problem will often mean a more serious problem later. A problem or suspected
problem which can threaten injury to the operator or others should be given the highest
priority.
! WARNING!
It is essential that the park brake and the service brakes be maintained properly at all times.
If one is to go near any part of the machine for refuelling or any other reason, the machine
wheels must be blocked and all brakes must be set as even slight movement of the machine
when a person is in a vulnerable position can cause death or serious injury.
! WARNING!
You must always be certain that the park brake and service brakes are working at all times.
PERFORM THE PARK BRAKE TEST EXACTLY AS SET FORTH BELOW:
1. Start the engine/motor and check all instruments and gauges.
2. Make sure that the park brake is applied.
3. Observe instrument panel to check that park brake light is on.
4. Roll back the bucket to the carry position.
5. Select second (2nd) gear and forward direction. Rev the engine to full power.
CAUTION: The machine must not move!
6. Repeat the test in reverse direction.
CAUTION: If the machine does not move, do not keep the engine at full power for more than five (5)
seconds.
CAUTION: If the machine does move, do not move it more than a few feet. If the machine moves
there is a problem with the brakes and the machine should be immediately shut down
for maintenance.
! WARNING!
If the machine fails any part of the park brake test, push the park brake light/button, shut
down the engine and dismount the machine. Block the front and rear wheels. If blocks are
not available, turn the wheel into sidewall or bank. Do not operate the machine again until
corrective action is taken.
S07003/02/01 7-2
Operating the Bucket/Dump Box
Important
With practice and experience the bucket can be rolled back and lowered at the same time by
moving the lever to the left and toward you simultaneously. Moving the lever to the right and
away from you will raise and tip the bucket. The ability to become a more efficient operator will
come with practice and experience.
! WARNING!
Never stand or allow other personnel to stand under a raised bucket, unless the bucket is
safely supported.
! WARNING!
Always use extreme caution when moving the machine with a raised bucket. Where
possible, always lower the lift arms on the stops in the carry position before moving.
Boom/Bucket Control Lever

