s07 Tramming Axera Robolt Solo 5 en

C-24-01-2007 SR-RB-FL
5 RANGE TRAMMING
MAINTENANCE MANUAL
SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 MEYZIEU cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
PAGE 1
PAGE 2
TRAMMING 5 RANGE

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C-24-01-2007 SR-RB-FL
TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
PAGE 3
CONTENTS
1
PRELIMINARY REMARKS
1/1
SAFETY
1/2
ABOUT THIS BOOKLET
DESCRIPTION
2/1
EXPLANATION
2/2
FEATURES
2/3
MAIN COMPONENTS
MAINTENANCE
10
3/1
FIRST ENTRY INTO SERVICE
10
3/2
OPERATIONS AT EACH SHIFT
10
3/3
50-HOURS OR WEEKLY OPERATIONS
10
3/4
600-HOURS OPERATIONS
10
3/5
1800-HOURS OR ANNUAL OPERATIONS
11
3/6
5800-HOURS OPERATIONS OVERALL INSPECTION AND RECONDITIONING
11
TIGHTENING TORQUES
12
4/1
STANDARD TIGHTENING TORQUES
12
4/2
SPECIFIC TIGHTENING TORQUES :
12
LUBRICATION
12
5/1
LUBRICANT
12
5/2
GREASE POINTS
13

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TRAMMING 5 RANGE
PAGE 4
C-24-01-2007 SR-RB-FL
OPERATING METHODS
14
6/1
MOUNTING OF CONICAL PINS OF THE CENTRAL ARTICULATION
14
6/1/1
CHECK AND ADJUSTMENT
15
6/2
BRAKE CYLINDER ADJUSTEMENT
16
6/3
AXLES DISMANTLING AND MOUNTIG METHODS
16
6/4
HYDRAULIC MOTOR AND GEAR BOX OPERATING METHODS
16
6/5
TRAMMING PUMP OPERATING METHODS
17
6/6
WHEEL CHECK
17
6/7
BRAKE TEST
17
PERIODIC MAINTENANCE TABLE
18

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C-24-01-2007 SR-RB-FL
TRAMMING 5 RANGE
PRELIMINARY REMARKS
1.1
Safety
PAGE 5
The informations contained in this manual must be studied and thoroughly assimilated before
undertaking any maintenance work on the equipment
Remember: SAFETY FIRST!

Always observe the warnings accompanied by the following symbols.
WARNING Operation, maintenance and adjustments are only allowed to persons with
specific training in operation and maintenance of the equipment. Read the operating
and maintenance instructions before using or servicing the equipment.
WARNING
WARNING: Before starting any maintenance operation ensure that the machine is in a
safe location with good safety, ventilation and lighting conditions. Ensure that lifting
equipments and pedestals are compatible with elements weight. Follow all the safety
instructions and ware safety protections as gloves, goggle, helmet, safety boots, ear
protectors.
WARNING
WARNING
WARNING: Before any operation stabilize and fix steadily all the elements on suitable
pedestals. Stop the power packs, switch the general power breaker. Place a tag or a
board to warn other members of the personnel that maintenance work on the machine
is in progress.
WARNING: Pressurized oil jets could cause severe injuries. Before any operation on
hydraulic circuit, STOP the power packs and release remaining pressure in
components by operating hydraulic control levers several times. Always release the
static pressure in cylinders before disassemble them.
NEVER WORK ON AN OPERATING CIRCUIT.
WARNING: While tests are in progress, do not allow any other member of the
personnel to stand in the area surrounding the machine. Stay at the control station to
be able to stop the movement and switch off the power pack.
WARNING
WARNING: Maintenance, adjustment and repairs are restricted to qualified personnel

with special training for the particular equipment. Always read the instructions
carefully before starting any maintenance work.
CAUTION: Always use suitable tools and work in a clean place when dismantling and
assembling hydraulic components. After removing cylinders the hydraulic inlet/outlet
ports must be plugged to prevent dirt and air intrusion during operation.
WARNING: The operator must always wear required personal protection, such as
safety helmet, protective overall, safety boots, hearing protectors, safety goggles etc.
WARNING: Danger of high pressure oil jets.

High pressure oil jets can cause serious personal injuries.
Release the pressure in the hydraulic circuits before opening caps or connections.
WARNING

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TRAMMING 5 RANGE
PAGE 6
C-24-01-2007 SR-RB-FL
WARNING: Danger of hot surface.

