01_prevmaint_s281.821_v1_en_260116_248

Sandvik UJ440iPreventive Maintenance

Doc. no. S 281.821 en Ver. 1

This document is valid for:

Serial no. / Machine no. Sign.

Sandvik UJ440i© Copyright 2007 Sandvik SRP AB.All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints.

Document number: S 281.821 enIssue: 20071210Version: 1

Sandvik SRP ABStationsplan, SE-233 81 Svedala, SwedenTel: +46 (0)40 409000, Fax: +46 (0)40 409260www.sandvik.com

Table of contents

1. Preventive Maintenance1.1 General ................................................................................. 51.2 Caterpillar engine (option) .................................................... 61.3 Daily inspection..................................................................... 91.4 Daily inspection (Continued)............................................... 111.5 After 50-600 hours .............................................................. 131.6 Weekly inspection............................................................... 151.7 When required .................................................................... 171.8 After 80 hours ..................................................................... 191.9 After 250 hours ................................................................... 211.10 After 500 hours ................................................................... 231.11 After 750 hours ................................................................... 251.12 After 1 000 hours ................................................................ 271.13 After 1 000 hours (Continued) ............................................ 291.14 After 1 250 hours ................................................................ 311.15 After 1 500 hours ................................................................ 331.16 After 1 750 hours ................................................................ 351.17 After 2 000 hours ................................................................ 371.18 After 2 000 hours (Continued) ............................................ 391.19 After 2 250 hours ................................................................ 411.20 After 2 500 hours ................................................................ 431.21 After 2 750 hours ................................................................ 451.22 After 3 000 hours ................................................................ 471.23 After 3 000 hours (Continued) ............................................ 491.24 After 3 250 hours ................................................................ 511.25 After 3 500 hours ................................................................ 531.26 After 3 750 hours ................................................................ 551.27 After 4 000 hours ................................................................ 571.28 After 4 000 hours (Continued) ............................................ 591.29 After 8 000 hours ................................................................ 601.30 After 10 000 hours .............................................................. 611.31 After 12 000 hours .............................................................. 611.32 Every 6 months................................................................... 611.33 Yearly.................................................................................. 621.34 Every 3 years...................................................................... 631.35 Every 6 years...................................................................... 631.36 Every 14 400 litres of fuel ................................................... 631.37 Every 114 000 litres of fuel ................................................. 641.38 Every 170 400 litres of fuel ................................................. 641.39 Every 380 000 litres of fuel ................................................. 64

3UJ440i © Sandvik SRP AB – Doc. no. S 281.821 en Ver. 1

Table of contents

1.40 Completed maintenance jobs ............................................. 65

4 © Sandvik SRP AB – Doc. no. S 281.821 en Ver. 1 UJ440i

1. Preventive Maintenance1.1 General

The person who carries out preventive maintenance work must have good knowledge of the mobile unit and must know when and how adjustments should be made

Most of the maintenance instructions are followed by a reference to a part in another UJ440i manual. The following manuals are referred to:

PD = Product Documentation

OM = Operator’s Manual

Example: The reference PD:12 stands for Part 12 “NF Conveyor” in the manual “UJ440i Product Documentation”.

For assistance, contact the nearest Sandvik company, agent, representative or directly:

Sandvik SRP ABService Dept.SE-233 81 Svedala, SwedenTelephone +46 40-40 90 00Telefax +46 40-40 92 60

WARNING!

This instruction is only intended as a guideline of the activities to be performed. For validity of the guarantee it is essential to check the detailed instructions for the different components presented in each specific section.

NOTE! The section headings in this manual stands for the counted time from when the mobile unit was initially started. The maintenance cycle continues after 4 000 hrs. Repeat the maintenance instructions for 250 hrs. when 4 250 hrs. has passed.

5© Sandvik SRP AB – Doc. no. S 281.821 en Ver. 1UJ440i

1. UJ440i Preventive Maintenance

6 © Sandvik SRP AB – Doc. no. S 281.821 en Ver. 1

UJ440i

1.2 Caterpillar engine (option)Records should be kept for the following items:

• Fuel consumption• Service hours• Documents - all documents should contain: date, service hours, fuel

consumption, unit number and engine serial number.For warranty, keep the following types of documents as proof of maintenance or repair:

• Dealer work orders and itemized bills• Owner’s repair costs• Owner’s receipts• Maintenance logAccurate maintenance records can be used to show compliance with the required maintenance practices and maintenance intervals.