This machine is equipped with a single boom/bucket control lever which moves in four directions.
NOTE: Right and left refer to the lever, NOT the machine’s right and left.
1. To raise the lift arms, move the lever to the right.
2. To lower the lift arms, move the lever to the left.
3. To dump (tip) the bucket, move the lever forward.
4. To roll back the bucket, move the lever backward.
S08001/02/02 8-1
Operating the Bucket/Dump Box
Notes
S08001/02/02 8-2
Work Cycle
Tramming
! WARNING!
Inspect the machine and test the brakes before putting the machine to work.
NOTE: This machine is designed to travel in forward and reverse direction.
1. Ensure that the engine or motor is running, and the bucket is rolled back to the carry
position.
! WARNING!
Always travel up and down grades with the bucket facing downhill. It could be used to stop
the machine in case of an emergency.
2. Select forward (F) or reverse (R) direction of travel, and first gear.
3. Release the park/emergency brake by pulling the park/emergency brake light/button out
fully.
NOTE: Refer to the Instrument Panel chapter for more information.
4. Apply light pressure to the accelerator pedal until the machine is travelling at a controlled
speed.
! WARNING!
Practise steering while the machine is travelling slowly. After completing a turn, new
operators may make the machine wander back and forth before travelling in a straight line.
CAUTION: Do not rest your foot on the service brake pedal during tramming, unless braking is
required. Excessive use of the service brakes, even slight pressures, will reduce the
machine’s ability over time to stop effectively.
5. Shifting from one gear to another can be done at any time conditions permit. When shifting
down, apply slightly more pressure to the accelerator pedal.
6. Do not shift to a lower gear unless the machine is moving at a speed low enough to permit
this.
NOTE: Always shift one gear at a time.
7. Use the transmission to slow the machine down, finally stopping it with the brake pedal.
This will reduce wear and extend the life of brake components.
S09001/11/04 9-1
Work Cycle
! WARNING!
Test the park brake before operating the machine on an incline.
! WARNING!
Never move the gear shift lever into neutral while tramming, especially while travelling on
an incline. The brakes will automatically apply.
Tramming Up a Grade Without a Load
When tramming up a grade with an empty bucket, choose a gear that will allow you to travel at a
safe speed. When possible, avoid severe grades.
Tramming Down a Grade Without a Load
When descending down a grade with an empty bucket, choose a gear that allows you to drive
without any unnecessary braking.
Tramming Up a Grade With a Load
When carrying a load, travel up grades in second (2nd) gear. If engine performance and vehicle
speed decrease, shift the transmission to first (1st) gear. When possible, avoid severe grades.
Tramming Down a Grade With a Load
When descending down a grade with a load, select a gear which provides a controlled descent. As
you approach the downgrade, release the accelerator pedal to allow the machine to slow, and
choose a suitable gear.
CAUTION: Do not put the machine into motion when it has a load until the engine and torque
converter have warmed to normal operating temperatures. All gauges should be
displaying normal readings.
Braking
The machine can be brought to a full stop during tramming by pressing the brake pedal, located at
the operator’s feet.
NOTE: Refer to the Controls chapter for more information.
When pressed, the brake pedal operates the service brakes in each wheel end. The amount of
braking force is equal to how far down the brake pedal is pushed by the operator.
1. To bring the machine to a full stop immediately, press the brake pedal down fully.
2. To slow the speed of the machine, apply the necessary pressure to the brake.
CAUTION: Do not rest your foot on the service brake pedal during tramming, unless braking is
required. Over time, excessive use of the service brakes, even slight pressures, will
reduce the machine’s ability over time to stop effectively.
S09001/11/04 9-2
Work Cycle
! WARNING!
Always wear a seat belt, if equipped on the machine. If the machine is equipped with a
ROPS/FOPS canopy, wear the seat belt and a hard hat. Be prepared for a sudden stop.
Loading
NOTE: Obtain maximum loading efficiency by adjusting the loading cycle to operating
conditions.
NOTE: If possible, work the outer edges of the muck pile first and then the centre. This will
prevent spreading of loose material in the loading area.
CAUTION: If the machine is equipped with an ejector plate, make sure that the ejector plate is fully
retracted before mucking.
1. Lower the lift arms on the stop blocks and tip the bucket to the desired digging angle.
2. Drive the machine in first (1st) gear, forward direction and full power, forcing the bucket
cutting lip into the muck pile. Alternate dump and roll back movements will assist in good
penetration.
CAUTION: Avoid spinning or lifting the wheels off the ground while loading the bucket. This will
accelerate tire wear and cause premature structural problems.
3. As the bucket achieves maximum penetration, gradually roll back the bucket to fill it
completely.
4. Shake any excess load off the bucket. This will assist in keeping roadways clean and
prevents spillage.
5. Select reverse direction and slowly withdraw from the muck pile. Keep the bucket low and
rolled back. Drive to the dumping area.
6. Always carry a loaded bucket as low as possible, to ensure good stability, and unobstructed
vision of the roadway.
Dumping
1. When approaching the dumping area, release the accelerator pedal and bring the machine to
a controlled stop with the service brakes. Shift the direction control lever to the neutral
position. The park/emergency brake system should apply automatically, after approximately
10 seconds.
2. Accelerate the engine to full speed.
3. Raise the bucket to the maximum height required to clear the object being loaded. Tip the
bucket to dump the load. If the machine is equipped with an eject plate, extend the plate o
push out the load.
CAUTION: Do not allow the bucket to contact the “back” (ceiling).
S09001/11/04 9-3
Work Cycle
4. Roll back the bucket and lower it to the carry position. If equipped, fully retract the ejector
plate.
Parking
1. Stop the machine on flat ground, if possible.
2. When the machine is completely stopped, put the transmission directional control lever in
neutral.
3. Lower the lift arms and roll the bucket forward until the bucket is resting on the ground.
4. Apply the park brake.
5. Let the engine idle for two to five minutes to cool gradually.
6. Turn the ignition switch to the OFF position. The engine should stop within ten seconds.
7. Slowly move the steer control lever back and forth. The machine should not move.
8. Exit the operator’s compartment, then turn the master disconnect switch to the OFF
position.
! WARNING!
Do not leave the operator’s compartment unless the engine is stopped, the park brake is
applied, and the bucket is resting on the ground.
9. Report any faults or damage immediately.
S09001/11/04 9-4
Tramming the Machine
Important
! WARNING!
Tramming distance is limited by the length of the trailing cable. The machine is equipped
with a cable limit switch to shut down the motor when 9 wraps of cable remain on the reel.
As the motor shuts down, the park brake will automatically apply. When this happens,
release the clutch pedal. Press and hold the cable reel override button. Restart the motor,
then release the park brake. Select first gear and move the machine until 14 or 15 wraps of
cable are on the cable reel. At this point the cable warning light and cable reel caution lights
will go out. Release the cable reel override button and continue normal operations.
! WARNING!
Do not use the cable reel override button to increase tramming distance. To do so may cause
the cable to separate from the machine, resulting in possible electric shock to the operator
and other personnel in the area.
! WARNING!
To slow down or stop the machine, release the clutch pedal and press the service brakes
pedal.
! WARNING!
Avoid backing up the machine past the cable tie off point. If required to do so, be very
careful not to run over or foul the trailing cable.
! WARNING!
Apply the park brake if the motor stops for any reason. Do not restart the motor unless you
are seated in the operator’s seat. Wear seat belt if machine is equipped with a canopy.
S10006/07/01 10-1