Hot surface can cause serious injuries.
Components rod, shank or hydraulic component can be hot and before
starting a maintenance work, please let them cool off.
The operator must have adequate wears as gloves.
WARNING: Crushing hazard : do not stay in dangerous area, for instance: central
articulation, front chassis and rear chassis.
WARNING
SAFETY
Always follow the marked safety instructions, and observe caution while working
The following safety instructions are general rules.
Keeps tools and drilling equipment clean
Dot not attempt any such repairs or adjustments that you do not fully understand
ABOUT THE SAFETY OF REPAIRS

Certain workstages require the use of the feed mechanism during the repair.
- no danger is caused to anybody.

- the machine can be immediately stopped when necessary.
- The powerpack is stopped again before the repair work is continued.
Before starting any repair-work move away from the aera where you have just drilled.
Use proper tools.
Allways wear protective clothing, eye protection , earmuffs, safety footwear and
other safety equipment requiered by the work.

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C-24-01-2007 SR-RB-FL
1.2
TRAMMING 5 RANGE
PAGE 7
ABOUT THIS BOOKLET
The present manual is destined for the use of personnel in charge of carrying out, servicing and
maintenance operations on Jumbos.
It contains maintenance operations schedule and operating methods concerning the main elements
of the TRAMMING 5 RANGE.
Note that servicing and maintenance operations must be carried out by personnel with the required
qualifications, technical knowledge, and proper training on the machine.

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TRAMMING 5 RANGE
PAGE 8
DESCRIPTION
2.1
Explanation
Axera 5 / Robolt 5 / Solo 5 : Single boom electro hydraulic jumbo.

Power full four-wheel-drive articulated carrier.
Automotive hydrostatic transmission.
2.2
Features
Tramming dimensions (mm) :
(AXERA 5 SHOWN)
Total machine weights :

AXERA 5 : 12 000 Kg.
ROBOLT 5 :14 000 Kg.
SOLO 5 : 14 000 Kg.

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C-24-01-2007 SR-RB-FL
2.3
PAGE 9
TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
Main components
8
10
9
11
1 : TRAMMING PUMP
2 : TRAMMING HYDRAULIC MOTOR
3 : CENTRAL GEAR BOX FRONT DRIVE LINE
4 : REAR SLIDING DRIVE LINE
5 : REAR AXLE BOLSTER PIN
6 : CENTRAL SLIDING DRIVE LINE
7 : FRONT FIXED DRIVE LINE
8 : AXLE
9 : BRAKE CYLINDERS (SPRING APPLIED, PRESSURE RELEASED)
10 : STEERING CYLINDERS
11 : CENTRAL ARTICULATION PINS

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TRAMMING 5 RANGE
PAGE 10
C-24-01-2007 SR-RB-FL
MAINTENANCE
CAUTION: The safety of users and the reliability of the tramming components depend on the
maintenance operations and imply the use of genuine SANDVIK spare parts.
All defective parts must be immediately replaced.
WARNING
WARNING: While tests are in progress, do not allow any other member of the personnel
to stand in the area surrounding the machine. Stay at the control station to be able to
stop the movement and switch off the power pack.
WARNING
3.1
FIRST ENTRY INTO SERVICE
After 20 working hours or 1 week of service, check that all the screws and all the expendable pins
are tighten.
3.2
OPERATIONS AT EACH SHIFT
Before starting up:

Check the overall condition of the equipment (cylinders, hoses, tube, hydraulic unions,...).
Look for leaks.
Tests brakes
3.3
50-HOURS OR WEEKLY OPERATIONS
Check the overall condition of the equipment (cylinders, hoses, tube, hydraulic unions,...).
Look for leaks.
Lubricate all the grease points.
Check the wheels.
3.4
600-HOURS OPERATIONS
Carry out the 50-hours operations again.

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3.5
TRAMMING 5 RANGE
PAGE 11
1800-HOURS OR ANNUAL OPERATIONS
Check the overall condition of the equipment.