NOTE! Other maintenance agreements for Caterpillar engines may apply. Contact Sandvik for more information.

WARNING!

Products that operate in severe operating conditions may require more frequent maintenance.


7

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Daily inspection

See drawing 191.2575See drawing 191.2575

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1.3 Daily inspectionNOTE! Listen for abnormal noises.

Continues

AlarmsCheck the alarm log list and take care of any warnings OM:11

HydraulicsCheck for leakage and damage, hoses, valves and cou-plings

PD:01

Check hydraulic oil level in tank 1

1. First week

PD:01

1 Discharge conveyorCheck the pull cord stop PD:06

Check the belt for damage PD:06

Check rollers for damage PD:06

Check that tail pulley is running smoothly PD:06

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)Inspect engine and engine compartment PD:03

Check lubricating oil level, if necessary refill PD:03

Check coolant level 1

1. NOTE! The first coolant change is only made after 10 000 hours or 1 year.

PD:03

Check the main air filter status on the display PD:03, OM:11

Check the fuel system primary filter (water separator), drain when necessary

PD:03

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Visual inspection of engine for leaks PD:03

Check the cooling system PD:03

Check coolant level PD:03

Check the air filter (air cleaner) service indicator PD:03

Check oil level PD:03

Check battery and battery cable connections PD:03

Check the primary fuel filter (water separator), drain when necessary

PD:03

Check/Adjust/Lubricate Power Take-Off Clutch. PD:03

2 Power unit - Fluid coupling (21 KPTO)Check oil level 1

1. First week

PD:04

Check for leaks PD:04

2 Power unit - Power take-off gearbox (OMKA)Check oil level 1 PD:04

Filter indicator (visual) 2 PD:04


1. First week. Check at working rpm and warm oil. Warm up hydraulic oil above0 °C, at low temp <0 °C by activating the warm up button with diesel engineat idle before starting up the process.

2. First week

4 Jaw crusherCheck bearing temperatures and drive motor load OM:12

Lubrication OM:12

5 Track unit - Trackline D6Clear all material from around the sprocket, idler and track group

PD:05

Check the track tension PD:05

Check for loose bolts, if necessary tighten them PD:05

Check for oil and grease leaks, seal any leaks immedi-ately

PD:05

5 Track unit - Track One T0650C02 / T0650C03Inspect the extent of track undercarriage dirtiness PD:07

Inspect the general condition of the track undercarriage components

PD:07

Inspect the fastening elements of the frame sections and the track undercarriage fastenings

PD:07

Inspect the seal of gear-motor unit and the possible hydraulic connections

PD:07

Inspect the general state of the spring and tensioning system of the front idler unit

PD:07

Check for leakage on the track rollers PD:07

Check for leakage on the carrier roller or wearing rails PD:07

Check for leakage on the track group (only on lubri-cated track group)

PD:07

Inspect the track group pre-tensioning (track sag) PD:07

6 Feeder GF1246Listen for abnormal noises OM:13

Check suspension and attachment of hydraulic hoses below the feeder. Make sure there is no wear between hoses or between hoses and chassis

8 Dust filter (OPTION)Check that the suction capacity is normal PD:10

Check visually if there is any changes of the emission from the stack

PD:10

If necessary, clean the shaker device PD:10



Daily inspection (Continued)


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1.4 Daily inspection (Continued)NOTE! Listen for abnormal noises.

