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Preventive Maintenance
Doc. no. S 281.821 en Ver. 1
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 en Issue: 20071210 Version: 1
Sandvik SRP AB Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com
Table of contents
1. Preventive Maintenance
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 UJ440i General ................................................................................. 5 Caterpillar engine (option) .................................................... 6 Daily inspection..................................................................... 9 Daily inspection (Continued)............................................... 11 After 50-600 hours .............................................................. 13 Weekly inspection............................................................... 15 When required .................................................................... 17 After 80 hours ..................................................................... 19 After 250 hours ................................................................... 21 After 500 hours ................................................................... 23 After 750 hours ................................................................... 25 After 1 000 hours ................................................................ 27 After 1 000 hours (Continued) ............................................ 29 After 1 250 hours ................................................................ 31 After 1 500 hours ................................................................ 33 After 1 750 hours ................................................................ 35 After 2 000 hours ................................................................ 37 After 2 000 hours (Continued) ............................................ 39 After 2 250 hours ................................................................ 41 After 2 500 hours ................................................................ 43 After 2 750 hours ................................................................ 45 After 3 000 hours ................................................................ 47 After 3 000 hours (Continued) ............................................ 49 After 3 250 hours ................................................................ 51 After 3 500 hours ................................................................ 53 After 3 750 hours ................................................................ 55 After 4 000 hours ................................................................ 57 After 4 000 hours (Continued) ............................................ 59 After 8 000 hours ................................................................ 60 After 10 000 hours .............................................................. 61 After 12 000 hours .............................................................. 61 Every 6 months................................................................... 61 Yearly .................................................................................. 62 Every 3 years...................................................................... 63 Every 6 years...................................................................... 63 Every 14 400 litres of fuel ................................................... 63 Every 114 000 litres of fuel ................................................. 64 Every 170 400 litres of fuel ................................................. 64 Every 380 000 litres of fuel ................................................. 64
Sandvik SRP AB Doc. no. S 281.821 en Ver. 1
UJ440i
1. Preventive Maintenance
1.1 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
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.
WARNING!
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 = Operators Manual Example: The reference PD:12 stands for Part 12 NF Conveyor in the manual UJ440i Product Documentation.
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. For assistance, contact the nearest Sandvik company, agent, representative or directly: Sandvik SRP AB Service Dept. SE-233 81 Svedala, Sweden Telephone +46 40-40 90 00 Telefax +46 40-40 92 60
UJ440i
Other maintenance agreements for Caterpillar engines may apply. Contact Sandvik for more information.
Products that operate in severe operating conditions may require more frequent maintenance.
WARNING!
UJ440i
UJ440i
E1-S90F
Daily inspection
UJ440i
Alarms
Check the alarm log list and take care of any warnings OM:11
Hydraulics
Check for leakage and damage, hoses, valves and couplings Check hydraulic oil level in tank 1
1. First week
4 Jaw crusher
PD:01 PD:01 Check bearing temperatures and drive motor load Lubrication OM:12 OM:12
1 Discharge conveyor
Check the pull cord stop Check the belt for damage Check rollers for damage Check that tail pulley is running smoothly
Check for leakage on the track group (only on lubricated track group) Inspect the track group pre-tensioning (track sag)
6 Feeder GF1246
Listen for abnormal noises Check suspension and attachment of hydraulic hoses below the feeder. Make sure there is no wear between hoses or between hoses and chassis OM:13
1. NOTE! The first coolant change is only made after 10 000 hours or 1 year.
Check that the suction capacity is normal PD:04 PD:04 Check visually if there is any changes of the emission from the stack If necessary, clean the shaker device
Continues
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E1-S90F
10
12
10
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10
12 NF Conveyor (OPTION)
Check the pull cord emergency switch Check the belt for damage Check that tail pulley is running smoothly PD:12 PD:12 PD:12
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11
E1-S90F
12
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1. Oil change intervals will vary depending upon the grade of the oil and the amount of sulfur in the fuel. 2. NOTE! Oil filter must be changed with every oil change. 3. At least once a year.
The oil change intervals can vary between 50600 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.
NOTE!
Oil grade
Sulphur content in fuel, by weight < 0.3 % 0.3 0.5 % > 0.5 % 1
150 hrs / 12 months 100 hrs / 12 months
50 hrs / 12 months
1. If the sulfur content is > 1.0% by weight, use oil with TBN > 15. 2. The engine oil must comply with both quality requirements.
NOTE!
Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality requirements above. 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.