Look for leaks .
Check the condition of the hydraulic equipments (cylinders, hoses, hydraulic unions,...).
Check the tightening torque of the central articulations expendable pins and axles fixing bolts.
3.6
5800-HOURS OPERATIONS OVERALL INSPECTION AND RECONDITIONING
Check the shape of the ball joints and the shim washers. Remove all defective parts.
Test for correct operation.
NB : You can recover all these operations in the periodic maintenance table (last page of this
manual) we invite you to use this document.

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TRAMMING 5 RANGE
PAGE 12
TIGHTENING TORQUES
4.1
Standard tightening torques
C-24-01-2007 SR-RB-FL
For basic genuine SANDVIK screws and nuts use the following tightening torques :
metric dimension
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M33
M36
M39
M42
4.2
torque in Nm
torque in Nm
HEX BOLTS
GRADE 8.8
SIX CUT HOLLOW

BOLTS
GRADE 12.9
10
25
50
85
130
200
280
400
530
670
1000
1780
2300
3000
3700
16
40
80
140
210
330
460
650
880
1130
1650
2200
3850
5050
6250
Specific tightening torques :
Axles fixing :
600
Central articulation :
530
LUBRICATION
5.1
Lubricant
Use Mobilith SHC 220, Mobilgrease HP 222 or equivalent.

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TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
5.2
GREASE POINTS
Grease nipples location :
1 : On the axle bolster pin (grease nipple access near power pack).
2 : On drive lines (grease U-joints and schaft sliding part too).
3 : On the both central articulations
4 : On the both steering cylinders

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PAGE 13
TRAMMING 5 RANGE
PAGE 14
C-24-01-2007 SR-RB-FL
OPERATING METHODS
WARNING: Before starting any maintenance operation ensure that the machine is in a
safe location with good safety, ventilation and lighting conditions. Ensure that lifting
equipments and pedestals are compatible with elements weight. Follow all the safety
instructions and ware safety protections as gloves, goggle, helmet, safety boots, ear
protectors.
WARNING
6.1

Mounting Of Conical Pins Of The Central Articulation

5
1
6
Position the shaft 1 in the bore.

Using the non-threaded conical bush 2, push the schaft down to the dimension A of 4.5 mm.
Install the threaded conical bush 3.
Install the screw and washer 4 and 5 and apply the torque progressively to the value of 530 Nm.
BE CAREFUL : Lenght of screw = 220 mm.
Install the nut 6 and apply the torque of 530 Nm.
Steer the machine several times over a tramming distance of 100 m.
Check torques of 530 Nm.
Re-check after about 300 diesel hours.
For cylinders operating methods, see SECTION 1.

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TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
6.1.1
PAGE 15
Check and adjustment
2mm
(mini)
2mm
(mini)
CENTRAL ARTICULATION
Check clearance value must not be inferior 2mm (minimum) in the central articulation

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TRAMMING 5 RANGE
PAGE 16
6.2
C-24-01-2007 SR-RB-FL
BRAKE CYLINDER ADJUSTEMENT
1 : SPRING
2 : CAP
3 : LOCK NUT
4 : ADJUSTING NUT
P : PRESSURE PORT
B : BLEEDER PLUG
P
Start diesel engine, lift up the machine using stabilzers until there are no tyres in contact with the
ground.
Release the brakes by pulling the unbreaking hand pump.
Make sure that the tramming charge pressure reaches a minimum of 15 bar. Read the 0-60 b
gauge at the tramming compartment. The spring 1 must be no fully compressed.
Remove the cap 2 together with the light spring.
Undo the lock nut 3.
Screw in the adjusting nut 4 until feeling a light resistance when trying to rotate the wheel by hand.
That indicates that the brake discs start to be in contact.
Apply the brakes.
Tighten the lock nut 3. When tightening the lock nut, make sure not to rotate the adjusting nut 4.
6.3
AXLES DISMANTLING AND MOUNTIG METHODS
AXLES
See D45 AXLE maintenance manual.
(Supplier documentation)
Weight : 400 kg
6.4
HYDRAULIC MOTOR AND GEAR BOX OPERATING METHODS

GEAR BOX
See supplier maintenance manual
HYDRAULIC MOTOR
See supplier maintenance manual

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TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
6.5
PAGE 17
TRAMMING PUMP OPERATING METHODS

1
TRAMMING PUMP
See VARIABLE PUMP A4VG
maintenance manual.
(Supplier documentation)
(1) : Filter element
6.6
WHEEL CHECK
1
Visualy check the tyres 1, look for

damages.
Make sure the nuts 2 are correctly tighten
(Wheel tightenning torque : 400 Nm).
Make sure the lock ring 3 is correctly in
place.
Check the tyres pressure (10 bar for