9 Hydraulic hammer (OPTION) (Described in a separate binder)Grease the tool shank and the tool bushings

Observe hydraulic oil temperature, all lines and con-nections as well as impact efficiency and evenness of operation. Check visually if there is any changes of the emission from the stack

Tighten loose connections

Check the swivel pin clearances of the hydraulic ham-mer boom, if necessary replace the pins and bush-ings

Lubricate all grease nipples

Check the hoses, pipes and couplings

Check the locking bolts of swivel pins

Check the mounting bolts of the hydraulic hammer

10 Crusher lubrication pump (OPTION)Check the filling level in the lubricant vessel, if neces-sary vent the system and/or refill it

PD:13

12 NF Conveyor (OPTION)Check the pull cord emergency switch PD:12

Check the belt for damage PD:12

Check that tail pulley is running smoothly PD:12



50-600 hours inspection


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1.5 After 50-600 hours

The oil change intervals can vary between 50–600 hours depending upon the grade of the oil and the sulphur content of the fuel. Note that the oil change intervals may never exceed a period of 12 months. If change intervals longer than those provided are desired, the condition of the oil must be checked by the manufacturer of the oil by regular testing.

For selection of viscosity, refer to the Volvo Penta manual in PD:03. The abbreviations in the table above can also be found in the Volvo Penta manual.

NOTE! This maintenance interval applies specifically to the Volvo diesel engine:

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)Change engine oil 1 2 3

1. Oil change intervals will vary depending upon the grade of the oil and theamount of sulfur in the fuel.

2. NOTE! Oil filter must be changed with every oil change.3. At least once a year.

PD:03

Change oil filter / bypass filer 2 3 PD:03

NOTE! Oil filter must be changed with every oil change.

Oil grade Sulphur content in fuel, by weight< 0.3 % 0.3 – 0.5 % > 0.5 % 1

1. If the sulfur content is > 1.0% by weight, use oil with TBN > 15.

Oil change interval, reached first in operationVDS-3 600 hrs / 12 months 300 hrs / 12 months 150 hrs / 12 months

VDS-2 and ACEA: E7 2 VDS-2 and ACEA: E5 2 VDS-2 and Global DHD-1 2

VDS-2 and API: CI-4 2

VDS-2 and API: CH-4 2

2. The engine oil must comply with both quality requirements.

400 hrs / 12 months 200 hrs / 12 months 100 hrs / 12 months

VDS and ACEA E3 2ACEA: E7, E5, E4API: CI-4, CH-4, CG-4

200 hrs / 12 months 100 hrs / 12 months 50 hrs / 12 months

NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality requirements above.



Weekly inspection


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1.6 Weekly inspectionNOTE! Listen for abnormal noises.

Safety controlCheck the presence and condition of all safety guards

Make a test of all emergency stops

HydraulicsCheck for leakage and damage, hoses, valves and cou-plings

PD:01

Check hydraulic oil level in tank 1

1. First week

PD:01

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Check the jacket water heater PD:03

Drain water and sediment from the fuel tank PD:03

2 Power unit - Fluid coupling (21 KPTO)Check oil level PD:04

2 Power unit - Power take-off gearbox (OMKA)Check oil level 1

1. Check at working rpm and warm oil. Warm up hydraulic oil above 0 °C, at lowtemp <0 °C by activating the warm up button with diesel engine at idle beforestarting up the process.

PD:04

Filter indicator (visual) PD:04

3 Crusher drive beltsCheck the protection hood

Check the V-belts for wear and tension

Remove debris

4 Jaw crusherGrease all four bearings OM:12

Lubrication OM:12

Check tightness of all threaded fasteners OM:12

Check preload in retraction springs OM:12

Check wear on jaw plates and check plates OM:12

Inspect dust seals OM:12

Check toggle plate and toggle seats for wear or damage OM:12

Inspect V-belt drive OM:12

5 Track unit - Track One T0650C02 / T0650C03Inspect the seal of the front idler and tensioning system (front idler unit)

PD:07

Inspect the re-tensioning span of the track front idler unit (max possible tensioning span reached)

PD:07

Check the condition of and wear on the front idler and sliding bracket

PD:07

8 Dust filter (OPTION)Check that the suction capacity is normal PD:10

Check visually if there is any changes of the emission from the stack

PD:10

If necessary, clean the shaker device PD:10

9 Hydraulic hammer (OPTION - Described in a separate binder)Remove the tool retaining pin and the tool and check their condition, if necessary grind the burrs away

Check that the tool has received sufficient grease, if necessary grease more frequently