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13
E1-S90F
10
Weekly inspection
14
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Safety control
Check the presence and condition of all safety guards Make a test of all emergency stops
Hydraulics
Check for leakage and damage, hoses, valves and couplings Check hydraulic oil level in tank 1
1. First week
Check the condition of and wear on the front idler and sliding bracket PD:01 PD:01
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 inspection
1. Check at working rpm and warm oil. Warm up hydraulic oil above 0 C, at low temp <0 C by activating the warm up button with diesel engine at idle before starting up the process.
10
4 Jaw crusher
Grease all four bearings Lubrication Check tightness of all threaded fasteners Check preload in retraction springs Check wear on jaw plates and check plates Inspect dust seals Check toggle plate and toggle seats for wear or damage Inspect V-belt drive OM:12 OM:12 OM:12 OM:12 OM:12 OM:12 OM:12 OM:12
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15
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when required
16
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2 Air filters
Main air filter element 1 Secondary air filter element
2
OM:09 OM:09
1. Change when the Filter guard alarm on the machine control panel display is activated. 2. Changed every 2-3 times the primary air filter is replaced
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17
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80 hours inspection
18
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Hydraulics
Change all hydraulic oil filters Change high pressure filter Change return filter cartridge Change drain filters Change breather filter element on hydraulic tank Check hydraulic oil level Check couplings and hoses PD:01 PD:01 PD:01 PD:01 PD:01 PD:01 PD:01
Check the condition of and wear on the drive gear box sprocket Check the condition of and wear on the track rollers Check the condition of and wear on the carrier roller Check the condition of and wear on track link running surfaces, bushings (other diameter) and stretching of track Check the condition of and wear on the track group grouser shoes
1. The oil change is recommended, the new engine oil should be one that is recommended by Volvo Penta. NOTE! Oil filter must be changed with every oil change.
PD:07
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PD:04
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check all wear limits Check track group alignment and levelness Check the gearbox oil level and add if necessary
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather Clean the radiator 2 Obtain an engine oil sample 2 Drain water and sediment from the fuel tank Renew engine oil 3 4 Renew oil filter 4 Replace the primary fuel filter (water separator) 2 Replace the secondary fuel filter 2
2
PD:07
1. At least once a year. 2. Or for every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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22
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Hydraulics
Drain condensing water from hydraulic tank PD:01
1 Discharge conveyor
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06
PD:07
Check the alternator belt, if necessary adjust it Check batteries electrolyte level 1
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
12 NF Conveyor (OPTION)
Check the conveyor belt Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or for every 14 400 litres of fuel or yearly - which ever occurs first. 4. After the initial 500 hours (for new systems, refilled systems and converted systems), then yearly. 5. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year.
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Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1 Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter
PD:07
PD:08
Drain water and sediment from the fuel tank Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 3 4 Renew oil filter 4
2
1. At least once a year. 2. Or for every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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Hydraulics
Drain condensing water from hydraulic tank PD:01
1 Discharge conveyor
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check/lubricate the pulleys Check the guiding boards Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06
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 Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
Continues
1. At least once a year. 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 after 10 000 hours or 1 year.
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather Clean the radiator
2 2
Drain water and sediment from the fuel tank Obtain a coolant sample (level 1)
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12
28
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12 NF Conveyor (OPTION)
Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device Check the pulleys Check the guiding boards PD:07 Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12
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30
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Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1
PD:07
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Drain water and sediment from the fuel tank Clean the crankcase breather Clean the radiator
2 2
Obtain an engine oil sample 2 Replace the secondary fuel filter 2 Replace the primary fuel filter (water separator) 2 Renew engine oil 3 4 Renew oil filter
1. At least once a year. 2. Or for every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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12
32
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Hydraulics
Drain condensing water from hydraulic tank PD:01
1 Discharge conveyor
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06
PD:07
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
12 NF Conveyor (OPTION)
Check the conveyor belt Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first.
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34
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PD:07
Drain water and sediment from the fuel tank Obtain an engine oil sample
2 2
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 2 Renew engine oil 3 4 Renew oil filter
4
1. At least once a year. 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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35
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36
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Hydraulics
Change hydraulic oil Change high pressure filter Change return filter cartridge Change drain filters Change breather filter on hydraulic tank Drain condensing water from hydraulic tank PD:01 PD:01 PD:01 PD:01 PD:01 PD:01
1 Discharge conveyor
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check/lubricate the pulleys Check the guiding boards Check the gear Check the pull cord em. switch Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check battery electrolyte level 6 Check the electronics grounding stud, if necessary clean and/or tighten it 6 Check hoses / clamps, if necessary replace them 6 Clean the crankcase breather 6 Clean the radiator 6 Drain water and sediment from the fuel tank Obtain an engine oil sample 6 Obtain a coolant sample (level 1) Replace the primary fuel filter (water separator) 6 Replace the secondary fuel filter Renew engine oil Renew oil filter 8
78 6
1. At least once a year. 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 after 10 000 hours or 1 year. 4. Or every 6 months - which ever occurs first. 5. Or yearly - which ever occurs first. 6. Or every 14 400 litres of fuel or yearly - which ever occurs first. 7. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 8. NOTE! Oil filter must be changed with every oil change.