SOLIDEAL tyres or 8 bar for NOKIA tyres).
6.7
BRAKE TEST
2
Emergency / Parking brake test :

Raise the machine on stabilizers, no contact between tyres and
ground.
3
4
Install a 600 bar gauge at the tramming test point (1) to verify
there is no problem on the tramming circuit (Caution, high
pressure).
Apply the parking brake by depressing the emergency button
(2).
Select one tramming direction and accelerate slowly => The
tramming pressure must increase to 440 bar and no wheel must
turn.
Service brake test :
Raise the machine on stabilizers, no contact between tyres and ground.

Select one tramming direction and accelerate to put the wheels in rotation. Release the accelerating
pedal (3) and push on the braking pedal (4).
=> Wheel must rapidly stop turning.
In case that the brakes are faulty, do not use the machine and refit it.
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TRAMMING 5 RANGE
PAGE 18
C-24-01-2007 SR-RB-FL
PERIODIC MAINTENANCE TABLE
CHECK
TEST
LUBRICATE
REPLACE
(IF NECESSARY)
CLEAN
FLUSH
SERVICE
When
completed
FREQUENCY (TRAMMING HOURS)
TRAMMING
20
or
wee
k
20
0
60
0
12
00
18
00
24
00
36
00
58
00
At each shift
All the grease points

All tightenning torques
Condition of the hydraulic equipment
Ball joints and shim washers (shape)
Tramming motor
Wheels (tightenning torque, pressure..)
At each shift
Leakage
Central articulation expendable pin
Axles fixing
Brakes (park and service)
At each shift
OVERALL
Overal inspection
For all lubrication operations, see the lubrication schedule in section 02 of this manual.

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C-24-01-2007 SR-RB-FL

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

ABOUT THIS BOOKLET

FIRST ENTRY INTO SERVICE

OPERATIONS AT EACH SHIFT

50-HOURS OR WEEKLY OPERATIONS

1800-HOURS OR ANNUAL OPERATIONS

5800-HOURS OPERATIONS OVERALL INSPECTION AND RECONDITIONING

STANDARD TIGHTENING TORQUES

SPECIFIC TIGHTENING TORQUES :

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

MOUNTING OF CONICAL PINS OF THE CENTRAL ARTICULATION

CHECK AND ADJUSTMENT

BRAKE CYLINDER ADJUSTEMENT

AXLES DISMANTLING AND MOUNTIG METHODS

HYDRAULIC MOTOR AND GEAR BOX OPERATING METHODS

TRAMMING PUMP OPERATING METHODS

PERIODIC MAINTENANCE TABLE

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

Remember: SAFETY FIRST!

WARNING: Maintenance, adjustment and repairs are restricted to qualified personnel

WARNING: Danger of high pressure oil jets.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

WARNING: Danger of hot surface.

The following safety instructions are general rules.

Keeps tools and drilling equipment clean

ABOUT THE SAFETY OF REPAIRS

- no danger is caused to anybody.

Use proper tools.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

ABOUT THIS BOOKLET

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

Axera 5 / Robolt 5 / Solo 5 : Single boom electro hydraulic jumbo.

Tramming dimensions (mm) :

Total machine weights :

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

FIRST ENTRY INTO SERVICE

OPERATIONS AT EACH SHIFT

Before starting up:

50-HOURS OR WEEKLY OPERATIONS

Carry out the 50-hours operations again.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

1800-HOURS OR ANNUAL OPERATIONS

Check the overall condition of the equipment.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

Standard tightening torques

SIX CUT HOLLOW

Specific tightening torques :

Use Mobilith SHC 220, Mobilgrease HP 222 or equivalent.

Grease nipples location :

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

WARNING: Maintenance, adjustment and repairs are restricted to qualified personnel

Mounting Of Conical Pins Of The Central Articulation

Position the shaft 1 in the bore.

For cylinders operating methods, see SECTION 1.

Check and adjustment

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

BRAKE CYLINDER ADJUSTEMENT

AXLES DISMANTLING AND MOUNTIG METHODS

HYDRAULIC MOTOR AND GEAR BOX OPERATING METHODS