Tighten bolts and couplings

Check the oil level in the oil tank, if necessary add oil

Clean off the dust from the cover of oil tank

Check the tool shank and tool bushings for wear

Check the hydraulic hoses, if necessary replace them

Contact your local dealer for the initial 50-hour inspec-tion

10 Crusher lubrication pump (OPTION)Check the filling level in the lubricant vessel, if neces-sary vent the system and/or refill it

PD:13

Check that grease is dispensed to crusher bearings PD:13



when required


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1.7 When required

Engine heater Webasto (OPTION)Webasto fuel filter PD:20

2 Air filtersMain air filter element 1

1. Change when the Filter guard alarm on the machine control panel display isactivated.

OM:09

Secondary air filter element 2

2. Changed every 2-3 times the primary air filter is replaced

OM:09

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Replace battery PD:03

Clean the air filter (air cleaner) element, if necessary replace it

PD:03

If the engine is to be stored, check the engine storage procedure first

PD:03

Check the fuel system, if necessary prime it PD:03

Check operating conditions (Severe Service Application)

PD:03

2 Power unit - Fluid coupling (KPTO)Breather filter PD:04

2 Power unit - Power take-off gearbox (OMKA)Breather filter PD:04



80 hours inspection


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1.8 After 80 hours

HydraulicsChange all hydraulic oil filters PD:01

Change high pressure filter PD:01

Change return filter cartridge PD:01

Change drain filters PD:01

Change breather filter element on hydraulic tank PD:01

Check hydraulic oil level PD:01

Check couplings and hoses PD:01

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)Renew oil1

1. The oil change is recommended, the new engine oil should be one that is rec-ommended by Volvo Penta. NOTE! Oil filter must be changed with every oilchange.

PD:03

Renew filters PD:03

2 Power unit - Fluid coupling (21 KPTO)Renew oil PD:04

Renew oil and filters (25 micron) PD:04

Check the bolts on the drive pulley PD:04

2 Power unit - Power take-off gearbox (OMKA)Renew oil PD:04

Renew filter PD:04

Check the tightness of all bolts, retighten if necessary PD:04

5 Track unit - Track One T0650C02 / T0650C03Inspect the fastening elements of frame sections and track undercarriage fastenings - grouser shoe fastening (spot-checks)

PD:07

Check the condition of and wear on the drive gear box sprocket

PD:07

Check the condition of and wear on the track rollers PD:07

Check the condition of and wear on the carrier roller PD:07

Check the condition of and wear on track link running surfaces, bushings (other diameter) and stretching of track

PD:07

Check the condition of and wear on the track group grouser shoes

PD:07



250 hours inspection


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1.9 After 250 hours

n

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)Drain fuel tank (sludge collector) 1

1. At least once a year.

PD:03

Check the alternator belt, if necessary adjust it 1 PD:03

Check batteries electrolyte level 1 PD:03

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Check supplemental coolant additive concentration, if necessary renew

PD:03

Check battery electrolyte level 2

2. Or for every 14 400 litres of fuel or yearly - which ever occurs first.

PD:03

Check the electronics grounding stud, if necessary clean and/or tighten it 2

PD:03

Check hoses / clamps, if necessary replace them 2 PD:03

Clean the crankcase breather 2 PD:03

Clean the radiator 2 PD:03

Obtain an engine oil sample 2 PD:03


Renew engine oil 3 4

3. If the engine oil is being analyzed, using Caterpillar’s S·O·S oil analys pro-gram, the oil change interval may be increased to 500 hours for the Deep oilpan (used for motors with serial numbers higher than LGK05295). NOTE! Oilmust be changed at least once a year.

