Sandvik Loader LH517 Service and Repair Manual – PDF DOWNLOAD
FILE DETAILS:
Sandvik Loader LH517 Service and Repair Manual – PDF DOWNLOAD
Language : English
Pages :1690
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Sandvik Loader LH517 Service and Repair Manual – PDF DOWNLOAD
SERVICE AND REPAIR MANUAL 1
TABLE OF CONTENTS 3
1 FOR THE READER OF THIS MANUAL 15
2 GENERAL SAFETY INSTRUCTIONS 17
21 Warning and information symbols used in this manual 19
211 Safety Symbols Pertaining to the Machine 19
22 General safety precautions during operations 25
23 Safety rails user safety instructions 26
231 Getting up on top of the unit and building safety rails up 27
232 Lowering safety rails and getting down from the unit 30
24 Incident reporting 32
3 GENERAL REPAIR INSTRUCTIONS 33
31 Location of the main switch 35
32 Hydraulics maintenance 36
33 Pressure accumulators 38
34 Electric system maintenance 39
35 Battery maintenance 40
36 Welding 43
37 Blocking the machine for repair procedures 44
38 Lifting methods and lifting points 45
39 Lifting the boom using a hoist 48
310 Lowering the boom using a hoist 52
4 FRAME STRUCTURES 55
41 Locking devices 56
411 Frame articulation locking device 56
412 Boom locking pins 59
42 Middle hinge joint 63
421 Design features of upper hinge 63
422 Lower hinge pin 65
423 Disassembly of middle hinge joints 66
424 Assembly of the middle hinge joint 68
425 Adjusting of middle hinge joint 71
43 Oscillating axle 73
431 Disassembly of oscillating axle 76
432 Assembly of oscillating axle 79
44 Pins 80
441 Design features of the pins 80
442 Pin removal 81
443 Pin removal with a puller 81
444 Pin removal without special tools 82
445 Pin installation 82
45 Lift arm 83
451 Design features of the lift arm 83
452 Bushing replacement 84
46 Bucket stopper adjustment 85
47 Removing the bucket 87
48 Installing the bucket 90
49 Removing the swing lever 93
410 Installing the swing lever 96
411 Removing the dogbone 99
412 Installing the dogbone 101
413 Welding 102
4131 Precautions before welding 103
4132 Basic quality requirements 103
4133 Frame welding 104
4134 Bucket welding 104
4135 Edge preparation 105
4136 Working temperature and pre-heating 106
4137 Heat-input – number of welding passes 107
4138 Welding to other steels 108
4139 Gas cutting 110
5 LUBRICATION SYSTEM 111
51 Centralized manual lubrication 112
511 Lubrication points rear frame 113
512 Lubrication points front frame 114
52 Automatic central lubrication 116
521 System description 116
522 Safety interlocks 116
523 Inputs 117
524 Outputs 117
525 Functional description of the components 118
526 Removing the lubrication unit 120
527 Installing the lubrication unit 123
53 Checking and adjusting 126
531 Forced functions (requires service password) 127
532 Diagnostics 130
533 Filling the central lube reservoir 130
534 Bleeding the pump 131
535 Main piping 131
536 Doser adjustment 132
54 General troubleshooting 135
55 VCM system troubleshooting 136
6 FIRE SUPPRESSION SYSTEM 139
61 Ansul 140
611 Main components 140
612 System description 141
613 Inputs 141
614 Outputs 141
615 Specifications 141
616 System components 142
617 Location of nozzles 143
618 Ansul system operation 144
619 Ansul Checkfire system (optional) 145
62 Sandvik FS 1000 147
621 System components 147
622 System description 148
623 Specifications 148
624 Location of nozzles 149
625 System operation 150
63 Checking and adjusting 152
631 Forced functions (requires service password) 152
632 Diagnostics 154
64 VCM system troubleshooting 155
7 CABIN 157
71 Functional description of components 160
711 Steering joystick 160
712 Boom and bucket joystick 160
713 Throttle pedal 161
714 Door switch 162
715 Brake pedal 162
72 Heating and air conditioning system 163
721 System description 164
722 Component descriptions 165
73 Window washer and wiper 166
731 Inputs 166
732 Outputs 167
733 Removing the wiper motor assembly 167
734 Installing the wiper motor assembly 168
74 Removing the cabin 169