1. Follow all safety procedures and local traffic rules and regulations while operating the
machine.
2. Always start out in first gear and shift into higher ranges as the machine accelerates and as
conditions permit.
3. To stop the machine, press the brake pedal and release the clutch pedal.
4. Before changing direction, press the brake pedal, release the clutch pedal, and bring the
machine to a full stop.
5. Always stop and test brakes before ascending or descending a grade.
6. Always travel up and down grades with the bucket pointing downhill. The bucket could be
used to stop the machine in case of emergency.
7. Select an appropriate gear when descending and ascending a grade, and fully apply the
clutch pedal. (In each of the transmission gear selections, there is a maximum speed.) DO
NOT RELEASE THE CLUTCH PEDAL. Applying the clutch pedal will prevent the speed
from increasing beyond the normal for the gear selected.
8. Shifting from one gear to another may be done as conditions required. Do not shift down
unless the machine is travelling at a speed slow enough to permit this.
9. When shifting down, slightly rev the engine. When shifting up, momentarily release the
clutch pedal.
10. Do not change gears on a grade.
11. Always make sure that transmission control levers are fully shifted.
12. If the transmission overheats, stop the machine from tramming, but do not shut down the
motor.
13. On reaching the dump site, do the following.
• Bring the machine to a controlled stop.
• Move the direction control lever to neutral and apply the park brake.
• Raise the lift arms to the required height and dump the load.
• Lower the lift arms and roll back the bucket on the respective stops.
• Select the required gear range.
• Release the park brake and return to the loading point.
S10006/07/01 10-2
Operating Hints
NOTE: Always report any faults or problems with your machine as soon as possible. Minor
malfunctions can quickly grow to major fault if ignored.
1. ALWAYS sound the horn before starting the motor. Sound the horn frequently, especially in
areas of limited visibility and congestion.
2. ALWAYS keep the loading and dumping areas as clean and level as possible to ensure equal
distribution of weight and improve stability.
3. If possible, work the outer edges of the muck pile first and then the centre. This will prevent
spreading of loose material in the loading area.
4. When loading the bucket, shake any excess load off the bucket before moving to the dump
area. This will assist in keeping roadways clean and prevent spillage.
5. Avoid spinning or lifting the wheels off the ground while loading the bucket. This will
accelerate tire wear and cause premature structural problems.
6. ALWAYS carry a loaded bucket as low as possible to ensure good stability and visibility.
7. ALWAYS test the park brake before operating on an incline.
8. ALWAYS travel in first (1st) gear and avoid excessive use of the brakes when carrying a
loaded bucket down an incline.
9. When dumping, only lift the bucket high enough to clear the object being loaded.
CAUTION: Never contact the roof with the bucket.
S11005/07/01 11-1
Operating Hints
Notes
S11005/07/01 11-2
Maintenance and Check Points
Introduction
This section contains a checklist of items to be checked and/or serviced before the machine is put
to work. For more information regarding these procedures, or for maintenance other than required
on a daily basis, refer to the Service Manual.
NOTE: The correct type and quantities of various lubricants used in the different systems on this
machine are specified in the Service Manual.
! WARNING!
Report all damage and faulty operations immediately. Do not operate a faulty machine.
Ensure the frame lock is fitted before working in the central articulation area. Never service
or adjust the machine while it is motion. Do not work around the loader end of the machine
with the lift arms and bucket raised, unless the lift arms are properly supported.
Engine Off
NOTE: Inspect the following points before starting the engine/motor.
1. General Inspection
1. Walk around the entire machine to make sure it is in good condition.
2. Report any damage or faults immediately.
1. Make sure the operator’s compartment is clean.
2. Remove all debris which could interfere with the correct operation of the pedals.
3. Presence of Transmission Oil
Remove the transmission dipstick (1) and check it for presence of oil. Replace dipstick.
DOC ID NO./MONTH/YEAR 12-1