4. NOTE! Oil filter must be changed with every oil change.

PD:03

Renew oil filter 4 PD:03

Replace the primary fuel filter (water separator) 2 PD:03

Replace the secondary fuel filter 2 PD:03

2 Power unit - Fluid coupling (21 KPTO)Check the bolts on the drive pulley PD:04

5 Track unit - Trackline D6Renew gearbox oil1

1. First change after 200 hours.

PD:07

Re-tighten all bolts, especially the sprocket bolts PD:07

Check all wear limits PD:07

Check track group alignment and levelness PD:07

Check the gearbox oil level and add if necessary PD:07

5 Track unit - Track One T0650C02 / T0650C03Check gear box oil level. If necessary, refill. PD:07

7 Magnet conveyor (OPTION)Check the self-lubricating bearings, separator belts and Flexlok couplings

PD:08





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1.10 After 500 hours

HydraulicsDrain condensing water from hydraulic tank PD:01

1 Discharge conveyorCheck/adjust the conveyor belt PD:06

Check/adjust the belt cleaning devices PD:06

Check the roller systems PD:06

Check the belt scale PD:16

Checks/adjustments/replacements/lubrication accord-ing to Service Diagram (drawing):- Tail pulley- Impact bars- Skirt boards- Belt scrapers- Drive gear- Idlers

PD:06



PD:03




PD:03

Check belts, if necessary adjust and/or replace them PD:03

Check the starting motor PD:03

Check the turbocharger PD:03

Check the water pump PD:03

Check the engine protective devices 2

2. Or every 6 months - which ever occurs first.

PD:03



PD:03


PD:03





Obtain a coolant sample (level 1) PD:03

Obtain a coolant sample (level 2) 4

4. After the initial 500 hours (for new systems, refilled systems and convertedsystems), then yearly.

PD:03




PD:03






Renew filter PD:04


5 Track unit - Trackline D6Re-tighten all bolts, especially the sprocket bolts PD:07




5 Track unit - Track One T0650C02 / T0650C03Check gear box oil level. If necessary, refill or change oil1.

1. The gear box oil must be changed at least once a year.

PD:07


PD:08

9 Hydraulic hammer (OPTION - Described in a separate binder)Lubricate all grease ripples




Check that swivel pins have no excessive play in their bushes, if necessary replace pins and bushes

Replace all filter elements

Contact your local dealer for the 600-hour (or yearly) inspection

12 NF Conveyor (OPTION)Check the conveyor belt PD:12

Check the cleaning devices PD:12

Check the roller system PD:12

Checks/adjustments/replacements/lubrication accord-ing to Service Diagram (drawing):- Tail pulley- Wear plates- Skirt boards- Belt scrapers- Drive gear- Idlers- Bearing housings

PD:12





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1.11 After 750 hours



PD:03



Charge air pipes, check for leaks PD:03

Change the primary fuel filter PD:03

Change the secondary fuel filter PD:03

Change the external primary fuel filter PD:03


PD:03



PD:03


PD:03











PD:03








PD:07


PD:08



1 000 hours inspection


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1.12 After 1 000 hours
Continues





Check the drive motor PD:06

Check the drive mechanism PD:06

Check the screw take-up device PD:06

Check the counterweight take-up device PD:06

Check/lubricate the pulleys PD:06

Check the guiding boards PD:06


PD:06



PD:03



Change coolant filter 2 3

2. NOTE! Do not change the coolant filter and coolant at the same time!3. Or every 6 months - which ever occurs first. NOTE! This maintenance cycle

(every 1 000 hours or 6 months) only starts after the first coolant change after10 000 hours or 1 year.

PD:03


PD:03





Check the engine protective devices 1 PD:03

Check battery electrolyte level 2 PD:03


PD:03









Renew engine oil 3 4 PD:03


1. Or every 6 months - which ever occurs first.2. Or every 14 400 litres of fuel or yearly - which ever occurs first.3. If the engine oil is being analyzed, using Caterpillar’s S·O·S oil analys pro-

gram, the oil change interval may be increased to 500 hours for the Deep oilpan (used for motors with serial numbers higher than LGK05295). NOTE! Oilmust be changed at least once a year.