Continues
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12
38
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6 Feeder GF1246
Lubricate vibrator bearings OM:13
12 NF Conveyor (OPTION)
Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device PD:12 PD:12 PD:12
Check the pulleys Check the guiding boards Check the pull cord emergency switch Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12
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40
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Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter
PD:07
PD:08
Drain water and sediment from the fuel tank Obtain an engine oil sample
2
Drain water and sediment from the fuel tank Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 3 4 Renew oil filter 4
2
1. At least once a year. 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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42
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Hydraulics
Drain condensing water from hydraulic tank PD:01
1 Discharge conveyor
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06
Check track group alignment and levelness Check the gearbox oil level and add if necessary
PD:07
12 NF Conveyor (OPTION)
Check the conveyor belt PD:03 PD:03 PD:03 Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12
Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather Clean the radiator 3 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) 3 Replace the secondary fuel filter 3 Renew engine oil Renew oil filter
5 45 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first. 4. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 5. NOTE! Oil filter must be changed with every oil change.
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PD:07
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 2 Renew engine oil 3 4 Renew oil filter
4
1. At least once a year. 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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Hydraulics
Drain condensing water from hydraulic tank PD:01
1 Discharge conveyor
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check the pulleys Check the guiding boards Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06
Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the crankshaft vibration damper 2 Check the electronic unit injector, if necessary adjust it 2 Check the engine mounts 2 Check the engine speed / timing sensors, if necessary clean and/or calibrate them 2 Check the engine valve lash, if necessary adjust it 2 Check the engine valve rotators 2 Check battery electrolyte level
3
Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3
Clean the crankcase breather Clean the radiator PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
3
Clean and test the after cooler core 4 Clean the engine 2 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) 3 Replace the secondary fuel filter
3
Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter Change coolant filter
23
Replace the water temperature regulator 5 Renew coolant extender (ELC) 5 Renew coolant (DEAC) Renew engine oil Renew oil filter 7
67 5
1. At least once a year. 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 after 10 000 hours or 1 year.
1. Or every 6 months - which ever occurs first. 2. Or every 170 400 litres of fuel - which ever occurs first. 3. Or every 14 400 litres of fuel or once a year - which ever occurs first. 4. Or every 114 000 litres of fuel - which ever occurs first. 5. Or every 3 years - which ever occurs first. 6. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 7. NOTE! Oil filter must be changed with every oil change.
Continues
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12 NF Conveyor (OPTION)
Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device Check the pulleys PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12
Check the guiding boards Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings
PD:07
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Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1
PD:07
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather 2 Clean the radiator 2 Drain water and sediment from the fuel tank Obtain an engine oil sample 2 Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 3 4 Renew oil filter 4
2
1. At least once a year. 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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Hydraulics
Drain condensing water from hydraulic tank PD:01
1 Discharge conveyor
Check/adjust the conveyor belt Check the belt cleaning devices Check the roller systems Check the belt scale Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06
PD:07
Check the alternator belt, if necessary adjust it Check batteries electrolyte level
1
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
12 NF Conveyor (OPTION)
Check the conveyor belt Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12
Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather Clean the radiator 3 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) 3 Replace the secondary fuel filter 3 Renew engine oil Renew oil filter
5 45 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first. 4. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 5. NOTE! Oil filter must be changed with every oil change.
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Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1 Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter
PD:07
1. At least once a year 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
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Hydraulics
Change hydraulic oil Change high pressure filter Change return filter cartridge Change drain filters Change breather filter on hydraulic tank Drain condensing water from hydraulic tank PD:01 PD:01 PD:01 PD:01 PD:01 PD:01
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
1 Discharge conveyor
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check the pulleys Check the guiding boards Check the gear Check the pull cord em. switch Check the safety switch Check the rotation detector Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06
Check the alternator 2 Check battery electrolyte level 3 Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather 3 Clean the radiator 3 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 4 5 Renew oil filter 5
3 3
1. Or every 6 months - which ever occurs first. 2. Or yearly - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first. 4. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 5. NOTE! Oil filter must be changed with every oil change.