1. Dipstick
2. Fill Port
Figure 1: Transmission Dipstick and Fill Port
4. Tires
NOTE: Numbers in the description refer to the illustration on the following page.
Inspect all four tires. Look for cuts or damage to the tire (1), wheel nuts (2), rim (4), and air valve
(5).
Check the wear indicator (3). If the tire is worn down to the bottom of the wear indicator, the tire
should be replaced immediately.
! WARNING!
Only trained, authorized service personnel may service tire and rim assemblies. Operators
and service personnel must be alerted to the risk involved when working on multi-piece rim
wheels. Refer to Occupational Safety and Health Administration (OSHA) Regulation 29
CFR Part 1910.277.
NOTE: OSHA is affiliated with the United States government.
1 3
Figure 2 : Tire (Typical)

5. Fire Extinguisher (If Equipped)

1. Verify that pressure is in the safe zone.
2. Check condition of trigger handle and hose. Ensure that the fire extinguisher is securely
mounted, but easily removable.
Figure 1: .Fire Extinguisher
6. Fire Suppression System (If Equipped)

1. Check that the dry chemical tank and gas expellant tanks are installed, hoses and fittings are
in good condition, and that both actuators are fitted with safety lockout rings.
NOTE: One actuator is located in the operator’s compartment; the other is located on the rear
frame.
Figure 2 : Fire Suppression System
7. Hydraulic Oil Level

Hydraulic oil level should be near the top of the sight glass (1) when the lift arms and bucket are
fully lowered and the bucket is in the carry position.
If necessary, remove filler cap and add clean hydraulic oil if necessary. Replace filler cap.
! WARNING!
Do not overfill the tank! Hydraulic oil expands when heated. Open the filler cap slowly, as
there may be pressure in the tank.

Turn the filler cap counter-clockwise to open, and clockwise to close. Clean up any hydraulic oil
splashed on the machine.
Figure 3 : Hydraulic Tank (Side View)
8. Bucket
Look for signs of damage or wear to bucket cutting lip (not shown), bucket stops (1), and bucket
welds. Apply grease to pins inside bucket (not shown), on dump cylinder (2), and lift arms to
bucket bushings (3).
! WARNING!
Do not work around the bucket end of the machine with the lift arms and bucket raised,
unless the lift arms are properly supported.
CAUTION: Insufficient lubrication may cause premature wear and failure of pins and bushings.
NOTE: Bucket may not be exactly as shown.
Figure 4: Bucket
9. Trailing Cable
1. Check hookup of the trailing cable at the disconnect station.

2. Be sure the cable is securely anchored at the receptacle.

3. Look for cracked or damaged insulation, or other signs of cable damage.
Figure 5 : Trailing Cable
10. Front Lights

Look for signs of damage to lights.
Figure 6 : Front Lights (Typical)
11. Greasing
Apply grease to points described in “Section 14: Greasing the Machine”.
12. Frame Lock
Make sure that the frame lock is NOT installed in the center hinge area.