2 Power unit - Fluid coupling (21 KPTO)Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm)

PD:04


Renew filter PD:04




1 000 hours inspection (Continued)


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1.13 After 1 000 hours (Continued)







PD:07


PD:08





Check the pulleys PD:12



PD:12





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PD:03




PD:03



PD:03


PD:03











PD:03

Renew oil filter PD:03







PD:07


PD:08

9 Hydraulic hammer (OPTION - Described in a separate binder)Lubricate all grease ripples




Check that swivel pins have no excessive play in their bushes, if necessary replace pins and bushes

Replace all filter elements

Refill the tank with new clean oil

Replace tank breather element





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PD:06



PD:03








PD:03







PD:03


3. Or every 14 400 litres of fuel or yearly - which ever occurs first.

PD:03


PD:03







Renew engine oil 4 5 PD:03







Renew filter PD:04








PD:07


PD:08


Check the cleaning devices



PD:12





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PD:03




PD:03



PD:03


PD:03











PD:03








PD:07


PD:08





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Continues

HydraulicsChange hydraulic oil PD:01




Change breather filter on hydraulic tank PD:01

Drain condensing water from hydraulic tank PD:01









Check/lubricate the pulleys PD:06


Check the gear PD:06

Check the pull cord em. switch PD:06


PD:06



PD:03






PD:03


PD:03







PD:03

Check the alternator 5

5. Or yearly - which ever occurs first.

PD:03



PD:03


PD:03












PD:03






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2 Power unit - Fluid coupling (21 KPTO)Renew oil and filters (25 micron) PD:04


Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm)

PD:04


Renew filter PD:04


If necessary renew seals PD:04

5 Track unit - Trackline D6Renew gearbox oil PD:07




5 Track unit - Track One T0650C02 / T0650C03Change gear box oil1

1. The oil needs not to be changed after 2 000 hours if it already has beenchanged between 500 and 1 750 hours. If so, make sure that the oil ischanged within 2 000 hours (or at least a year) from the previous change.

PD:07

6 Feeder GF1246Lubricate vibrator bearings OM:13


PD:08



Check the roller system


Check the pulleys


Check the pull cord emergency switch PD:12


PD:12





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PD:03








PD:03



PD:03


PD:03












PD:03



Renew filter PD:04








PD:07


PD:08





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PD:06



PD:03




PD:03







PD:03



PD:03


PD:03












PD:03








PD:07


PD:08





PD:12





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PD:03




PD:03



PD:03


PD:03











PD:03








PD:07


PD:08





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Continues













PD:06



PD:03










PD:03


PD:03







PD:03

Check the crankshaft vibration damper 2

2. Or every 170 400 litres of fuel - which ever occurs first.

PD:03

Check the electronic unit injector, if necessary adjust it 2

PD:03

Check the engine mounts 2 PD:03

Check the engine speed / timing sensors, if necessary clean and/or calibrate them 2

PD:03

Check the engine valve lash, if necessary adjust it 2 PD:03

Check the engine valve rotators 2 PD:03


3. Or every 14 400 litres of fuel or once a year - which ever occurs first.

PD:03


PD:03




Clean and test the after cooler core 4


PD:03

Clean the engine 2 PD:03






Replace the water temperature regulator 5

5. Or every 3 years - which ever occurs first.

PD:03

Renew coolant extender (ELC) 5 PD:03

Renew coolant (DEAC) 5 PD:03




PD:03






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2 Power unit - Fluid coupling (21 KPTO)Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm)

PD:04


Renew filter PD:04








PD:07


PD:08








PD:12





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PD:03




PD:03



PD:03


PD:03











PD:03








PD:07


PD:08





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Check the belt cleaning devices PD:06




PD:06



PD:03




PD:03







PD:03



PD:03


PD:03












PD:03



Renew filter PD:04








PD:07


PD:08





PD:12





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1. At least once a year

PD:03








PD:03



PD:03


PD:03











PD:03








PD:07


PD:08





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Continues

HydraulicsChange hydraulic oil PD:01




Change breather filter on hydraulic tank PD:01

Drain condensing water from hydraulic tank PD:01











Check the gear PD:06

Check the pull cord em. switch PD:06

Check the safety switch PD:06

Check the rotation detector PD:06


PD:06



PD:03






PD:03


PD:03







PD:03

Check the alternator 2

2. Or yearly - which ever occurs first.

PD:03



PD:03


PD:03












PD:03


2 Power unit - Fluid coupling (21 KPTO)Renew oil and filters (25 micron) PD:04

Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm)

PD:04


Renew filter PD:04


If necessary renew seals PD:04




NOTE! The maintenance cycle continues after 4 000 hrs. Go back to Section 1.9 and repeat the maintenance instructions for 250 hrs. when 4 250 hrs. has passed.