75 Installing the cabin 173
76 Removing the cabin seat 176
77 Installing the cabin seat 178
78 Removing the cabin window 180
79 Installing the cabin window 181
710 Removing the cabin door 182
711 Installing the door to the cabin 183
712 Checking and adjusting 184
7121 Testing the door switch 184
7122 Forced functions (requires service password) 185
7123 Throttle pedal calibration (requires service password) 189
7124 Diagnostics 190
713 VCM system troubleshooting 193
8 POWERPACK 203
81 Engine 205
811 Technical data 205
812 System description 206
813 Explanation of concepts 207
814 Starting and stopping the engine 207
815 Overspeed protection 210
816 Jump-starting 211
817 Restarting an out of fuel engine 212
818 DDEC stop engine and engine error codes 214
819 Changing engine oil and filter 215
8110 Engine mounts inspection 217
8111 Removing the engine 220
8112 Installing the engine 227
82 Fuel system 235
821 System description 235
822 Fuel filters 236
823 Fuel lines 236
824 Fuel gauge 237
83 Air cleaning system 238
831 System description 238
832 Air filter 239
833 Restriction indicator 240
84 Exhaust system 241
841 System description 241
842 Exhaust piping 241
843 Exhaust purifier 242
844 Servicing the exhaust purifier 242
845 Removing the exhaust purifier 243
846 Installing the exhaust purifier 244
85 Turbocharger 244
851 Servicing the turbocharger 244
852 Removing the turbocharger 245
853 Fitting the turbocharger 247
86 Cooling system 248
861 Main components of the engine cooler 248
862 System description 248
863 Functional description of the components 249
864 Cleaning the engine cooler cores 252
865 Engine cooler tube and sealing removal 253
866 Removing the engine cooler assembly 255
867 Installing the engine cooler assembly 260
868 Removing the engine thermostat 264
869 Installing the engine thermostat 266
8610 Removing the water pump 267
8611 Installing the water pump 270
87 Checking and adjusting 271
871 Checking the blower pump pressures 272
872 Forced functions (requires service password) 274
873 Diagnostics 277
88 General troubleshooting 278
89 VCM system troubleshooting 279
9 POWERTRAIN 285
91 System description 286
92 Transmission hydraulics 287
93 Transmission 289
931 Gearbox 289
932 Transmission filter unit 290
933 Gear selection 291
934 Controlling manual transmission 293
935 Controlling automatic transmission 295
936 Filling instructions 297
937 Removing the transmission 300
938 Installing the transmission 305
939 Transmission speed sensor 309
9310 General troubleshooting 311
94 Transmission cooling 312
941 System description 313
942 Removing and installing the transmission oil cooler 313
95 Torque converter 313
951 System description 314
952 Converter lock (option) 315
953 Functional description of components 317
954 Torque converter replacement 318
96 DeClutch 323
961 Inputs 323
962 Outputs 324
97 Wheels 325
971 Removal of the rear tires 327
972 Removal of the front tires 330
973 Installing the tires 332
974 Rim 334
975 Structures and functions of the off-road tyre components 335
976 Tire mounting and dismounting on rim 337
98 Axles 343
981 Technical data 344
982 Planetary hub and differential oil change 348
983 Tightening torques of power train flanges and bolts 350
984 Removal of the rear axle 351
985 Installing the rear axle 355
986 Removal of the front axle 359
987 Installing the front axle 362
988 Disassembling wheel ends 365
989 Assembling wheel ends 366
99 Cardan shafts 366
991 General maintenance and inspection 367
992 Cardan shaft speed sensors 367
993 Removing the cardan shaft 368
994 Installing the cardan shaft 370
910 Checking and adjusting 372
9101 Measuring speed and travelled distance, and sensor diagnostics 372
9102 Measuring the transmission pressure 374
9103 Forced functions (requires service password) 376
9104 Diagnostics 380
9105 The measurement data of the modules (requires service password) 381
9106 Counting transmission hours 382
9107 Tire pressure monitoring system (option) 384