Figure 7 : Frame Lock In Stored Position
Motor On
NOTE: Inspect the following items after inspecting the motor.
1. Operate levers and pedals to make sure they are working properly.
2. Make sure gauge needles rise to normal levels.
3. Make sure warning lights go out.
2. Hourmeter
1. Make sure hourmeter is working. If the hourmeter stops working, inform supervisor or
mechanic.
2. Make sure that the preventive maintenance schedule is performed according to the
Preventive Maintenance Schedule in the Service Manual.
Figure 8 : Hourmeter

3. Lights
1. Check for damage to wiring and mountings.
2. Switch all lights on and verify that they are working.
Figure 9 : Lights
4. Transmission Oil Level

1. Run the engine at half throttle until the transmission reaches normal operating temperature.
2. With the engine running at low idle, remove the dipstick and wipe it clean with a clean shop
cloth.
3. Insert the dipstick into the tube fully. Remove it again and read the level.
4. Add oil as necessary to bring the oil level to the full mark on the dipstick.
1. Dipstick
2. Fill Port
Figure 10: Transmission Dipstick and Fill Port
5. Hydraulics and Steering

1. With the engine running at half speed, raise the lift arms, roll back the bucket and lower the
lift arms. This ensure that the bucket controls are working correctly.
2. Sound the horn and articulate the machine from left to right.
3. Have an assistant look for oil leaks from the steer, hoist and dump cylinders while they are
being operated.

Figure 11 : Bucket Hydraulics
6. Brakes
Test all brakes according to procedures in “Section 7: Brake Tests”.

Greasing the Machine
The proper and regular application of grease to this machine and any other machine working in a
mining environment, is one of the most important aspects of preventative maintenance. If a
machine is not properly lubricated, the premature failure of vital bearings, bushings, and pins will
occur. This will further lead to poor performance of the machine and increased maintenance
costs.
Automatic Lubrication System

This machine is equipped with an automatic lubrication system that provides multi-purpose
grease to vital areas of the machine that can not be accessed easily by the operator. It consists of
a grease pump and three divider valves located in and around the central articulation area on the
opposite side of the operator’s compartment.
AUTO LUBE PUMP
6 7
8
Grease Fitting 9
Plug
SECONDARY VALVE
Cross Port OPERATOR’S COMPARTMENT
10
11 1 2
12 3
13 4
14 5
SECONDARY VALVE PRIMARY VALVE SECONDARY VALVE

OPERATOR’S COMPARTMENT FRONT FRAME CENTRE REAR FRAME CENTRE
ARTICULATION ARTICULATION
1. Oscillation 8. Right Lift Cylinder, Base End
2. Oscillation 9. Left Boom to Frame Pin
3. Steer Cylinder, Base End 10. Pillow Block
4. Upper Centre Articulation Pin 11. Right Lift Cylinder, Rod End
5. Lower Centre Articulation Pin 12. Left Lift Cylinder, Base End
6. Steer Cylinder, Rod End 13. Left Lift Cylinder, Rod End
7. Dump Cylinder, Base End 14. Right Boom to Frame Pin
Figure 1: Automatic Lubrication System Layout
S14028/11/04 13-1
Automatic Lubrication Pump