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l

5 Track unit - Trackline D6Renew gearbox oil PD:07





5 Track unit - Track One T0650C02 / T0650C03Change gear box oil1

1. The oil needs not to be changed after 4 000 hours if it already has beenchanged between 2 2500 and 3 750 hours. If so, make sure that the oil ischanged within 2 000 hours (or at least a year) from the previous change.

PD:07

6 Feeder GF1246Lubricate vibrator bearings OM:13


PD:08

11 Screen (OPTION)Lubricate the vibrator bearings PD:12







Check the pull cord emergency switch PD:12

Check the rotation detector PD:12


PD:12



• After 10 000 hours• Every 6 months• Yearly

• After 8 000 hours• After 12 000 hours• Every 3 years• Every 6 years• Every 14 400 litres of fuel• Every 28 500 litres of fuel• Every 114 000 litres of fuel• Every 170 400 litres of fuel• Every 380 000 litres of fuel.s


NOTE! These maintenance intervals applies both to the Volvo and the Caterpillar diesel engines:

NOTE! These maintenance intervals applies specifically to the Caterpillar diesel engine:

NOTE! This maintenance interval applies specifically to the Caterpillar diesel engine.

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Check the driven equipment 1


PD:03


E1-S90FE1-S90F

Panel P1Panel P1

2





1.32 Every 6 months

NOTE! This maintenance interval applies both to the Volvo and the Caterpillar diesel engines.

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)

Date for the first coolant change

Change coolant for the first time 1 2

1. NOTE! Do not change coolant and the coolant filter at the same time!2. Or after 1 year - which ever occurs first. NOTE! The normal maintenance cycle for coolant change (every 1 000 hours or 6

months) only starts after the first coolant change.

PD:03

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Consider an overhaul 3


PD:03


2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Renew coolant (ELC) 1


PD:03

NOTE! This maintenance interval applies both to the Volvo and the Caterpillar diesel engines.

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)Change coolant filter 1 2

1. NOTE! Do not change the coolant filter and coolant at the same time!2. Or every 1 000 hours - which ever occurs first. NOTE! This maintenance cycle


PD:03

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Check the engine protective devices 3

3. Or every 500 hours - which ever occurs first.

PD:03



1.33 YearlyNOTE! This maintenance interval applies both to the Volvo and the Caterpillar diesel

engines.

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)

Date for the first coolant change


1. NOTE! Do not change the coolant filter and coolant at the same time!2. Or every 1 000 hours - which ever occurs first. NOTE! This maintenance cycle (every 1 000 hours or 6 months) only starts

after the first coolant change after 10 000 hours or 1 year.

PD:03

Change air filter element PD:03

Clean / paint engine PD:03

Change air filter (tank ventilation) PD:03

Drain fuel prefilter from water or impurities 3

3. At least once a year, but weekly is preferred.

PD:03

Change engine oil 4

4. At least once a year, but shorter time intervals (50-600 hours) are preferred. Oil change intervals will vary depending uponthe grade of the oil and the amount of sulfur in the fuel. NOTE! Oil filter must be changed with every oil change.

PD:03

Change oil filter / bypass filer 4 PD:03

Check the main air filter status on the display 5

5. At least once a year, but daily is preferred.

PD:03, OM:11

Drain fuel tank (sludge collector) 6

6. At least once a year, but every 250 hours is preferred.

PD:03



Charge air pipes, check for leaks 7

7. At least once a year, but every 750 hours is preferred.

PD:03

Change fuel pre-filter 7 PD:03

Change fuel filter 7 PD:03

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Check the alternator 8

8. Or every 2 000 hours - which ever occurs first.

PD:03


9. Or every 250 hours or every 14 400 litres of fuel - which ever occurs first.

PD:03


PD:03





Obtain a coolant sample (level 2) 10

10. NOTE! A new, refilled or converted system requires maintenance after the initial 500 hours, then yearly.

PD:03


Replace the fuel system secondary filter element 9 PD:03

Renew engine oil 11

11. Or every 250 hours (for mobile units with a standard oil pan) / 500 hours (for mobile units with a deep oil pan) or every28 500 litres of fuel - which ever occurs first.