911 VCM system troubleshooting 389
10 GENERAL HYDRAULICS 407
101 Hydraulic oil 408
102 Schematic diagram of hydraulic 409
103 General hydraulic maintenance 411
1031 General troubleshooting 412
1032 Basic causes of hydraulic system failures 413
1033 Checking hydraulic system for leaks 414
1034 Low temperature starting 414
1035 Prevent of cavitation formation 415
1036 Oil filters 415
1037 Servicing filters and strainers 415
1038 Level of oil in tank 415
1039 Oil storage and handling 416
104 Hydraulic oil tanks 417
1041 Design features 417
1042 Filter diagnostics 419
1043 Inputs 419
1044 Outputs 419
1045 Functional description of components 420
1046 Level sensors for the oil tanks 422
1047 To change filter element 422
1048 Changing oil in hydraulic system 423
1049 Repairing the tank 431
10410 Hydraulic tank cover resealing 432
105 Suction lines 437
1051 Design features 437
1052 Bleeding the suction lines 438
106 Priority block 440
107 Pressure measuring points 441
108 Hoses and tubing 448
1081 Marking of hydraulic hoses 449
109 Hydraulic oil coolers and return lines 450
1091 System description 451
1092 Functional description of the components 452
1093 Cleaning the hydraulic cooler cores 453
1094 Removing the hydraulic oil coolers 454
1095 Installing the hydraulic oil coolers 462
1096 Removing the hydraulic cooler fan motor 468
1097 Installing the hydraulic cooler fan motor 471
1010 Pumps 474
10101 Safety interlocks 475
10102 Inputs 475
10103 Outputs 475
10104 Pump unit P3121 476
10105 Pump P3211 482
10106 Pump P3511 492
10107 Starting new pumps 498
1011 Checking and adjusting 500
10111 General default pressure chart 501
10112 Sequence valve pressure adjust 502
10113 Pilot valve pressure adjust 503
10114 Measuring the temperatures of the hydraulic oils 504
10115 Forced functions (requires service password) 506
1012 VCM system troubleshooting 509
1013 Hydraulic component symbols 516
11 STEERING 523
111 Main components 524
112 Hydraulic diagram 525
113 System description 525
1131 System description of hydraulics 526
1132 System description of VCM 526
114 Functional description of components 528
1141 Steering main valve 528
1142 Steering cylinder 529
1143 Priority block 529
1144 Steering pump 529
1145 Steering limit switch 529
115 Emergency steering (option) 529
1151 System description 529
1152 Components 530
1153 Safety interlocks 530
1154 Inputs 530
1155 Outputs 531
116 Steering cylinder 532
1161 Removing the steering cylinder 534
1162 Installing the steering cylinder 537
1163 Cylinder disassembly 539
1164 Inspection and repair 540
1165 Reassembly and installation 540
117 Steering main valve 541
1171 Removing the steering main valve 541
1172 Installing the steering main valve 543
118 Checking and adjusting 544
1181 Checking of the steering pump pressures 545
1182 Checking steering valve pressures 547
1183 Steering cylinder bypass test 551
1184 Forced functions (requires service password) 556
1185 Diagnostics 559
119 VCM system troubleshooting 564
12 BOOM / BUCKET HYDRAULICS 575
121 Main components 576
122 Hydraulic diagram 577
123 System description 578
1231 System description of hydraulics 578
1232 System description of VCM 578
124 Functional description of components 581
1241 Boom and bucket main valve 581
1242 Boom / Bucket proportional servo valves 584
1243 Tilt cylinder A2222 585
1244 Lift cylinder A2221 585
1245 Priority block V3112 585
1246 Pump P3057 585
1247 Pump P3111 585
1248 Return filter Z3421 585
1249 Other boom / bucket hydraulic components 586
125 Bucket counter and weighing (option) 587
1251 Inputs 587
1252 Outputs 587
126 Ride control (option) 588
1261 Components 589
1262 Safety interlocks 589
1263 Inputs 590
1264 Outputs 590
1265 Releasing pressure from the ride control pressure accumulators 591
127 Boom float (option) 593
1271 Safety interlocks 593
1272 Inputs 593
1273 Outputs 594
128 Bucket shaking 594
1281 Safety interlocks 594
1282 Inputs 594
1283 Outputs 595
129 Lift and tilt cylinders 596