The lubrication pump stores the multi-purpose grease and automatically dispenses it to select
areas on the machine. The pump is located on the front frame, on the opposite side of the
operator’s compartment.
Replenishing the Automatic Lubrication Pump
The following instructions describe how to replenish the reservoir in the automatic lubrication
pump:
1. Locate the grease fitting on the front of the automatic lubrication pump.
2. Use a hand-held grease pump to inject multipurpose grease into the reservoir.
NOTE: Before injecting grease into the reservoir, refer to a service technician or the Fluid
and Lubricant Specifications section in the Service Manual to determine the correct
type of multipurpose grease to use.
! WARNING!
Only work in the centre articulation area if the machine is turned off and the frame lock has
been installed.
General Maintenance
In order for the automatic lubrication system to properly grease the machine, it must be monitored
and replenished on a daily basis.
1. Check the automatic lubrication pump at least twice per shift to ensure it is functioning
correctly.
2. Inspect all grease fittings, divider valves, and grease hoses for damage, excessive leaking,
and fraying.
3. If a divider valve is suspected of malfunctioning:
a. Clean any grease from the exterior of the valve and have an operator start the machine.
b. Watch the divider valve and wait for multipurpose grease to escape through the grease
fittings.
c. If no grease is present after application, contact service personnel for further
assistance.
S14028/11/04 13-2
Manual Lubrication
Bucket
The following grease points connecting the bucket to the dump cylinder and lift arms must be
manually lubricated at the start of every shift:
• Dump cylinder to bucket pin, right side
• Dump cylinder to bucket pin, left side
• Lift arms to bucket pin, right side
• Lift arms to bucket pin, left side
Figure 2: Bucket Lubrication Points
Drivelines
Apply multi-purpose grease to the grease fittings on each driveline every 50 hours of operation.
Reference to the hourmeter on the machine when scheduling greasing intervals.
Applying Grease
To properly lubricate the machine, perform the following steps at the beginning of every shift:
1. Inspect all grease fittings for damage.
2. Inspect all grease hoses for damage, leaking, and fraying.
3. Apply multi-purpose grease to each grease fitting until the old grease is pressed out by the
new.
4. Ensure that grease is reaching the bearings and bushings. Where visibility is obstructed,
have an assistant look for grease coming out between bearings and bushings while grease is
being applied.
NOTE: For additional information on grease points, refer to the Service Manual.
S14028/11/04 13-3
Notes
S14028/11/04 13-4
Troubleshooting
Important
The following tables identify common machine problems and their suggested remedies. If the
operator cannot correct the problem, inform supervisor as soon as possible. Most of the following
problems can be avoided by following operating procedures correctly and carrying out scheduled
maintenance on time.
! WARNING!
Do not operate the machine until any malfunction or problem has been corrected.
! WARNING!
High voltage. Only trained and authorized personnel shall service electrical system and
electrical components.
NOTE: The following table are only guides to the simple remedies within the scope of an
operator. Any doubt as to the fault must be referred to qualified maintenance personnel.
1. Motor Will Not Start
Cause Remedy
Control box breaker off. Turn circuit breaker on.
Loose or dirty battery terminals (if fitted). Clean and/or tighten terminals.
Weak or dead battery (if fitted). Recharge or replace battery (if fitted).
Transmission not in neutral. Shift to neutral.
Any other problem. Report to maintenance.
S15004/07/01 15-1
Troubleshooting
2. Motor Overheats
Cause Remedy
Low voltage at motor cause by too small a diameter Report to maintenance. Use a trailing cable with the
of cable or too long a line from the power source. same length and diameter as the one supplied with the
machine.
Low voltage at motor caused by insufficient Have maintenance personnel install a proper sized
transformer capacity for required power. transformer.
Poor voltage regulation at the generating plant. Report to maintenance.
Lines are overloaded with other equipment. Reduce power supply.
3. Motor Overloaded
Cause Remedy
Operator used bucket controls while tramming. Do not tram and use bucket at the same time.
Incorrect voltage. See table below. Report to maintenance.
4. Voltage Drop
Cause Remedy
Feeder cable diameter too small. Use only cable of correct diameter specified for the
machine.
Circuit breaker tripped. Report to maintenance.
Capacity of the transformer not great enough. Report to maintenance.
Poor voltage regulation. Report to maintenance.
Lines overloaded with other equipment. Disconnect unnecessary equipment or attach a new
power source.
NOTE: The electric motor will operate successfully at the rated load voltage with a frequency
variation shown in the table below.
Allowable Frequency
Rated Frequency
In Cycles Per Second Maximum Minimum
50 51 49
60 61 59
S15004/07/01 15-2
Troubleshooting
5. Cable Reel Inoperable
Cause Remedy
Reel shifter valve out of adjustment. Report to maintenance.
Drive chain broken or disconnected. Report to maintenance.
Defective hydraulic drive motor. Report to maintenance.
Loose parts jamming cable reel. Check entire cable reel compartment for loose parts
and hardware. Report to maintenance.
6. Control Box Circuit Breaker Tripped
Cause Remedy
Short circuit in motor cables or motor protection/ Report to maintenance.
combination control box.
Defective circuit breaker. Report to maintenance.
7. Hydraulic Oil Foams
Cause Remedy
Incorrect type of hydraulic oil. Check for correct type and amount of fluid. See
“Fluid and Lubricant Specifications” in the Service
Manual.
8. Torque Converter/Transmission Overheats
Cause Remedy
Machine overloaded. Reduce load.
Transmission oil level low. Check oil level and top up.
Low oil pressure. Report to maintenance.
Incorrect type of oil. Check oil type. Report to maintenance to drain and
refill transmission.
Severe oil leaks. Check oil level with engine running. Report to
maintenance.
Incorrect gear being used. Shift to lower gear.
S15004/07/01 15-3
Troubleshooting
9. Machine Will Not Move
Cause Remedy
Park brake applied. Release park brake.
Low clutch oil pressure. Report to maintenance.
Transmission in neutral. Shift into gear.
Motor stopped. Start motor.
10. Machine Will Not Turn
Cause Remedy
Frame lock installed. Move frame lock to storage position.
Obstruction (i.e. rock) between frames. Remove obstruction.
11. Little or No Bucket Action
Cause Remedy
Low transmission oil pressure. Report to maintenance.
Bucket overloaded. Reduce load.
Low hydraulic oil level. Check and top up.
Severe leakages. Report to maintenance.
12. Defective Lighting System
Cause Remedy
Defective light bulb. Replace bulb.
Light assembly wiring loose or broken. Tighten or replace ground wire.
Defective light control switch. Report to maintenance.
Circuit breaker tripped. Report to maintenance.
S15004/07/01 15-4
EJC Mining Equipment Inc.
Burlington, Ontario
Canada L7L 2A4
Telephone: (905) 632-4940
Fax: (905) 632-2172