1. At least once a year. 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 after 10 000 hours or 1 year.
Continues
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11
12
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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6 Feeder GF1246
Lubricate vibrator bearings OM:13
PD:08
11 Screen (OPTION)
Lubricate the vibrator bearings PD:12
12 NF Conveyor (OPTION)
Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device Check the pulleys Check the guiding boards Check the pull cord emergency switch Check the rotation detector Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12
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NOTE!
These maintenance intervals applies both to the Volvo and the Caterpillar diesel engines: After 10 000 hours Every 6 months Yearly
NOTE!
These maintenance intervals applies specifically to the Caterpillar diesel engine: 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
PD:03
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This maintenance interval applies both to the Volvo and the Caterpillar diesel engines.
2 Power unit - Diesel engine (Volvo Penta TAD1252VE)
Change coolant for the first time 1 2 2 PD:03
PD:03
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 PD:03
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1.33 Yearly
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 Change air filter element Clean / paint engine Change air filter (tank ventilation) Drain fuel prefilter from water or impurities 3 Change engine oil 4 Change oil filter / bypass filer
4
Check the main air filter status on the display 5 Drain fuel tank (sludge collector) 6 Check the alternator belt, if necessary adjust it 6 Check batteries electrolyte level 6 Charge air pipes, check for leaks Change fuel pre-filter Change fuel filter 7
7 7
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Obtain a coolant sample (level 2) 10 Replace the primary fuel filter (water separator) 9 Replace the fuel system secondary filter element Renew engine oil
11 9
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. 3. At least once a year, but weekly is preferred. 4. At least once a year, but shorter time intervals (50-600 hours) are preferred. Oil change intervals will vary depending upon the grade of the oil and the amount of sulfur in the fuel. NOTE! Oil filter must be changed with every oil change. 5. At least once a year, but daily is preferred. 6. At least once a year, but every 250 hours is preferred. 7. At least once a year, but every 750 hours is preferred. 8. Or every 2 000 hours - which ever occurs first. 9. Or every 250 hours or every 14 400 litres of fuel - which ever occurs first. 10. NOTE! A new, refilled or converted system requires maintenance after the initial 500 hours, then yearly. 11. Or every 250 hours (for mobile units with a standard oil pan) / 500 hours (for mobile units with a deep oil pan) or every 28 500 litres of fuel - which ever occurs first.
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1. Or every 3 000 hours - which ever occurs first. 2. Or every 8 000 hours - which ever occurs first.
PD:03
PD:03
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PD:04
PD:04
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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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Date
Signature / Stamp
Date
Signature / Stamp
Date
Signature / Stamp
NOTE! NOTE!
The after 10 000 hours maintenance interval applies both to the Volvo and the Caterpillar diesel engines. The after 8 000 hours and the after 12 000 hours maintenance intervals applies specifically to the Caterpillar diesel engine.
EVERY 6 MONTHS
Time interval 6 months 12 months 18 months 24 months 30 months 36 months 42 months 48 months 54 months 60 months Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!
The every 6 months maintenance interval applies both to the Volvo and the Caterpillar diesel engines. 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.
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NOTE!
The yearly maintenance interval applies both to the Volvo and the Caterpillar diesel engines. 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
Time interval 3 years 6 years Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!
The every 3 years maintenance interval applies specifically to the Caterpillar diesel engine. 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.
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NOTE!
The every 6 years maintenance interval applies specifically to the Caterpillar diesel engine. 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.
NOTE!
The every 14 400 litres of fuel maintenance interval applies specifically to the Caterpillar diesel engine. 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.
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NOTE!
The every 114 000 litres of fuel maintenance interval applies specifically to the Caterpillar diesel engine. The maintenance cycle continues after 228 000 litres of fuel. Go back to Section 1.37 and repeat the maintenance instructions for every 114 000 litres of fuel when 228 000 litres of fuel has been used.
NOTE!
The every 170 400 litres of fuel maintenance interval applies specifically to the Caterpillar diesel engine. The maintenance cycle continues after 340 800 litres of fuel. Go back to Section 1.38 and repeat the maintenance instructions for every 170 400 litres of fuel when 340 800 litres of fuel has been used.
NOTE!
The every 380 000 litres of fuel maintenance interval applies specifically to the Caterpillar diesel engine. The maintenance cycle continues after 760 000 litres of fuel. Go back to Section 1.39 and repeat the maintenance instructions for every 380 000 litres of fuel when 760 000 litres of fuel has been used.
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