1291 Removing the tilt cylinder hoses 598
1292 Installing the tilt cylinder hoses 600
1293 Removing the tilt cylinder 602
1294 Installing the tilt cylinder 605
1295 Tilt cylinder disassembly 607
1296 Removing the lift cylinder hoses 608
1297 Installing the lift cylinder hoses 611
1298 Removing lift cylinders 613
1299 Installing lift cylinders 616
12910 Lift cylinder disassembly 618
12911 Inspection and repair 619
12912 Reassembly and installation 619
1210 Checking and adjusting 620
12101 Bleeding of the bucket valve 621
12102 Checking of the bucket pump pressures 623
12103 Lift cylinder leakage test 626
12104 Tilt cylinder leakage test 628
12105 Switching the control directions of the control joystick 630
12106 Forced functions (requires service password) 632
12107 Diagnostics 637
12108 Testing the buttons 639
12109 Testing the movement of the control joystick 640
121010 Control joystick calibration (requires service password) 641
121011 Adjusting boom end attenuation 642
121012 The measurement data of the modules (requires service password) 643
1211 VCM system troubleshooting 644
13 BRAKE SYSTEM 667
131 Main components 668
132 Hydraulic diagram 669
133 System description 671
1331 System descripton of hydraulics 671
1332 System description of VCM 673
134 Functional description of components 676
1341 Brake charging valve 676
1342 Pressure accumulator Z3537 678
1343 Sequence valve 679
1344 Brake pedal valve 679
1345 Filter unit Z3511 680
1346 Brake release 682
1347 Pressure accumulators 683
135 Pressure accumulators 684
1351 Recharging piston accumulators 685
1352 Disassembly and assembly of the piston accumulator 686
1353 Recharging diaphragm accumulators 688
136 Brake flushing 691
1361 Hydraulic diagram 692
1362 System description 694
1363 Functional description of components 694
137 Automatic Brake Activation 695
138 Neutral brake (optional) 695
1381 Inputs 695
1382 Outputs 696
139 Electrohydraulic retrieval hook (optional) 697
1391 System description 699
1392 Testing the operation and adjusting the pressures 701
1393 Checking the pressure accumulator pre-charge pressure 702
1394 Adjusting the hook valve spool clearance 703
1395 Checking the pressure accumulator charging pressure 706
1396 Testing the hydraulic power unit function 707
1397 Checking / adjusting the release pressure 712
1398 Checking the front axle releasing pressure 713
1399 Checking the safety function 714
13910 Performing the electrohydraulic retrieval hook test 716
1310 Disassembly of brakes 718
1311 Assembly of brakes 718
1312 Checking and adjusting 719
13121 Brake flushing pressure check 720
13122 Brake pump pressure check / adjustment 721
13123 Brake charging valve pressure check / adjustment 723
13124 Test service and parking brake function 725
13125 Automatic brake activation test (requires service password) 733
13126 Brake friction disc lining wear check procedure 736
13127 Brake Slack Adjuster Adjustment (Posi-Stop) 738
13128 Testing the brake accumulator 740
13129 Measuring the brake accumulator pre-charge pressure P0 741
131210 Measuring brake pressures 742
131211 Forced functions (requires service password) 744
131212 Diagnostics 747
1313 VCM system troubleshooting 750
14 GENERAL ELECTRICAL SYSTEM 763
141 System description 764
142 Lights 765
1421 Location of components 765
1422 Driving lights 768
1423 Parking lights 769
1424 Brake lights and blinkers 770
1425 Cabin’s corner lights 771
1426 Loading lights 772
1427 Warning light (beacon) 772
1428 Direction indicator lights (optional) 773
143 Horn signal and reversing warning 774
1431 Horn signal 774
1432 Alarm signal and light for reversing 774
144 Emergency stop 775
1441 Diagnostics 775
1442 E-stop chain status 776
1443 E-stop enable interlocks 777
1444 Enabling emergency stop diagnostic windows (service password required) 778
145 Warning and alarm condition 779
1451 Outputs 780
146 Batteries 781
1461 Battery technical data 781
1462 Removing the batteries 785