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EJC 116E

FOR SERIAL NUMBER: 116-3757 REVISION 02

Ignition Switch.......................................................................................................... 4-16

Intended Use of Operator’s Manual

Intended Use of Machine

Figure 1: Name Plate

Safety Notations in Operator’s Manual

Figure 2: Loader Components (Side View)

No. Item Purpose

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

Figure 3: Loader Orientation

Only trained authorized personnel shall operate this machine.

Typical Work Cycle

Optional Fire Extinguisher

Optional Fire Suppression System

Optional ROPS/FOPS Canopy

Always wear seat belt.

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

1. Steer Control Lever 5. Boom/Bucket Control Lever

1. Steer Control Lever

1. Steer Control Lever 5. Boom/Bucket Control Lever

Figure 3 : Operator’s Seat - ISRI 6000 Model

1. Steer Control Lever 5. Boom/Bucket Control Lever

4. Service Brakes Pedal

5. Boom/Bucket Control Lever

Figure 5 : Boom/Bucket Control Lever

1. Steer Control Lever 5. Boom/Bucket Control Lever

6. Transmission Control Levers

1. Direction Control Lever

Direction Control Lever

1. Steer Control Lever 5. Boom/Bucket Control Lever

7. Master Disconnect Switch

Figure 9 : Master Disconnect Switch

1. Tow Switch 12. Horn Button

2. Motor Run Light

3. Motor 150% Load Light

4. Motor Overloaded Light

Be prepared for a sudden stop.

1. Tow Switch 12. Horn Button

5. Converter Oil Pressure Gauge

6. Converter Oil Temperature Gauge

1. Tow Switch 12. Horn Button

8. Brake Impending Light

9. Front Lights Switch

10. Rear Lights Switch

1. Tow Switch 12. Horn Button

11. Audible Alarm

12. Horn Button

13. Motor Fault Light/Button

Be prepared for a sudden stop.

1. Tow Switch 12. Horn Button

14. Cable Reel Limit Override Button

15. Cable Reel Empty Light

Be prepared for a sudden stop.

16. Cable Reel Limit Light

1. Tow Switch 12. Horn Button

17. Circuit Breaker Lights

1. Tow Switch 12. Horn Button

19. Brake Fault Light/Button

1. Tow Switch 12. Horn Button

20. Park/Emergency Brake Light/Button

FIRST POSITION SECOND POSITION THIRD POSITION

BRAKES APPLIED BRAKES OFF BRAKES RELEASED