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5 RANGE TRAMMING
MAINTENANCE MANUAL
PAGE 1
PAGE 2
TRAMMING 5 RANGE
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
DESCRIPTION
2/1
EXPLANATION
2/2
FEATURES
2/3
MAIN COMPONENTS
MAINTENANCE
10
3/1
10
3/2
10
3/3
10
3/4
600-HOURS OPERATIONS
10
3/5
11
3/6
11
TIGHTENING TORQUES
12
4/1
12
4/2
12
LUBRICATION
12
5/1
LUBRICANT
12
5/2
GREASE POINTS
13
TRAMMING 5 RANGE
PAGE 4
C-24-01-2007 SR-RB-FL
OPERATING METHODS
14
6/1
14
6/1/1
15
6/2
16
6/3
16
6/4
16
6/5
17
6/6
WHEEL CHECK
17
6/7
BRAKE TEST
17
18
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
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
TRAMMING 5 RANGE
PAGE 6
C-24-01-2007 SR-RB-FL
SAFETY
Always follow the marked safety instructions, and observe caution while working
Dot not attempt any such repairs or adjustments that you do not fully understand
Before starting any repair-work move away from the aera where you have just drilled.
Allways wear protective clothing, eye protection , earmuffs, safety footwear and
other safety equipment requiered by the work.
C-24-01-2007 SR-RB-FL
1.2
TRAMMING 5 RANGE
PAGE 7
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.
TRAMMING 5 RANGE
PAGE 8
DESCRIPTION
2.1
Explanation
2.2
Features
(AXERA 5 SHOWN)
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
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: 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.
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
After 20 working hours or 1 week of service, check that all the screws and all the expendable pins
are tighten.
3.2
3.3
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
C-24-01-2007 SR-RB-FL
3.5
TRAMMING 5 RANGE
PAGE 11
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.
TRAMMING 5 RANGE
PAGE 12
TIGHTENING TORQUES
4.1
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
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
Axles fixing :
600
Central articulation :
530
LUBRICATION
5.1
Lubricant
TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
5.2
GREASE POINTS
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
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
1
6
TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
6.1.1
PAGE 15
2mm
(mini)
2mm
(mini)
CENTRAL ARTICULATION
Check clearance value must not be inferior 2mm (minimum) in the central articulation
TRAMMING 5 RANGE
PAGE 16
6.2
C-24-01-2007 SR-RB-FL
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
See D45 AXLE maintenance manual.
(Supplier documentation)
Weight : 400 kg
6.4
HYDRAULIC MOTOR
See supplier maintenance manual
TRAMMING 5 RANGE
C-24-01-2007 SR-RB-FL
6.5
PAGE 17
TRAMMING PUMP
See VARIABLE PUMP A4VG
maintenance manual.
(Supplier documentation)
(1) : Filter element
6.6
WHEEL CHECK
1
6.7
BRAKE TEST
2
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 :
TRAMMING 5 RANGE
PAGE 18
C-24-01-2007 SR-RB-FL
CHECK
TEST
LUBRICATE
REPLACE
(IF NECESSARY)
CLEAN
FLUSH
SERVICE
When
completed
TRAMMING
20
or
wee
k
20
0
60
0
12
00
18
00
24
00
36
00
58
00
At each shift
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.
Y
yes
N
no