1463 Installing the batteries 787
147 Alternator 789
1471 Removing the alternator 790
1472 Installing the alternator 792
148 Circuit breakers 794
1481 Circuit breaker descriptions 798
149 Radio remote control (RRC) 799
1491 RRC joystick configuration 799
1492 RRC joystick configuration of the boom and the bucket 800
1493 RRC configuration for the steering and the driving direction 801
1494 Enabling the RRC option (service level password required) 801
1410 VCM-integrated scale 802
14101 System description 802
14102 Main components 803
14103 User interface 805
14104 System notifications and troubleshooting 813
1411 AutoMine button visibility 825
14111 Enabling AutoMine option (service level password required) 825
1412 Vehicle Control and Management system user interface 826
14121 Using the display module 826
14122 Symbols on the display windows 827
14123 Main window 830
14124 Gauge windows 831
14125 Alarm log 835
14126 Service windows for the user 836
14127 Service windows for service personnel (requires service password) 841
1413 Service password 854
1414 VCM system self test on start-up 855
14141 Conditions for starting the system (the enable) 855
1415 Checking and adjusting 856
14151 Display settings 856
14152 Status data of the CAN bus (requires service password) 857
14153 Forced functions (requires service password) 858
14154 Diagnostics 862
14155 Checking emergency stop and shutdown system 865
14156 Common rules for checking cables 866
1416 VCM system troubleshooting 867
1417 Module I/O list and signal levels 904
14171 I/O lists 904
14172 Signal level and scaling of the sensors 922
1418 Changing the control modules 926
14181 Location of the control modules 926
14182 Changing a single I/O module 927
14183 Changing several I/O modules 929
14184 Changing the display module 930
14185 Programming a new module (requires service password) 931
14186 Updating manually the programs of system modules (requires service password) 933
14187 System implementation 934
1419 Downloading new installation package into machine 935
14191 How to check installation package version 935
14192 Loading new installation package into machine 936
1420 Controlling optional functions (options) 936
14201 Controlling the optional functions on the service window (requires option password) 937
1421 Parameter control 938
14211 Restoring parameters 938
14212 Saving parameters 939
1422 How to read electric diagrams 939
14221 Marking 939
14222 Marking of the actuators 940
14223 Parts location 941
14224 The consecutive number 941
14225 Marking of cables 941
14226 Drawing sheets 942
14227 VCM system module connections 946
1423 Electric diagrams 946
15 VCM SYSTEM ERROR CODES 947
151 Alarm log 949
1511 How to upload alarm log with update display 951
152 VCM system troubleshooting 952
1521 Error codes 957
16 LH517 APPENDICES 989
1 The tightening torques for screws and nuts 991
2 Diaphragm accumulators 993
3 Piston accumulator Operation and Service instructions1003
4 Rexroth piston pump repair instructions1021
5 Dana transmission Maintenance / Service manual1047
6 Dana converter Service manual1115
7 Axle Service manual1183
8 Hydraulic oil cooler Installation and Servicing manual1273
9 Radiator Service manual1277
10 Tank breather filter1285
11 Exide battery1291
12 Dana cardan shafts1297
13 Donaldson air filter manual1313
14 Wiggins refueling system Technical manual (option)1327
15 Wiggins Installation and Operators manual (option)1343
16 Sandvik FS1000 fire suppression system manuals (option)1359
17 ANSUL fire suppression system Installation, Recharge, Inspection and Maintenance manual (option)1415
18 SGH-50 Hydraulic pumping unit1553
19 Function of lubrication system1565
20 Doser groups1571
21 Sandvik GET (option)1579
22 Emergency radio Operation instruction (option)1601
23 Air conditioner Service1609
24 USB Tool user instructions1651
25 Update display Operating instructions1666
IMAGES PREVIEW OF THE MANUAL:
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