PD:03

Renew oil filter cartridge 11 PD:03



1.34 Every 3 years

1.35 Every 6 years

1.36 Every 14 400 litres of fuel


2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Renew coolant (DEAC) 1


PD:03

Renew coolant extender (ELC) 1 PD:03

Replace the water temperature regulator 1 PD:03

Check the driven equipment 2


PD:03


2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Renew coolant (ELC) 1


PD:03


2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Clean and test the aftercooler core 1

1. Or every 250 hours or yearly - which ever occurs first.

PD:03







2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Clean and test the aftercooler core 1


PD:04


2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Check the crankshaft vibration damper 1


PD:04

Check the electronic unit injector, if necessary adjust it 1

PD:04

Check the engine mounts 1 PD:04

Check the engine speed / timing sensors, if necessary clean and/or calibrate them 1

PD:04

Check the engine valve lash, if necessary adjust it 4 PD:04

Check the engine valve rotators 1 PD:04

Clean the engine 1 PD:04


2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)Consider an overhaul 1


PD:04



1.40 Completed maintenance jobsAFTER 80 HOURS TO 4 000 HOURS

The maintenance cycle continues after 4 000 hrs. Go back to Section 1.9 and repeat the maintenance instructions for 250 hrs when 4 250 hrs has passed.

Working hours Date Signature / Stamp

Date Signature / Stamp


80

250

500

750

1 000

1 250

1 500

1 750

2 000

2 250

2 500

2 750

3 000

3 250

3 500

3 750

4 000



AFTER 8 000, 10 000 AND 12 000 HOURS

EVERY 6 MONTHS

The maintenance cycle continues after 60 months. Go back to Section 1.32 and repeat the maintenance instructions for every 6 months when 60 months. has passed.

Working hours Date Signature / Stamp



8 0001

1. Applies only to the Caterpillar diesel engine.

10 0002

2. Applies both to the Volvo and the Caterpillar diesel engines.

12 0001

NOTE! The “after 10 000 hours” maintenance interval applies both to the Volvo and the Caterpillar diesel engines.

NOTE! The “after 8 000 hours” and the “after 12 000 hours” maintenance intervals applies specifically to the Caterpillar diesel engine.

Time interval Date Signature / Stamp



6 months

12 months

18 months

24 months

30 months

36 months

42 months

48 months

54 months

60 months

NOTE! The “every 6 months” maintenance interval applies both to the Volvo and the Caterpillar diesel engines.



YEARLY

The maintenance cycle continues after 5 years. Go back to Section 1.33 and repeat the maintenance instructions for every year when 5 years has passed.

EVERY 3 YEARS

The maintenance cycle continues after 6 years. Go back to Section 1.34 and repeat the maintenance instructions for every 3 years when 6 years has passed.




1 year

2 years

3 years

4 years

5 years

NOTE! The “yearly” maintenance interval applies both to the Volvo and the Caterpillar diesel engines.




3 years

6 years

NOTE! The “every 3 years” maintenance interval applies specifically to the Caterpillar diesel engine.



EVERY 6 YEARS

The maintenance cycle continues after 12 years. Go back to Section 1.35 and repeat the maintenance instructions for every 6 years when 12 years has passed.

EVERY 14 400 LITRES OF FUEL

The maintenance cycle continues after 144 000 litres of fuel. Go back to Section 1.36 and repeat the maintenance instructions for every 14 400 litres of fuel when 144 000 litres of fuel has been used.




6 years

12 years

NOTE! The “every 6 years” maintenance interval applies specifically to the Caterpillar diesel engine.

Fuel interval Date Signature / Stamp



14 400 litres

28 800 litres

43 200 litres

57 600 litres

72 000 litres

86 400 litres

100 800 litres

115 200 litres

129 600 litres

144 000 litres

NOTE! The “every 14 400 litres of fuel” maintenance interval applies specifically to the Caterpillar diesel engine.












114 000 litres

228 000 litres





170 400 litres

340 800 litres





380 000 litres

760 000 litres




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